Post on 18-Feb-2022
NRC Pre-application Meeting for the Model No. 9979 USA/9979/AF-96 (DOE) Package
Paul S. Blanton Program Manager, Design Authority for 9979
NRC One White Flint North 11555 Rockville Pike, 09-B-04, Rockville, MD
Outline
• Introduction of Attendees • History of 9979 Development
– Program Overview – Design Overview – Patents and License Agreements – Comparison with DOT UN1A2 Specification Packaging
• Basis for Request of NRC License • Content Description and Envelope Limits • Structural Design Evaluation (Testing, Overview, Weights, Insulation Bag) • Thermal Evaluation Results • Shielding / Criticality Evaluation Results • Package Operations • Procurement and Fabrication History • Program History • Closing Discussion
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History of 9979 Development
• Program Overview – Replacement for DOT UN1A2 Specification Packaging (see comparison)
• Title 49 of the Code of Federal Regulations, Part 173.417 (2004) – Joint EM and NNSA program to develop the 9979
• rulemaking specifying UN1A2 packagings removed from service by September 30, 2008
• Design Overview – Performance Packaging Compliant with 10CFR71.71 and 10CFR71.73 – Design features:
• Steel construction • Standard, removable 30-gallon Drum with Silicone Gasket • Reusable 55-gallon Overpack with integral Liner • Overpack reinforced with polyurethane foam • 55-gallon and 30-gallon Split-Ring Closure Rings • Insulation Bag
• Patents and License Agreements – Split-Ring Closures for the 55-gallon and 30-gallon drums (SRNL); used on Type B packaging
• Design presented to DOT – 55-Gallon Drum Stepped Integral Liner Drum Assembly (SILDA) SRNL/Paragon D&E – NucFil Industries; Split-Ring Closures
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Model 9979 USA/9979/AF-96 (DOE)
9979 Design: Overview
Drum Steel Liner
DOW Polyurethane BETAFOAM
TID
Comparison with DOT UN1A2 Specification Packaging
• Configuration Similarities and Comparison – Content Envelope is maximized
(30-gallon drum, 18-1/4” Ø by 27-1/2 ” high) – Carbon Steel Construction – Standard 30-gal and 55-gal Drums – Fabrication: utilizes commercial parts – Operation: standard tools & handling – Compatible with Nevada Test Site
• Disposal Waste Acceptance Criteria
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Typical UN1A2 Specification Packaging 9979 Type AF Packaging
• Package gross weight - 350 lbs
• Standard commercial C-Ring closure
• Miscellaneous packing securing inner drum; 30-gallon or less
• < 350 grams 235U
• Package gross weight - 415 lbs • Reinforced split-ring closures
• Engineered liner securing inner
drum; 30-gallon
• < 350 grams 235U; specified contents
Basis for Request of NRC License
• SRNL Contacted by ReNuke Services regarding use of 9979 (May 2015) – DOE Certificate, Package ID Number: USA/9979/AF-96 (DOE)
• Purpose: Relocate Material from Texas A&M University’s AGN Reactor to the TRIGA Reactor Site
• AGN Content Description: – Fuel Disks (~Ø10.25” x up to 2”thick) and Control Rods – Material: <20% enriched uranium fuel embedded in polyethylene matrix – Resembles new fuel: reactor does not operate full time and operates at < 5 MW; low Effective
Full Power Hours (EFPH) – Disks (Qty. 9): The highest U-235 mass is just under 100 grams. – Control Rods: <20 grams Uranium each. Estimate 5 drums in 2-3 shipments. – The fuel (disks and rods) will be transported on public roadways for about 3-5 miles from one
Texas A&M site to another over non-university (public) land.
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9979 Content Description
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Payload Categories Material Form General Description
COM
BUST
IBLE
Filters Roughing, sock, demister, HEPA and other uranium filters
Rubber, Plastics, Cellulose Products Clothing, gaskets, bottles, filter frames, paper, wood, mop heads etc.
Floor Sweepings Miscellaneous materials collected from cleaning activities
Process Solids Furnace residues. (pan filter cloth and scrapings, wipes/sponges, etc.)
NO
N-C
OM
BUST
IBLE
Graphite/Carbon Carbon and graphite scrap molds
Slag and Liner Residue that contains magnesium oxide, calcium fluoride and/or lithium fluoride
Ceramics/Glass Crucibles, glassware and borosilicate rings
Borax Pellets From analytical x-ray operations.
Reduction Sand granular magnesium oxide (MgO)
Asbestos/Firebrick Insulation, floor tiles, etc.
Solid Compounds
Uranyl Fluoride, UO4, ammonium diuranate and residues and solid mixtures, scrapped unirradiated fuel rods and pellets,; e.g., size reduced Light Water Breeder Reactor (LWBR) fuel rods.
Standards and Sources
Encapsulated calibration standards, LEU Plates/Cube
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9979 Structural Evaluation (Testing and Analysis)
Structural Design Features
Summary of Structural Evaluation
NCT / HAC Evaluation
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Model 9979 Shipping Package – Structural Design Features
DOW Polyurethane closed cell Foam 24 lb/ft3; Drum Body and Lid
12 vent holes (9 in drum wall; 1 in lid; 2 in drum bottom;
prevent over pressurization during HAC Fire
55-Gallon Drum Lid Liner 16-gauge
12-gauge carbon steel with ½- 13UNC-2A ASTM A574
Socket Head Screw
55-gallon drum 12-gauge carbon steel clamshell closure
with 5/8-11UNC-2A ASTM A320-L7 Bolts with jam nut
55-Gallon Drum Liner Cylinder 18-gauge; all other components 16-gauge.
4-¼” carbon steel rods welded between lid and liner
30-gallon drum; 18-gauge carbon steel, DOT 7A drum
55-gallon drum: 16-gauge; DOT 7A drum
9979 Design: Weights
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• 55-Gallon Overpack Assembly Weights – Drum Only 139 lbs
• Drum 84 lbs • Drum Foam 55 lbs
– Lid Only 25 lbs • Lid 15 lbs • Lid Foam 10 lbs
– Closure Ring 10 lbs – Total 55-gallon Assembly 174 lbs
• Maximum Payload 250 lbs (Includes 30-gallon Drum Assembly, ~53 lbs) • Maximum Package Weight 415 lbs
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9979 Structural Evaluations • Chemical, Galvanic, or other Reactions
– No galvanic cell interactions between packaging components and contents; CS, BETAFAOM, Silicone, Epoxy Paint, Insulation Materials, Plastics, etc.
• Effects of Radiation – No effect. Dose is much less than 10^6 rads/year
• Lifting and Tie-Down Devices – No structural features have been included to lift the package or tie-down the package
• Heat and Cold – Heat under NCT and HAC was evaluated by analysis; package performance was determined to be
acceptable – Cold; Package were tested to -40°F with no effect on safety – Differential thermal expansion based on material differences has no effect on safety
• Reduced/ Increased External Pressure – Analysis of reduced 3.5 psia pressure and increased external pressure does not effect package
safety • Vibration
– Shipping and Vibration loads were evaluated by analysis and comparison to similar designed packages. Fatigue and bolt torque evaluations found acceptable. Testing of 9977, AT-400 and BTSP showed no indications of package degradation due to shock and vibration testing.
9979 NCT Evaluation (Testing and Analysis)
• Structural, NCT – Pressure, Thermal gradients, Stresses: by Analysis – Vibration and Shock: by Analysis and Comparison – Water Spray: by Test – Free Drop (4-ft), Corner Drop (1-ft): by Test – Compression, Penetration: by Test
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Water Spray 1-ft drop 4-ft drop Compression Penetration (1-hr) (8 quadrants) (2,165 lbs)
9979 HAC Structural Evaluation (Testing)
• Structural, HAC – Free Drop (30-ft) : by Test – Crush (30-ft, 1,100-lb) : by Test – Puncture (40-in): by Test
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30-ft top down 30-ft horizontal Horizontal Crush
Puncture
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9979 Evaluation (Testing) – Destructive Examination
SN-02 (Center of Gravity 30-ft Drop - Crush SN-01 (Center of Gravity 30-ft Drop - Horizontal Crush)
Max weight
Min weight
Some damage to 55-gallon drums (resulting from crush); minimal damage to 30-gallon drums; No material loss
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9979 Structural Evaluation
• Conclusions • 1-Hr water spray has no affect; no ingress of water into drum • 24-hr compression test; no observable effect • 1-ft (8); 4-ft drops; minimal damage, scuffed paint • 30-ft drop tests (center of gravity, horizontal, top down, etc.); very minor
damage to packages; • dented hoops, • closure lugs bent inward, • scuffed paint, etc.
• Crush test (center of gravity, horizontal, top down, etc.); greater damage but does not significantly change the bulk configuration of the drum
• hoops dented further • CG impact damage just at location of impact. No gross buckling observed • Horizontal impact damage some flattening of package; No gross buckling • Top down impact some flattening of package extensions; No gross buckling
• Puncture • No effect; slight indication at impact location.
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9979 Thermal Evaluation (Analysis)
Thermal Design Features
Summary of Thermal Evaluation
NCT / HAC Thermal Evaluation
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Model 9979 Shipping Package – Thermal Features
Drum Steel Liner
DOW Polyurethane BETAFOAM in 55-gallon drum Lid and between drum wall and Liner
Insulation Cover
Vent holes; 9 in drum (3 vertical 120º apart)
Polyurethane fill hole for Lid (vent)
Polyurethane fill hole (vent) 2 places on drum bottom
Insulation Bag and Cover in 30-gallon drum (only used for
combustible content) not shown
Pressure Relieving Plug
Drum Lid Steel Liner
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9979 Thermal Evaluation (Analysis)
Thermal Design Features
– Polyurethane foam and Insulation Cover for fire protection
– Insulation Bag for combustible contents
– 30-Gallon Drum high temperature silicone gasket for increased thermal performance
– Drum and Lid vent holes to prevent overpack pressurization during thermal event
– Drum and Lid Liners for foam pour
– Pressure relieving plug (not continuous venting)
9979 Design: Insulation Bag
Keep going for information on SRNL family colors.
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• Used with Combustible Contents • Superwool® Fiber Blanket stitched closed with E-glass • ~1800°F operating temperature
Insulation Bag (cinched closed)
Insulation Bag - Top
30-Gallon Drum
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9979 Summary of Thermal Evaluation
Condition Method
55-Gallon Overpack (ºF)
30-Gallon Drum (ºF)
Drum BETAFOAM™ Insulation
Drum Liner Body Gasket Contents
NCT in Shade Calculated 110 111 104 105 103 152
NCT w/ Insolation Calculated 154 154 144 149 143 189
HAC 30-Minute Fire
Calculated < 1475 n/a 1450 523 326 152
HAC Post-Fire Cool-down w/ Insolation
Calculated (Maximum) < 1475 n/a < 1450 523 501 326
HAC Post-Fire Cool-down w/Insolation
Calculated (Steady State)
196 n/a 177 180 170 211
9979 Component Temperatures
Temperature limits: • BETAFOAM 24 lb/ft3 ; maximum continuous operating temp 200°F • Silicone gasket 500°F (short periods) • Contents 400°F threshold temperature • Insulation blanket material 1,800°F
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Models developed vis MSC.PATRAN/THERMAL Model Parameters – Upright orientation both transportation and storage, – Axisymmetric geometry including all the gaps; excludes drum rolling hoops – Fill gas air – Temperature dependent material properties – Surface to surface radiation and conduction in gaps; convection not modeled – 3.5 watts of heat generation and – Insolation all around except at the bottom – Pre-fire; ambient at 100°F; 3.5 Watts
Boundary Conditions – Bottom adiabatic – Natural convection and radiation heat losses from the drum surface – Solar heat flux all around except at the bottom
9979 Thermal Evaluation General Parameters and Conditions
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9979 HAC Thermal Evaluation
• Methodology • Benchmarked computational model against AT-400A, 9977, and BTSP • AT-400A, 9977 and BTSP are polyurethane foamed packages • Each Fire Tested; 9977 also tested without foam; insulation blanket material present
around drum liner • Parameters
– Forced convection 20 m/s air velocity – Thermal radiation from fire to all drum surfaces – Fire temperature 1475°F (800°C) , 3.5 watts – Post fire solar heat fluxes of 245.77 Btu/ft2-hr on the top of the package and 122.88 Btu/ft2-hr on the side of the package are applied continuously. These values are based on drum surfaces covered with black residue after the fire and solar absorptivity of 1.0.
• Conclusions • HAC analysis results show that the temperatures of the contents are safely below the
threshold temperature of 400°F. Temperatures are well below auto-ignition and pyrolysis temperatures of packing materials such as plastic bagging.
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Maximum Pressures (psia)
1. HAC pressure from temperature increase 20.25 psia; moisture evaporation 41.89 psia 2. NCT pressure from temperature increase 17.03 psia; moisture evaporation 4.13 psia 3. Water assumed to be 1% of payload weight of 200 lb.
Drum 30 55 Comments
NCT 21.16 NA Pressure plug relieves at 12-15 psig
HAC 62.14 NA 55-gallon gasket material degraded; Pressure plug controls 30-gallon overpressure
Design Limit NCT NA NCT – within UN pressure rating
9979 Pressure Evaluation
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9979 Shielding Evaluation – Dose Rate
Isotopic Masses for Spectra Determination for Dose Rate Calculations
Isotope Mass (g)
Tc-99 1,430
Th-232 90,000
U-232 5.00E-05
U-233 16.7
U-234 26.1
U-235 3,500
U-236 2,500
U-238 90,000
Np-237 76.9
Pu-238 1.59E-03
Pu-239 4.35E-01
Pu-240 1.19E-01
Pu-241 1.58E-02
Am-241 7.69E-03
The Model 9979 Type AF shipping package design does not include any features intended to shield the material within the packaging
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9979 Shielding Evaluation – Dose Rate
Summary Table of External Radiation Levels (Non-Exclusive Use)
Normal Conditions of Transport
Package Surface mSv/h (mrem/h)
1 Meter from Package Surface
mSv/h (mrem/h) Radiation
Gamma 1.365 (136.5) 0.0040 (0.40) Neutron 0.364 (36.4) 0.0011 (0.11)
Total 1.729 (172.9) 0.0051 (0.51) 10 CFR 71.47(a) Limit 10 CFR 71.43(f)
2 (200) 0.1 (10)*
* Transport index may not exceed 10.
• The Transport Index is the maximum dose rate at 1 meter from the package surface in units of mrem/hr.
• The calculated Transport Index is 0.6.
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– Analyze 100 wt. % U-235 metal • Single Unit
– Optimally Moderated • Normal Conditions of Transport Array
– Optimally Moderated • Hypothetical Accident Conditions Array
– Optimally Moderated
9979 Criticality Evaluation
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9979 Criticality Evaluation
• LEU - 19.192 kg of uranium enriched to <19.9 wt.% U-235 • HEU grams of U-235equivalent mass
• Evaluation demonstrates compliance with the performance requirements for each content envelope as specified in: a) 10 CFR 71.55 – General requirements for fissile material packages b) 10 CFR 71.59 – Standards for arrays of fissile material packages
Hydrocarbon Mass Limit
Carbon+ Beryllium Mass Limit
Fissile Material Fixed on Graphite Pieces
U-235 (eq) Mass Limit **
≤ 1 kg ≤ 1 kg No 350 g ≤ 1 kg No beryllium Yes 350 g > 1 kg ≤ 1 kg No 300 g ≤ 1 kg ≤ 90 kg carbon No 150 g
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9979 Criticality Evaluation – Single Unit Results
Single Package Water surrounding package
Hydro-carbon Mass
Carbon* + Beryllium
Mass
Fissile Material Fixed on Graphite Pieces
U-235 Mass **
Internal Moderation
H/X Case Name Maximum
keff ksafe
≤ 1 kg ≤ 1 kg No 350 g
Not analyzed, bounded by NCT and HAC
≤ 1 kg No beryllium Yes 350 g
> 1 kg ≤ 1 kg No 300 g
≤ 1 kg ≤ 90 kg carbon No 150 g 700 sp700 0.9283 0.931
LEU Cube 3,79161 g† - sp_c_poly 0.593 0.912
LEU Plates 3,0337 g† - sp_hpl_poly.103 0.683 0.912
• Single Unit model • 30 cm of water on all sides • LEU Cube; bottom and center of package; dry and filled with water/poly • LEU Plates; stacked vert/horiz; varied water/poly spacing
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9979 Criticality Evaluation – NCT Results
NCT Array 512 packages (8x8x8), no interstitial moderation, water surrounding array
Hydro-carbon Mass
Carbon* + Beryllium
Mass
Fissile Material Fixed on Graphite Pieces
U-235 Mass **
Internal Moderation
H/X Case Name Maximum
keff ksafe
≤ 1 kg ≤ 1 kg No 350 g 700 nct700be 0.9083 0.931
≤ 1 kg No beryllium Yes 350 g Bounded by nct700be where fissile can be
homogeneously mixed with water
> 1 kg ≤ 1 kg No 300 g 700 nct700p300 0.9166 0.931
≤ 1 kg ≤ 90 kg carbon No 150 g 500 nct500carbon 0.7972 0.931
3375 packages (15x15x15) inner and outer drum flooded, water surrounding array LEU Cube LEU Cube LEU
Cube 3,7916 g† - nct_poly 0.591 0.912
LEU Plates LEU Plates LEU
Plates 3,0337 g† - nct_hpltb_poly 0.675 0.912
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9979 Criticality Evaluation – HAC Results
HAC Array 108 packages (6x6x3), no interstitial moderation, water surrounding array
Hydro-carbon Mass
Carbon* + Beryllium
Mass
Fissile Material Fixed on Graphite Pieces
U-235 Mass **
Internal Moderation
H/X Case Name Maximum
keff ksafe
≤ 1 kg ≤ 1 kg No 350 g 600 hac600dsbe 0.9175 0.931
≤ 1 kg No beryllium Yes 350 g Bounded by hac600dsbe where fissile can be
homogeneously mixed with water > 1 kg ≤ 1 kg No 300 g 700 hac700p300 0.9253 0.931
≤ 1 kg ≤ 90 kg carbon No 150 g 500 hac500c150a 0.9305 0.931
3375 packages (15x15x15) inner drum flooded, no outer drum, water surrounding array LEU Cube LEU Cube LEU
Cube 3,7916 g† - hac_poly 0.768 0.912
LEU Plates LEU Plates LEU
Plates 3,0337 g† - hac_vpltb_poly 0.859 0.912
• Model assumptions • Only 30-gallon drum
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9979 Criticality Evaluation – CSI Results
– Criticality Safety Index • The analysis demonstrates that the package is subcritical for all single package and
array configurations consistent with the package CSI of 1.0.
Normal Conditions of Transport (N = 0.5) Number of undamaged packages that remain subcritical in array
8x8x8
Most reactive credible physical and chemical form of fissile material
100 wt. % U-235 metal
Most reactive interspersed hydrogenous moderation No interstitial moderation, water surrounding array
Most reactive reflecting material Carbon Reflection surrounding the array Water surrounding array
Hypothetical Accident Conditions (N = 1.0) Number of damaged packages to remain subcritical 6x6x3 Most reactive credible physical and chemical form of fissile material
100 wt. % U-235 metal
Most reactive interspersed hydrogenous moderation No interstitial moderation, water surrounding array
Most reactive reflecting material Carbon Reflection surrounding the array Water surrounding array
9979 Procurement and Fabrication
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• Primary Supplier – Paragon D&E – NQA-1
• Sub Suppliers – Skolnik Industries – Drum Parts Midwest – Parker – Morgan Thermal Ceramics – DOW Automotive – Reike Packaging Systems
9979 Procurement and Fabrication History
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Year User/Customer Quantity
2011 Y-12 Purdue
SNL INL
350 96 35 6
2012 Y-12 145
2013 KAPL LANL Y-12
6 42
320
2014 KAPL INL Y-12 SNL
Portsmouth
14 25
420 45 75
2015/2016 LANL Y12
180 575
9979 Program History
• April 2008: Project Start / Design Requirements Document • April/August 2008: Conceptual Design/Analysis • August/October 2008: Pre-prototype Testing (5-separate designs evaluated) • November/January 2009: Prototype Fabrication • January 2009: Prototype Regulatory Testing • February 2009: SARP Submitted to Argonne National Laboratory (ANL) for
Regulatory Review • March/April 2009/2010: ANL Review • April 2010: Procurement Request for Quote (RFQ) Issued • June 2010: RFQ Return • June 2010: DOE Certificate of Compliance (CoC) Issued • September 2010: SRNL Issue Procurement
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