ML20199G262
| ML20199G262 | |
| Person / Time | |
|---|---|
| Issue date: | 10/20/1997 |
| From: | Dan Collins NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | Humbert P EG&G FLORIDA, INC. |
| Shared Package | |
| ML20199G244 | List: |
| References | |
| NUDOCS 9711250136 | |
| Download: ML20199G262 (59) | |
Text
- - - .- _ ._ . -- ___ . . _,
UNITED STATES 9
/g* "84 %, NUCLEAR REGULATORY COMMISSION :
- b . ATLANTA ERA CENTER k_ #ETtlItA.G hb sd October 20, 1997 dJy ). ,
Paul V. Humbert, MD t EG&G Florida. Inc. Rec'd p p '5 /-
f ATTN: Paul V. Humbert. M.D. / k Chairman. Radiation l / y Protection Committee P.O. Box 21296 .
Kennedy Space-Center. Florida 32815
SUBJECT:
RESPONSE TO REQUEST FOR USE OF CUSTOM RIGID GUIDE TUBES / STOPS AT CAPE CANAVERAl. AIR FORCE STATION UNDER RECIPROCITY
Dear Dr. Humbert:
This refers to your letter dated September 11, 1997, which requests that NRC grant the same exemption to NRC regulations in 10 CFR 34.20 as that granted by the State of Florida. The specific exemption granted by the State of Florida was to their regulations requiring testing of devices in accordance with American Nati il Standards Institute (ANSI) N432-1980
- Radiological Safety for the Design and Construction of Apparatus for Gamma Radiography.'
While it is within the purview of the State of Florida to grant such an exemption within the context of the Florida State regulations, it remains appropriate for NRC to use its rules contained in 10 CFR 34.20. The rules specify:
" Engineering analyses may be submitted by an applicant or licensee to demonstrate the applicability of previously performed testing on similar individual radiography equipment components. Upon review, the Commission may find this is an acceptable alternative to actual testing of the component pursuant to the referenced standard."
The State of Florida accepted your request for exemption from the Florida rules. In your request to the State of Florida. no engineering analyses were 3 resented. Your request to NRC does not contain sufficient information that 4RC could evaluate for suitability of the rigid guide tube /stop device as an alternative to actual testing.
Should you-wish to pursue this issue, please be aware that we shall submit the request-to our Sealed Source Safety Section at Rockville. Maryland. Prior to submittal to that office, we will evaluate the reouest to determine that the request meets the requested information in Information Notice 95-58: "10 CFR 34.20: Final Effective Date. The Information Notice (enclosed) states that exemptions may be considered only for limited special or unique cases where the licensee can demonstrate that the engineered safety features, use limitations and procedures would compensate for not meeting the requirements and afford similar or increased radiation safety protection. In presenting information.-please address the particulars of the information Notice.
EG&G Florida. Inc. 2 If you have any questions please call me at 404/562-4735, or send a facsimile to 404/562-4955.
Sincerely.
dvid J. Co ins. Health Physicist Materials Li ensing/ Inspection Branch 2 Division of luclear Materials Safety ,
Enclosure:
Information Notice 95-58 e a-. - . .
David Collins, (
Attached is the engineering anaylsis package for the rigid guidetubes/ stops.
I spoke with John Potter after receiving your input on the proposal and he suggested we the analysis to you for review.
Rod Nickell 407-867-3540
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OCCUPATIONAL MEDICINE KENNEDY SPACE CENTER.FL 32016 !
AND EWlRDNMENTAL ;
HEALTH $tMVICl3 October 24, 1996 E310-96-679 {
State of Florida !
Department of Health and !
Rehabilitative Services ;
1317 Winewood Boulevard ;
Tallahassee, FL 32399-0700 ;
i ATT Mr. Walter L. Cofer, PHP III, HSERM i AUTHORIEATION TO USE CUSTON RIGID GUIDE TUBES / STOPS REF: 1) State of Florida, Office of Radiation i Control Ltr. dtd. June 4, 1996 l
- 2) State of Florida Radioactive Materials License Number 1219-1 Enclosed is the response to your request for additional information in the consideration of authorizing use of custom fabricated rigid source guide tubes. In response to our telecon of August 29, 1996, rationale supporting EG&G NDE's '
recommendations for the type and frequency of equipment functional tests is addressed. The attached operating and '
emergency procedures have been revised, as requested, to provide specific instructions for radiographers to perform a daily inspection of the rigid source guide tube each shift prior i to use. A visual and functional test will be conducted with an inert source to assure the source and drive cable assembly travel. smoothly through the source guide tube (s), connections and return to the exposure device stored position without binding <
or application of excsssive force. The rigid guide tubes will be labeled or tagged with instructions to test the tube prior to.use. <
EG&G recommends rigid guide tube inspections to be perfortued once each shift prior to use or at any other time the condition of the equipment may become suspect. The inspection should normally be conducted prior to transporting the equipment to a remote field I site to assure marginal or unacceptable equipment is tagged and i removed from service. This is in accordance with manufacturers' prescribed daily maintenance checks for isotope projection-
. equipment and EG&G NDE's current practice. Checking equipment >
prior to transporting to the job site reduces any temptation to use questionable equipment, plus-it eliminates the need to transport training devices or "dummya sources to field sites.
-The concerns posed with using~a_ dummy source for each setup prior to actual source exposure are numerous. First of all, it would
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i require twice as many setups which doubles the time personnel l aro working and the time a restricted area is established. This- !
could pose significant impacts to productivity, accelerate !
personnel fatigue and decrease equipment longevity. In addition, other operations scheduled in the area may be delayed or effected i j
by the extended times. Radiography operations are often conducted in areas which pose other safety hazards such as r working at heights, in or adjacent _to toxic materials or in !
confined spaces. The fact that most iield radiography is accomplished at night or during other than normal working hours !
is sufficient to conclude that personnel would be subjected to j increased and unwarranted safety risks. !
l The material and design of the-proposed rigid source guide tubes- ~
makes them inherently less susceptible to kinking or crushing j damage than flexible source guide tubes. Use of rigid source
- guide tubes also eliminates the potential for problems to occur-. I in source retraction due to excessive bends sometimes encountered ,
with flexible guide tubes. Although , the proposed rigid source guide-tube design has not been tested in accordance with the -
requirements of ANSI N432-1980, it is believed that the design, -
materials and fabrication process demonstrate through previously-submitted engineering analysis that the product exceeds the performance standards desired by ANSI. s Based on the previously submitted engineering analysis, the i socioeconomic factors addressed above and the implementation of 4 additional equipment inspection measures, EG&G Florida requests exemption of the rigid source guide tubes from 10D-91.5031(6) (g)
- FAC_ requirements. It_ appears likely, in view of the industries expressed concern, that the USNRC will also make special ,
provisions-for associated equipment to relieve the burden currently imposed by their interpretation and application of :
the regulations.
If there are any questions concerning the above, please contact tlus undersigned at (407) 867-2025 or R. E. Nickell at (407) 867-3540. .
Pail V. Humbert, M.D. ,
Chairman, EG&G Florida, Inc. =
Radiation Protection' Committee rectrea >
Attachments: a/s -
cc w/o attchs
- G.M. Marmaro M.E. McDaniel i
R.E.' Martin' R'.E.- Nickell Lt. Col. Scott
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' Pcge I of 4 a NOE I.30 Rev. 5 f i
10/11/96 Supersedes:
NOE: 1.30 Rev. 4 03/31/96 ,
llASE OPERATIONS CONTRACTOR NONDESTRUCTIVE OPERATING & EMERGENCY INSTRUCTION ;
5XPOSURE DEVICES GENERAL REQUIREMENTS FOR LADELING AND USE e REVISED BY:
) Xbq R. E. Castlen NDE ARSO Al' PROVED:
/
M. E. McDaniel Manager: Nondestructive Evaluation NDE RSO
{
- NOTES REVISION l
l
. . .J
Page 2 of 4 l
. NOE 1.30 Rev. $ !
10/l1/96 1.0. PURPOSE :
Describe the labeling requirements and give general direction for use of exposure devices. '
' 2.0. TYPES OF DEVICES [
2.1. Specific exposure devices for which NDE is licensed to use are detailed in the State of Florida Radioactive Materials Licenses issued to the BOC. A copy of ,
the license is maintained in the NDE central fde and is available for review.
2.2. DOC NDE is licensed to use radioisotope radiography exposure devices, :
employing sources ofIridium 192 and Cobalt 60. Specific instructions for use !'
of each type of device is contained in NOE Section 3.0. In addition, LRay machine exposure devices are utilized in accordance with State of Florida Regulations for Radiation Control, and instructions for use are in,NOC Section 2,0.
2.3 Whenever using, performing maintenance or conducting quarterly inventories ,
of sources of radiation be sure to make an entry in the equipment's utilization log identifying the assigned radiographer, location / date of use and the source !
ofradiation.
3.0. RADIATION LEVEL,I,lMITS FOR EXPOSURE DEVICES i 3.1, Radiographic exposure devices that measure less than 4" from the shielded .
source location to any exterior surface shall not have a dose rate greater than 50 mR/hr at 6" from the exterios surface with the source in the shielded or "ofP position. M tridium 192 exposure devices used by NDE fall in this category.
3.2. Radiographic exposure devices or changers measuring greater than 4" from the shielded source location to any exterior surface shall not have a dose rate greater than 200 mR/hr at any exterior surface and 10 mR/hr at 39" from the surface with the source in the shielded or "ofP position. M Cobalt 60 exposure devices used by NDE fall in this category.
4.0. 1,AllEl.ING AND POSTING OF EXPOSURE DEVICES 4.1. Each exposure device containing radioactive material shall have attached a durable, clearly visible label that states at least the following: type of radioactive material contained, (i.e. Ir 192, Co 60), source activity (number of curies), source serial number, date orloading, and manufacturer.
4.2. Each radioisotope exposure device shall, in addition, have a durable, clearly visible label bearing the radiation caution symbol and the words, " Caution Radioactive Material". It shall also have the ID number / " TYPE D " package marked on the exterior and the proper shipping name / number (Radioactive Material, Special Form, n.o.s. UN 2974). The weight (ifless than 110 lbs) 50 kg) should be marked on the exterior surface. ,
4.3. An identification tag shall be securely attached to each exposure device with 4 the company name, address, and telephone number.
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Page 3 of 4 NOR I.30 Rev. 5 10/11/96 .
4.4. Exposure devices shall have a current decay chart and leak test (within 6 months) provided in an attached pouch.
4.5. Each X ray tube and each X ray machine control panel shall bear a durable, clearly visible label with the adiatica caution symbol and the words,
- Caution, this machine produces X rays or rad!ation when energized".
l
'5.0. llSE OF COLLIM ATORS AND SOtIRCE GIIIDE TtfilES .
5.1. Whenever the exposure setup allows, a collirnator shall be used to lirnit the area of the direct radiation beam.
5.2. Specific care should be taken to assure the radiation beam is not directed toward occupied areas, if at all possible, if the direct beam must be directed ,
toward such areas, assure that the area is appropriately restricted using direct '
beam calculations.
' 5.3 Where possible minimize the length of guide tubes employed to reduce open source radiation levels. Rigid guide tubes and combinations of guide tubes exceeding 21'shall be tested by running a dummy source through them prior to using a radioactive source. Each rigid guide tube shall have instructions aflixed to the tube with directions to
- test prior to use" 6.0. SIIRVEY & OPERATING TECilNIOllES m 6.1. Survey Instrument instructions are detailed in NOE 1.60.
6.2. Always observe the Survey Instrument when approaching an exposure device upon termination of exposure. This is the most critical survey to be made.
Never approach the device if the meter needle is pegged. Wait for the reading to stabilize, turn the scale selector " upscale", or press the " reset" button to provide an on scale reading for assessing the radiation levels.
6.3. On crank style exposure devices, only one (1) radiation worker shall approach the exposure device, surve) it and lock it, aller termination of exposure. Then the other individual may appnach the device.
6.4 Whenever transferrmg devices to and fromjobsites ensure a survey of the device is conducted upon arrival at and return from thejobsite to verify the source is properly stored. Surveys of the device for compliance with radiation level limits (3.0) shall be recorded on the DRSR when removing and returning the device to storage.
7.0 DEFECTIVE OR NONCOMPLIANT EOUIPMENT
- 7.1 An equipment daily inspection shall be performed on all exposure devices or source changers / shipping containers and associated equipment prior to first use each shill. The results of the daily inspection shall be recorded on the responsible radiographer's DRSR.
7.2 If a defect is observed, a malfunction or unusual equipment operating function experienced or if excessive radiation levels eminating from the device are detected DO NOT USE Tile EQLilPMENT.
Page 4 of 4 NOE 1.30 Rev, 5 10/11/96 7.3 Secure the equipment ind notify the NDE RSO and Supervisor as soon as possible. An AVO shall be prepared and submitted to the RSO and '
supervision describing the circumstrnces of the defect or noncompliance.
7,4 Suspect equipment shall be tagged out and removed flom senice until the :
RSO authorizes disposition.
7,5 Do not modify or use equipment that has not been authorized by the NDE RSO.
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- Page I of 5 -
NOB 1.40 Rev. 7 1 10/1I/96 Supersedes NOE: 1.40 Rev. 6 11/17/95 i, 11ASE OPERATIONS CONTRACTOR ,
NONDESTitUCTIVE OPERATING & EMERGENCY INSTRUCTION !
DAILY RADIOLOGICAL SURVEY REPORT (DRSR)
(
REVISED 13Y:
6 a b
' R. E. Castlen NDE ARSO APPROVED:
Y Sf M. E. McDaniel Manager: Nondestructive Evaluation NDE RSO f(R. E. Castien a-Ct_
i
- NOTES REVISION 1 l
Page 2 of 5
. NOE I A0 Rev. 7 10/I1/96 1.0. PlfRPOSE Describe the method for recording daily survey, personnel monitoring, utilization and exposure device inspection data on the Daily Radiological Sun ey Report (DRSR).
2.0. GENERAL,
- a. This report serves as documentation for daily radiation surveys, personnel monitoring equipment, dosimetry data, source utilization, equipment inspection, and checklist.
- b. The NDE Radiographer performing or directing the Radiographic setup, exposure and souice retraction, shall complete a DRSR, Parts 1 VI, and sign the report. All NDE radiography personnel assisting the Radiographer shall each prepare a separate DRSR, applicable portions of Part I,11 and 111, and sign their report. N/A shall be entered in all spaces that do not ppply,
- c. This report shall be turned in to th : Operations Supervisor daily.
- d. The Operations supervisor will forward the report to the RSO or his designee.
- c. An example of a " Daily Radiological Survey Report" is attached on Page S.
- f. All data on the report must be legibly entered (i.e. printed) as performed.
- g. NOTE: Anuronrinte portions of Part I. II. Ill, and IV shall be completed -
before leavine the lab. where possible, and prior to commenelne :
radiographie operations.
3.0. COMPI,ETING Tile REPORT 3.l. Part i TechnicinqRalA
- a. The personnel completing this report shall clearly print his/her name, circle his/her appropriate radiography classification (trainee, ast. rad.,
rad XL, rad-G), date, shill, and the operation number The radiographer responsible for an Assistant Technician who is completing a report shall ensure that his name is printed in the " Responsible Radiographer" blank and indicate his classification. Enter "same" when the technician completing this report is the Responsible Radiographer" 3.2. Eart _11 - Survev InElmmenL&lhpmme Device Data
- a. In the survey instrument block, record the model number, serial number, and calibration expiration date, if the instrument is out of enlibration. do not use it. Switch the instrument on, check the batteries and the operation of the instmment (NOE 1.60). If acceptable, enter "ok" in the " operable blank" and
- BAT" blank. This shall be completed prior to checking a device out of storage. Each radiography personnel shall record the information for the survey instrument he/she is using in this section.
- b. In the Source block, insert the source serial number, type of source (e g. Ir-192, Co 60), number of curies, and leak test due date.
Page 3 of 5 .
NOE 1.40 Rev. 7 10/11/96
- c. In the Exposure Device block, record the make, model number, and serial number of the device (includes x ray machines). Next, inspect the device as directed in NOE Sections 2, & 3 as applicable. When utilizing an x-ray machine perform and record required warm up cycle i per the applicable NOE. If the equipment is acceptable for use, insert "ok"in the device blank. lbwngsplablg, "DO NOT USE" and record details in the comments section and notify supervision.
- d. In the Accessory Check Block, record the serial number of the source conduit (s) and the source Drive Assembly. Next inspect the conduit (s) and drive assembly prior to using. If they are acceptable as dermed in the appropriate NOE, insert "nk" in the blanks provided.
- c. In the Device Storage Block, record storage location and the time you
' checked the device out from storage and the time you, returned it to storage.
- f. In the Device Survey Readings Block, record the maximum dose rate indicated by the survey instmment when measuring radiation levels 360 degrees around (4 sides & top) the exposure device at 6" for devices where the sealed source is stored less than 4" from the exterior surface or at "the surface" and at 39 inches for devices where the scaled source is stored a minimum of 4.0" from the exterior surface (Ref.
NOE 1.30). This survey must be taken when removing the device from storage and when returning the device to storage, to assure the source is in the shielded position. The dose rate (mR/hr) should be essentially the same for each survey as the initial survey when removed from storage if no lunch is taken, or task does not fall within the lunch period write N/A in the lunch blanks. If a Lray device is being used, write N/A through this block.
3.3. l'attill. Dosimetry D_ata
- a. Record your TLD badge number and the month ofissut..
- b. When performing radiography and maintenance, an alarming ratemeter (ARM) is required. Record the ARM serial number, calibration due date and results of the mechanical check (press to-test).
- c. Record your 0 200 mR pocket dosimeter serial numbers and calibration due date. Record the initial reading and fmal (shin completion) reading. Initial readings should be zero or slightly above zero, but no more than 5 (never position the hairline before the zero graticule).
- d. In the Previous Total blank record your total dosimeter dose since the beginning of the week;if zero so indicate. This is normally the running total from the previous days report.
e, in the "Today's Exposure" blank, record total dosimeter emosure for the day,
- f. At the end of the shin add the previous total and today's exposure and record in " Running Week Total" blank.
Page 4 of 5
, NOE 1.40 Rev. 7 10/11/96 3.4. hrt IV- Admi31istralits t
- a. Acknowledge use or proper operation of the items listed in Part IV by entering an "X" in the *YES" blank. Enter "X"in the N/A blank where the item does not apply or does not function properly.
3.5. Part V- ArcitSyrysy.mtdjiadidgtaphy_ Location
- a. Indicate the general location of radiography for the shift by completing ,
the " Location" blank as appropriate. Exa.nples would be KSC, Pad !
39A, I th10, VAll, etc.
- b. Indicate in the " Radiography Location Identification" space the location of the actual exposure. An example would be SRI) AFT Skirt, SRht- :
hiht 111.
- c. Under the KV h1A column record KV and hfA settings when using x-ray devices. ,
- d. b!cxt indicate in the "collimator" blank if a collimator was used to directionalize the beam during exposure. Example: Yes or No.
- e. Record the " Number of Exposures" performed at the location described to the left. Example: 14.
- f. Next, record the exposure time in seconds or minutes for each erposure as appropriate. Example: 1.5 minutes
- g. In the " Dose Rate Restricted lloundary" block, record the maximum (highest) and minimum (lowest) dose rate in mrem /hr at the restricted boundary limit. Example 2 mR/hr - 0.5 mR/hr.
- h. In the " Distance to Restricted Iloundary" block, record the minimum (shortest) and maximum (longest) distan:e (in feet) from the source to the restricted area boundary. Example: 20R.,60n.
- i. On the reverse side of this form sketch the Radiography setup showing barrier / sign locations and approximate distances from exposure device to restricted areas for all operations, unless conducted within aa exposure cell, include details of area as deemed appropriate.
3.6. Pmt VI . Natifntion. CertifmalimLand Signature
- a. In the notification section, check the appropriate agencies notified of Radiography operations and the times of notiGcation.
- b. In the block provided, sign and date the report.
- c. This report is :rtified Radiological Record when signed, and as such, it is auditable loi accuracy, completeness, etc.
- d. Recording ofitems on this report before their completion and any other falsification is subject to disciplinary action.
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.! NOE 1.40 Rev. 7 10/11/96 Daily Radiological Survey Report l op .ieo o.t. - su Persarret Congdebtg itse Regoft Classtbaten liggge/AST JtADRAD. XUR AD G l Rescgsgier Re storste Classicatum liggggl6f t -R ACVR AD . XL41 AD_ O Regewt Revow (ty.atwe) (R 60 or Destwe)
Survoy instrJmont Source E8Pesure Dev6ceIA Ray 14schine Modelteo _ Settel ido Model Set 940 Type Senalf40 Cal Esp Dete too of Cue twytoe Ch / WernH4' oserews Dat Leek Test Da Device Survey Reedings (n**t) li Aues.e,y Ch.cn Devi.. .io,e ,. vp e . " .. e.
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&eret ide Tore _ gnVpm Def(re Lurch Drive Assemldy Retwred to Aftet Lwth Seret ido tone enVJan l Tosh tfa$
Conrrent(s)
TLD Dadge No Mordh Prevous 1otal . frH nA l'Inal Iodsy's Fap rnR g Doorreter EA4 Cat Due Date tretmi ne4
[terveter GA4 Cat Due Date Irvt al trA Feel pH Rurrung Wk Total tra ARM Make n Set No ,. _ _ ._. . Cal Due CWe _ _ _ _ Mech Ck _ _ . _ ___
Admsnistrative VES N/A Controls YES N/A Mese. YES N/A 0:eral ng & E nergerv y Prime $ses (TOE s) Sagre Posted Vetecie Ptacerd E nerpenry Responsa Infarnatum Eiheet tierter Rose Esposure Cell Mars 1#armierteten LMeunette4' agers f lastung Ugre Alarm Furrbcmal t rKatum KitC / CCA!i # O*er tudo No Room No 9adog*agti No Resticted itowdefy [nstance 'Ft' lo Locatum of [up mRAW Realnetod ikurtlary identificaten KV M A Collem Esp Time Man Mm Man Min V
E indicate which AgencyContacted and Times DOC Health Phys 6cs Ran e Support IDC ce gq g g Ates Safety Rep.
9474640 9 53 211 Duty Oncer Prot to Jut > Time _ Piet to Jot > Time Prmr to JotsTeve Pror to Jot > Time Upon Cong*len Time Upon Cormleton Tate Upon Completen Tine Upon Comple* ion Time
] , aent m.e en m.m.
Sgrature of Persontvl Conrieting tNs form Date NOTIC5; Allinformation en this report inust t=e completed.
i
Page I of 6 i NOE 3.16 Rev, 4 l 10/11/96 1
Supersedes:
NOE: 3.16 Rev. 3 1 03/31/96 IIASE OPERATIONS CONTRACTOR NONDESTitUCTIVE OPEllATING & EMEl(GENCY I N S T 11 U C T I O N OPERATION AND DAILY h1AINTENANCE INSTRUCTIONS FOR AhiERS!!AhiffECilNICAL OPERATIONS h10 DEL 660 A/B EXPOSURE DEVICE REVISED BY:
( 4 lbl!. Castle'n NDE ARSO APPROVED:
hi. E, hicDaniel hianager: Nondestmetive Evaluation NDE RSO I ct.N 4 R. ETCasIlen NDE ARSO
- NOTES REVISION J
Page 2 of 6 '
NOE 3.16 Rev. 4 l 10/11/96 i 1.0. PilRPOSE To provide instructions for the safe operation of Tech Ops Model 660 A/B gamma exposure device. 4 2.0. GENERAI, 2.1. This device produces ionizing radiation and is potentially dangerous. Only Radiographers or Assistant Radiographers under the direct supervision of a Radiographer may operate this equipment.
2.2. Assure the area is restricted and posted in accordance with NOE 1.70 prior to making any exposures or cranking out the source.
2.3. Assure that all radiography personnel working in the restricted area have two (2) currently calibrated and zeroed pocket dosimeters, a current TLD, and a calibrated alarm rate meter. In addition, all radiography persopnel working in the area will have an operable and currently calibrated survey instrument. At -
least two (2) survey instruments will be avalidle for use at eachjob site.
2.4. Clear the restricted area of all unauthorized personnel prior to initiating operation of the equipment and immediately prior to each exposure.
3.0. DAllN INSPECTION AND CONNECTING INSTRllCTIONS NOTE STEPS 3.1 TilROUGil 3.11 SilOULD IIE COMPLETED llEFORE LEAVING K7-569 3.1. Immediately upon removing the exposure device from storage or returning to storage, make a complete survey of the exposure device to ensure the source is in the shielded position.
3.2. Survey the exposure device from all four sides and top. Record the highest reading obtained 6" from any exterior surface of the device on the Daily Radiological Survey Report. If rn3flatlen level exceeds 50 mR/hr at 6".
secure the device and notify your supervisor immediately.
3.3. The following inspections are to be made cach day prior to the first use of the exposure device and immediately after any incident in which the device may be damaged.
3,4. Inspect the exterior of the device for any visible signs of damage which might impair the operation of the device.
3.5. Inspect the labeling. Verify the device displays a legible Caution Radioactive Material" label and a current source identification tag. All labels must be legible. Verify that there is a current leak test report (within 6 months) and decay chart with the device for the scaled source (reference NOE 1.30).
3.6. Unroll the drive cable and check the drive assembly conduit for sharp kinks and deep cuts or dents that could cauw binding or excessive wear of the drive cable,
Page 3 of 6 NOB 3.16 hev. 4 10/11/96 3.7. Remove the control cable protective cap and crank out approximately 3 feet of drive cable. Check the cable and connector for broken or frayed wires, rust, damage, cuts and resiliency. Protect the connector and drive cable from picking up dht or other contamination. Reinstall the cap and record Nspection results of the drive assembly under " Accessory Check"on the Daily Radiological Survey Report (DRSR).
3.8. Unlock the exposure device and rotate the selector level to the " Connect" position to release the connector cover.
3.9. Inspect the connector for evidence of damage, wear, rust, etc. The spring loaded connector should be examined carefbily to ensure there is no sand or dirt inhibiting the locking action of the con wetor.
3.10. Remove the safety plug nom the source conduit connection point on the device, inspect the source outlet and assure it is round and srpooth and will match the source tube. Check the threaded connector ring for damaged threads and freedom of movement. Reinstall the shipping plug. Record the exposure device inspection results in the provided block on the DRSR.
'3.11. Inspect the source conduit (s), (rigid and flexible guide tubes), for crimps, fraying, obstruction and damaged threads. A " dummy" source or pigtail shall be inserted into the tube and run the full length to assure there are no obstructions or restrictions to source ravel. Verify rigid guide tubes, if used, have clear legible instructions affixed to the tube with directions to
- test the tube prior to use". If the conduit (s)is acceptable record the serial number in the " Accessory Check" area of the DRSR and insert "ok" in the blank provided.
- NOTE Tile EXPOSURE DEVICE IS NORh1 ALLY LIMITED TO A MAXIMUM OF 3 SEVEN FOOT FLEXIBLE SOURCE GUIDE TUDES OR A COhiBINED 21 FEET OF SOURCE CONDUlT WilEN USING A RIGID GUIDE TUBE VERIFY TilAT Tile DRIVE CABLE LENGTil IS ADEQUATE FOR USING Tile RIGID GUIDE TUBE PLUS Tile FLEXIBLE SOURCF CONDUlT(S) AND TilAT Tile TUBES ARE FREE OF OBSTRUCTIONS OR DAMAGE TilAT MlGitT IMPAIR SOURCE TRAVEL. Tills SilALL DE ACCOMPLISilED EllliQJE LEAVING FOR Tile JOB SITE CONNECT Tile DRIVE ASSEMBLY TO Tile TRAINING EXPOSURE DEVICE (WITil DUMMY SOURCE), ATTACil TIIE SOURCE GUIDE TUBES (RIGID AND FLEX 1BLE) TilEN OPERATE Tile EQUIPMENT TO PROPEL Tile SOURCE TIIE FULL LENGTil OF TRAVEL AND BACK. IF ANY PROBLEMS ARE ENCOUNTERED DO NOT USE Tile EQUIPMENT AND NOTIFY YOUR SUPERVISOR.
Pagu 4 of 6 NOE 3.16 Rev 4 10/11/96 3.12. Form a loop with the drive cable assembly so that both the crank handle and the connector are at the rear of the exposure device.
1.13. Slide the :onnector collar on the drive cable back and open the jaws of the connector.
3.14, Connect the drive cable to the pigtail connector by retracting the locking sleeve and inserting the male connector sidways until engaged in the female connector. Release locking sleeve. Verify connection has been properly made by pulling both parts of the connector at right angles to the connection.
3.15. Close the connectorjaws over the pigt:al assembly. Slide the connector collar over the connector jaws. Hold collar flush against the device lock assembly and rotate the selector ring to the " Lock" position. Do not rotate past
" LOCK". Depress the locking plunger to lock the device.
3.16. Verify the source conduit has a cimed end or that a collimatqr is attached to the conduit. If a collimator is being used, verify that the collimator is securely attached to the source wnduit. Remove the safety plug and connect the source conduit to the front of the device.
3.17. During the first exposure of the shift check the lock for ease of operation. The locking plunger should pop up at least 1/2" when the device is unlocked. As the source is propelled through the conduit check to ensure there are no indications that the drive cable is binding or challing.
3.18. If any condition is noted that may impair the operation of the device or any of the accessories, or if there is any doubt that they will operate correctly.
Document the problem on a 3 part AVO, notify your supervisor and the NDF.
RSO, and attach one part of the AVO to the item and return it to storage. DO NOT ATTEMPT TO USE ANY OUESTIONABl.E ITEM. _
4.0. OPERATING INSTRUCTIONS 4.1. Place the storage tip or collimator in the desired location to make the exposure. Inspect the conduit to ensure there are no sharp turns or kinks that would restrict the movement of the source or drive cable.
4.2. Place fiim in the desired position.
4.3. Hold the handle and crank assembly and stretch the control cable in as straight a line as poscible away from the device and position the crank so as to take advantage of distance and available shielding.
- NOTE DO NOT APPLY EXCESSWE FORCE TO THE CONTROL HANDLE IN THE EXPOSED DIRECTION AS Tills COULD CAUSE MOVEMENT OF THE SOURCE FROM THE STORED POSITION WHEN THE LOCK SLIDE IS RELEASED. LIKCWISE, DO 'NOT APPLY FORCE IN THE RETRACT POSITION AS THIS MAY PREVENT THE POSI-LOCK SLIDE BAR FROM RELEASING THE SOURCE LOCKING MECHANISM WHEN POSITIONED TO 2
THE EXi 0SE POSITION (RED).
- . - . - -,- . ..~ . . . . . . -- - .. - _ ._- . , - . . - . - - . - .
" - LPage 5 of 6 :
j
+ ~ NOE 316 Rev. 4
'10/11/96 4.4. With survey instrument in hand unlock the device and rotate the' selector lever -
to_ the " Operate" position. Push the slide bar (green narking) laterally from left - l
'. to right (as seen from behind the projector) until the slide bar red marking fully : i appears on the right side of the selector ring. You should feel or hear.the ;
sleeve snap into the slide.; The source is now free to' expose or retract, 4.5. Verify that no unauthorized personnel have entered the restricted arcai 4.6. - Briskly crank out the source as smoothly as possible, counting the number of--
turns required to reach the fully exposed position. Remember to count the
- number of turns, it can prove useful as an aid in ensuring the source is in fact ;
- fullyin or outi i
4.7. Quickly retreat to a safe distance. To minimize exposure during very short ;
exposures quickly move away from th- device for 1/2 the exposure timeithen .'
quickly return to the crank to retract the source. . ,
4.8. ' Main: in visual surveillance of the entire restricted area during the exposure. *
. Survey the perimeter of the restricted area to ensure that radiation levels at the perimeter are 2 mP/hr or less. Adjust the boundaries as necessary, ,
4.9. After the required exposure time, quickly approach the crankJ . Crank the source in quickly and smoothly, counting the number of turns required to return the source to the " stored" position. Slow the cranking speed for the last half turn. You should hear the slide bar " click" back into the safe position and - :
the gre.en marking on the slide bar should be observed when the source is fully -
retracted. Apply a slight amount of forwnrd pressure as if to expose the source to ensure that the positive locking mechanism has actuated.
e 4.10, Approach the device while . observing your survey instnament. Survey '
completely around the device and the eatire length of the source conduit and cc "mator, if used. The source exit port should be surveyed carefully to ensure F there ere no streaming e8Tects.
4.11. Survey the device to verify similar readings as initially recorded. If the reading is.the same, rotate the. selector ring to the " lock" position and lock the .
exposure device, if not, verify source location.
~
i NOTE-IF IT APPEARS THE SOURCE HAS NOT FULLY RETRACTED, RETURN TO THE CRANK AND ATTEMPT TO RETRACT THE SOURCE COMPLETELY.
REPEAT 4.10 AND 4.11. IF TiiE SURVEY READING STILL DISAGREES
..WITil THE ORIGINAL READIN1, NOTIFY.YOUR SUPERVISOR. DO NOT 1 ATTEMPT TO OPERATE THE DEVICE UNTIL' INSTRUCTED TO DO SO BY THE EG&G NDE RSO. DOCUMENT THE MALFUNCTION ON YOUR DRSR J AND A 3 PART AVO.
9 W
F rr +- , - - v -, e,e -r- n n. m - . d,e r,-.. - ,_
Page 6 of 6 - ,
, NOE 3.16 Rev. 4 10/11/96 4.12. For additiona! exposures requiring the same set up repeat 4.2 through 4.11.
4.13. After the final exposure, conduct a complete survey of the exposure device (four sides and top), source guide tube and collimator to assure the source is properly stored. Rotate the selector ring to the lock position, lock & remove the key.
4.14. - Before moving the device, or returning the device to storage, survey the source conduit, disconnect it from the exposure device, and screw the safety plug into the source exit port. Coil the source conduit loosely without excessive bends and screw the ends together to form a closed loop.
4.15. Form a loop with the control cable by bringing the crank assembly to the device. Unlock the exposure device and rotate the selector lever to the
" Connect" position to release the connector.
4.16. Crank the drive cable out approximately 6" and disconnect the d[ive cable fre -
the pigtail connector by retracting the locking sleeve and retracting the nv connector sideways until disengaged from the female connector.
4.17. Place the connector cover over the connector. While holding the cover -
position, rotate the selector ring to the " lock" position and lock the exposure device. Remove the key from the device. '
4.18. Completely retract the drive cable and install the protective cap over the end of the control cable. Wrap the control cable around the crank frame and secure the end with a piece of rope or cord.
4.19. When conducting operations in the field or at temporary job sites place the device in the shielded storage container provided and lock it. Upon return to storage, survey the exposure device from all four sides and top. Record the highest radiation level detected '" from any exterior surface on the DRSR.
Place the device in storage and L.are the storage vault.
Page 1 of 6
, NOE 3.17 Rev 4 10/11/96 Supersedes:
NOE: 3.17 Rev. 3 03/31/96 IIASE OPERATIONS CONTRACTOR NONDESTRUCTIVE OPERATING & EMERGENCY INSTRUCTION OPERATION AND DAILY MAINTENANCE INSTRUCTIONS FOR AMERSHAM / TECHNICAL i OPERATIONS MODEL 680 A/B EXPOSURE DEVICE REVISED BY:
- 1 d-b1 R. E. Castien NDE ARSO APPROVED:
}Y hY M. E. McDaniel Manager: Nandestructive Evaluation NDE RSO n
?)k nks
' R. E.'C'asilen '
- NOTES REVISION
Page'2 of 6
. NOE 3,17 - Rev. 4 10/11/96 1.0. PURPOSE To provide instructions for the safe operation of Tech Ops Model 680 A/B gamma exposure device.
2.0. GENERAL 2.1. This device produces ionizing radiation and is potentially dangerous. Only Radiegraphers or Assistant Radiographers under the direct supervision of a Radiographer may operate this equipment.
2.2. Assure the area is restricted and posted in accordance with NOE 1.70 prior to making any exposures or cranking out the source.
2.3. Assure that all radiography personnel working in the restricted area have two (2) currently calibrated and zeroed pocket dosimeters, a current TLD, and a calibrated alarm rate meter, in addition, all radiography personnel working in the area will have an operable and currently calibrated survey instrument.- At least two (2) survey instruments will be available for use at each job site.
2.4. Clear the restricted area of all unauthorized personnel prior to initiating operation of the equipment and immediately prior to each exposure.
3.0. DAlfN INSPECTION AND CONNECTING INSTRUCTIONS NOTE STEPS 3.1 TilROUGli 3.11 SIIOULD DE COMPLETED BEFORE LEAVING K7-569.
3.1. Immediately upon removing the device from storage, make a complete survey of the exposure device to ensure the source is in the shielded position.
3.2. The following inspections are to be made each day prior to the first use of the exposure device and immediately after any incident in which the device may be damaged.
3.3. Survey the exposure device at the surface of all four sides and top. Record the highest radiation level obtained from any surface and at 39 inches on the Daily Radiological Survey Report. If radiation levels exceed 200 mR/hr at the surface or 10 mR/hr at 39 inches secure the device and notify your supenisor immediately.
3.4. Inspect the exterior of the device for any visible signs of damage whith might impair the operation of the device. Verify the cart tires are properly inflated.
3.5. Inspect the labeling. Verify the device displays a legible " Caution Radioactive Material" label and a current source identification tag. All labels must be legible. Verify that there is a current leak test report (within 6 months) and decay chart with the device for the sealed source (reference NOE 1.30).
3.6. Unroll the drive cable and check the drive assembly conduit for sharp kinks and deep cuts or dents that could cause binding or excessive wear of the drive cable.
- o- Page 3 of 6 e NOE 3.17- Rev. 4, <
10/11/96
-3.7. ' Remove the contr_ol cable protective cap and crank out approximately 3 feet of-fdrive cable; Check the cable and connector'for b'roken or frayed wires, rust,
~ '
- damage,l cuts _ and resiliency. Protect the connector and drive cable: from picking up dirt or other contamination. Reinstall the protective _ cap.; Record
- inspection results cf the drive assembly under " Accessory Check"on the Daily .t
. Radiological Survey Report (DRSR).-
3.8. Unlock _the exposure device and rotate the selector level to the " Connect" '
position to release the connector cover.
3.9. Inspect the connector for evidence of damage, wear, rusti ete: The spring loaded connector should be examined carefully to ensure there is no sand or dirt inhibiting the locking action of the connector.
3.10. Remove the safety _ plug from the source conduit connection _ point on the _
device, inspect the source outlet and assure it is round and snjooth and will-match the source tube. Check the threaded connector ring for damaged threads and freedom of movement. Reinstall the shipping plug. Record the exposure ;
device impection results in the provided block on the DRSR.
- 3.11. Inspect the source conduit (s),L (rigid and. flexible guide tubes), for crimps, .
- fraying, obstructions,' and damaged threads. A " dummy" source or pigtail shall -!
- be inserted into the tube and run the full length to assure there are no obstructions or restrictions to source travel. Verify rigid guide tubes, if used, ,
. have clear legible instructions aflixed to the tube with directions to " test the tube prior to use"t if the conduit (s) _ is acceptable record the serial number in the " Accessory Check" area of the DRSR r ..d insert "ok" in the blank-provided.
- NOTE
-THE EXPOSURE DEVICE IS NORMALLY LIMITED TO A MAXIMU A OF 3 SEVEN FOOT FLEXIBLE SOURCE GUIDE TUBES OR A COMBINED 21 FEET <
OF SOURCE CONDUlT. WHEN USING A RIGID GUIDE TUBE VERIFY THAT
- THE DRIVE CABLE LENGTli IS ADEQUATE FOR USING THE RIGID GUIDE TUBE AND FLEXIBLE SOURCE CONDUIT (S) AND THAT THE TUBES
~ ARE FREE OF OBSTRUCTIONS OR DAMAGE THAT MIGHT IMP _ AIR SOURCE TRAVEL. Tills SHALL BE ACCOMPLISilED BEFORE LEAVING FOR Tile JOB SITE. CONNECT THE DRIVE ASSEMBLY TO TIIETRAINING EXPOSURE DEVICE (WITH DUMMY-SOURCE), ATTACH THE SOURCE GillDE TUBES (RIGID AND FLEXIBLE), THEN OPERATE Tile EQUIPMENT TO PROPEL THE SOURCE THE FULL LENGTH OF TRAVEL AND BACK.1F ANY PROBLEMS ARE ENCOUNTERED DO NOT USE THE EQlPMENT AND
, ; NOTIFY YOUR SUPERVISOR. ,
3.12. Form a loop-with the drive cable assembly so that both the crank handle and -
the connector are at the rear of the exposure device. . i r-,, N ,. ~
< , - + < -. e ~s - --,.n, ,. ,--.-e--,,,, . ~,---,-nv e a JA -~v
Page 4 of 6 NOE 3.17 Rev. 4 10/11/96 3.13, Slide the connector collar on the drive cable back and open the jaws of the connector.
3.14. Connect the drive cable to the pigtail connector by retracting the locking sleeve and inserting the_ male connector sideways until engaged in the female connector, Release locking sleeve. Verify connection has been properly made by pulling both parts of the connector at right angles to the connection.
3.15. Close the connector jaws over the pigtail assembly. Slide the connector collar over the connector jaws. Hold collar flush against the device lock assembly and rotate the selector ring to the " Lock" position. Do not rotate past
" LOCK", Depress the locking plunger to lock the device.
3.16. Verify the source conduit has a closed end or that a collimator is attached to the conduit. If a collimator is being used, verify that the collimator is securely attached to the source condttit. Remove the safety plug and connect the source conduit to the front of the device.
3.17. During the first exposure of the shift check the lock for case of operation. The locking plunger should pop up at least 1/2" when the device is unlocked. As the source is propelled through the conduit, check to assure there are no indications of the drive cable binding or chafling.
3.18. If any condition is noted that may impair the operation of the device or any of the accessories, or if there is any doubt that they will operate correctly.
Document the problem on a 3 part AVO, notify your supervisor, and attach one part of the AVO to the item and return it to storage. DO NOT A' ITEM PT TO IISE ANY OUESTIONAiEE ITEM, _
4.0. OPERATING INSTRIICTIONS 4.1. Place the storage tip or collimator in the desired location to make the exposure. Inspec' the conduit to ensure there are no sharp turns or kinks that would restrict the movement of the source or drive cable.
4.2. Place fdm in the desired position.
4.3. Ilold the handle and crank assembly and stretch the control cable in as straight a line as possible away from the device and position the crank so as to take advantage of distance and available shielding.
aNOTE DO NOT APPLY EXCESSIVE lORCE TO TIIE CONTROL HANDLE IN Tile EXPOSED DIRECTION AS Tills COULD CAUSE MOVEMENT OF THE SOURCE FROM Tile STORED POSITION WilEN THE LOCK SLIDE IS RELEASED. LIKEWISE, DO NOT APPLY FORCE IN THE RETRACT POSITION AS THIS MAY PREVENT THE POSI-LOCK SLIDE DAR FROM RELEASING THE SOURCE LOCKING MECHANISM WHEN POSITIONED TO THE EXPOSE POSITION (RED)
Page 5 of 6 NOE 3.17 Rev. 4 10/11/96 4.4. With survey instrument in hand unlock the device and rotate the selector lever to the " Operate" position. Push the slide bar (green marking) laterally from len to right (as seen from behind the projector) until the slide bar red marking fully appears on the right side of the selector ring. You should feel or hear the sleeve snap into the slide. The source is now free to expose or retract.
4.5. Verify that no unauthorized personnel have entered the restricted area.
4.6. Briskly crank out the source as smoothly as possible, counting the number of turns required to reach the fully exposed position. Remember to count the number of turns, it can prove useful as an aid in ensuring the source is in fact fully in or out.
4.7. Quickly retreat to a safe distance. To minimize exposure during very short exposures quickly move away from the device for 1/2 the exposure time, then quickly return to the crank to retract the scarce. ,
4.8. Maintain visual surveillance of the entire restricted area during the exposure.
Survey the perimeter of the restricted area to ensure that radiation levels at the perimeter are 2 mR/hr or less. Adjust the boundaries as necessary.
4.9 Aner the required exposure time, quickly approach the crank. Crank the source in quickly and smoothly, counting the number of turns required to return the source to the " stored" position. Slow the cranking speed for the last half turn. You should hear the slide bar " click" back into the safe position and the green marking on the slide bar should be observed when the source is fully retracted. Apply a slight amount of forward pressure as if to expose the source to ensure that the positive locking mechanism has actuated.
4.10. Approach the device while observing your survey instmment. Survey completely around the device and the entire length of the source conduit and collimator, if used. The source exit port should be surveyed carefully to ensure there are no streaming effects.
4.11. Survey the device to verify similar readings as initially recorded. If the reading is the same, rotate the selecear ring to the " lock" position and lock the exposure device, if not, verify source location.
NOTE IF IT APPEARS Tile SOURCE IIAS NOT FULLY RETRACTED, RETURN TO TIIE CRANK AND ATTEMPT TO RETRACT THE SOURCE COMPLETELY.
REPEAT 4.10 AND 4.11. 11' THE SURVEY READING STILL DISAGREES WITil Tile ORIGINAL READING, NOTIFY YOUR SUPERVISOR. DO NOT ATTEMPT TO OPERATE TiiE QEVICE UNTIL INSTRUCTED TO DO SO BY THE IlOC NDE RSO. DOCUMENT THE MALFUNCTION ON YOUR DRSR AND A 3 PART AVO.
4.12. For additional exposures requiring the same set up repeat 4.2 through 4.11.
- Page 6 of 6 NOE 3,17 Rev. 4 10/11/96 4.13. Aller the final exposure, conduct a complete survey ( all four sides & top) of the exposure device, source guide tube and collimator (if used). Rotate the selector ring to the lock position, depress lock and remove the key.
4.14. Before moving the device, or returning the device to storage, survey the source conduit, disconnect it from the exposure device, and screw the safety plug into the source exit port. Coil the source conduit loosely without excessive bends and screw the ends together to form a closed loop.
4.15. Form a loop with the control cable by bringing the crank assembly to the device. Unlock the exposure device and rotate the selector lever to the
" Connect" position to release the connector.
4.16. Crank the drive cable out approximately 6" and disconnect the . rive cable from the pigtail connector by retracting the locking sleeve and retracting the male connector sideways until disengaged from the female connector.,
4.17. Place the connector cover over the connector. While holding the cover in position, rotate the selector ring to the " lock" position and lock the exposure device. Remove the key from the device.
4.18. Completely retract the drive cable and install the protective cap over the end of the control cable. Wrap the control cable around the crank frame and secure the end with a piece of rope or cord.
1.19. When conducting operations in the field or at temporary job sites place the device in an authorized storage area or shield the container as necessary until it can be returned to the permanent storage facility. Upon return to storage, survey the exposure device from all four sides and top. Record the highest radiation level detected from any surface and at 39" on the DRSR. Place the device in storage and secure the storage vault,
T o Page 1 of 4 l
NOE 3.30 Rev. 5 10/11/96
. rsedes:
M- 3.30 Rev. 4 03/3 36 IIASE OPERATIONS CONTRACTOR NONDESTitUCTIVE OPERATING & EMERGENCY INSTRUCTION QUARTERLY MAINTENANCE INSPECTION FOR THE AMERSilAM TECilNICAL OPERATIONS (A.T.0) MODEL ,
660 A/B AND 680 A/D EXPOSURE DEVICES REVISED BY:
} Ei ,
' R. E. Castleri~
NDE ARSC APPROVED:
M. E. McDaniel Manager: Nondestructive Evaluation NDE RSO
), i% ~
' NOTES REVISION I
i
. Page 2 of 4
-n NOE 3.30 Rev. 5
'10/11/96 ~ q 1.0. PURPOSE _
i Detail the Quarterly inspection and Maintenance to be performed on the A.T.O.
Model 663A & 660B and Model 680A & 6808 exposure devices. ,
- 2. 0. . INSPECTION & MAINTENANCC '
2.1.- Visually inspect the exterior of the exposure device for visible signs of damage i.e., dents, cracks, etcc Evaluate all such indications, determine if they effect :
~ operations of the device and record this data.
NDlE PERFORM - ALL MAINTENANCE . WITH THE SOURCE IN THE LOCKED / SHIELDED CONDITION UNLESS OTHERWISE SPECl[ LED IN THIS .
' INSTRUCTION.
2.2. . Survey the exposure device from all sides and top. Record the highest survey :
readings obtained at the surface, at 6" and at 39" from the surface. The survey readings should be relatively consistent with the previous Quarterly survey for this device. This inspection is to assure the shield has not shifled or developed a crack that could produce " streaming" (refer to NOE 1.30). ,
2.3. Inspect all labeling, including manufacturers label and caution Radioactive Material Labd. If the labels are not easily readable and clean, replace or clean to assure they are readable (refer to NOE 1.30).
2.4. Visually inspect the device for loose or missing hardware such as bolts, screws, or fasteners. Tighten or replace as applicable.
2.5. Inspect the key and lock plunger, if the. key is bent, replace it. Unlock the plunger. It should pop up in a smooth and quick motion, a minimum of 1/2".
Wipe the plunger area and apply a light coating of WD-40 or lubricating oil.
2.6. Rotate the selector lever to -the connect position checking for smooth operation. Store the protective cover to prevent loss or damage.
.2.7. Visually inspect the pigtail connector for evidence of damage, corrosion and
. dirt. Test proper operation of the spring actuated lock pin. Use the ATO model 550 connector "CO-NO-GO" guage to check the pigtail for excessive wear.
2.8. Replace protective cover Rotate selector lever to the lock position, depress I:ey lock and remove the key.
2.9. Remove safety plug from sourct exit fitting. Assure. screw on connector t
rotates freely and there is no evidence of galling. .
2.10. Exaniine exit port for concentricity of source tube with nut. Mis-alignment indicates a damaged housing or shilling of shielding. If mis-alignment is found, do not attempt repir; notify RSO.- If no discrepancies are found,- replace
- safety plug.
Page 3 of 4 NOE 3.30 Rev. 5 10/1I/96 2.11. Inspect the drive assembly conduit for kinks, cuts or dents. Crank the cable through the conduit. If any binding occurs determine the location and if it cannot be freed replace the drive cable and/or conduit as applicable. Examine end fittings for tightness.
2.12. Use the Technical Operations Model 550 Connector "GO-NO GO" Gage to check the drive cable connector for excessive wear.
2.13. Crank the drive cable into a series orloops (~30 cm diameter) and tie together.
Inspect the entire length for rust and brittle spots while forming the loops.. If any secticn of the drive cable cannot be flexed through 90 degrees and pop back the.. the temper of the cable has been lost and has the potential for snapping. Replace if this occurs. Clean the device cable with mineral spirits and a stifT brush as necessary to remove dirt, foreign material and/or " caked" lubricant. ,
NOTE TIIE LAST 3 FEET IN Tile VICINITY OF Tile FEMALE CONNECTOR IS MOST CRITICAL.
IF Tile CABLE IS OTilERWISE ACCEPTABLE, WIPE IT CLEAN WITil A LINT-FREE CLOTil AND APPLY A LIGilT COAT OF GREASE - MIL-G-23827 B OR EQUlVALENT.
2.14. Inspect the crank assembly for slippage and " play
- If excessive play exists replace bushing and/or gear assembly s appropriate when disassembling.
Disassemble the telellex gear housing, inspect and clean all components, and lubricate with light machine oil or a light coat of grease. Rinse inside of cable housing with small amounts of mineral spirits and blow dry with GN2 -
2.15. Reassemble crank assembly, insert drive cable in conduit and inspect crank assembly for proper operation.
- 2.16. Inspect the source conduit (s) for kinks, frays, crushing or other damage that could restrict travel or jam a source. Examine the threaded connectors for burrs, gaulding and dirt. Clean the connector and conduit internal passageway with mineral spirits and dry with compressed air. Test the guide tube by dropping a " dummy source" through the tube to insure freedom of movement.
If the conduit will not allow the " dummy source" to pass through, scrap and replace with new source conduit. Verify rigid source conduits have instructions aflixed to the tube with Cections to " test tube prior to use" 3.0. REASSEMHIN & CIIECKOUT 3.1. Aner all maintenance inspections, lubrication and replacement of worn parts is completed, perform an operational check.
3.2. Connect the exposure device and accessories and set up as if you were to make an exposure in accordance with operating instructions and restricted area requirements.
Page 4 of 4
-. NOE 3.30 Rev. 5 10/11/96-3.3. Unlock -the device and cycle it through at least three (3) expose / shield
- sequences.; Assure operation is smooth and all components are working as
' required; Correct noted discrepancies as applicable.
3.4 - Check the ATO 680B mobile cart tires for proper inflation, signs of excessive wear or damage. Service as required.
4.0. DOCUMENTATION & APPROVAL 4.1. Document the quarterly exposure device inspection on- the Quarterly -
Inspection Report and complete a DRSR.
4.2. Note acceptance and/or discrepant conditions and submit to the RSO for concurrence / approval.
4.3. This report shall be maintained in the NDE central equipment maintenance file.
t 9
1
-.g % g , r - -
"w
'," Page 1 of 5
+w' NOE 3.40 Rev.1
. 10/11/96 Supersedes:
NOE: 3.40 Rev. 0 04/30/96 BASE OPERATIONS CONTRACTOR NONDESTRUCTIVE OPERATING & EMERGENCY INSTRUCTION DESIGN, FABluCATION, AND OPERATION OF GAMMA RIGID SOURCE GUIDE TUBE / STOPS PREPARED BY:
{
R. E. Castien NDE ARSO APPROVED:
M. E. McDanTel Manager: Nondestructive Evaluation NDE RSO I M '
- NOTES REVISION
- _-in m ,af :$.. @ p_ sp.u- - % l Page 2 of 5
," - NOE 3.40 Rev. I 10/1I/96 1.0 : PURPOSE L To provide instmctions for the design, fabrication and operation _of rigid source guide tubes / source stops for use with the Amersham Models 660A/B and 680A/B exposure.
device systems in conducting gamma radiography.
2.0 GENERAL
- 2.1 Requirements Fabrications shall comply with and meet or exceed the minimum requirements i
of the following regulations and specifications where applicable:
- a. USNRC Title 10 CFR 34.20
- b. FAC 10D 91.5031
- c. ANS! N432-1980 ,
- d. KSC-SPEC-Z-0003 -
- e. KSC-SPEC-Z-0020
- f. AWS Dl.1
- g. ASME B31.1 h' SPC-BOC Welding Manual 2.2 Alternate mechanical tests have been substituted in lieu of the system tests ;
psescribed by ANSI N432-1980.
2.3 Welding equipment shall be capable of providing consistent and repeatable operating characteristics in accordance with the limitation of essential variables and general workmanship practices specified in the Kennedy Space Center SPC-BOC Welding Manual, Section 7.3.1.
3.0 - DESIGN 3.1 Materials _
- a. All materials shall be 300 series CRES or from a compatible materials group.
- b. Tubing material shall be .500" OD x 0.050" wall (.400"+/-0.015" minimum ID).
- c. The tube "end stop" shall be made from a 2.750" long. 375"-16NC bolt, stud or threaded bar stock,
- d. The flexible source guide tube connector shall be a machined fitting with a .400" ID and the tube end counterbored to accept the .500" tubing. The counterbored end shall have a 0.060" wall, minimum.
3.2 Preparation
- a. All components shall be inspected for damage, obstructions and concentricity prior to fit-up for welding.
- b. Joint fit-up for welding shall be such that the ids exhibit minimal mismatch and where necessary shall be ground to ensure smooth source travel.
- c. Weld joints shall be cleaned to remove dirt, dust, contaminates and foreign material immediately prior to welding. 1
- _ . . . .. . . - ~ .
. Pcge 3 of 5 NOE 3.40 _ Rev.1
. 10/11/96 ,
3.3 Joining Process
- a. Fabrications shall be assembled for nd welded utilizing the GTAW process as specified in the SPC-DOC Welding Manual, WPS 8.3.1.
- b. Welding operators' current Performance Qualification status shall be -
verified -
- c. The assembly shall be configured for and welded per Figure 1. ,
S 4.0 - TESTS AND INSPECTION 4.1 Visual a.- All welded joints shall be inspected to ensure there are no indications of cracks, tack of fusion, porosity open to the surface or insumcient weld build-up.
- b. The ID shall be inspected to verify there are no indicatiops of burn through or weid penetration through the tube wall,
- c. The "end stop" shall be measured to ensure suflicient insertion (N.L.T.
.750").
4.2 Nondestructive Evaluation
- a. Visible dye penetrant NDE shall be perfctmed of the weld joints and adjacent areas for cracks and fusion indications. All relevant indications shall be repaired and re-examined 4.3 Destructive Testing
- a. Prototype fabrications shall have iwo (2) tensile specimens prepared and tested that exemplify production weld joints.
- b. Tensile test results shall meet or exceed the minimum tensile strength of the material being tested and shall not er.hibit ultimate failure in the weld joint.
5.0 . OPERATION 5.1 Daily inspectior,
- a. A visualinspection shall be performed each shift prior to use for evidence of damage, dents, obstructions or other conditions which
, might impair safe use.
- b. Verify the rigid source tube / stop ID tag is intact (should be a RST 2XX series). The tube shall have clear, legible instructions aflixed by tag or label with directions to " test prior to use",
- c. Verify the control drive cable is of adequate length for the specific rigid source tube / stop to be used.
c NOTE AN INERT (DUMMY) SOURCE AND TRAINING DEVICE SHALL DE UTILIZED FOR PRE-OPERATIONAL TESTS, 4
-g w -- ,. __
_ _ ._ __. _ _, ~. _ . _ _ . _ _. -
f*
- Page 4 of 5 -
4 NOE 3.40 Rev. I 10/11/96 )
-5.2' Functional Operation .
- a. Remove the covers of the rigid and flexible source guide tubes.'
- b. - Assemble the training device, drive cable and flexible source guide tube. Fasten the flexible source guide tube to the threaded connector
- on the rigid guide tube / stop. . _ .
- c. During transfer of the source through the guide tubes verify smooth ;
operation and that no excessive resistance is encountered when moving '
the source in or out of the full length of the tubes. - If difficulty is ,
encountered, return the source to the fully shielded position, 3
~
disassemble and secure the device. Notify the supervisor and NDE RSO of problems encountered DO NOT USE FAULTY -
EQUIPMENT.
f 6.0 DOCUMENTATION 6.1_ - New fabrications shall be identified by a unique serial _ number, tagged and -
documentation archived in the equipment maintenance file.
6.2 The NOW network equipment maintenance program shall be updated to incorporate the new equipment.
FIGURE 1 i
4 9
I
1 Page 5 of 5 NOE- 3.40 Rev. I-
,: 10/11/96
( f f /
/ 5 } } }
e O rs e- '
20" j 7 p
--oj . ... .. h,p .. ... ...... . .............. ......
w.. v. 7...... ,,,,,.,,,,,,,
g;,,.... ... .
c... ... ........................ ........ ,
p...... i,nm o , m ,s LL.r\ d- ,1l h h \3/816NC
\ h tb# - 0 5" CD s 0 05" WALL 300 SERIESSTAINLESS TUBE 4
0 05 ' BOLT i
27 SOURCE TUBE STOP S/N RST.203 lEG40 FLORIDA. KEtMDY SPACE CENTER l 26hJUN 1:1 95 l l i
e
- {;i ; e; IApril 12,' 1996
LState of Florida Department of Health and -
ty Rehabilitative Services 1317 Winewood Boulevard -
- Tallahassee, Florida 32399-0700
- AttnL Mr. Walter Cofer, PIIP 111. HSERM '
CONCURRENCE TO UTILIZE FABRICATED GAMM A SOURCE GUIDE TUDE / STOP ,
REFRS: 'l)'10D-91.5031. F. A C. " State of Florida Control of Radiation Hazard Regulations"
- 2) ll lFR 34.20 "USNRC Rules and Regulations" EG&G Florida, Inc. requests concurrence to use rigid source guide tubes / stops designed and --
manufactured in accordance with the attached design package when conducting isotope radiography under license number 12191. The equipment design, mechanical tests and functional use demonstrate compliance with 10D-91.5031/10CFR 34.20 and the requirements of the referenced specification, ANSI N432-1980.-
EG&G Florida, Inc., as the Base Operations Contractor to the National Aeronautics imd Space Administration (NASA), has the responsibility of providing radiography support in the evaluation of flight hardware and critical ground support equipment at the Kennedy Space Center and the
' Cape Canaveral Air Station. The performance of mission critical tasks are ollen dependent upon providing timely nondestruedve evaluation (NDE) support, such as radiography. In a time where safety, quality and productivity we all absolutely essential in the continued existence of the nation's space program, it is imperative we do everything in our power to maintain the highest of standards.
- It is with this in mind tiiat EG&G requests an expeditious review and response to the stated request.' Delays or failure to respond in a timely manner will place EG&G Florida, Inc. and
. NASA in a position of considering options that will result in significant increases in program
" costs, reductions in product quality, pose poteatial impacts to mission milestones and subject
- radiography personnel to unnecessary radiation exposure.
/ .
I o
b
i o '. -
As an example; pressure vessel radiography initially conducted with a rigid guide tube / stop, utilized a centerlined,80 curie, Ir 192 source. The same vessel without the use of a rigid source guide tube / stop would now have to employ a 65 curie Co 60 source placed on the outside of the vessel. The Co 60 technique would increase the distance to the restricted area perimeter approximately fourfold (with a collimator), each exposure increases from filleen (15) minutes to one hundred (100) minutes, and each weld joint would now require seven (7) exposures vs. one (1) exposure. The increase in the restricted area would require an additional person to safely monitor the area. The increase in duration and number of exposures would result in expending about 4500 man hours for twelve (12) vessels, where otherwise, the same work could be accomplished with less than 400 man hours. Radiographers would be subjected to seven (7) times the number of exposures as required when using a centerlined source and the levels of radiation would be much higher. The pressure vessel radiography example is not hypothetical. It is real and a current NDE backlog.
Although revie'w of 10D-91, F.A.C., does not reveal a requirement to submit documentation for approval of associated equipment prior to use, in view of the emphasis placed on the subject by the USNRC (IN 95-58) and their direction, it is believed to be advisable. EG&G Florida, Inc.
would appreciate your immediate attention to the request for concurrence to continue use of the subject equipment. If possible, verbal consent or acknowledgment would be desired to convey interim agreement to continue to use the equipment.
if there are any questions concerning the above, please contact the undersigned at (407) 867-2025 or R.E. Nickell at (407) 867-3540.
Paul V. Ilumbert, ht.D.
Chairman, EG&G Florida, Inc.
Radiation Protection Committee REC: Attachments als cc: hl.E.hicDaniel G.ht.htarmato Lt. Col. Scott R.K hfartin
l' d EdnG INTEROFFICE CORRESPONDENCE EasorLomDA,We.
00C 321 KENNIDY SPACE CENTER, FL 32899 PHONE: 1407) 8615158 FAX: 1407) 861-8163 oun Apiil 12,1996 o Radiation Protection Conunittee R.E.Castlen, EGG-C210/BOC-321[ k svover: RADIOGRAllPilY EQUIPMENT ENGINEERING ANALYSIS EG&G Nondestmetive Evaluation (NDE) has conducted a review of"in house" manufactured rigid source guide tube / end stop equipment designed for operation with Amersham ganuna radiography exposure device systems, models ATO 660A/B and ATO 680 A/B. The review or engineering analysis was conducted to assess the equipment design and function for compliance to requirements speciDed by the USNRC (10 CFR 34.20) and the FSDilRS (FAC 10D-91.5031), in each case, the regulations refer to compliance with the provisions contained in ANSI N432-1980, " Radiological Safety for the Design and Construction of Apparatus for Gamma Radiography" The purpose and function of the cigid source guide tube / end stop is to provide a means for containing and positioning the radioactive source pigtail and drise cable assembly at a predetermined distance within a pressure v:ssel. When attached to a Hexible source guide tube, the rigid source tube can be inserted through narrow apertures and supported in the pr,:ssure vessel to accommodate panoramic radiography techniques. The application of panoramic radiography techniques facilitates the use oflower energy radiation sources, shorter exposure times, less exposures and reduced radiation levels outside the vessel. This technique promotes ALARA principals for personnel t.xposure and provides an increased measure of safety by eliminating the need for heavy collimators and several Dexible source guide tubes. Ileavy collimators have been the cause of many radiography incidents reported in the Nuclear Licensing Reports prepared by the USNRC and Agreement States.
Although, .he use of a rigid source tube involves guiding the source to a predetermined point, the primary function of the tube is source containment and end stop. The design, materials and ftmetion of the equipment would more likely dictate it bc tienned as an exposure head or end cap rather than a guide tube. EG&G NDE believes the intent of the regula: ions for kinking and crushing tests specified for source guide tubes was for Ocxible tubes not rigid tubes. T he design, materials, and fabrication process employed by EG&G in the production of rigid source tubr.s would indicate that ANSI kinking tests are not applicable and the crushing test to simula'e the force applied by the heel of a walking man would not result in tubing deformation. Therefore, EG&G NDE believed the tr.nsile test for exposure heads or end caps specified by the regulations would be the more ap9ropriate method for evaluating rigid source tube integrity.
use mw a a mav m enevous eonoss ws cesant
Several methods and parameters are addressed in ANSI N432-1980 (8.7) for control unit tensile tests. Ilowever, the maximum applied force is one thousand Newton (1000 N) for ten (10) seconds. The force applied appears to simulate that of a man pulling against the control cable while the opposite end is secured. Rather than incur the expense of obtaining special fixtures and instrumentation for conducting similar tension tests, EG&G clected to utilize equipment available at the NASA KSC hiaterials Science Department. Tensile spucimens simulating the rigid source tube design, materials and fabrication process were subjected to tension loads until failure. The result of the tests far exceeded the minimum reqcirements stated previously. Ultimate failure of the specimens occurred in the parent metal under load exceeding a force of twentyfive thousand Newton (25,000 r4 The procedures for fabricating rigid source guide tubes, NOE 3.40, and excerpts from the KSC SPC-DOC Welding hianual for procedure qualifications specific to the design joints are enclosed, along with the tensile test results for review.
!!ased on the testing information addressed and the fact that utilization of similar fabricated rigid source tubes at KSC have resulted in in pmve<1 safety with radiography operations, EG&G NDE submits that the requirements set forth in the USNRC and FSDilRS regulations for such equipment has been complied with.
cc: h1.E.htcDaniel l
I 1
l' age 1 of 4 NOE 3.40 Rev. 0 -
04/30/96 Supersedes:
-NOE: N/A Rev. N/A N/A
'llASE OPERATIONS CONTRACTOR NONDESTitUCTIVE OPEllATING & EMEltGENCY I N S T 11 U C T I O N DESIGN, FADRICATION, AND OPERATION OF GAMMA RIGID SOURCE GUIDE TUDE/ STOPS PREPARED BY:
-- j. I R. FCasilen NDE ARSO APPROVED:
/Y Y M. E. McDaniel Manager: Nondestructive Evaluation NDE RSO 7 1 I{. ICastlen '
- NOTES REVISION i l
l l.
i l
1
Page 2 of 4 NOE 3.40 Rev. 0 04/30/96 1.0 PUltPOSE To provide instructions for the design, fabrication and operation of rigid source guide tubes / source stops for use with the Amersham Models 660A/B and 680A/D exposure device systems in conducting ganuna radiography.
2.0 GENERAL, 2.1 Requirements Fabrications shall comply with and meet or exceed the minimum requirements of the following regulations and specifications where applicable:
, a. USNRC Title 10 CFR 34.20
- b. FAC 10D 91.5031
- c. ANSI N432-1980 ,
- d. KSC-SPEC-Z-0003
- c. KSC-SPEC Z-0020
- f. AWS Dl.1
- g. ASME B31.1
- h. SPC-DOC Welding Manual 2.2 Alternate meclianical tests have been substituted in lieu of the system tests prescribed by ANSI N432-1980.
2.3 Welding equipment shall be capable of providing consistent and repeatable operating characteristics in accordance with the limitation of essential variables and general workmanship practices specified in the Kennedy Space Center SPC-DOC Welding Manual, Section 7.3.1.
3.0 DESIGN 3.1 Materials
- a. All materials shall be 300 series CRES or from a compatible materials group.
- b. Tubing material shall be .500" OD x 0.050" wall (.400"+/-0.015" minimum ID).
- c. The tube "end stop" shall be made from a 2.750" long, .375"-16NC bolt, stud or threaded bar stock.
- d. The flexible source guide tube connector shall be a machined fitting with a .400" ID and the tube end counterbored to accept the .500" tubing. The counterbored end shall have a 0.060" wall, minimum.
3.2 Preparation
- a. All components shall be inspected for damage, obstructions and concentricity prior to fit-up for welding.
- b. Joint fit-up for welding shall be such that the ids exhibit minimal mismatch and where necessary shall be ground to ensure smooth source travel.
. c. Weld joints shall be cleaned to remove dirt, dust, contaminates and foreign material immediately prior to welding.
.t
'fr > Page 3 of 4: ,i NOE 3.40 L Rev c 0
- I 04/30/96- .
i 3.3 ---Joining Process as . Fabrications shall be assembled for and welded utilizing the GTAW - - -
_ process as specified in_ the SPC DOC Welding Manual, WPS 8.3.1,
_ b, _ ; Welding operators' current Perfonnance Qualification status shall be ;
verified, e
- c. . The assembly shall be configured for and welded per Figure 1. - -3 J 4.0.- TESTS AND INSPECI'lOh[
i 4.1 - Visual
- a. All welded ioints shall be inspected to ensure there are no indications of ,
,__ 3 racks, laclh of fusion, porosity open to the. surface or insutTecient weld build-up.
a
- b. . The ID shall be inspected to verify there are no indications of burn through or weld penetration through the tube wall.
^ '
- c. The "end stop" shall be measured to ensure sumcient insertion'(N.L.T.
,750").
4.2 Nondestructive Evaluation
- a. Visible dye penetrant NDE shall be perfornied of the weld joints rad adjacent areas for cracks and fusion indications. All televant indications shatt be repaired and re-examined.
4.3 Destructive Testing
- a. Prototype fabrications shall have two (2) tensile specimens prepared
. and tested that exemplify production weld joints.
- b. Tensile test results shall meet or exceed the minimum tensile strength of the material being tested and shall not exhibit ultimate failure in the wcld joint.
. 5.0 OPERATION 5.1 Daily inspection t
- a. A visual inspection shall be performed each shill prior io use for evidence of damage, dents, obstructions or other conditions which might impair safe use,
- b. Verify the rigid source tube / stop ID tag is intact (should be a RST 2XX series).
- c. Verify the control drive cable is of adequate length for the specific rigid, source tube / stop to be used.
NOTE
- AN INERT (DUMMY) SOURCE AND TRAINING DEVICE SilALL DE UTILIZED FOR INITI AL OPERATIONAL TESTS.
8 .
Y
, , , . , - - ~ . . _,_ . . . . _ . . _ - - _ _ , . _,-_._ _ _ _ _ _ _
.=. . . . . .. . .-- .. . . . . . . -- - . -
Page 4 of 4-
.. NOE 3.40 Rev. 0 ,
04/30/96- ,
. 5.2 -- . Functiorial Operatioi; _
3 Remove the covers of the rigid and flexible source guide tubes.
- b. Fasten the flexible source guide tube to the threaded connector on the <
rigid guide tube / stopl .
- c. During transfer of the' source through the guide tubes verify smooth =
operation and that no excessive resistance is encountered when nieving .
the source in or out of the full length of the tubes, if dilliculty is .;
encountered, return the source to the fully shielded position, '
disassemble and secure the device. Notify the supervisor and NDE RSO of problems encountered. ' DO NOT USE FAULTY
,, EQUIPMENT. .
6.0 RQCUMENTATION .
6.1 New fabrications shall be identified by a unique serial number, tagged and-
- documentation archived in the equipment maintenance file.
6.2 The NOW network equipment maintenance program shall be updated to . ,
incorporate the new equipment.
FIGURE 1
/ 2r ', ', ,
' 0 75' '- '
2.0" ,
..... .. v...................................-c<=.......
. ...... ..................... ........ y u ...... -
~. d . k- r: _ 3/8-16HC 0 06 V 300 SENE $1 $
O
MATERIALS SCIENCE LABORATORY TASK REQUEST REQUESTER INFORMATION
- 1. IIEQUESTEil 2. CO' APAN Y 3.PHONC 4. Mall CODE J. Arvoson EGSG Florida, Inc. *B61-5131 DOC-321 6.1ECHNICAL CON I ACI 4. PilONE f. MAIL CODE 8. COMPANY R. Castion 861-5158 DOC-321 EGSG Florida, Inc.
- 9. DATE SUGMillEU 10. DESinED COMPLEllON DATE 11.1 ESI ODJEC11VE 05/01/95 07/nl/95 2o.ss110 & Clongation MATEnlAL TEST INFORMATION it. WillUAL NAMb 13. MM4UiAC IUHbil CRES 300 Serics Launch Equipment Shop (LES)
Lockheed Martin Manned Spaco Systerns I4. LO I HO. isTUATUitNo. iDAlti No. 'ii~sEiliAD10.
N/A N/A RST-20X ~1 & -2
- 18. SPECIFICAllON 19. UllEMICAL CLASS 20. INIENUEU APPLICAllON KSC-SPEC-0003 N/A Rigid Source Tubc/Stop FOR NHD 0000.1 CERTIFICATION AND ENVIRONMENTAL TESTING
- 21. lEMPERATUllE 22.USE ATMOSPHERE /FLulU 23, USE PRESSURE 24.USE ilflCKf4ESS N/A N/A 1000N N/A
- 26. VEHICLE 28. PHOJEC T 27. PARf Of1 SEntAL No.
N/A Pressuto Vessel RT RST-20X
- 28. SUPPOfli flEQUESIED (Please spedfy test meltwsd. If applicable) .
Ucstructively Test Tension specimen to provido Lcusih attength and parcent of alongation for wolefod members of .500" CRES Tubing to .375 - 16NC bolt.
- 29. nEMARKS Of10PGCIAllNSinUCT IONS Sample Load (lbs) Arca (in#1 Tensile (psi) clongation (%)
M1 6918. 0.0706 97,988 34.6 H2 6735. 0.0706 95,396 25.6 FOR LABORATORY USE ONLY
- 31. l ASK tWMOER 32. Uhl E COMPLE1EU 33. PHIOHil Y Xh INVESilOA10R D. Lowls FAMEll/ NASA 95-2T0248 06/16/95 N/A l
isc roms taillnEv.6wi rtEvivus tmicen A14 0esoLEts i
SPC-BOC WELDING MANUAL.
10 KLD JOINT PROCEDURES & WELDER PERFORMANCE QUAllFICATIONS j) OENERAL PROVISIONS l.1 PYlf0$(
This manual is a guide to the NASA velding specifications and the At3 and ASME velding codes that are to be used by $PC/tES shop and s0C/N40 Shop personnel when velding ground support equipment, systems and structures at X$C.
2.0 121 s This manual contains the tests for quaiification of velding technicians and weld joint procedures asspecifiedinthereferencedsoldingcodesandspecifications. Also included are the individual' qualified veld joint procedures contained in Sectie: 8 that are generated by the corresponding qualification tests in section f.
At$ and ASME Hiding codes referenced by NASA niding specifications require an independent veld jointprocedureforenrysoldjointconfiguration. Also a change in any one of the essential verlables some of which include the velding process, nelding position, material thictness, pipe dianter a.;J base metal specification, requires the qualification of e nes nid joint procedure, this requirement inds to an enormous number of niding technician performance and sold joint pro-cedurequellficationteststhatwouldbeentresslydifficulttoadministerandstatus, insrdertoreducethenumberofveldjointprocedures,-thequalificationtestecontainedinSec-s tion i have bun setup to include the most difficult test configuration, that is, a flied pipe in-M clined at 45 degrees inis configuration qualifies the niding technician and veld joint proce-
%# dures for all velding positions, furthermore, the velding of a 3" schedule 40 and an l' schedule 80 pipe coupon in most cano qualifin the velder and nld joint procedures for virtually all pipe, plate and structural sites and thicknesses ly using this method of testing, approilmately
~
fifty sold joint procedures contained in Section are qualified each time one corresponding uld jointprocedureinSectioniisquellfied, these qualified veld joint procedures include all com-eenly used u ld joint configurations.
3.0 #EFEIENCES Copies of the following solding codes and specifications are essential components of .this manual and are contained in Sections I and 10.
R$0$PECi0002 felding Alusinus Alloy Pipe, Tubing and fittings ISC SPEC 2 0003 relding Austenitic Stainless Steel and lov Espansion Alloy Pip;.
Tubing & Fittings K$CSPEC2-0004 solding Structural carbon Steel, tov Alloy steel, stainless steel &
AluminumAlloys X$C SPEC l-0010 Relding T 1 sad T l irpes A and 8 Structural steels AIS D1.1 90 Structural Steel Belding Code -
AIS08.290 _ Structural Aluminus solding Code At$010.g Qualification of selding Procedures 6 nelders for velding Pipe & Tubing SecticaIX ASNE loller and Pressare Yesul Code, velding Qualifications t
p
.i l ' ;
SPC-BOC wuDNO WANUAl. 1.0 MLD JOINT PROCEDURES er Mt.Dt:R Pr.RFORMANCit QUAuriCATIONS l
fp GEMMAl. PROVISIONS d.0 Lil(11 selders shall h thornshir unledenble of the truntini nd ute prutico esiled for in in-tien it of this senval.
5.0 10pt conip0L PLAN ih procn Ing of docunntatin for gnlification of nid joint procedures ud ulding tuhnicians shell be performed as shown la fisere I.
l.8 91LAllf1CHil!Llululff!1El .
solding procedurn and selders shall be quellfled in accordance with the appropriate gnlificitlen tuts centslud in $ntion i of this anual.
6.1 H t0lp0 ft011E M QvillflC4fl04 telding procedure entification tuts in sution i shall 6e esta6lished for us requireente not e contained in nitting quellfled uld jelnt procedures. the enlillestion test obli h setup in accordance with the applicable solding code er.d specificitlen. the qualification docuentation shallincludethefollevinu 6.6.1 teldineProcedureleecification(IPS)
(.4 J A iri shii is ,re,sred to iniede th , siding ,.r.seien u e6o.n in intin i.x.i.x. . ne ni is a gulds'for the utop and perforesace of the quellficalla test coupon niding.
l.1.1 kgubre QualifictUn fecord (PQR1 A PQt shall prepared to record th actual velding pareseters uplored for velding th's test coupon si sheen in $ntin 1.I.1.I.6. Thecompleted700establishesthequellficationparsutersandis used to generste the corresponding quellfled veld joint procedures contained in section 8.
6.1.3 hallficationtestluord(018)
A qvalification test ruerd shall be prepared to record the results of viini and redlegraph en-aninstion as nll se intractive test reivits 4: shown in section f I.I.X.c.
l.1.4 ItlUttLlulfHin A nidins gnlification tut coupon : shown in section 1.1.I.I.d shall be prepared in accordance with the e,plicable niding codu ud specifications.
'l.l.5 hidine test $ntion hnd and tension test ottien for acid joint procedure qualifications that require destructin tuts shall h proired n thosn in $ntions f.II.I.e of thl sanval.
J
[] SPC-BOC wi1 DING WANUAl-ELD JOINT PROCEDURES er Mt. DER PERFORMAN(M QUAllFICA110N5 1.0 ;
gy GENEMAL PROVISIONS 6.! lRQ:Rtisf0tMANC[QUAllflCAfl0{
Personnel she perfore solding in accordance with the seld joint procedures contained in lection 4 ,
shall be teillfled 6y the successful completion of the corresponding velding precedure test cen-tained in lection f. for esseple, a velder iho performs soldiq of joints contained in section 1.1.1 suit be quellfled by the pesting the sold joint procedure test section I l.l. The perfor- ;
mance quellfication test shall be the same as the sold joint procedure quellfication test. A veldersuitperforssoldingintheprocessforwhichheisqualilledsithinsinmonthstonelattin
. hisqualifiedstates.
6.3 ty8t!flCAfl0N flli IN$ficil0N 6 (VALUAfl0N 6,3.1 Upon the initial set up of a quellf! cation test isld coupon, NASA 0/A and the appropriate $PC 0/1 or IOC Q/A shall buy off the setup and steep the etsy to proceed. block on the IPs as shown in tec-tionI.X.I.I.a.
l.).! for procedure qualif' lenonly, $PC or 600 Gestity Engineering thall witness the velding of the testcoupon.
l.3.3 Duringinitialseldlesofacoupon, $PC or 100 0/A shall record the actual gelding parameters on the PQt and that! ilgn off the on velding ve'lfled r bloct see section i.I.I.I.b.
6.3.4 Uponctopletionofvelding,thecouponshallbesubsittedtoNDIforradicgraphicevolvation, t .
- )9 '
6.3.5 for veld joint procedure qualification only, bend and tension test specisen shall be prepared from the uld coupon in accordance with I.I.I.I.e. specimenaretobesubmittedtotheNatA Meterials l 1estingLabfordestructivetests.
6.3.6 Upon receipt of ray and destructive test results, $PC 0/t or IOC 0/t shall evaluate the test ,
reports and deny or accept qualification by signing off the qualification test record I.I.I.I.c.
Ifaqualificationisdenied,thequalificationpackegeshallbedestroyed, i.4 Ptif0tMANCIQUAllflCAll0NIfficilVllt A v61 der's qualification status la effective for periods of sin months. lenesal of a velder's quilfled status is obtained by the successful performance of the applicable tests contained in lection1.0.
s
, - - - - - ., - ,--n.-- - - - ~ - . , - - , ~,nr-
.. , / .
' '[' SPC-BOC wu2NO MANUAL OuAunCOON EST FOR MLD J084T PftonDUES & WEtMAs 7.3.1
$ TAINT 1SS STEE1,300 SDK5 (CTAW-il0) l f I.3.1.a 91RilAL3).QU1104$_f)Ll!)J191]Ill)L)]tP199_9L))ijnlilULIE1.Um l I this ention providu the tuts for enlillection of velding technician and the sold jelet prece- l
. dern contained la Intion 1.3.1 for en tungsten are solding (stas) of strutersi stainless stol ,
and ,ress.,e ,i,e in suordence ,iti iis fen..ing ,euin, codes and s,ecinnuensi
$teinlest 8t:el fruture Pipe t$C$PICi0003andAll010.9 ;
8tructurel $tsialets steel. t$ClPICl0004andAll01.1 4vellfitellen teste shall be edeleistered in accordance eith the applicable stading codes' end spulficatione listed eben and $ntin 1.0 of this suval, then eut the solding spcification i and e61 ding code are la conflict, the ist niding specification shell* tete pruedence over the Ass 3 veldingcode, f.3.I.6 . tilt}llilty . Prler te perferning the entifiution tute enteind in this actin, the older shall rnies the refereced esiding socifications nt velding coin. l
.- I.3.1.c ,19Hungjf.
[t, the ,,e,erso n, .ste.u,, ,e, sir ,s.iie, associated ,re.eu ud ,est .eu ..ri shan se ,er-i foru d in ucordu n eith R$C SPIC i 000), prographs 3.3 nd 3.4, All01.1,$ntion3,and$n-tionsi.3.1.1and1.3.1.!ofthissenval. 1.3.1.4 1[qgityj , Ovalilitation tut velding shall be performed in accordance eith ElC $PIC l 0003, paragrnh 3.6 andAe801.1,$ntion4. i.3.1.e HAUll((11Q1 Qualification of nld joint prendures shall cessly eith the rouirnute of Esc 3PEC 2 0003, , nretro)3.5,as01.1, $ntion i for strutural italnini stui, ns 010.1 for steinien eni pr u sere pfp u d $ntion t.0 of this u n n l. f.3.1.g. 'tiMliAtlesofElstbilAtVARIAliff flittlEf.Qttlllitditt , J
- Varianen from ihe pernators ilsted in the IP8 east be ilthin the limitation of essential nel-elln IIsted in ISC SPEC I 403 Paragraphs 3.4 and 1.5, nit 01.1 lection 5.5 for structural and Ae3 010.9, $ntion 14 for presure pipe.
. .. \ <
f,.
..m , ..;-- - .___-_
e
*.,f"
/ SPC-BOC WuneNG WANUAl. 7.3.1 I QUAUF1CAfl0N W.ST fr0ft MLD JOINT Pft0EDUllES er WHDuts i
1.i{k STAMISS SED. 300 501100 (CTAW-110) l.).l.3 PerformanJLgn11D;tiha Chantes from the persweters listed in the sps are lleited by the earlsbles contained la ilC sp(C. l 0003, perstrophs 3.4 and 1.1, Ass 01.18ection 6.14 for structural itsinless steel and All 010.8 paratroph 3.1 for presse q pipe. ! l.3.1.h iAtoftC0ytitoifTHis0VAllflCAll0N flottivtti langes of seterial elles and types covered by thl section are listed in Asl 01.1 tables 5.) and
. l.4 for structural steel and Asl 010.t Isble I for pressure pipe.
Perforetatt tantes of asterial sites and types covered by this section are listed in Asl 01.1, tables 5.5and l.1forstructuralstainlesssteelandAsl010.I,tableIforpressurepipe. l.1.1.1 1l$PECilON AND fili Rf 0EL8MMLt
,,, sondestructive end destructive tests reports shall be evolusted in accordance with (1C 1910 2-f- 000), paragraph J.1, Asl 01.1, lection I for struct.r I statales steel, Asl 010.9 inble i for (VA,, pipeandlection6.)ofthissinual, ff. tit (EL9ullificajton fests ProcedurequalificationtestscontInedinthl section r o vire the follosing inspectins and destructive tests in accordance with ist 01.1, table 5.1, Ass 010.9 inble I and sections f.3.1.1.e andf.J.l.t.eofthissenval, vioulinspection Required 1004 rar lequired Tensiletest !Iquired
- facebendtest tRequired .
, foot land test tlesIred Performance QugDUs.stion f.e:11 Procedure quellfication tests contained in the section require the following inspection in accord-sacewithAsl01.1. Table $.1andAsl010.9Isble6.
Visualinspection lequired 1001 ray Required Qf E
)" SPC-BOC WELDING MANUAL .
7.3.1.20
. PROCEDURE QUAURCATION .g,4/ PAGE 6 of 10' g~ MLDING PROCEDURE SPEQMCATION SET-UP VERinED BOC iLSO NASA T WORK ORDER f 0000-Jf17 OKAY 10 PROCEED 0/C $/ O/C $ 0/A b f ,, yq suPPORTwo PQR 7.J f.26 TYPE OF ELECTRODE 2X THOR /ATED TUNGSTEN TYPE Or JONT BuT7.ONT WilDNO CURRENT OCSP J0WT CONN 3JRAVON .1-CR00W ENELDNQ GAS ARCM TYRE OF n1D CouPLETE PENETRA TION CAS PURCE ARCON MIDNQ PROCESS CTAW T/C PRDIEAT/WTERPASS TDIP. NONE ,
t IPE RZE J' SCH 40 TECHOUE KSC-SPEC-Z-0003B J6.J WAL' TFDCKNESS .216* JONT PREPARATI'N KSC-SPEC-I-000JB J6.5 aAsE WETAL 300 SERIES RESTRicDONs KSC-SPEC-Z-00038 J6.6 nLLER WETAL ER-308 CLLANNO KSC-SPEC-Z-00038 J6.7 WODE OF OPERATION uANUAL WQDNQ POSTION 6C A= 60' A ~-
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/ SPC-BOC wuWO WANUAL 7.3.1.2b 4 PRolEDURE QUAUFICADON PROCEDURE QUAUFICADON RECORD PAOC 7 of 10 SUPPORTNG PGR 7.31.2a Tvrt w nicTR00t 2X THORfATfD TUNOS7EN TTPt or J0nf Surr.cwr utLDWO CURRDif DCSP J0MT 00Nn0URADON ./-OROOW setumso cAs A400#
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- J0MT PREPAAADON KSC-SPfC-I-000J8 16.5 Bast WETAL J00 SDWES REstacDONI KSC-SPEC-I-000.N Jf.8 F1L12R WitAL EN-J08 (11 ann 0 KSC-SPEC-I-000J8 af.7 WOct Or 'OPERADON - MANFAL DEIDWO P05 DON . $G 60*
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SPC-BOC wium0 WANUAL 7.3.1.2c Mt0CEDM QUAUF1 Call 0N (' TEST K SULTS . PAGE 8 of 10 v TomoN SPtoucl usf arttaso AMA Actoes AcwAL AcwAL isausen le ucan SEc160N a 16 0 . LOAD LOAo (Ks) LOAD (KS) 1 .057' 5432/ 95649 75.000 PASSED 2 .056* A625$ N.962 75 000 PASSED __ QuetD SDS W2T spetaEN No. TYPE or DDS 904 J0 RAews REsulTS 3 FA% BDVD .25' PASSED 4 TAM 800 .25* PASSED
. 5 MOOT 800 .25' PASSED 6 M00T BOO .25' PASSED WsuAL EXAMmeATIcei MauAL DWaNA110N ACEPTAaLE IEKCT T1Pt AND OWIACER OF FAEillE J & /AY'Vl J ', /9 4 &
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Os J# _,. SPC-BOC WELDING MANUAL . 7.3.1.2 f l PROCEDURE QUAUFICADON ') DESTRUCTIVE TEST RESULTS
- NASA DIRECTOR OF ENGINEERING DEVELOPMENT DIRECTOR, HECHANICAL ENGINEERING
. MATERIALS SCIENCE LABORATORY
- FAILURE ANALYSIS AND HATERIAL EVALUATION BRANCH PHYSICAL TESTING SECTION OH-MSL-24 ROOH 1218 O&C BUILDING KENNEDY' SPACE CENTER, FLO810A 32899 91-5363 tUBJECT! $ELDCERTIFICATION./WELDINGPROCEDUREOUALIFICATION FOR 304 CRES STAIN'LESS STEEL 3" PIPE.
WELDED BY R. WATERMOLEN, LSOC 3341 USING QTAW TIG. MEOUESTOR: JACK THOMPSON MAIL CODE: LSO-071 PHONE 8 : 867-0733 TEST HETHODt PER KSC SPEC Z-0004 PROCEDURE 7.3.1.2.
4" # sasssssssssssssssssssssssssssssssssssssssssssssssssssssssssa .
RE1CIMEN LQAQ AREA TENSILE STRENGTH PASS / FAIL (LOS) 11Q 1M1 (PSI) - 8 1. 5,452 0.057 95,649 PASS 8 2. 6,625 0.058 96,982 PASS assssssssssssssssssssssssssssssssssssssssssssssssssssssssssa SIMQ lElla EQQI EAQE REMARKS 8 1. PASSED 8 1. PASSED NO CRACKS EXCEEDING 1/8" 8 2. PASSED 8 2. PASSED HEASURED IN ANY DIRECTION COMPLETED ONt 12/02/91 sassasssssssssssssssssssssssssssssssssssssssssssssssas INVESTIGATORt *
- D. LEWIS, FAMEB/ NASA APPROVAL: Ne -
N. SALVAIL, CHIEF, FAME 8/ NASA
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SPC-BOC, wEwlNG MANUAL 7.3.1.2 g PROCEDURE QUAURCADON (.re) RADIOGRAPHIC TEST RESULTS 9- . wA-f ts T_ n4 o t 4 M M." 't'Aus *Ti Cn / 3 e A C tt. c. ,b* e c w 4 0 PAGE s I OF I NONDESTRUCf1VE EXAMINATION * * "EW"'" "'I V'*ES "D' "'#0"I "U"'N RADOOAAPHIC DeSP9C* TION RSPONT W MShaeQONL A&QVttlOf4 PHONS (.,0 7 9/5/ LAAM LOCAloh 9006C 7 iL f. HOWAA(,/ Calf, e&$ 4442O l k'Y" 7/4v.erov 7.o?f: n. E,9 O vss E) NO ALPOitTDAIf
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< SPC-BOC WELDING MANUAL 8.3.1 , p WELDING PROCEDURE SPECIFICATION (WPS) (, OAS TUNGSTEN ARC WELDING (GTAW) STRUCTURAL STAINLESS STEEL 300 SERIES wtLDING PEJtruMWED iN ACCORDANCC WITH THiS ANY DEMATION FROW THIS WPS OR WELD JOINT WPS SHALL COMPLY WTH THE REQUIREMENTS OF DRAWNOS CONTAlHED IN THIS SECTION SHALL KSC-SPEC-I-0004D & AWS D1.1 REQUIRE THE QUAunCATION OF A NEW WPS. THIS WPS & THE WE1D JOINTS CONTAINED IN 8.3.1 THE WELD JOINT PROCEDURES CONTAINED IN THIS ARE QUAunED BY THE 1EST CONTAINED IN SECTION SECTION ARE N01 YAUD FOR PRESSURE PIPE AND 7.3.10F THIS MANUAL TUDING. WELDING PROCESS GTA W~ D0 ELECTRODES 2% THatIATED ITJNGSTEN WELDING CURRENT UCSP TEO N OUE KSC-SPEC-Z-C5038 3. 6.3 WilELDING CAS ARGON CLEANING K5G-bPEC-Z-00038 3. 6. 7 WODE Or OPERATION MANUAL J0tHT PREP KSC-SPEC-Z-00039 3.6.5 DASE WETAL CRES J00 SER/ES PREHEAT /INTERPASS TEMP NONE FILLER WE1AL ER-JO8Y POST WL1D HEAT TREATWENT NONE SUCOESTED TUNCSTEN MLLIR A/C CAS WELDING CAS CUP or N0ZZLE SIZE WATERIAL ELECTRODE WETAL CURRENT FLOW SPEED CERAMIC HIGl WETAL
.s THICKNESS DIAWETER DIAMETER RANCE (Cni) (IPW) CUP IMPACT N0ZZLE h 1/16" 1/16* 1/16" 60-100 10 10- 12 4,5,6 4.5,6 6 3/32" 1/16" 1/16"-3/3k 90-120 10 10-12 4. 5,6 4.5,6 6 1/8" 1/16' 3/32' 110-140 10 10-12 4,5,6 4,5,6 6 3/16" 3/32' I/8" 150-225 15 6-10 6,7,8 6,7,8 6,8 1/4" 1/8* 3/16" 200-375 15 6-10 - - 8
'I/2" 1/8 *-3/16" 1/8*-3/16" 225-475 15 1-8 - - 8 TOLIRANCES FOR CROOVE WELDS ROOT FACE f f[ ROOT OPENING WTH BACKING 1(h ROOT OPENING NTHOUT BACKING f(h JOINT CROOVE ANGLE + 10 *- 5
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SPC-DOC WELDING MANUAL 8.3.1 OUAuflED WELD JOINT PROCEDURES l 1., j 0AS TUNOSTEN ARC WELDING (OTAW) STRUCTURAL STAINLESS STEEL 300 SERIES NOTES FOR WELO JOINTS 8.3.1.1 THROUGH 8.3.1.11 1 A BACKCOUCC MOOT TO SOUND METAL KFMC J T FELET M1DC MC UstD N STARCMLY10A0tD ntDwo otHEM 90t. stMUcTLnEs to Mwrmw PAnnAL PENE1MAMM , MLDs M CORNDr J0NTS THEY SHALL DE EQUAL n er nutr utDs int Ust0 n sTAnCALLY 1/4 H. LOADED STRUCTUMC5 TO MEwr0MCt CR00W MLDS W CONNEW OM T JONTS, THEY SHALL K 00VRE N00W MLDS MAY HAW OM00W5 Of M EQUAL TD 1/4T DUT MWD NOT EXWED J/>* WEQUAL LLNGM PM0 Hot 0 REY CONRMM TD CMOOW KLDs m c0MNEM k T J0tNTS N THE lneTAnms W N017.t ALSO THE MID 52E OtNAMICALLY LOADED STMUCTURES SHALL SC C ICSS ANY MEDUCQuN, APPLIES NOlHOUALLY MmrmenD um inter tuDs [0UAL 101/4T 10 EAM CMOOW. BUT NEED NOT EXWED J/8*, L 1HE UNBEWLED EDCC IS LOMEM EDCC 70M C If T > J/4* A UGM00W CM M00tfxD V CM00W HORIZONTAL MtDS. uAr et UsED. Ir nuti ntDS AMt Ust0 m sTAnCAuY u er Tis LEss MAN 1.s', A DOUBLE U GM00W m u00nED DnuaLE V cM00W MAy at UsEu. D DOUR.t cM00W nLDs MAY haw cM00sts or
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, 8,3,1,1 QUAUFIED ELD JOINT PROCEDURES 4 j 4,
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