Safety Analjsp IReport

for thg

NCI-21PF-1 Protective Shipping Package

Revision 2March, 1997

Submitted by:Nuclear Containers, Inc.125 Iodent Way, Suite B

Elizabethton, Tennessee 37643

Prepared by:Transnuclear, Inc.

Four Skyline DriveHawthorne, New York 10532

9703040387 970226PDR ADOCK 07109234B PDR

SAFETY ANALYSIS REPORTFOR THE

NCI-21PF-1 PROTECTIVE SHIPPING PACKAGE

TABLE OF CONTENTS

CHAPTER ONE - GENERAL INFORMATION

1.1 INTRODUCTION ........................................... 1-1

1.2 PACKAGE DESCRIPTION ................. .................... 1-11.2.1 Packaging ............................................ 1-11.2.2 Operational Features ..................................... 1-51.2.3 Contents of Packaging .................................... 1-5

1.3 APPENDICES1.3.1 UF6 Cylinder 30B .................................... 1.3.1-11.3.2 General Drawings of Model NCI-21PF-1 Overpack .... .......... 1.3.1-21.3.3 General Drawings of Valve Protection Device ................. 1.3.1-31.3.4 Calculation of Package Contents ........................... 1.3.1-4

CHAPTER TWO - STRUCTURAL EVALUATION

2.1 STRUCTURAL DESIGN ...................................... 2-12.1.1 Discussion .......................................... 2-12.1.2 Design Criteria ......................................... 2-2

2.2 WEIGHTS AND CENTERS OF GRAVITY ....... .................. 2-3

2.3 MECHANICAL PROPERTIES OF MATERIALS ...... ................ 2-5

2.4 GENERAL STANDARDS FOR ALL PACKAGES ......... ............ 2-62.4.1 Minimum Package Size . ................................... 2-62.4.2 Tamper Proof Feature . ................................... 2-62.4.3 Positive Closure ........................................ 2-62.4.4 Chemical and Galvanic Reactions ......... ................... 2-6

2.5 LIFTING AND TIEDOWN STANDARDS FOR ALL PACKAGES . .2-92.5.1 Lifting Devices .2-92.5.2 Tiedown Devices .2-9

i Rev. 2, 03/97

TABLE OF CONTENTS(continued)

2.6 NORMAL CONDITIONS OF TRANSPORT ........................ 2-132.6.1 Heat . ....................................... 2-132.6.2 Cold .......................................... 2-132.6.3 Reduced External Pressure ................................. 2-132.6.4 Increased External Pressure . .............................. 2-132.6.5 Vibration .......................................... 2-142.6.6 Water Spray ....................................... 2-142.6.7 Free Drop ........................................ 2-142.6.8 Corner Drop ....................................... 2-142.6.9 Compression ....................................... 2-152.6.10 Penetration . .................................... 2-152.6.11 Conclusion .......... ...................... 2-15

2.7 HYPOTHETICAL ACCIDENT CONDITIONS ...................... 2-172.7.1 Free Drop .......... ...................... 2-192.7.2 Puncture ................................ 2-182.7.3 Thermal ................................ 2-202.7.4 Immersion - Fissile Material .............................. 2-212.7.5 Immersion - All Packages ................................ 2-212.7.6 Summary of Damage ................................ 2-212.7.7 Conclusion .......... ...................... 2-23

2.8 SPECIAL FORM .......... ...................... 2-35

2.9 FUEL RODS ................................ 2-35

2.10 APPENDICES2.10.1 Wood Properties ............. a........................ 2.10.1-12.10.2 Material and Equipment Specification of

Phenolic Foam .2.10.2-12.10.3 Chemical and Galvanic Reactions - Test Report .... 2.10.3-12.10.4 Buckling Analysis of the 30B Cylinder .. . 2.10.4-12.10.5 Compliance Testing of the NCI-21PF-1 Packaging .... 2.10.5-12.10.6 Historical Testing and Valve Protection Device

Performance Testing .. . 2.10.6-1

ii Rev. 2, 03/97

TABLE OF CONTENTS(continued)

CHAPTER THREE - THERMAL EVALUATION

3.1 DISCUSSION .............................................3.1.1 Thermal Source Specification ..............................3.1.2 Thermal Acceptance Criteria ..............................

3.2 SUMMARY OF THERMAL PROPERTIES OF MATERIALS ............

3.3 TECHNICAL SPECIFICATION OF COMPONENTS.

3-13-13-1

3-4

3-5

3.4 THERMAL EVALUATION FOR NORMAL CONDITIONS OF3.4.1 Conditions Evaluated ........................3.4.2 Acceptance Criteria for Normal Conditions of Transport3.4.3 Thermal Model ............................3.4.4 Maximum Temperatures ......................3.4.5 Minimum Temperatures .......................3.4.6 Maximum Pressure ..........................

TRANSPORT. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

. . . . . . . . .

3.5. THERMAL EVALUATION FOR HYPOTHETICAL ACCIDENT CONDITIONS3.5.13.5.2

Conditions Evaluated ..................................Acceptance Criteria for Hypothetical Accident Conditions .........

3-53-53-53-63-83-83-8

3-83-83-93-93-9

3-103-103-153-173-173-17

3.5.3 Thermal Model .........3.5.43.5.53.5.63.5.73.5.83.5.93.5.10

Package Conditions and EnvironmentPackage Temperatures ...........Analysis of Test Data ...........Minimum 30B Cylinder Load ......Maximum Temperatures .........Minimum Temperatures ..........Maximum Pressure .............

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

3.6. THERMAL EVALUATION AND CONCLUSIONS ......

3.7 REFERENCES ...............................

3-17

3-18

..M Rev. 2, 03/97

TABLE OF CONTENTS(continued)

CHAPTER FOUR - CONTAINMENT

4.1 CONTAINMENT BOUNDARY .4.1.1 Containment Vessel .....................................

4.1.2 Containment Penetrations ..................................4.1.3 Seals and Welds ........................................4.1.4 Closure ..............................................

4.2 REQUIREMENTS FOR NORMAL CONDITIONS OF TRANSPORT ........4.2.1 Containment of Radioactive Material ..........................4.2.2 Pressurization of Containment Vessel .........................

4.2.3 Containment Criterion ....................................

4.3 CONTAINMENT REQUIREMENTS FOR HYPOTHETICAL ACCIDENTCONDITIONS.4.3.1 Fission Gas Products .4.3.2 Containment of Radioactive Material .4.3.3 Containment Criterion.

4.4 APPENDICES4.4.1 Calculation of Permissible Leak Rate for Normal Conditions ....... 4.4.4.2 Calculation of Permissible Leak Rate for Accident Conditions ....... 4.'

CHAPTER FIVE - SHIELDING EVALUATION

5.0 SHIELDING EVALUATION ....................................

CHAPTER SIX - CRITICALITY EVALUATION

6.1 DISCUSSION AND RESULTS .

6.2 PACKAGE LOADING ........................................

6.3 MODEL SPECIFICATION.

6.4 CRITICALITY CALCULATION .................................

6.5 CRITICALITY BENCHMARK EXPERIMENTS.

6.6 REFERENCES .............................................

4-14-14-14-14-1

4-24-24-24-2

4-34-34-34-3

4.1-1.4.2-1

5-1

6-1

6-1

6-3

6-3

6-3

6-3

iV Rev. 2, 03/97

TABLE OF CONTENTS(continued)

CHAPTER SEVEN - OPERATING PROCEDURES

7.1 PROCEDURES FOR LOADING PACKAGE .........................7.1.1 Receipt and Filling of 30B Cylinder ..........................7.1.2 Final Cylinder Inspection ..................................7.1.3 Overpack and Valve Protection Device Inspection .................7.1.4 Procedure for Loading the NCI-21PF-1 Overpack .................

7.2 PROCEDURES FOR UNLOADING PACKAGE ......................

7.3 PREPARATION OF EMPTY PACKAGE FOR TRANSPORT .............

CHAPTER EIGHT- ACCEPTANCE TESTS AND MAINTENANCE PROGRAM

8.1 ACCEPTANCE TESTS .......................................8.1.1 Acceptance Tests for the NCI-2 1PF- 1 Overpack ..................

8.1.2 Acceptance Tests for the Valve Protection Device .................8.1.3 Acceptance Tests for the 30B Cylinder ........................

7-17-17-17-17-2

7-3

7-4

8-18-18-28-2

8.2 MAINTENANCE PROGRAMS ............... ................... 8-28.2.1 Maintenance Programs for the NCI-21PF-1 Overpack .... .......... 8-28.2.2 Maintenance Programs for the Valve Protection Device .... .......... 8-5

8.2.3 Maintenance Programs for the 30B Cylinder ..................... 8-5

Rev. 2, 03/97v

LIST OF TABLES

1-1 Materials of Construction . ...................................... 1-3

6-1 Summary of Criticality Evaluation ........... ..................... 6-2

LIST OF FIGURES

2.2-la Center of Gravity of Unloaded NCI-21PF-1 Package ...... .............. 2-42.2-lb Center of Gravity of Loaded NCI-21PF-1 Package ........... . 2-4

2.5-1 NCI-21PF-1 Package Lifting Configuration ......................... 2-11

2.5-2 NCI-21PF-1 Package Transport Configuration ....................... 2-12

2.7-1 NCI-21PF-1 Package with Valve Protection Device Testing Program .... .... 2-25

2.7-2 NCI-21PF-I Package with Valve Protection Device, 13.50 Drop Test Set Up . . 2-28

2.7-3 NCI-21PF-1 Package with Valve Protection Device, 13.50 Puncture Test Set Up 2-29

2.7-4 Fire Test Set Up 1, Overall Test Layout ........................... 2-302.7-5 Fire Test Set Up 2, Containment Pan Configuration .................... 2-30

2.7-6 NCI-21PF-1 Package with Valve Protection Device, External Damagefollowing 13.50, 30 ft Drop Test ................................. 2-31

2.7-7 NCI-21PF-1 Package with Valve Protection Device, External Damagefollowing 13.50, 40 in Puncture Test .............................. 2-31

2.7-8 NCI-21PF-1 Package with Valve Protection Device, ValvePosition Measurement Locations ................................. 2-32

2.7-9 NCI-21PF-1 Package with Valve Protection Device, Valve ProtectionDevice Permanent Deformation ................................. 2-34

3.5-1 Measured Fire Temperature - Time History ......................... 3-113.5-2 Measured Cylinder Temperature - Time History ...................... 3-12

3.5-3 Energy Absorbed between 1000F and 250'F ......................... 3-13

3.5-4 Cylinder Temperature - Time History ............................. 3-16

LIST OF PHOTOS

2.6-1 Compression Testing ......................................... 2-16

vi iRev. 2, 03/97

CHAPTER ONEGENERAL INFORMATION

TABLE OF CONTENTS

1.1 INTRODUCTION ........................................... 1-1

1.2 PACKAGE DESCRIPTION ..................................... 1-11.2.1 Packaging ............................................ 1-11.2.2 Operational Features . ..................................... 1-51.2.3 Contents of Packaging ............ ........................ 1-5

1.3 APPENDICES1.3.1 UF6 Cylinder 30B .................................... 1.3.1-11.3.2 General Drawings of Model NCI-21PF-1 Overpack ..... ......... 1.3.2-11.3.3 General Drawings of Valve Protection Device ..... ............ 1.3.3-11.3.4 Calculation of Package Contents ......... .................. 1.3.4-1

LIST OF TABLES

1-1 Materials of Construction . ....................................... 1-3

l-i Rev. 2, 03/97

CHAPTER ONEGENERAL INFORMATION

This Safety Analysis Report for Model NCI-21PF-1 Protective Shipping Packages issubmitted in support of a request to amend and re-issue Certificate of Compliance No. 9234,Rev. 10, as a Type B Certificate of Compliance with the requirements of 10 CFR 71 andIAEA Safety Series No. 6, 1990 Edition.

This Safety Analysis Report applies to both present (and future packages) which have been(and will be) fabricated in accordance with drawings and specifications presented in thisreport.

1.1 INTRODUCTION

The NCI-21PF-1 is a Type B package (assigned minimum Transport Index of 5.0) and isdesigned to provide safe transport of Model 30B cylinders containing up to 5% enriched UF6.Each cylinder is limited to 5,020 pounds of UF6; for recycled uranium, the package is furtherlimited to not more than 1,150A2 quantities of radioactive materials as determined per 10CFR 71, Appendix A. The package contents are further described in Section 1.2.3.

The package can be separated into three parts: (1) the standard Model 30B cylinder; (2) thevalve protection device; and the (3) NCI-21PF-1 overpack. The NCI-21PF-1 overpack is amodification of the DOT-21PF-1B overpack. The modifications are described in Section2.1.1.

The valve protection device protects the cylinder valve from damage due to the 30 foot dropand the 40 inch puncture hypothetical accidents.

1.2 PACKAGE DESCRIPTION

1.2.1 Packaning

The NCI-21PF-1 overpack together with the valve protection device (VPD) is designed toprotect a standard ANSI N14.1 30B cylinder filled with enriched uranium hexafluoride. Theoverpack is shown on NCI drawings DED-206-B, Sheet 1 through 11 provided in Appendix1.3.2.

The VPD is shown on drawings VPD-0001 and VPD-0002 as provided in Appendix 1.3.3.The valve protection device was designed with two basic criteria: prevent the overpack wallfrom impacting the valve and prevent the cylinder skirt from collapsing thereby exposing thevalve to further damage.

A general assembly diagram of hte NCI-21PF-1 packaging is provided in Appendix 1.3.2.The package components are described in the following sections.

1-1 Rev. 2, 03/97

The basic components of the NCI-21PF-1 package are:

- the U176 30B Cylinder;- the VPD (3 aluminum inserts, 1 spacer and 1 spider);- the two halves (top and bottom) of the overpack; and- ten (10) toggle closures.

1.2.1.1 Gross Weights

The gross weights of the loaded NCI-21PF-1 protective shipping package components aresummarized below:

Package Weight (ibs)

UF6 Maximum Load 5,020

30B Cylinder 1,400

Valve Protection Device 170

NCI-21PF-1 Overpack 2,280

Maximum Gross Weight of Loaded Package 8,870

1.2.1.2 Materials of Construction

The materials of construction of the 30B cylinder, overpack, and valve protection device areprovided in Table 1-1.

1.2.1.3 External Dimensions and Cavity Size. Internal and External Structures

The package consists of the 30B cylinder as defined in ANSI N14.1, a VPD which isinserted into the 30B cylinder skirt on the valve end and an overpack which consists of twohalves which form a right circular cylinder with toggle closures.

The valve protection device consists of the following components:

- 3 aluminum inserts which are designed to fit against the cylinder head and occupy thevoid volume within the cylinder skirt around the valve. Each aluminum insert isroughly a 1200 section within the cylinder skirt. These inserts are held in place withthe use of a spacer that fits against the cylinder head and a spider which locks theinserts against the cylinder skirt. The primary insert fits over the valve. The twosecondary inserts fill the remaining sections of the cylinder skirt.

1-2 Rev. 2, 03/97

Table 1-1Materials of Construction

Item

Cylinder and valve

Valve Protection Device

Aluminum Insert

Spacer

Spider

Overpack

Skin

Plates

Angles

Toggle Castings and Swing Pins

Toggle Bracket and Base Castings

Pipe

Boat Nails, Lag Screws, Set Screws,Pad Eyes, and Washers

Wood

Foam

Gasket

Material

In accordance with ANSI N14.1

ASTM B26, Alloy 514, or 356 T6'

ASTM A36 Carbon Steel, Painted

ASTM A36 Carbon Steel, Painted

ASTM A240 Type 304 or 304L SST

ASTM A240 Type 304 or 304L SST

ASTM A276 Type 304 or 304L SST

17-4PH SST

Type 304 or 304L SST

ASTM A312 Type 304 or 304L SST

300 SST 18-8 or 17-4PH SST

Oak

Phenolic Foam

Silicone

I In addition to the requirements of B26, the aluminum shall have a minimum yieldstrength of 20 ksi, minimum ultimate strength of 25 ksi and minimum elongation of5%.

1-3 Rev. 2, 03/97

The overpack is constructed of two stainless steel shells, which are described below:

- the outer shell has a 43 inch diameter and is 92 inches long (end plates are 1/4 inchthick and the walls are 14 gage); and

- the inner shell has a 30-7/8 inch inner diameter and is 82-5/8 inches long (end platesare 1/4 inch thick and the walls are 14 gage).

The volume between the two shells is filled with the following materials:

- the annular space between the shells is filled with fire retardant, phenolic foam perspecification NCI-PF-1 (provided in Appendix 2.10.2); and

- the space between the 1/4 inch plates at the ends of the two shells is filled with oakwood blocks which are made of three cross-laminated layers of boards glued andnailed together.

The overall outside dimensions of the package (including the tie-down structures describedbelow in Section 1.2.1.5) are 49-1/8 inches wide by 49-1/8 inches high by 92 inches long.

1.2.1.4 Outer and Inner Protrusions

There are no inner protrusions on the NCI-21PF-1 package. Outer protrusions on the NCI-21PF-1 package consist of only the lifting/tiedown points (Section 1.2.1.5) and the closures(Section 1.2.1.8) for shipping.

1.2.1.5 Lifting and Tiedown Devices

The bottom half of the package is fitted with 1/2-inch thick tie-down plates for bolting to thefloor of the carrier vehicle with eight 3/4-inch bolts. The top half of the package is fittedwith inverted tie-down plates on which the empty packages can be stacked; four 3/4-inch U-bolts in the inverted plates are used for lifting the package as well as for securing stackedpackages together.

1.2.1.6 Shielding

Shielding is not required for the payload of the 30B cylinder.

1.2.1.7 Pressure Relief Systems

There are no pressure relief systems.

1.2.1.8 Closures

The package consists of a top half and a bottom half. A stepped horizontal joint permits thetop half of the package to be removed from the base; the horizontal closure joint of each

1-4 Rev. 2, 03/97

package half is covered with stainless steel , and a flat, 5/8" thick silicon gasket seals thejoint. The package halves are secured with ten 1 inch diameter stainless steel toggle closures.

1.2.1.9 Containment

Containment of UF6 is provided by the 30B Cylinder. The 30B cylinder is fabricated,inspected, tested, and maintained in accordance with ANSI Standard No. N14.1 and the latestrevision of USEC Report USEC-651. ANSI No. N14.1 requires that the cylinder befabricated in accordance with Section VIII, Division 1, of the ASME Boiler and PressureVessel Code and be ASME Code "U" stamped.

1.2.2 Operational Features

The two secondary inserts of the valve protection device are placed in the cylinder skirtfollowed by the spacer. The third (primary) insert is placed over the valve location. Thespider is placed among the inserts and clamped into place. The cylinder with the valveprotection device is loaded into the overpack.

The NCI-21PF-l overpack is closed by ten (10) 1-inch quick opening toggle closures whichare secured from accidental opening by 1/2-inch diameter ball-lock pins. Each closure isadjustable, but socket set-screws must be loosened to release the adjusting collar.

The package is tied-down for transport by bolting to the carrier floor and is interchangeablewith the DOT Specification 21PF-1A and -1B packages because all three packages haveidentical tie-down bolt patterns. The package is lifted by means of four 3/4 inch U-boltsmounted in two inverted tie-down bases which are also used for stacking empty packages; thestacked packages may be secured together using either the 3/4 inch steel bolts or the lifting U-bolts. The package may also be lifted by fork truck tines under the angle reinforced bottomof the package.

The closure joint of the package is stepped down to the outside to minimize water in-leakageinto the cylinder cavity and provides a metal-to-metal seat on the outboard side such thatcompression of the inboard gasket is controlled. The gasket is a 5/8" thick medium density,closed-cell silicone sponge rubber with a minimum continuous temperature rating of 400'F.

1.2.3 Contents of Packaging

The package contents are limited to a maximum of 5,020 pounds of UF6 enriched to not morethan 5 wt% U-235. The 30B cylinder may contain either virgin or recycled uranium. Thematerials must meet the requirements of ASTM C-787 for feed materials and ASTM C-996for UF6 which has been processed through an enrichment plant. The expected radionuclidecontent and the A2 value of a 30B cylinder filled with recycled UF6 is summarized below andcalculated in Appendix 1.3.4.

1-5 Rev. 2, 03/97

Uranium Components:

U-232U-234U-235U-236U-238

0.05 gg/gU0.002 g/gU0.05 g/gU0.025 g/gU0.923 g/gU

= 5E-08 g/gU

Thorium-228 content:

The maximum Th-228 content is assumed solely from the decay of U-232.Th-228 content is 1.21E-09 g/gU.

Technetium:

Tc-99 5 jig/gU = 5E-06 g/gU

Transuranics:

The alpha activity from neptunium and plutonium is less than 3.3 Bq/gU.

Fission products:

The maximum

106Ru/106Rh103Ru/103Rh144Ce/144Pr/144m Pr125Sb134Cs137Cs/137 mBa95Zr95Nb

2.10e-09 TBq/gU8.85e-10 TBq/gU8.35e-09 TBq/gU1.03e-09 TBq/gU2.84e-10 TBq/gU7.79e-10 TBq/gU5.99e-10 TBq/gU5.74e-10 TBq/gU

From the contents described above, the A2 value for the mixture is calculated as 8.42E-04TBq. The shipping limit for UF6 in a 30B cylinder is 2,277 kg and its maximum uraniumcontent of the 30B cylinder is 1,540 kg. The total activity of the filled 30B cylinder is 0.972TBq.

For a mixture with different A2 value (A2 jjmtw)d the maximum radioactive content is: (0.972TBq/filled 30B cylinder} / {8.42E-04 TBq/A2 mixture} (w {1150 * A2-mjtue}TBq.

1-6 Rev. 2, 03/97

APPENDIX 1.3.1UF6 30B CYLINDER

TABLE OF CONTENTS

1.3.1 UF6 30B Cylinder ................. 1.3.1-1

1.3. 1-i Rev. 2, 03/97

APPENDIX 1.3.1UF6 30B CYLINDER

Attached to this appendix is a reprint of Figure 7 - UF6 Cylinder 30B, pages 44-45, ANSIN14.1, American National Standard for Nuclear Materials - Uranium Hexaflouride -Packaging for Transport.

1.3.1-1 Rev. 2, 03/97

lwalcourt

New Stamp

APPENDIX 1.3.2GENERAL DRAWINGS OF NCI-21PF-1 OVERPACK

TABLE OF CONTENTS

1.3.2 General Drawings of NCI-21PF-1 Overpack ........ .. .............. 1.3.2-1

1.3.2.1 General Assembly Drawing of the NCI-21PF-1 Package ..... 1.3.2-1

1.3.2.2 General Drawings of NCI-21PF-1 Overpack .... .......... 1.3.2-3

1.3.2-i Rev. 2, 03/97

APPENDIX 1.3.2GENERAL DRAWINGS OF NCI-21PF-1 OVERPACK

1.3.2.1 General Assembly Drawing of the NCI-21PF-1 Package

Attached is a general assembly drawing of the NCI-21PF-l package to illustrate the 30B

cylinder, valve protection device and the NCI-21PF-1 overpack.

1.3.2-1 Rev. 2, 03/97

( C C

VALVE PROTECTION DEVICE(SEE DETAILS ON VPD-0001 AND VPD-0002) 30B CYLINER

-1. . . . . . . . . . . . I . . . . . . . . . . . . . . . .. . . . . . . . . . . . I . . . . I . . . . I . . . I . . I . . ' . . . . , . . . . . . . . . . . . . . . . . . I .. . . . . . . . . . . . . . . I . . . . . . . . . . . . . . . . . . . . . I . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . , , , . , . . . , . . , . , . . . . . . . . . . . . . . . . . . . . . . . .

I . . . . . I . . . . . . . . . . . . I , I , . . . . ' ' . . . , . . . . I .. . I . , . , . . . . . , . , . . . . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . I . . . I

I I I A

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30- (NOMNAL)

()A�( (5() A

��, <4() A( Ir

43

I:-

tlbj 30

I)A

() /I�.,, /I 5

............................... . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . ............................

. . . . . . . . . . . . . . .... . . . . . . . ......................

1jfIs~$ .5sI -�

.. I

IJL- JLL82 5/8'

e vz

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-4

TYPICAL NCI-21PF-I PACKAGE ASSEMBLY

1.3.2.2 General Drawings of the NCI-21PF-I Overpack

Attached are the general drawings and materials specification for the NCI-21PF-1 overpack.

1.3.2-3 Rev. 2, 03/97

APPENDIX 1.3.3GENERAL DRAWINGS OF VALVE PROTECTION DEVICE

TABLE OF CONTENTS

1.3.3 General Drawings of Valve Protection Device ...................... 1.3.3-1

1.3.3-i Rev. 2, 03/97

APPENDIX 1.3.3GENERAL DRAWINGS OF VALVE PROTECTION DEVICE

Attached are the general assembly drawings and materials specification for the valveprotection device.

1.3.3-1 Rev. 2, 03/97

APPENDIX 1.3.4CALCULATION OF PACKAGE CONTENTS

TABLE OF CONTENTS

1.3.4 Calculation of Package Contents . ........................... 1.3.4-1

1.3.4-i Rev. 2, 03/97

APPENDIX 1.3.4CALCULATION OF PACKAGE CONTENTS

This appendix calculates the package radioactive contents for a 30B cylinder filled with 5,020pounds of recycled UF6 enriched to 5%.

The source term is determined from ASTM Standard C 996, "Standard Specification forUranium Hexaflouride Enriched to Less Than 5% U-235;" ASTM Standard C 787, " StandardSpecification for Uranium Hexaflouride for Enrichment;" and CEGB Report RD/B/N 4942.An A2 value is calculated for the mixture from the criteria provided in 10 CFR 71 AppendixA. The expected radionuclide content and the A2 value of a filled 30B cylinder filled with5% enriched reprocessed UF6 is described below.

Uranium Components:

U-232 0.05 jig/gU = 5E-08 g/gUU-234 2000 pLg/gU = 2E-03 g/gUU-235 0.05 g/gUU-236 0.025 g/gUU-238 0.923 g/gU

Thorium-228 content:

The maximum Th-228 content is assumed solely from the decay of U-232. The maximumTh-228 is 1.21E-09 g/gU.

Technetium:

Tc-99 5 Rig/gU = 5E-06 g/gU

Transuranics:

The alpha activity from neptunium and plutonium is less than 3.3 Bq/gU.

1.3.4-1 Rev. 2, 03/97

Fission products:

For enriched reprocessed UF6, the gamma radiation from fission products is limited to:"for each detectable gamma emitting fission product the sum of the values obtained by

multiplying the activity (Bq/kgU) of each parent nuclide species by the appropriate meangamma energy per disintegration (MeV/d) shall not exceed 4.4 x 105 MeVBq/dkgU (4.4 x 105MeV/sec kgU)." After four years of decay the main gamma emitters are:

Total ContributionMean decay of Gamma Maximum

energy Emitters activityRadionuclide (MeV/d*) (MeV Bq/d gU) (TBq/gU)

106Ru/106Rh 0.21 440 2.1 Oe-09

103Ru/103Rh 0.497 8.85e-10

144Ce/144Pr/144 m Pr 0.0527 8.35e-09

125Sb 0.427 1.03e-09

134Cs 1.555 2.84e-10

137Cs/137mBa 0.565 7.79e-10

95Zr 0.735 5.99e-10

95Nb 0.766 5.74e-10

Total: 1.46e-08d = decay

1.3.4-2 Rev. 2, 03/97

From the contents described above, the following A2 value for the mixture is calculated:

Specific AWMass Activity Activity Activity A2 f(i)/A2(i)

Radionuclide (g/gU) (TBq/g) (TBq/gU) (no dimen) (TBq) (l/gU)

U-232 5.00e-08 8.30e-01 4.15e-08 6.58e-02 3.00e-04 2.19e+02

U-234 2.00e-03 2.30e-04 4.60e-07 7.29e-01 l.OOe-03 7.29e+02

U-235 5.00e-02 8.00e-08 4.00e-09 6.34e-03 unlimited

U-236 2.50e-02 2.40e-06 6.00e-08 9.5 le-02 l.OOe-03 9.5 le+O1

U-238 9.23e-01 1.20e-08 1. lle-08 1.76e-02 unlimited

Th-228 1.21e-09 3.00e+01 3.63e-08 5.76e-02 4.00e-04 1.44e+02

Tc-99 5.00e-06 6.30e-04 3.15e-09 5.00e-03 9.00e-01 5.55e-03

Transuranics** 3.30e-12 5.23e-06 2.00e-05 2.62e-01

Fission Products

106Ru/106Rh 2.1 Oe-09 3.32e-03 2.00e-01 1.66e-02

103Ru/103Rh 8.85e-10 1.40e-03 9.00e-01 1.56e-03

144Ce/144Pr/144 m Pr 8.35e-09 1.32e-02 2.00e-01 6.62e-02

125Sb 1.03e-09 1.63e-03 9.00e-01 1.82e-03

134Cs 2.84e-10 4.50e-04 5.00e-01 9.00e-04

137Cs/137"Ba 7.79e-10 1.23e-03 5.OOe-01 2.47e-03

95Zr 5.99e-10 9.49e-04 9.00e-01 1.05e-03

95Nb 5.74e-10 9.1le-04 1.OOe+00 9.1 Ie-04

Total: 6.3 1e-07 1188

* Per 1OCFR 71, Appendix A, f(i) = Activity / XActivity** General value A2 for alpha emitters, 10 CFR 71, Table A2,

individual Pu or Np values.

Therefore:

is more conservative than

I f(i)/A2(i) = 1188/TBqA2 for the Mixture = 1/E f(i)/A2(i) = 8.42E-04 TBq

1.3.4-3 Rev. 2, 03/97

For a 30B cylinder filled with 5% enriched reprocessed UF6 , the A2 value is 8.42E-04 TBq.The maximum uranium content of the 30B cylinder is 1,540 kg. The total activity of thefilled 30B cylinder is 0.972 TBq.

For a mixture with different A2 value (A2m~ture), the maximum radioactive content is: (0.972TBq/filled 30B cylinder} / {8.42E-04 TBq/A2 mixture} % (1150 * A2-mixre}TBq

1.3.4-4 Rev. 2, 03/97

CHAPTER TWOSTRUCTURAL EVALUATION

TABLE OF CONTENTS

2.1 STRUCTURAL DESIGN ...................................... 2-12.1.1 Discussion ............................................ 2-12.1.2 Design Criteria . ......................................... 2-2

2.2 WEIGHTS AND CENTERS OF GRAVITY ......................... 2-3

2.3 MECHANICAL PROPERTIES OF MATERIALS ...................... 2-5

2.4 GENERAL STANDARDS FOR ALL PACKAGES ......... ............ 2-62.4.1 Minimum Package Size ......... .......................... 2-62.4.2 Tamper Proof Feature .......... .......................... 2-6

2.4.3 Positive Closure .............. .......................... 2-62.4.4 Chemical and Galvanic Reactions ............................ 2-6

2.5 LIFTING AND TIEDOWN STANDARDS FOR ALL PACKAGES ... ...... 2-82.5.1 Lifting Devices .............. .......................... 2-9

2.5.2 Tiedown Devices ............. .......................... 2-9

2.6 NORMAL CONDITIONS OF TRANSPORT ........... ............. 2-132.6.1 Heat ............................................... 2-132.6.2 Cold ............................................... 2-13

2.6.3 Reduced External Pressure ................................ 2-132.6.4 Increased External Pressure ............................... 2-132.6.5 Vibration ............................................ 2-13

2.6.6 Water Spray . ......................................... 2-142.6.7 Free Drop . ........................................... 2-142.6.8 Corner Drop . ......................................... 2-15

2.6.9 Compression . ......................................... 2-152.6.10 Penetration . ......................................... 2-152.6.11 Conclusion . ......................................... 2-15

2.7 HYPOTHETICAL ACCIDENT CONDITIONS ......... ............. 2-172.7.1 Free Drop . ........................................... 2-192.7.2 Puncture . ........................................... 2-192.7.3 Thermal . ........................................... 2-202.7.4 Immersion - Fissile Material .............................. 2-21

2.7.5 Immersion - All Packages ................................ 2-212.7.6 Summary of Damage and Test Results ........................ 2-212.7.7 Conclusion . ......................................... 2-23

2-i Rev. 2, 03/97

TABLE OF CONTENTS(continued)

2.8 SPECIAL FORM .......................................... 2-35

2.9 FUEL RODS ....................................... ... 2-35

2.10 APPENDICES2.10.1 Wood Properties ...................................... 2.10.1-12.10.2 Material and Equipment Specification of

Phenolic Foam ...................................... 2.10.2-12.10.3 Chemical and Galvanic Reactions - Test Report ..... .......... 2.1Q.3-12.10.4 Buckling Analysis of the 30B Cylinder ...... ............... 2.10.4-12.10.5 Compliance Testing of the NCI-21PF-1 Packaging .... ......... 2.10.5-12.10.6 Historical Testing and Valve Protection Device

Performance Testing . ................................. 2.10.6-1

LIST OF FIGURES

2.2-la Center of Gravity of Unloaded NCI-21PF-l Package .2-42.2-lb Center of Gravity of Loaded NCI-21PF-1 Package .. 2-42.5-1 NCI-21PF-1 Package Lifting Configuration ......................... 2-112.5-2 NCI-21PF-1 Package Transport Configuration ....................... 2-122.7-1 NCI-21PF-1 Package with Valve Protection Device Testing Program .... .... 2-252.7-2 NCI-21PF-1 Package with Valve Protection Device, 13.50 Drop Test Set Up . . 2-282.7-3 NCI-21PF-1 Package with Valve Protection Device, 13.50 Puncture Test Set Up 2-292.7-4 Fire Test Set Up 1, Overall Test Layout ........................... 2-302.7-5 Fire Test Set Up 2, Containment Pan Configuration .................... 2-302.7-6 NCI-21PF-1 Package with Valve Protection Device, External Damage

following 13.5°, 30 ft Drop Test ................................. 2-312.7-7 NCI-21PF-1 Package with Valve Protection Device, External Damage

following 13.5°, 40 in Puncture Test .............................. 2-312.7-8 NCI-21PF-1 Package with Valve Protection Device, Valve

Position Measurement Locations ......... ........................ 2-322.7-9 NCI-21PF-1 Package with Valve Protection Device, Valve

Protection Device Permanent Deformation .......................... 2-34

LIST OF PHOTOS

2.6-1 Compression Testing . ......................................... 2-16

2-ii Rev. 2, 03/97

CHAPTER TWOSTRUCTURAL EVALUATION

2.1 STRUCTURAL DESIGN

This chapter presents the structural evaluation of the NCI-21PF-1 package. This evaluationconsists of analytical and test results demonstrating that the NCI-21PF-1 package satisfies therequirements for a Type B package as defined in 10 CFR 71.

2.1.1 Discussion

The NCI-21PF-1 overpack is designed to safely transport a 30B cylinder (as defined in ANSIN14.1) filled with UF6. For purposes of this SAR, the term "filled" means containing up tothe maximum amount of UF6 allowed by ANSI N14.1. The NCI-21PF-1 overpack providesthe protection for the 30B cylinder. The 30B cylinder provides containment of the UF6.

The NCI-21PF-1 overpack is similar to the DOT-21PF-1B overpack. The differences betweenthe NCI-21PF-1 overpack and the DOT-21PF-1B (as delineated in Union Carbide DrawingNumbers E-S-31536-J, Rev. P, and SIE-31536-J2, Rev. B) are provided below:

- The inner and outer ends have been changed from 14 gage (2.1 mm) sheet metal to1/4" (6.4 mm) plate.

- The fourteen 3/4" (19.0 mm) carbon steel closure bolts have been replaced by ten 1"(25.4 mm) stainless steel toggle closures which are quick-opening and have no looseparts.

- All stiffeners have been eliminated from the ends reducing the overall length from 96"(243.8 cm) to 92" (233.7 cm).

- The center angle stiffener ring has been changed to a band made of 1.4" x 3" (6.4mm x 7.6 cm) Flat Bar.

- The other angle stiffener rings, which were 3-1/2" x 3-1/2" x 3/8" (8.9 cm x 8.9 cm x9.5 mm) on the bottom and 3" x 2" x 1/4" (7.6 cm x 5.1 cm x 6.4 mm) on the top,have been changed to 3" x 3" x 3/8" (7.6 cm x 7.6 cm x 9.5 mm) top and bottom.

- A set of inverted tie-down bases has been added to the top to facilitate stacking.

- The four lifting shackles have been eliminated and replaced with four 3/4" (19.0 mm)U-bolts in the inverted stacking frame; when packages are stacked, these U-bolts maybe used to bolt the packages together.

2-1 Rev. 2, 03/97

- All attachments to the outer shell of the package are joined by continuous welds.

- Material specifications have been changed to allow the use of Type 304 stainless steelin place of Type 304L stainless steel.

- Wood specifications have been changed to allow the used of red or white oak and toallow the use of No 2 common grade lumber in the wooden laminations. At the sametime, the wood specifications have been tightened to disallow specific defects and toeliminate end splicing. Also, essentially clear lumber is specified for the wooden railsand cap boards, and must be single boards with no splicing or lamination allowed.

- Quality Assurance requirements for the NCI-21PF-1 are essentially the same as for theDOT-21PF-1B package. Specific Quality Control requirements regarding materialspecifications including the requirements for test reports and certifications, tolerances,weld specifications, and inspections are specified in NCI Drawing No. DED-206-B,Sheets 9 through 11, Rev. 5 (see Appendix 1.3).

The NCI-21 PF- 1 shipping package together with the valve protection device are described inChapter One and are shown on drawings provided in Section 1.3, Appendix.

2.1.2 Design Criteria

The package consists of two major components:

- NCI-21PF-I overpack with valve protection device- Model 30B UF6 cylinder

The NCI-21PF-l package is designed to meet all of the applicable structural requirements of10 CFR 71. The containment vessel is the Model 30B UF6 cylinder. The NCI-21PF-1packaging is designed to assure that the cylinder containment vessel is protected undernormal or hypothetical accident conditions.

The NCI-21PF-1 package is similar to the DOT-21PF-1B. The differences are described inSection 2.1.1.

The original DOT-21PF-IB packages have been tested for both normal and accidentconditions of transport.

For normal conditions of transport, compliance of the NCI-21PF-1 overpack is demonstratedthrough analysis and past testing of both the NCI-21PF-1 and the similar DOT-21PF-1Boverpack.

2-2 Rev. 2, 03/97

For accident conditions of transport, compliance of the NCI-21PF-1 overpack is demonstratedthrough the performance of testing on a full scale model of a 30B cylinder, valve protectiondevice and NCI-21PF-1 overpack. The test program is fully described in Section 2.7.

Structural evaluation of other conditions utilize yield and ultimate material properties aspresented in the ASME Boiler and Pressure Vessel Code, Section II, Part D.

The UF6 containment vessel, being fabricated from ASTM A516, Grade 55, 60, 65 or 70,ferritic steel, has been evaluated with respect to NUREG/CR-1815, "Recommendations forProtecting Against Failure by Brittle Fracture in Ferric Steel Shipping Containers Up to FourInches Thick." Brittle fracture of the NCI-21PF-1 overpack is not of concern because theoverpack does not provide containment itself and because it is primarily constructed ofstainless steel, wood and phenolic foam.

2.2 WEIGHTS AND CENTERS OF GRAVITY

The calculated gross weight of the NCI-21PF-1 package (including contents) is 8,870 pounds.Approximate weights of major individual components or subassemblies are tabulated below.

Weights of Components

Component Weight

Overpack 2280 lbs

Valve Protection Device 170 lbs

30B Cylinder 1400 lbs

Maximum UF6 Load (Content) 5020 lbs

Gross Package Weight 8870 lbs

The center of gravity of the unloaded package is located 42.6 inches from the top outersurface and 0.37 inches from the longitudinal axis as shown on Figure 2.2-la.

The center of gravity of the loaded package is located 45.78 inches from the top outer surfaceand 2.96 inches from the longitudinal axis as shown on Figure 2.2-lb.

2-3 Rev. 2, 03/97

Figure 2.2-laCenter of Gravity of Unloaded NCI-21PF-I Package

.1

.1

Figure 2.2-lbCenter of Gravity of Loaded NCI-2lPF-I Package

2-4 Rev. 2, 03/97

2.3 MECHANICAL PROPERTIES OF MATERIALS

The mechanical properties of materials used in the design of the NCI-21PF-1 packaging arepresented below:

Component Material Yield Stress Ultimate Reference(psi) Stress See Notes

(psi) Below

30B Cylinder ASTM, A516 Grade 55 30,000 55,000 1

Overpack ASTM, A240 Type 304 30,000 75,000 1

17-4PH SS 105,000 135,000 1

Oak - Perpendicular to Grain 2,070 N/A 3

Oak - Parallel to Grain 7,920 N/A 3

Foam - Perpendicular to Rise 42 - 81 N/A 4

Foam - Parallel to Rise 44 - 93 N/A 4

Valve A 36 Carbon Steel 36,000 58,000 1ProtectionDevice ASTM B-26 Aluminum 20,000 25,000 2

Alloy 514 or 356 T6

1. ASME Boiler and Pressure Vessel Code 1995, Section II, Part D.Weakest cylinder material has been selected. In accordance with ANSIN14.1, the 30B cylinder can be fabricated using ASTM A516 Grade 55,60, 65 or 70.

2. These values are higher than the minimum values specified byASTM B26, Alloy 514. Minimum elongation requirement forAlloy 356 T6 is 5%, which is also higher than specified inASTM B-26.

3. Wood data is provided in Appendix 2.10.1.4. Foam data is provided in Appendix 2.10.2.

2-5 Rev. 2, 03/97

2.4 GENERAL STANDARDS FOR ALL PACKAGES

The NCI-21PF-1 package meets the General Standards for All Packages per 10 CFR 71.43.

2.4.1 Minimum Package Size

The overall NCI-21PF-1 package dimensions exceed the minimum dimension requirement of4 in (10 cm) size specified in 10 CFR 71.43(a).

2.4.2 Tamper Proof Feature

The overpack is equipped with two locations for installing tamper indicating devices (typicallyuniquely numbered cup seals). The presence of these seals demonstrate that unauthorizedentry into the package has not occurred.

2.4.3 Positive Closure

The NCI-21PF-1 package is closed by ten (10) one-inch toggle closures which are made ofType 17-4PH Stainless Steel. Each closure is prevented from opening accidentally by a ball-lock pin on its handle. The ball-lock pins have 0.5" diameter shanks made of 17-4PHStainless Steel. The Ball-lock pin is designed such that a button must be depressed in orderto remove the pin.

2.4.4 Chemical and Galvanic Reactions

The components of the NCI-21PF-I overpack will not cause chemical, galvanic, or otherreactions in the packaging or between the package and its contents. The major components ofthe NCI-21PF-1 package are the 30B cylinder (carbon steel), 304 Stainless Steel (OverpackShell), 17-4PH Stainless Steel (Overpack Closures), Red or White Oak (within end walls), andPhenolic Foam (within cylindrical walls).

The phenolic foam is in contact with the 304SS. The stainless steel in contact with the foamis coated with an epoxy primer (DP40 manufactured by PPG Industries, Inc).

In the past, hydrochloric acid was used to reduce the alkalinity of the foam. Severaloverpacks experienced pitting of the stainless steel. The pitting was evaluated and found tobe caused by the high chloride content of foam. Overpacks fabricated with the high chloridefoam are not included in this application. Since 1991, the hydrochloric acid has beenreplaced by oxalic acid. This replacement has significantly reduced the chloride content ofthe foam.

2-6 Rev. 2, 03/97

The NCI-21PF-1 overpack foam is composed of the following:

- Phenolic Resin 66 wt%- Surfactant 2 wt%

Freon TF 7 wt%Boric Anhydride (B203) 8 wt%

- Oxalic Acid (H2C2 0-2H2 0) 8 wt%- Fiberglass 9 wt%

Of the foam components listed above, the chloride content of the phenolic resin has thepotential to corrode stainless steel. All other components do not contain chlorides.

Testing was performed to verify that the specified 300 ppm limit on chloride content of theresin is adequate to prevent corrosion of the stainless steel shells over the life of thepackaging. Tests were performed in accordance with ANSI G-48 "Pitting and CreviceCorrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric ChlorideSolution"; ANSI G-46 "Examination and Evaluation of Pitting Corrosion"; and ANSI D-1654"Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments." Toaccelerate corrosion and to simulate an ambient temperature environment of a U.S. location(Columbia, South Carolina) over a period of twenty years, a test at 420C for 30 days wasdetermined to be necessary.

Stainless steel samples which were representative of the overpack stainless steel were takenand placed in 400 ppm ferric chloride baths for 30 days at 50'C. This temperature wasslightly higher than necessary adding conservatism. The sample combinations that weresubjected to this test were:

- bare stainless steel;- stainless steel coated with primer;- stainless steel coated with primer containing a scribe mark (to simulate a defect

in the coating);- bare stainless steel with foam attached; and- stainless steel coated with primer with foam attached.

Following the test, the samples were evaluated for weight loss, pitting, blisters, loss ofadhesion, and hardness. The hardness measurements were taken to help evaluate subsurfacecorrosion effects. The following results were obtained:

- Bare stainless steel specimens did not show visible pitting and a weight loss of0.002% was recorded.

- Stainless steel primer coated specimens showed blister attack of coating but themetal surface underneath was not attacked. A weight loss of 0.009% wasrecorded.

2-7 Rev. 2, 03/97

- Stainless steel coated and inscribed specimens showed a good adhesion of thecoating, the metal surface underneath was not attacked and a weight loss of0.008% was recorded.

- Stainless steel/foam specimens recorded a weight loss of 0.05%.- Stainless steel coated with primer with foam attached recorded a weight loss of

0.05%.- No significant hardness changes were noted in any of the specimens.

The testing facility concluded that a 400 ppm chloride content in the foam will notsignificantly pit or corrode the stainless steel material over a twenty year service life.Corrosion protection is not dependent on the epoxy primer. The final report provided by thelaboratory is provided in Appendix 2.10.3.

The actual chloride content of the phenolic resin (NCI-PF-1) used in the NCI-21PF-1overpacks is typically less than 100 ppm and does not exceed .300 ppm. The resin is less than2/3 of the foam by weight, so the chloride concentration in the foam is less than 200 ppm.At 200 ppm, the chloride density in the foam is substantially less than half that of the 400ppm ferric chloride baths because of the low density of the foam compared to water. Thefoam specification is included as Appendix 2.10.2.

The overpacks built with NCI-PF-1 foam have been in use since 1991. Overpacks areinspected for corrosion on both in-coming and out-going shipments. No corrosion has beenobserved since the time the foam formulation was changed in 1991.

Therefore, it is concluded that the components of the NCI-21PF-1 overpack will not havechemical, galvanic, or other reactions with one another.

2.5 LIFTING AND TIEDOWN STANDARDS FOR ALL PACKAGES

The top half of the overpack is fitted with 1/2" thick inverted tie-down plates on which theempty package can be stacked; four 3/4" U-bolts in the inverted plates are used for lifting thepackage as well as for securing stacked packages together. Detailed dimensions are shown ondrawings provided in Section 1.3, Appendix. The total weight of 8,870 pounds is used forlifting calculations. The lifting condition is analyzed in Section 2.5.1 to demonstrate aminimum safety factor of three against yield in accordance with 1OCFR71.45(a). Figure 2.5-1provides the key dimensions of the lifting configuration.

The bottom half of the overpack is also fitted with 1/2" thick tie-down plates for bolting tothe floor of the carrier vehicle with eight (8) 3/4" bolts. Detailed dimensions are also shownon drawings provided in Section 1.3, Appendix. In the transport configuration (see Figure2.5-2), the regulatory tie down loads II 1OCFR71.45(b)(1) I are shared by the eight (8) 3/4"bolts.

2-8 Rev. 2, 03/97

2.5.1 Lifting Devices

As discussed in the previous section, the maximum loading condition for lifting occurs when

the weight of the fully loaded package is carried entirely by the four (4) lifting U-bolts withthe package in the horizontal position. The lifting attachments must be capable of supporting

3 times the weight of the package without yielding and 5 times the weight of the packagewithout exceeding the ultimate strength.

Based on the lifting configuration shown on Figure 2.5-1, the maximum vertical lift load for 3

g's at each U-bolt is:

FV = 8870 x 3/4 = 6,653 lbs

The resultant load for a 450 lift is:

Fr = 6653/(cos 450 xcos 450) = 13,306 Ibs

The tensile stress at 3/4" U-bolt threads is (the tensile area for 3/4" bolt is 0.334 in2):

St = 13,306/(2 x 0.334) = 19,920 psi < Sy = 30,000 psi

The shear stress at 3/4" U-bolt lifting point is:

Ss = 13,306/(2 x 7t x 0.752/4) = 15,060 psi < Sy = 30,000 psi

The bearing stress at each bolt hole area is:

Sb = 13,306/[2 x 7i (1.252 - 0.8752)/41 = 10,630 psi < Sy = 30,000 psi

Based on the results of the above analyses, it is concluded that the design of the packagelifting attachment is structurally adequate to withstand the maximum lifting loads.

2.5.2 Tiedown Devices

The package is tied-down to the trailer at eight bolted locations in the footings by using 3/4W,

A-193 B-7 bolts. The attachments are designed to withstand the 2/5/10 g tiedown loads.

a. Stress due to maximum transverse load

Based on the transport configuration shown on Figure 2.5-2, the maximum resultant transverseloading is (102 + 52)12 or 11.18 G's. The maximum shear stress at the bolt under thistransverse load is:

Ss = 8,870 x 11.18/(8 x 0.334) = 37,115 psi < Sy= 105,000 psi

2-9 Rev. 2, 03/97

b. Stress due to maximum vertical load

Based on the transport configuration shown on Figure 2.5-2, the maximum resultant vertical

load is calculated as follows:

The longitudinal (10 g) load is taken by four bolts:

V, = 10 x 8870 x (21.5"/40") = 47,676 lbs

This force affects four bolts. Therefore: Vh = 11,919 lbs per bolt

The transverse (5 g) load is also taken by four bolts:

Vt = 5 x 8870 x (21.5"/58") = 16,440 lbs

This force affects four bolts. Therefore: Vt = 4,110 Ibs per boltCombining the maximum total vertical load on each bolt calculated above, plus that due to a

2g vertical load:

Vtotal = (2 x 8870)/8 + 11,919 + 4,110Vtotal = 18,247 lbs

The maximum tensile stress per bolt is:

St = Vtotal / Abolt = 18,247 Ibs / 0.334 in2 = 54,632 psi < Sy = 105,000 psi

Based on the results of the analyses, it is concluded that the tiedown device is structurally safe

for the specified loads.

2-10 Rev. 2, 03/97

Figure 2.5-1NCI-21PF-1 Package Lifting Configuration

FR

DIA. U-BOLT0.875- DIA.-

BOLT HOLE DETAIL

2-11 Rev. 2, 03/97

Figure 2.5-2NCI-21PF-I Package Transport Configuration

. 21. BOLTED TO FLATBED2n IN EIGHT LOCATIONS

2-12 Rev. 2, 03/97

2.6 NORMAL CONDITIONS OF TRANSPORT

2.6.1 Heat

Normal conditions of transport effects from heat are described in Chapter 3.

2.6.2 Cold

An ambient temperature of 40'F will not have an adverse effect on the NCI-21PF-1 and the

valve protection device. The ductility of the aluminum and stainless steel in the overpack isnot seriously affected by temperatures in this range.

The UF6 cylinder is fabricated in accordance with ANSI N14.1 which specifies materialssuitable for use at -400F.

At very low temperatures the internal pressure of the cylinder will be close to zero absolute.

Structurally, this is equivalent to an external pressure of one atmosphere or 14.7 psia. UnderANSI N14.1, the 30B cylinder is designed for an external pressure of 25 psig.

2.6.3 Reduced External Pressure

The internal pressure of a filled 30B cylinder will range from 0 to 14.7 psia (corresponding toUF6 temperature of 00F to 130'F, respectively). A reduced external pressure of 3.5 psia willresult in a net internal pressure of 3.5 psig. This pressure is significantly less than the designinternal pressure of the 30B cylinder (200 psig).

2.6.4 Increased External Pressure

An increased external pressure of 20 psia would result a net external pressure of 20 psig

(conservatively assumed minimum cylinder cavity pressure of 0 psia). The cylinder isdesigned for an external pressure of 25 psig as specified in ANSI N14.1.

2.6.5 Vibration

Vibration normally incident to transport has negligible effect on the NCI-21PF-I package.The UF6 cylinders are firmly clamped between Neoprene pads to prevent movement duringtransport and all parts which could loosen because of vibration have been secured by specialmeans as described below:

Lifting U-bolts of the NCI-21PF-1 are secured to the stacking frames with heavy hex nutswhich are tightened down on lock washers to prevent them from vibrating loose..

2-13 Rev. 2, 03/97

Toggle closures are protected from adverse effects of vibration:

- Adjusting collars are locked by three self locking set screws in each collar so thatneither the collars nor the set screws may vibrate loose.

- Toggle pivots (shoulder bolts) are tack welded after installation to prevent them fromvibrating loose.

- Toggle mechanisms are under tension when closed and the handles are locked down byself-locking ball-lock pins which cannot vibrate loose.

No other parts of the NCI-21PF-l package are subject to loosening or other damage byvibration.

2.6.6 Water Spray

Subjecting the NCI-21PF-1 package to a water spray simulating rainfall at a rate of 2 in/hr forone hour will have a negligible effect. The wood and foam insulation in the NCI-21PF-1package are totally encased in a welded stainless steel jacket with no penetrations other thanthe vents which are sealed and closed. The lids and bodies join at a closure joint which isstepped down to the outside with a soft gasket on the in-board side to keep water out of thecylinder cavity.

2.6.7 Free Drop

The packaging must withstand a free drop from a height of 4 feet (1.2 meters) onto a flat,essentially unyielding horizontal surface. Damage resulting from the four foot free dropcould result in some local deformation of the overpack. However, any local damage due tothe drop would not result in any reduction in the packaging effectiveness.

It is shown in Section 2.7 that the 30 foot hypothetical accident drops, which are performed inthe orientation for which maximum damage is expected to occur, does not result in damage tothe cylinder which would allow the release of radioactive materials. Therefore, it isdemonstrated that for the 4 foot free drop which are less severe than the hypothetical accidentdrops, there would also be no loss or dispersal of radioactive contents.

The damage of the overpacks due to the 30 foot drops was local. The four foot free drop ismuch less severe than the 30 foot drops. Evaluating the damage from the 30 foot free drops,reported in Section 2.7, indicates that the normal condition drop test would not substantiallyreduce the effectiveness of the packaging. Since only the 30B cylinder is required to meet theshielding requirements, there would be no significant increase in external surface radiationlevels. There is also no criticality concern, since as shown in Chapter Six, criticality ismaintained without the overpacks.

2-14 Rev. 2, 03/97

2.6.8 Corner Drop

Not applicable to the NCI-21PF-1 package.

2.6.9 Compression

The minimum vertical projected area of the phenolic foam in the NCI-21PF-1:

(43.5 in) (82.625 in) = 3,594 in2

Five times the weight of the package is:

(5) (8,870 Ibs) = 44,350 lbs

This is equivalent to a pressure of:

44,350 lbs / 3,594 in2 = 12.34 psi

This pressure is less than the minimum compressive strength of the foam which is 42.2 psi.This assumption neglects the presence of the 30B cylinder, the stainless steel shells of theoverpack and wood ends of the overpack.

M.S. = (42.2/12.34) - 1 = 2.4

As a further demonstration of this requirement, previous testing, uniformly loaded a half scaleNCI-21PF-1 test model with 6,000 pounds (more than 5 times its loaded weight of 1100pounds) for a period of 24 hours with no visible damage (See Photo 2.6-1).

2.6.10 Penetration

The 13 pound rod described in 10 CFR 71 will have a negligible effect on the 14 gage(0.0747") steel walls of the NCI-21PF-1 overpack. The first safety analysis report performedon the DOT-21PF-1 overpack (K-:1686, "Protective Shipping Packages for 30 Inch DiameterUF6 Cylinders") reports a drop test was performed in which a 13-pound, 1-1/4" diameter steelrod was dropped 4 feet onto the shell of the DOT-21PF-1 prototype. The rod did notpenetrate but caused a "barely discernable" indentation in the thin walled 16 gage (0.0598")steel. Since the thickness of the walls are greater than the thickness of the walls of the testmodel of the NCI-21PF-1 overpack, it is concluded that negligible damage to the NCI-21PF-1overpack due to the penetration test.

2.6.11 Conclusion

As shown in Chapter Six, criticality of the packagings is validated with and without the use ofoverpacks. Therefore, any local change to the package overall dimensions due to the free

2-15 Rev. 2, 03/97

Photo 2.6-1Compression Testing

I

2-16 Rev. 2, 03/97

drop test would not result in a criticality concern. Similarly, since the shielding requirementsare met by the 30B cylinder, any local change in the overpack dimensions will not result in adecrease in the shielding effectiveness of the package. Containment is shown to bemaintained after the hypothetical accident conditions, which are more severe than the NormalConditions of Transport conditions of 10CFR71.

From the analyses presented in Section 2.6, it is shown that the normal loads will not result inany significant structural damage of the NCI-21PF-1 package and the containment function ofthe 30B cylinder will be maintained.

2.7 HYPOTHETICAL ACCIDENT CONDITIONS

The NCI-21PF-1 overpacks and similar overpacks have undergone extensive testing since theywere originally designed. However, over the years various changes were made to theoverpacks, including a change in the formulation of the phenolic foam, which brought thevalidity of these tests into question. In addition, testing performed on similar packagesindicated that in certain orientations, these overpacks may not suitably protect the cylindervalve from the 30 foot drop and 40 inch puncture hypothetical accident drops. In order todetermine the worst drop and puncture test orientations, a survey of previous test programs onthe NCI-21PF-l and similar packagings was performed. This survey is summarized inAppendix 2.10.6. Based on these results, it was determined that two orientations, 13.5° fromvertical and 30° from vertical could result in damage to the valve, either by allowing thecylinder skirt to bend and impact the valve or allowing the overpack inside wall to impact thevalve. These impacts were only evident on packages with damaged cylinder skirts due toprevious drop testing. The valve protection device was designed to prevent these failuremechanisms.

High chloride overpacks which are no longer in service were used to determine which of thetwo "worst case" angles was more severe for the NCI-21PF-I overpacks. Since the highchloride and low chloride overpacks are essentially the same package with the exception ofthe foam formulation, these tests are valid for determining worst drop orientation. The testswere not intended as compliance tests nor were they intended for use in revalidating the highchloride overpacks.

Two high chloride NCI-21PF-I overpacks with valve protection devices installed weresubjected to the sequence of the drop and puncture tests of the hypothetical accidentconditions of 10 CFR 71.73 as required for Type B and fissile materials packagings. Thesepreliminary tests are described in Appendix 2.10.6. It was determined from these tests thatthe worst orientation for the NCI-21PF-l overpack was a 30 foot drop at an angle of 13.50from vertical such that the package landed directly onto the valve. This was followed by adrop onto the puncture bar in the same orientation.

2-17 Rev. 2, 03/97

A full-scale representative NCI-21PF-1 overpack with valve protection device was subjectedto the sequence of the drop, puncture and fire tests of the hypothetical accident conditions of10 CFR 71.73. A comparable hydrostatic test was performed for the 3 foot immersion test.An assessment of immersing the package 50 feet in water was also performed.

A detailed test program is provided as Appendix 2.10.5.

Test Program Summary

The testing program began with the preparation of the 30B cylinder. The cylinder valve wasremoved and the cylinder skirt was bent 1 inch toward the valve location and repaired. Thisactivity was performed to encompass the worst damage expected to be seen by the cylinderskirt during normal handling. The cylinder was loaded with steel shot to the maximum testarticle weight. The cylinder valve was replaced and the cylinder was leak tested for normalconditions using two methods: 100 psig soap bubble test and helium mass spectrometer test.The cylinder was not pressurized for compliance testing.

Temperature measuring devices were mounted to the exterior surfaces of the cylinder. Thevalve protection device was installed in the cylinder in accordance with the sequencedescribed in Chapter 7. The cylinder was loaded into the overpack. The overpack was closedutilizing the torque sequence described in Chapter 7.

The package was then placed into a cooling chamber until it cooled to a temperature ofapprox. -20'F. When the overpack approached the designated temperature, the 30 foot freedrop which was determined to result in maximum damage to the packaging (13.50 fromvertical C.G. over valve orientation) was performed followed by the 40 inch puncture test inthe same orientation. External deformation to the overpack was recorded. The package wasnot opened. The package was then warmed to 1000F in preparation for the 30 minute firetest. The package was subjected to a 30 minute fully engulfing hydrocarbon fire.

Following the fire, the overpack was opened and the 30B cylinder removed. The cylinderwas leak tested. The 30B cylinder was then subjected to a hydrostatic test at 19 psig which isequivalent to the 3 foot immersion test of lOCFR 71.73.

The results of the tests and analyses demonstrate that the NCI-21PF-I overpack with valveprotection device installed effectively protects the 30B cylinder from damage. The testingresults are detailed in the following subsections. Figure 2.7-1 provides a flow chart of thetesting program. The test report is provided in Appendix 2.10.5.

2-18 Rev. 2, 03/97

2.7.1 Free Drop

A full-scale representative NCI-21PF-l overpack (removed from service for this testing) withvalve protection device was used for the 10 CFR 71 hypothetical accident compliance testing.The valve protection device was designed to protect the cylinder valve.

The test was performed at an angle of 13.50 from vertical in the center of gravity over valveorientation. This 13.5° orientation was selected because it was indicated by previous testing(Appendix 2.10.6) that this drop angle has resulted in the most damage to the 30B cylindervalve. The test setup for the 13.50 orientation drop test is shown in Figure 2.7-2.

The 30 foot drop test was performed at low temperature to evaluate the adequacy of the woodand attachments. Due to the low thermal conductivity of the overpacks, the cylinder did notreach -20'F. The overpack was cooled to -210F (as measured in the wood of the overpack)and the cylinder was cooled to -80F (as measured on the cylinder skirt).

Once cooled, the package was positioned at an orientation of 13.5° from vertical, and raised30 feet as measured from the lowest position on the package. The package was rotated sothat the impact would be into the valve location.

The package was dropped onto an essentially unyielding surface. The drop pad was a 10' x10' x 6' reinforced concrete slab embedded in the ground. The concrete slab was covered bya 1" thick steel plate that was attached using J-bolts. The weight of the drop pad is estimatedat 95,000 lbs.

External deformation data was recorded and video and photographs were taken (See Appendix2.10.5 for photos). Section 2.7.6 summarizes the damage to the package. The package wasnot opened after the 30 foot drop. It was then subjected to the puncture test.

2.7.2 Puncture

The puncture bar was a six inch diameter by 16" high mild steel bar welded into a 2" thicksteel plate. The plate was then bolted to the steel plate on the drop pad. The test setup forthe 13.50 orientation puncture test is shown in Figure 2.7-3.

Following the 30 foot drop test, the package was positioned at an orientation of 13.50 fromvertical, and raised 40 inches above the puncture bar as measured from the lowest position onthe package. The temperature of the wood during the puncture test was -60F, and thetemperature of the cylinder skirt was 7.50F. The package was rotated so that the puncturewould be into the valve location.

Photographs and video were taken (See Appendix 2.10.5 for photos). External deformationmeasurements were taken (see Section 2.7.6). The package was not opened. The packagewas then subjected to the thermal testing.

2-19 Rev. 2, 03/97

2.7.3 Thermal

The cylinder was instrumented with thermocouples, maximum temperature sensors and heatsensitive paint. Fifteen thermocouples were installed on the cylinder, and an additional sixthermocouples were used to monitor the temperature of the fire. The maximum temperaturesensors had a range of 150'F - 500'F and were in the form of irreversible self-adhesivetemperature monitors consisting of heat sensitive indicators sealed under transparent heatresistant windows. Heat sensitive colored paint (range from 1250F - 11 000F) was also used tomonitor the maximum temperature during the test and cool down period.

All thermocouples consisted of 20 Gage, type K, Chrome-Alumel grounded junctions withmagnesium oxide insulation and Inconel 600 sheath. A hole was drilled in the end of theoverpack opposite the valve to serve as a conduit for the thermocouple wires. The hole waspacked with insulation. A metal cover was installed over the thermocouple leads to protectthem from secondary impacts during the drop testing.

Prior to the fire test, the package was heated to 1000F. The package was mounted 40" abovethe surface of the fuel source. The test stand was water cooled during the fire to preventcollapse of the structure.

Originally, the test stand was mounted in the center of a 15' x 15' fuel pool which wassurrounded by two containment pans, a 25' x 25' primary containment and a 30' x 30'secondary containment pan. Due to difficulties obtaining.a fully engulfing fire, the fuel poolsize was increased to include the 25' x 25' pan. Figures 2.7-4 and 2.7-5 illustrate the firetest layout. No 2 diesel fuel was floated on water within the 15' x 15' and the 25' x 25'pans. This resulted in a fire area slightly greater than that specified in the regulations on thesides of the package, but within the regulations for the ends of the package.

The fire was performed at dusk, when the wind speed was lowest. The wind speed during thefire test was 4-6 mph. The fire was fully engulfing, and lasted for 31 minutes. The wood inthe overpack continued to burn for about 10 minutes. The package was left on the test standto cool for 24 hours prior to moving.

Thermocouple data was obtained both during the fire and during cool down. Photographsand video were taken of the fire. The package was then opened for inspection and leaktesting (see Section 2.7.6).

2-20 Rev. 2, 03/97

2.7.4 Immersion - Fissile Material

As required by 10 CFR 71.73(c)(5), "in those cases where water inleakage has not beenassumed for criticality analysis the hypothetical accident conditions shall include immersionunder a head of water of at least 3 ft in the attitude for which maximum leakage is expected."The criticality analysis presented in Chapter 6 assumes that water does not enter the 30Bcylinder following the hypothetical accident conditions.

All seals on the 30B cylinder and in the valve are metal. The valve threads are tinned withsolder and then threaded into the cylinder. The tinning material is typically extruded from thethreads during the valve installation process. Since there are no elastomeric seals on thecylinder or in the valve, the leakage path into the cylinder would be identical to the leakagepath out of the cylinder.

On this basis, instead of performing a water immersion test, an equivalent hydrostatic pressuretest was performed. The test pressure is conservatively calculated assuming the internalpressure of the cylinder is zero absolute. Therefore, the test pressure is:

PHydro Test Patm + P 9.8 ft + Apinternal pressure= 14.7 psia + 4.24 psia + 14.7 psia= 33.6 psia= 19 psig

Following the 30 foot free drop, 40 inch punch, and 30 minute fire, the 30B cylinder wasfilled with water to 19 psig. The water was dyed to a blue color (which would contrastagainst the white painted cylinder). Periodically over an 8 hour period, checks were made atthe valve for any indication of leakage. Results of the hydrostatic test are presented inSection 2.7.6.

2.7.5 Immersion - All Packages

Under 10 CFR 71.73(c)(6), a second immersion test is required on an undamaged packageunder 50 feet of water (21.7 psig). For an undamaged filled 30B cylinder, the internalpressure could be 0 psia. The equivalent external pressure on the 30B cylinder would be39.3 psig.

The maximum allowable working pressure on the cylinder is 135 psig (see Appendix 2.10.4),Therefore, the 30B cylinder will not be adversely affected by the water pressure.

2-21 Rev. 2, 03/97

2.7.6 Summary of Damage and Test Results

Damage from the full compliance testing has been documented through photographs andvideo.

External Overnpack Damage

The overpack damage following the 30 foot drop is represented in Figure 2.7-6. No closuresbroke or loosened. The two toggles at the impact end were bent. One of the pins on the nonimpact end had come loose and fallen out of place. No opening of the overpack wasobserved. The seam of the overpack had opened up approximately 0.375 inch at the impactend. The rest of the seams were tight. The top of the overpack had moved axially about 0.3inch, with respect to the bottom of the overpack.

The overpack damage following the 40 inch puncture test is represented in Figure 2.7-7. Allclosures remained intact. The punch did not expose any wood.

The damage following the 30 minute fire is shown in photographs provided in Appendix2.10.5. All the plugs were burned.

Valve Protection Device and Cylinder Damage

Prior to drop testing, the original dimensions of the cylinder valve in relation to the cylinderskirt and the valve protection device were measured. The locations where measurements weretaken and their initial values are represented in Figures 2.7-8. Following the drop, punctureand fire tests, the cylinder was removed from the overpack.

When the cylinder was removed from the fire, a dark combustion residue was observed insidethe overpack. The overpack gasket present in the non-impacted areas was intact. The rubberpads which aid in holding the cylinder were also intact. The paint on the cylinder hadblistered in many places. The thermocouple gathered data and the irreversible maximumtemperature tapes were legible. Unfortunately, the temperature paints were covered by thecombustion residue and were not readable.

The dimensions of the cylinder valve in relation to the cylinder skirt and the valve protectiondevice were remeasured. The locations where measurements were taken and their finalvalues are represented in Figures 2.7-8.

The dimensions of the valve and cylinder with respect to the top and inside diameter of theskirt did not give a clear indication of the clearance beneath the VPD and the valve stem.This was attributed to allowable variations in the shape of the cylinder heads. A betterindication of whether the VPD will protect the valve from impact due to the drop andpuncture tests is a direct measurement of the distance between the bottom of the VPD bridgeand the top of the valve stem "g" on Figure 2.7-8. Any gap between the VPD and the

2-22 Rev. 2, 03/97

cylinder head must also be considered, since any gap would close upon impact and couldmake the "g" value appear larger.

As a result of the drop testing, the valve protection device "bridge" was permanentlydeformed as shown on Figure 2.7-9. The deformation included reduction in the overall heightof the VPD bridge (measurements h and i on Figure 2.7-9) and local deformation directlyabove the valve (deflection shown on Figure 2.7-9). The permanent deformation was 0.146inches.

Based on these test results, a "g - Gap" of at least 0.146 inches is required to providesufficient clearance around the valve to prevent impact. For conservatism, it is recommendedthat this value be measured prior to first use of a VPD device with each cylinder, and aminimum "g - Gap" value of 3/16 inches be required.

Leak Testing

Prior to full scale compliance testing, the 30B cylinder was subjected to leak testing to verifythat the package met the normal conditions containment criteria discussed in Chapter 4. Thecylinder was pressurized to 100 psig with air and a soap bubble test performed. The pressurewas held for 15 minutes. The soap film was applied to the valve threads, stem, packing nut,and cap. No air leaks were detected. Following the soap bubble test, the package wasevacuated for a helium leak test. No leaks greater than 1 x 10-7 std cc/sec were detected.

Following the drop and fire test, the cylinder was removed from the overpack. This cylinderwas subjected to the same air and helium leak tests described above. The bubble test at 100psig did not indicate any leakage. No leaks greater than I x 10-7 std cc/sec were detectedusing the helium mass spectrometer method.

Following the leak testing, the steel shot was removed from the cylinder using the bottomplug. The 19 psig hydrostatic test was performed. No water leakage from the cylinder wasdetected during a period of 8 hours.

2.7.7 Conclusion

Based on the results of the tests, it has been concluded that the NCI-21PF-1 overpack withvalve protection device will absorb the required energy and remain on the packaging afterundergoing the hypothetical accident events defined in 1OCFR71.73. The compliance testingdemonstrated:

- Though some deflection of the cylinder. skirt was evident as shown in Figures 2.7-8,the valve protection device prevented both the cylinder skirt from collapsing and theoverpack wall from impacting the cylinder valve.

2-23 Rev. 2, 03/97

- During the fit up of the valve protection devices in several cylinders for testing it wasapparent that the g and Gap values should be checked prior to use in a cylinder (seeChapter 8). The following pre-test dimensions must be considered prior to installationof the valve protection device (Refer to Figure 2.7-9):

(G, Distance between valve stem and VPD "bridge") minus (Gap, distance betweenunderside of VPD and 30B cylinder head) 2 3/16 inches (5 mm)

- The 30B cylinder remained leak tight after accident testing.

Therefore, the NCI-21PF-I overpack with the valve protection device will provide adequateprotection to the 30 B cylinder against the hypothetical accident conditions of 10 CFR 71.73.

2-24 Rev. 2, 03/97

( (CFigure 2.7-1

NCI-21PF-1 Package With Valve Protection Device Testing Program

2-25 Rev. 2, 03/97

Figure 2.7-1NCI-21PF-1 Package with Valve Protection Device Testing Program

(continued)

2-26 Rev. 2, 03/97

C (-Figure 2.7-1

NCI-21PF-1 Package with Valve Protection Device Testing Program(continued)

2-27 Rev. 2, 03/97

Figure 2.7-2NCI-21PF-1 Package with Valve Protection Device

13.50 Drop Test Set Up

2-28 Rev. 2, 03/97

I Figure 2.7-3NCI-21PF-1 Package with Valve Protection Device

13.5° Puncture Test Set Up

2-29 Rev. 2, 03/97

Figure 2.7-4Fire Test Setup 1

Overall Test Layout

DMtM Acqfusitaon

60

Figure 2.7-5Fire Test Setup 2

Containmnent Pan Configuration

\ ISo E I JO

4. 4

-4 4 I

x0 -

2-30 Rev. 2, 03/97

Figure 2.7-6NCI-21PF-1 Package with Valve Protection DeviceExternal Damage following 13.50, 30 ft Drop Test

Figure 2.7-7NCI-21PF-I Package with Valve Protection Device

External Damage following 13.50, 40 inch Puncture Test

2-31 Rev. 2, 03/97

Figure 2.7-8NCI-21PF-1 Package with Valve Protection Device

Valve Position Measurement Locations

ylinder Head \ Vcivewith Namre Plate

Valve' Protection Devic

|t(t \ Cr Ha vlvel ~~with Namie Plate \<G p

| I (at any Curved

2-32 Rev. 2, 03/97

Figure 2.7-8NCI-21PF-1 Package with Valve Protection Device

Valve Position Measurement Locations(continued)

Post-Test:Pre-Test:

- VPD BRGE'

30B VALVE

r- VPD BRDGE

30B VALVE

GAP

Location

A

B

C

D

g

gap

Pre-Test(inches)

0.70

5.00

2.30

81.3

0.63

0.186

Post-Test(inches)

0.576

4.80

1.94

81

0.41

0.0

2-33 Rev. 2, 03/97

Figure 2.7-9NCI-21PF-1 Package with Valve Protection Device

Valve Protection Device Permanent Deformation

Post-Test:Pre-Test:

DEFLECTION (IF ANY) VPD BRIDGE-VPD -BRDGE-

4- 30B VALVE

GAP PRESENT

30B VALVE

NO GAP

Location

h

i

deflection

Height at bridge*

Pre-Test(inches)

7.03

7.06

0.017

7.028

Post-Test(inches!

6.95

6.98

0.083

6.882

Permanent Deformation ofVPD**

0.146

* height at bridge is calculated by: {1/2 (h - i) - deflection)** permanent deformation is calculated by: (Height at Bridge)pre-tet - (Height at Bridge)posttest

2-34 Rev. 2, 03/97

2.8 SPECIAL FORM

Special form material as defined in 10 CFR 71 is not applicable to the NCI-2 1 PF- 1.

2.9 FUEL RODS

This section is not applicable to the NCI-21PF-1.

2-35 Rev. 2, 03/97

APPENDIX 2.10.1WOOD PROPERTIES

TABLE OF CONTENTS

2.10.1.1

2.10.1.2

Introduction ........................................ 2.10.1-1

Compression Test ....................................2.10.1.2.1 Compressive Strength, Perpendicular to Grain .......2.10.1.2.2 Compressive Strength, Parallel to Grain .

2.10.1-32.10.1-32.10.1-7

2.10.1-1

LIST OF TABLES

Compression Properties for Dry Red and White Oak .... ........ 2.10.1-2

LIST OF FIGURES

2.10.1-12.10.1-22.10.1-32.10.1-42.10.1-52.10.1-6

Stress vs Strain, Perpendicular to Grain (Sample No.Stress vs Strain, Perpendicular to Grain (Sample No.Stress vs Strain, Perpendicular to Grain (Sample No.Stress vs Strain, Parallel to Grain (Sample No. 5) . .Stress vs Strain, Parallel to Grain (Sample No. 6) . .Stress vs Strain, Parallel to Grain (Sample No. 21) .

1).........2) .........3) .........

. 2.10.1-4

. 2.10.1-5

. 2.10.1-6

. 2.10.1-8

. 2.10.1-92.10.1-10

2.10.1-i Rev. 2, 03/97

APPENDIX 2.10.1WOOD PROPERTIES

2.10.1.1 Introduction

This appendix presents the results of the wood compression testing. The NCI-21PF-1overpack is designed to absorb the kinetic energy resulting from four (4) foot and thirty (30)foot normal and hypothetical accident free drop events specified by l0CFR71. Red and whiteoak wood are used as the primary energy absorption materials in the overpack. Details anddimensions of the overpack are shown on drawings provided in Section 1.3, Appendix. Afunctional description of the overpack is given in Section 1.2.

The wood in the NCI-21PF-1 protective shipping package is specified as red or white oakwith a moisture content less than 15%. Published wood properties (Table 2.10.1-1) illustratethat the compression properties for dry oak vary. These values vary from 6,060 to 8,900 psifor compression parallel to grain and vary from 810 to 2,840 psi for compressionperpendicular to grain.

Testing was performed on representative samples of wood used by the manufacturer to buildNCI-21PF-1 overpacks to obtain sample stress-strain curves.

2.10.1-1 Rev. 2, 03/97

Table 2.10.1-1Compression Properties for Dry Red and White Oak(')

| Specific Gravity Compression CompressionI parallel to grain perpendicular tol (psi) grain (psi)

Oak, red:

Black 0.61 6520 930

Cherry bark 0.68 8740 1250

Laurel 0.63 6980 1060

Northern Red 0.63 6760 1010

Pin 0.63 6820 1020

Scarlet 0.67 8330 1120

Southern Red 0.59 6090 870

Water 0.63 6770 1020

Willow 0.69 7040 1130

Oak, white:

Bur 0.64 6060 1200

Chestnut 0.66 6830 840

Live 0.88 8900 2840

Overcup 0.63 6200 810

Post 0.67 6600 1430

Swamp Chestnut 0.67 7270 1110

Swamp White 0.72 8600 1190

White 0.68 7440 1070

1. Wood Handbook: Wood as an Enpineering Material, United States Department of Agriculture,Forest Service, Agricultural Handbook 72. 1987.

2.10.1-2 Rev. 2, 03/97

2.10.1.2 Compression Test

Six representative wood samples were taken from wood batches on hand at the overpackmanufacturer. Testing was conducted on these samples in accordance with ASTM StandardD 143, Small Clear Specimens of Timber, Subsections 55-58, "Compression Parallel to Grain"and Subsections 79-82 "Compression Perpendicular to Grain." The following sectionsprovide the results of the testing.

2.10.1.2.1 Compressive Strength. Perpendicular to Grain

Stress vs strain charts from the testing are provided in Figures 2.10.1-1, 2.10.1-2 and 2.10.1-3.A tabular summary of the results are provided below.

Summary of Test Results

Cross Average AverageSample Section Load at Compressive Sample Compressive

Sample Density Area Yield Strength Density StrengthNo. (1bs/ft ) (in2) (lbs) (psi) (lbs/ft ) (psi)

1 52.0 11.6 24,000 2,069 51.9 2,073

2 52.3 11.7 24,000 2,048

3 51.4 11.7 24,500 2,101 _]

2.10.1-3 Rev. 2, 03/97

Figure 2.10.1-1Stress vs Strain, Perpendicular to Grain (Sample No. 1)

U,

I I

2500

2250

2000

1750

v 1500

1250

1000'

750

500

250

0 -T---- | | I I , . . ,

0 0.05 0.1 0.15 0.2 0.25Strain

0.3

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

TN-1055W-IWidth = 1.95 inchesLength = 5.95 inchesHeight = I1A0 inches221.3 gramsShearing

2.10.1-4 Rev. 2, 03/97

Figure 2.10.1-2Stress vs Strain, Perpendicular to Grain (Sample No. 2)

2500

2250

2000

1750

.e:,' 1500

M 1250Go1 -i

v) 1000

750

500

250

*I 0 I .I ..

0 0.05 0.1 0.15 0.2 0.25Strain

0.3

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

TN-1055W-2Width = 1.97 inchesLength = 5.95 inchesHeight = 1.39 inches223.0 gramsShearing

2.10.1-5 Rev. 2, 03/97

Figure 2.10.1-3Stress vs Strain, Perpendicular to Grain (Sample No. 3)

3000

2750

2500

2250

2000

1750

1500

1250

1000

750

500

250

0

-I

-I

------ 4--

- - - - - - - --…

- - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - - - - - -- - - - -- - - - - - - - - - - - - - - - - -- - -

- - - - - -- - - - - - - - - - - - - - - - - - - - - -

- - - - - -- - - - - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -I - - - - -

- - - - - - --- - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - - - --…

- -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

0.0 I. 0.1 0. .2

I StrinI

.30

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

TN-1055W-3Width = 1.95 inchesLength = 5.98 inchesHeight = 1.40 inches219.7 gramsShearing

2.10.1-6 2. 1.1-6Rev. 2, 03/97

2.10.1.2.2 Compressive Strength. Parallel to Grain

Stress vs strain charts from the testing are provided in Figures 2.10.1-4, 2.10.1-5, and 2.10.1-6. A tabular summary of the results are provided below.

Cross Average AverageSample Section Load at Compressive Sample Compressive

Sample Densi 7 Area Yield Strength Density StrengthNo. (lbs/ft ) (in2) (lbs) (psi) (lbs/fti) (psi)

5 47.4 16.2 134,000 8,292 47.3 7,921

6 47.6 16.2 134,000 8,292

21 47.0 15.6 112,000 7,179

2.10.1-7 Rev. 2, 03/97

Figure 2.10.1-4Stress vs Strain, Parallel to Grain (Sample No. 5)

eu:~C,,

c)

co

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

00 0.05 0.1 0.15 0.2 0.25 0.3 0.35

Strain0.4

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

TN-1055W-5Width = 2.02 inchesLength = 8.00 inchesHeight = 1.50 inches301 gramsShearing

2.10.1-8 Rev. 2, 03/97

Figure 2.10.1-5Stress vs Strain, Parallel to Grain (Sample No. 6)

10000

9000

8000

7000

*-., 6000

V2 5000V

C- 4000

3000

2000

1000

00 0.05 0.1 0.15 0.2 0.25 0.3 0.35

Strain0.4

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

Th-1055W-6Width = 2.02 inchesLength = 8.00 inchesHeight = 1.50 inches302.2 gramsShearing

2.10.1-9 Rev. 2, 03/97

Figure 2.10.1-6Stress vs Strain, Parallel to Grain (Sample No. 21)

ca

CO2

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

00 0.05 0.1 0.15 0.2 0.25 0.3 0.35

Strain0.4

Sample Identification:Sample Dimensions:

Sample Weight:Failure Mode:

TN-1055W-21Width = 2.00 inchesLength = 7.80 inchesHeight = 1.38 inches265.2 gramsShearing

2.10.1-10 Rev. 2, 03/97

APPENDIX 2.10.2MATERIAL AND EQUIPMENT SPECIFICATION OF PHENOLIC FOAM

TABLE OF CONTENTS

2.10.2 NUCLEAR CONTAINERS, INC., NCI-PF-I FOAM SPECIFICATION .... 2.10.2-1

2.10.2-i Rev. 2, 03/97

APPENDIX 2.10.2MATERIAL AND EQUIPMENT SPECIFICATION OF PHENOLIC FOAM

Attached to this appendix is the material and equipment specification for the NCI-PF-1 fireresistant phenolic foam.

2.10.2-1 Rev. 2, 03/97

NUCLEAR CONTAINERS, INC.ELIZABETHTON, TN

SPECIFICATION NO:

PROCEDURE TYPE:

DESCRIPTION:

NCI-PF-1

MATERIAL AND EQUIPMENT SPECIFICATION

NCI-PF-1 FIRE RESISTANT PHENOLIC FOAM

This page is record of revisions to this procedure. Each time a revision is made, only therevised pages are reissued. Remarks indicate a brief description of the revision and are not apart of the procedure.

REVISIONS

0

1

2

DATE

6/09/95

9/27/95

12/08/95

AFFECTEDPAGE(s)

ALL

1,4

4

REMARKS

ORIGINAL

TECHNICALADJUSTMENTS

TECHNICALADJUSTMENTS

COC REQUIREMENTS3 2/28/97 ALL

Uncontrol 1 ed Copy

Page 1 of 8NCI-PF-1, Rev. 3

Nuclear Containers, Inc.Material and Equipment Specification

NCI-2 1 PF- 1Fire Resistant Phenolic Foam

Scope

This specification shall cover materials and procedures for mixing and applying foamed-in-place fire resistant phenolic foam with a density range of 6.5-9.0 lbs/ft3 .

Materials

All materials used in this phenolic foam shall be as listed below. Any substitutions not listedshall require approval of the competent authority prior to use in a specification package.

Material Specification Component Weight %

Phenolic Resin* Schenectady Chemical Company#HRJ-1 1825Chloride Content < 300 ppm

65.8 ± 0.2

Surfactant Dow Coming DC-193 2.0 ± 0.1

1,1,2-trichloro-1 ,2,2-triflouroethane

C 2 C13 F 3

(Dupont Freon TF or equivalent)6.6 ± 0.1

Boric Anhydride B 2 03

Practical grade or betterMesh Size: 50

minimum 8.0

Oxalic Acid

Fiberglass Rovings'/4" chopped length

H 2 C 2 0- 2H 2 0Technical grade or better

Coated for compatibility withphenolic resin(Owens Coming 405)

8.2 ± 0.1

9.6 ± 0.4

*Note: Phenolic Resins are required to have a chloride content of less than 300 ppm.Prior to use the chloride content shall be verified by an independent laboratory.

Page 2 of 8NCI-PF-1, Rev. 3

Basic Physical Properties

Thermal Conductivity

Based on testing performed on samples ranging in density from 6 lbs/ft3 to 10 lbs/ft3, thethermal conductivity of the foam ranges from 0.25 to 0.30 Btu-in/hr-ft2-°F at 750F. Testingwas performed in accordance with ASTM C-177, "Steady-State Heat Flux Measurements andThermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus"

Compressive Strength

Testing was performed in accordance with ASTM D-1621 " Compressive Properties of RigidCellular Plastics." Testing was performed on April 29, 1996, using a 10K Instron UniversalTesting Machine. The unit had a range from 0-10,000 pounds (Serial Number:89872,315,103; Calibration Date: 12/21/95; Calibration Due Date; 12/21/96).

The testing was performed on samples ranging in density from 6 Ibs/ft3 to 10 lbs/ft3 . Thefollowing compressive strength properties were identified:

Load Direction - Parallel to Rise - 44 psi to 92 psiLoad Direction - Perpendicular to Rise - 42 to 81 psi

Typical stress strain curves for the phenolic foam at low and high densities are attached asFigures 1 to 4.

Storage Requirements

Phenolic Resin

1. Store in airtight storage containers.2. Maximum shelf life at an average temperature below 80'F is three months from date

of receipt.3. Maximum shelf life at a temperatures of 40 ± 50F is six months from date of

manufacture.

Note: These dates shall be marked on the storage container or manufacturer's certificates asrequired.

All Other Materials

1. All other materials shall be stored at room temperature in properly sealed containersuntil ready for use in a manner to prevent contact with moisture.

2. Shelf life should be as recommended by the chemical manufacturer.

Page 3 of 8NCI-PF-1, Rev. 3

Receptacles

Receptacles shall be secured and anchored as necessary to prevent distortion by the foam andshould have vent holes to prevent voids in the finished foam and to provide gas relief, asdefined by the applicable drawings. In the event molds are used, they shall have a moldrelease applied to the surface or shall be coated with a permanent release coating prior tobeing filled with foam. Container components in contact with foam components shall have acoating (i.e. zinc epoxy primer, etc.*) applied to act as an additional barrier between the foamand the container. This coating shall be applied in less than 4 mils wet thickness asdetermined with a paint gauge or less than 1 /2 mils dry thickness as determined by a drythickness gauge. Surfaces shall be inspected prior to the foaming operations by inspectionpersonnel.

* NOTE: Zinc epoxy primers are currently being used although other coatings may beused if they prove to provide better protection.

Cleaning Before Foaming

Receptacles shall be free from foreign particles prior to the foam material being applied.

Temperatures

1. Receptacles shall be at room temperature, but not less than 60'F.2. Chemicals shall be at a minimum temperature of 60'F when mixed for foaming.3. The air temperature shall not be less than 60'F.

Mixing

1. Add liquid components to the mixer tub and stir to a uniform consistency for aminimum of 30 seconds.

2. Add all other powder components and mix to a uniform consistency for 1 to 2minutes.

3. Add fiberglass and mix no longer than necessary to achieve a uniform consistency.4. Transfer the mixed raw materials quickly to the receptacle so that the foaming action

takes place in the receptacle.

Page 4 of 8NCI-PF-1, Rev. 3

Placing Foam Material

The mixed foam material should be spread evenly over the bottom of the receptacle so thatthe foam expands in relatively level, uniform layers. When multiple pours are required, thefirst layer shall be tamped as necessary to control the height of the foam, thus controlling thefoam density. Sequential pours should be spread evenly over the initial layer after foamingaction of the first pour is complete.

Removal of Bracing

All bracing, molds or accessories not part of the finished product as defined by the drawingsshall be removed after foaming and hardening are complete.

Waterproofing

Seal all holes in the outer surfaces where applicable (e.g. vent holes, nail and screw holes,etc.) with RTV silicone caulking and caplugs as required by the drawings. All molded foamproducts or exposed foam surfaces shall be sealed using two coats of epoxy primer prior toany finish coat of paint as required.

OA

Prior to production of each product, Quality Assurance or Engineering shall establish thecorrect weight of the foam materials required to produce the correct density. QualityAssurance shall verify that the density of the foam installed in each package is that which isrequired by dividing the difference in package weight before and after the foaming operationby the volume of the foam cavity.

Patching

Voids in the finished foam surfaces shall be patched by filling with additional foam rawmaterial and allowing the material to expand and cure. Small imperfections may be filledusing automotive or other compatible fillers prior to painting.

Records

- A foaming record must be completed for foaming operations of individual packagesand shall become a part of the final QA record.

- The fabricator will also keep all records from the independent laboratory verifying thechloride content of the phenolic resin. This is for verification that the overall chloridecontent of the phenolic foam is below 200 ppm.

Page 5 of 8NCI-PF-1, Rev. 3

Figure ITypical Stress vs Strain, Perpendicular to Rise

High Density Foam Samples

Samplc No. 9Sample No. 8

100

90 _ _ _ _ _ _ _ _ _ _ _ _.-

BO_ - - F - -- - -- -- - --- - - - -

,50 __-_ J --- --- - - - -- -I - -- - - - -

20 | | |

i0 __________,__________

0 0.0 I. 0.1 0I 0.2 0. 0.530 _1_,___^___,___F___,___Str_,___

tzI#)

100

90

80

70

60

50

40

30

20

10

0

-4-I I4--4--I--I--f-41 - - - -

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4Strain

Sample No. 10

120. .

100 -- ___q__,___ - - - -

| I|

90 - - - _, - - - - -- - _ ,__ _ 1_ _ J___.

70 i |

so 50 -------J - - - -- -- - - - - - -

20 _i______ L ___ ___ I __4 ___+ L__

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4Strin

Sample ID

TN-1055LDF-8

TN-IO55LDF-9

TN-1055LDF-10

Width

1.95

1.96

2.04

Dimensions (inches)

HeiWht

2.10

2.05

2.00

Lenath

7.95

8.05

8.00

Weieht(Prams)

76.02

75.91

79.12

Page 6 of 8NCI-PF-1, Rev. 3

Figure 2Typical Stress vs Strain, Perpendicular to Rise

Low Density Foam Samples

Sample No. 15

50

05 0.0-- r. 01 0.2- 0.5 03 03 .

45 -- -- - - - -1 - - - - r- - - -'-, - - -

35 ' - - 9- - - -4 -- - - ,___-

50

a 0 - - - - a-/ - -- a--I i a a I I I I I I I I a

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Strain

1,Smpl No 1711

35 -- -, - - - - - -

2 .5 -. -1 -. -2 -. 0.3 -0.4I--

Strain

Sample No. 16

50

40 - - - - - - -__L____I

35 --_,_,25 IL - - - -

2= 0 re| , , S - - - -- _

-1 ---- - - - - - - -

5 1 , , , , --- - - - - '- - -

I I I I I I

° l I I I I I I I I~.0…

0 0.05 0.l 0.15 0.2 0.25 0.3 0.35 0.4Strain

Dimensions (inches)Sample ID Width Height

055LDF-15 2.10 1.88TN-V

TN-1055LDF-16

TN-1055LDF-17

Length

7.90

7.92

7.95

Weight(grams)

47.42

49.18

50.17

2.14

2.18

1.92

1.92

Page 7 of 8NCI-PF-1, Rev. 3

Figure 3Typical Stress vs Strain, Parallel to Rise

High Density Foam Samples

Sample No. 11 Sample No. 12

180

140

0 0 . . 0 0- - - - 2 - - - - 03 - 0 -

S - -F- - - - - - - --

0

60 J.0 _. J .1 0_ 0_2 0_ 0_3 0.4 ___ l____1_I I I I rInII

A

100

90-

80

70

60

50

40

30-

20

10

00

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

I I I I I I

I ~ ~ I I I

I I I I I I Ifi I I I I I I

1 I I I I I I I

I I , I I

1 I I I I I I

------- 1-- -1 - - - -I---- ----

I I I I I I I I

I I I I I I I I

I I I I I I

0.05 0.1 0.15 0.2Strain

.2.5 . . 0 .3..0.25 0.3 0.35 0.4

Sample No. 13

120-I~~ I0 -- ----

100

9! 0 ~~~1 8

9 0 ___ . ____ ____ ____ ________ ____ ____

20 _ I_ -| - - - - - - - -L________J____L - - - -

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4Strain

Sample ID

TN-1O55LDF-1 1

TN-1055LDF-12

Width

1.99

2.01

Dimensions (inches)

HeiRht

2.01

1.97

Leneth

7.90

8.00

Weight(grams)

IIIA2

66.78

68.83TN-lOSSLDF-13 1.90 2.05 8.00

Page 8 of 8NCI-PF-1, Rev. 3

Figure 4Typical Stress vs Strain, Parallel to Rise

Low Density Foam Samples

Sample No. 18 Sample No. 19

60-I I I

55-

50 0.05 0.-.5 . .2 .- 03 .45 -- St-ain

50

45-

40-

35

o 30-

V)20-

5-

0C

I I I I I I I-.-- I----I-…

I I I I I I

* I I I I I I II I I I I II I I I I I I

…

I I I I I I I

r- . . .0.05 0.1 0.25 0.2

Strain0.25 0.3 0.35 0.4

Sample No. 20

7065 - - - - - - - - - - - -

30

02.5 0.1 ---- 0.1 0. 0.2 0.3 0.35 0.4S2ai

Samole ID

T'N- 1055LDF- 18

T'N-1055LDF-19

Width

1.93

1.93

Dimensions (inhs

HeiAh

2.20

2.15

Length

7.95

8.00

Weight(grams)

57.06

50.70

50.99TN-1055LDF-20 1.91 Th 1 S L F 2 . 12.17 7.95

APPENDIX 2.10.3CHEMICAL AND GALVANIC REACTIONS - TEST REPORT

TABLE OF CONTENTS

2.10.3 Law Engineering, Test Report, "Corrosion Evaluation of StainlessSteel Samples, 400 ppm Ferric Chloride Solution, October 6, 1995 ........ 2.10.3-1

2.10.3-i Rev. 2, 03/97

APPENDIX 2.10.3CHEMICAL AND GALVANIC REACTIONS - TEST REPORT

Attached to this appendix is the test report for the corrosion evaluation of the stainless steelmaterial.

2.10.3-1 Rev. 2, 03/97