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Accession #: Dl9506221 6

Document #: SD-TP-OTR-002

TitlelDesc: FINAL EVALUATION REPORT FOR LlTC ARROW-PAK PACKAGING DOCKET 95-40-7A TYPE A CONTAINER PER DOT-7A

Pages: 110

Pap. 1 Of

l.EDT N! 6 1 1189 22 ENGINEERING DATA TRANSMITTAL

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- - - -

12. Major Assm. Dug. No.:

N/A

N/A 13. PermitIPermit Application No.:

14. Required Response Date:

2. TO: (Receiving Drgmization)

Packaging Operations & Development

84400/TH540 5 . Proj .IProg.lDept./Div. :

11. Receiver Remarks:

15. DATA TRANSMITTED

[El lith or DaswkU!nn of Data (AI IC) ID1 Sh0.t Rnr. IBI DocumentlDnwing No. TI.".mntsd NO. No. NO.

1 WHC-SD-TP-OTR-002 0 Final Evaluation Report for Lockhead Idaho Technologies Cnpany, ARROV-PM Packaging, Docket 95-40-7A, Type A Container

3. From: (Driginating Organization)

Packaging Operations & Development

D. L . Kel ly 6. Cog. Engr.:

4. Related EDT No.:

N/A

7. Purchase Order No.:

(LITCO/WHC) C95-K24120 9. Equip./Conpomnt No.:

10. Systnn/Bldg.lFaci l i t y : N /A

2. Rehais 5 . Poat-Revlew

BD-7400-172-2 (04194) GEF097

W-7-172-1

...

SUPPORTING DOCUMENT I 1. Totat P a a e s / o ~

?. T i t l e

Final Evaluation Report f o r Lockheed Idaho Techno1 ogi es Company, ARROW-PAK Packaging, Docket 95-40-7A, Type A Container.

Test Report, DOT-’IA, Type A, Radioactive Material, Package, Packaging, ARROW-PAK, LITCO, INEL

5. Key Uordo

3. Nunbcr 4. Rev No.

WHC-SD-TP-OTR-002 0

6. Author

N-: D. L. Ke l l y

d-2- SI mature

OrganizationlCharge ccdn 84400/TH540

The packaging may be used w i th o r without the two in ternal plywood spacers. This 3ackaging was evaluated and tested i n October 1995. The packaging conf igurat ion lescribed i n t h i s repor t i s designed t o ship Type A quant i t ies o f s o l i d rad ioact ive nater ia ls, Form No. 1, Form No. 2, and Form No. 3 .

A-6400-073 (08194) UEF124

8. RELEASE STAMP

WHC-SD-TP-OTR-002 Revision 0

CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 CONTAINMENT BOUNDARY VERIFICATION . . . . . . . . . . . . . . 1-4 . . . . . . .

1.3 PURPOSE AND SCOPE . . . . . . . . . . . . . . . . . . . . , . . 1-5'

2.0 PACKAGING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 .

2.1.1 Materials/Method o f Construction . . . . . . . . . . . . 2-3 2.1.2 Authorized Conf igurat ion . . . . . . . . . . . . . . . . 2-3

2.2 CONTAINMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3 AUTHORIZED CONTENTS . . . . . . . . . . . . . . . . . . . . . . 2-3

3.0 EVALUATION CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 TEST CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 PASS/FAIL CRITERIA . . . . . . . . . . . . . . . . . . . . . . 3-1

4.0 PREPARATION OF SPECIMENS FOR TESTING . . . . . . . . . . . . . . . . 4-1 4.1 PRELOADING INSPECTION . 49 CFR 173.462 . . . . . . . . . . . . 4-1 4.2 TEST CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 LOADING. ASSEMBLY. AND CLOSURE . . . . . . . . . . . . . . . . 4-2

5.0 PACKAGING EVALUATION RESULTS . . . . . . . . . . . . . . . . . . . . 5-1 5.1 DESIGN EVALUATION . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.1 49 CFR 173.24 - General Requirements f o r Packaqes . and Packagings . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.2 49 CFR 173.24a . Addit ional General Requirements f o r Non-Bul k Packagings and Packages . . . . . . . . . . . . 5-8

5.1.3 49 CFR 173.24b . Addit ional General Requirements f o r Bulk Packagings . . . . . . . . . . . . . . . . . . 5-13

5.1.4 49 CFR 173.411 . General Design Requirements . . . . . . 5-14 5.1.5 49 CFR 173.412 . Addit ional Design Requirements f o r

Type A Packages . . . . . . . . . . . . . 5.1.6 49 CFR 173.442 - Thermal L imi ta t ions . . . 5.1.7 49 CFR 178.3 - Marking o f Packagings . . .

5.2 COMPLIANCE TEST EVALUATION . . . . . . . . . . . 5.2.1 49 CFR 173.465 - Type A Packaging Tests . 5.2.2 49 CFR 173.466 - Addit ional Tests f o r Type

Designed f o r Liquids and Gases . . . . . . 5.2.3 49 CFR 178.608 - Vibrat ion Standards . . .

. . . . . . . . 5-16 . . . . . . . 5-20 . . . . . . . 5-21 . . . . . . . 5-22 . . . . . . . 5-22 A Packagings . . . . . . . 5-29 . . . . . . . 5-29

6.0 CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7.0 QUALITY ASSURANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . 7-1

8.0 PRIMARY USER/MANUFACTURER . . . . . . . . . . . . . . . . . . . . . 8-1

9.0 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10.0 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G L-1

iii


FINAL EVALUATION REPORT FOR LOCKHEED IDAHO TECHNOLOGIES COMPANY,

TYPE A CONTAINER ARROW-PAK PACKAGING, DOCKET 95-40-7A

1 .O INTRODUCTION

1.1 BACKGROUND

This repo r t documents the U.S. Department o f Transportation Spec i f i ca t ion 7A Type A (DOT-7A) compliance t e s t resu l t s o f the Lockheed Idaho Technologies Company (LITCO) sponsored ARROW-PAK Packaging. The tested packaging was designed and constructed by Arrow Construction, Inc. (Arrow), o f Montgomery, Alabama. The ARROW-PAK packaging conf igurat ion was evaluated and tested i n October 1995, a t the U.S. Department of Energy (DOE) approved t e s t f a c i l i t y located a t the Hanford s i t e , i n Richland, Washington.

Series 8000 (gas) o r Serifs 8600 ( i n d u s t r i a l ) r e s i n pipe, manufactured by Phil l ips-Driscopipe, Inc. , and i s sealed w i th dome-shaped end caps manufactured from the same mater ia ls ( r e f e r t o Appendix A, Figure A-1, o f t h i s repor t , f o r a diagram). A patented process, developed by Arrow, permanently seals the two end caps t o the pipe body. The patented process involves the use o f e l e c t r i c a l energy t o heat opposing faces o f the pipe and end caps, and hydraul ic rams t o press the heated surfaces together. During the fus ion process, the e x t e r i o r and i n t e r i o r wa l l surface o f the end caps and p ipe create beaded edges. e x t e r i o r wa l l surface about 0.635-cm (0.25-in). A seam i s v i s i b l e ; however, the seam does not run through the i n te rna l thickness o f these component pieces. The fus ion process produces a homogeneous bonding o f the end cap t o the pipe. The homogeneous bond extends over the f u l l wal l thickness o f the packaging ( r e f e r t o Section 2.1 o f t h i s repor t f o r f u r the r information regarding the homogeneous bond).

un i t s . The purpose o f these spacers was t o ho ld the simulated contents i n place dur ing the fus ion process. Refer t o Appendix B o f t h i s repor t f o r the assembly, loading, and closure procedure used f o r t es t i ng purposes. Basical ly, an end cap was fused t o one end o f the pipe/tube. This po r t i on o f the t e s t u n i t was then loaded w i th wrapped, lead br icks, leav ing an estimated 5.08-cm (2-in) head space. Steel shot f i l l e d the vo id space between the br icks [ leav ing the 5.08-cm (2-in) head space]. A plywood spacer was placed a t the "open" end o f the pipepube. (The spacer needs t o f i t down snugly onto the l aye r o f b r i cks and shot. It may be necessary t o wrap the outside edge o f the wooden spacer w i th several layers o f tape so t h a t the spacer does not move and/or s h i f t . ) leav ing an estimated 5.08-cm (2-in) head space. Steel shot f i l l e d the vo id space between the br icks [ leav ing the 5.08-cm (2-in) head space]. plywood spacer was placed a t the "open" end o f the end cap, i n the same manner

The ARROW-PAK packaging system consists o f a Marlex M-8000 Driscopipe,

These edges protrude away f r o m both the i n t e r i o r and

A t o t a l o f two plywood spacers were used ins ide the loaded ARROW-PAK t e s t It should be noted t h a t the use o f the plywood spacers i s opt ional .

The second end cap was loaded w i th wrapped, lead br icks,

The second

'Phi l l ips-Driscopipe, Inc. i s a subsidiary o f P h i l l i p s Petroleum Company.

1-1


as the f i r s t spacer. t h a t had prev ious ly been f i l l e d w i th simulated contents. NOTE: Adequate space (about 5.08-cm [2-in]) i s required for the placement o f the wooden spacers t o allow for fusion of the second end cap t o the tube/pipe,

The second end cap was then fused t o the pipe/tube piece

Due t o the complexity o f the thermal seal ing process and the machinery involved, the t e s t un i t s were f i l l e d w i th the simulated contents (wrapped, lead b r i cks and s tee l shot), assembled, loaded, and closed by BOH Brothers Construction Company, Inc. (BOH Brothers), New Orleans, Louisiana. (BOH Brothers i s a subcontractor t o Arrow.) The remainder o f the simulated contents ( f luorescein) was added a t the DOE-approved t e s t f a c i l i t y p r i o r t o tes t i ng . To add the f luorescein mater ia l and t o v e r i f y the containment boundary o f a l l the t e s t un i ts , the sponsor was responsible f o r d r i l l i n g and tapping two holes i n t o the center o f one end cap on the two t e s t u n i t s t o be f i l l e d w i t h the simulated t e s t load (40-TU-01 and 40-TU-02), and one hole i n t o the center o f one end cap on the "empty" t e s t u n i t (40-TU-03). The sponsor was also responsible f o r p lac ing a su i tab le hex-socket p lug i n t o each o f the holes. The hex-socket plugs were 1/2-inch normal pipe thread (NPT), and were f l u s h o r below the surface o f the end caps. Refer t o Appendix 6, Figure B-1, f o r a diagram o f the hole placements.

Both v i s i t s were t o witness the loading, assembly, and closure o f the three ARROW- PAK t e s t un i ts . The second t r i p was necessary as Arrow determined t h a t a f a u l t y pyrometer was used during the i n i t i a l loading and closure procedure. The manufacturer's procedures s ta te t h a t the Phil l ips-Driscopipe, Marlex r e s i n pipe, i s t o be heated t o 260'C (500°F) p r i o r t o the fus ion process. During the i n i t i a l process, the pipe and end cap pieces "smoked." This was ev ident ly not t yp i ca l o f the seal ing process. temperature o f the heater p l a t e used p r i o r t o fusing the components together, reached 293°C (560°F). guarantee t h a t the higher temperature would not have a negative e f f e c t on the performance o f the pipe. It was determined t h a t the seal ing process should be performed according t o the manufacturer's procedures, ra ther than r i s k f a i l u r e o f the packaging during tes t ing . A lso , a question could be ra ised i f the t e s t packagings passed, tha t the t e s t u n i t s passed due t o the higher temperatures used t o seal these packagings.

j o i n t s , and the simulated contents removed. Although the length o f the modif ied end caps was now s l i g h t l y less (due t o the fus ion j o i n t being cu t o f f the packaging), the o r i g i n a l end caps were reused f o r the actual t e s t u n i t packagings. The sponsor desired being able t o load as much content weight i n t o t h e t e s t un i t s as possible. To compensate f o r the length o f the HDPE mater ia l t h a t was el iminated from the end caps, the length o f the c y l i n d r i c a l tube/pipe sect ion o f the actual t e s t un i t s was s l i g h t l y longer than the previous, i n i t i a l t e s t un i ts .

Two v i s i t s were made by the WHC t e s t engineer t o BOH Brothers. -

Later, Arrow ind icated t h a t the

Phi l l ips-Dr iscopipe (product manufacturer) could not

The i n i t i a l l y loaded t e s t un i t s were cu t open on each side o f the fus ion

The o r i g i n a l (before facing) length o f each end cap piece was 30.48-cm (12-in). The average, maximum amount removed from each end cap was 3.175-cm (1.25-in), making the new length of each end cap about 27.3-cm (10.75-in). A t o t a l , average, maximum length o f 6.35-cm (2.5-in) was el iminated from the end caps. The average o r i g i n a l (before facing) length o f the c y l i n d r i c a l pipe/tube was 127.0-cm (50.0-in). Because o f the loss i n length from c u t t i n g

1-2


the end caps, i t was decided t o use new pipe/tube pieces. The new pipe/tube sections had an average length (before facing) o f 133.35-cm (52.5-in). This was 6.35-cm (2.5-in) longer than the o r i g i n a l t e s t un i ts . P r i o r t o fus ing the component pieces together, the end caps and pipe are faced, r e s u l t i n g i n loss o f high-density polyethylene (HDPE) material, which e f fec ts the t o t a l overa l l leng th o f the packaging.

used t o permanently seal the ARROW-PAK packaging, i s t h a t the areas adjacent t o the fus ion j o i n t s may eas i l y be cu t apart i f needed. The actual length o f the tested packagings' end caps was less than the manufactured component. To compensate f o r t he length o f the HDPE mater ia l t h a t was el iminated from the end caps, the actual length o f the tested packagings' pipe/tube component was more than what was o r i g i n a l l y intended. The packaging's overa l l length was w i t h i n the nominal design length (the average, overa l l length o f a l l the ARROW-PAK t e s t u n i t s [ i n i t i a l and actual ] was 182.88-cm (72-in). The maximum length o f the tested packaging was 187.96-cm (74-in). The performance o f the t e s t u n i t s was such t h a t i t can be determined t h a t these modif ied lengths d i d not have any impact on the packaging.

compressed a i r t o 55.2 kPa (8 ps i ) . The fus ion j o i n t s , plugged areas, and connections were coated w i th a so lu t ion o f water and l i q u i d d ish soap. This was t o ensure t h a t a l l three t e s t u n i t s were sound and d i d no t 1eak .pr io r t o shipment t o the DOE-approved t e s t f a c i l i t y . Upon rece ip t o f the three, actual t e s t u n i t s by the DOE-approved t e s t f a c i l i t y , an i n i t i a l containment boundary v e r i f i c a t i o n (soap bubble t e s t ) was conducted p r i o r t o tes t ing . This was t o ensure t h a t a l l three t e s t un i t s were sound, and tha t no damage occurred dur ing t ranspor ta t ion t o the t e s t f a c i l i t y . The center p lug was removed from the end cap, and compressed n i t rogen gas was connected t o the t e s t un i t s . The in te rna l pressure was increased t o 27.6 kPa (4 ps i ) t and held f o r 15 minutes. A low-v iscos i ty soap bubble so lu t ion ( i . e . , "Snoop" ) was coated around the area where the end caps are fused t o the c y l i n d r i c a l w a l l o f the packaging. The plugged areas and connections were also checked f o r leakage. o r foam were detected. The remainder o f the simulated contents ( f luorescein) was then added p r i o r t o tes t ing .

The maximum, overa l l length o f the tested ARROW-PAK package i s 187.96-cm (74-in). The maximum gross weight o f the tested packaging i s 519.82 kg (1146-lb). The ARROW-PAK packaging i s designed t o ship Type A, so l id , rad ioac t ive materials, normal form, Form Number 1, Form Number 2, and Form Number 3.

requirement i s appl icable t o the tested package configuration. Type A t e s t s performed included the v ibrat ion; water spray; penetrat ion bar drop (1.0 m [3.3 f t ] ) ; compression; and 1.2 m [ 4 f t] drop tes t . seal ing process used, the soap-bubble t e s t was performed a f t e r t he v i b r a t i o n and the drop t e s t s . This method, i n combination w i th v isual and black l i g h t inspection, was chosen f o r leak detect ion purposes.

An advantage o f the Marlex M-8000 res in pipe material, and fus ion process

I n both instances, the sponsor pressurized a l l three t e s t u n i t s w i t h

No bubbles

A l l DOT-7A Type A requirements o f 49 CFR are addressed whether the

Because o f the permanent

Z"Snoop" i s a reg is te red trademark o f the Nupro Company.

1-3


Documentation i s provided by t h i s repor t t o s a t i s f y the requirements o f 49 CFR 173.415(a), "Authorized Type A Packages," which states:

"U.S. Department o f Transportation (DOT) Spec i f i ca t ion 7A (178.350 o f t h i s subchapter) Type A general packaging. Spec i f i ca t ion 7A must maintain on f i l e f o r a t l e a s t one year a f t e r the l a t e s t shipment, and sha l l provide t o DOT on request, a complete documentation o f t es ts and an engineering evaluation o r comparative data showing t h a t the construction methods, packaging design, and mater ia ls o f construction comply w i th t h a t spec i f i ca t ion . Spec i f i ca t ion 7A packagings designed i n accordance w i th the requirements o f 178.350 i n e f f e c t on June 30, 1983, and constructed p r i o r t o Ju ly 1, 1985, may continue t o be used. Packagings e i t h e r designed o r constructed a f t e r June 30, 1985, must meet the requirements o f 178.350 applicable a t the time o f t h e i r design o r construction. 'I

Each shipper o f a

This document w i l l serve t o meet the above-stated requirements when the packagings are used as prescribed. packaging i s provided w i th an i l l u s t r a t i o n and/or drawings t o a l low the user/shipper t o obta in the packaging and v e r i f y t h a t the packaging hardware complies w i t h a l l o f the spec i f i ca t ions o f the tested packaging.

By i t s e l f , t h i s document does not ensure t o t a l compliance w i th a l l documentation necessary f o r making a shipment o f rad ioact ive mater ia l . add i t ion t o documentation o f tests, the shipper must maintain on f i l e other appropriate documentation such as comparison o f the physical proper t ies o f the actual contents t o be shipped w i th those o f the simulated payload used i n t e s t i n g t o demonstrate equivalency. Also, implementation and documentation o f a q u a l i t y con t ro l program are required.

I n addit ion, a descr ip t ion o f the

I n

1.2 CONTAINMENT BOUNDARY VERIFICATION

A hydrostat ic pressure t e s t was conducted t o simulate reduction i n ambient (external) pressure t o 24.1 kPa (3.5 psia). Test u n i t 40-TU-03, which was bas i ca l l y an empty packaging, was used f o r t h i s v e r i f i c a t i o n process. Upon rece ip t by the DOE-approved t e s t f a c i l i t y , t h i s t e s t u n i t underwent an i n i t i a l containment boundary v e r i f i c a t i o n (soap bubble t e s t ) as described i n Section 1.1 o f t h i s repor t . This t e s t u n i t was then f i l l e d w i th a half-cup o f f luorescein, and underwent the water spray tes t , penetrat ion bar drop, and compression tes t . Upon completion o f these tests, the t e s t u n i t was f i l l e d completely w i t h water. The external surface was cleaned and checked w i t h a black l i g h t f o r any t race o f f luorescent dye. Compressed n i t rogen gas was used t o pressurize the in te rna l cav i t y o f the packaging t o 80.66 kPa (11.7 ps ig ) . This pressure was held f o r 15 minutes. No leakage o f water o r f luorescent dye was observed under v isual and black l i g h t inspection.

1-4

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1.3 PURPOSE AND SCOPE

the packaging meets the design requirements o f 49 CFR 173.24, 173.24a, 173.24b, 173.411, 173.412, and 173.462. Testing was performed t o demonstrate tha t the packaging conf igurat ion noted i n Sections 1.1 and 2.0 o f t h i s repor t meets the requirements f o r a DOT-7A Type A packaging (Kelly 1995b). Testing was performed i n accordance w i th 49 CFR 173.465 using DOT-7A Packaging Test Procedure (Kelly 1995~) .

A design v e r i f i c a t i o n procedure (Kelly 1995a) was used t o document tha t

1-5


2.0 PACKAGING DESCRIPTION

2.1 DESIGN

Series 8000 (gas) o r Series 8600 ( i n d u s t r i a l ) r e s i n pipe, manufactured by Phi l l ips-Driscopipe, Inc., and i s sealed w i t h dome-shaped end caps manufactured from the same mater ia ls ( r e f e r t o Appendix A, F igure A-1, o f t h i s report , f o r a diagram). A patented process, developed by Arrow, permanently seals the two end caps t o the pipe body. The patented process involves the use o f e l e c t r i c a l energy t o heat opposing faces o f the pipe and end caps, and hydraul ic rams t o press the heated surfaces together. During the fus ion process, the ex te r io r and i n t e r i o r wa l l surface of the end caps and p ipe create beaded edges. The edges protrude away from both the i n t e r i o r and ex te r io r wa l l surface about 0.635-cm (0.25-in). the seam does not run through the i n t e r i o r thickness o f these component pieces. the pipe. The homogeneous bond extends over the f u l l wal l thickness o f the package.

The ARROW-PAK packaging system consists o f a Marlex M-8000 Driscopipe,

A seam i s v i s i b l e ; however,

The fus ion process produces a homogeneous bonding o f the end cap t o

The M-8000 Driscopipe (Series 8000 and 8600) has t y p i c a l l y been used i n commercial areas ( i . e . , natural gas l ines, water l i nes , and i n sewer treatment and u t i l i t y appl icat ions) . There i s no negative h i s t o r y o r known f a i l u r e o f the fus ion j o i n t areas when the patented, permanent seal technique has been appl ied i n these noted appl icat ions. described i n t h i s report , coupons were cu t from random sample specimens t o observe the thoroughness o f the homogeneous bonding o f the end caps and pipe. The only evidence o f a "seam" i s ind icated on the outer and inner wa l l surfaces where the fused beaded edge protrudes away from the wal l surfaces. No v i s i b l e weld i s evident w i t h i n the fused mater ia l .

P r i o r t o the 7A t e s t i n g a c t i v i t i e s

Driscopipe Series 8000 and Series 8600 were tested as a p a r t o f the ARROW-PAK packaging. The pipe/tube comprising t e s t u n i t 40-TU-01 was made from Series 8000, and the pipe/tube comprising t e s t u n i t s 40-TU-02 and 40-TU-03 were made from Series 8600. Both product l i n e s are extruded using only P h i l l i p s Chemical Company's Marlex 8000 polyethylene resin. This r e s i n i s a PE 3408 as l i s t e d by the P las t ics Pipe I n s t i t u t e , i s i d e n t i f i e d as Type 111, C5, P34 per the American Society f o r Testing and Mater ia ls (ASTM) 01248, and has a c e l l c l a s s i f i c a t i o n o f 355434C per ASTM D3350.

Both product 1 ines are extruded using Phi l1 ips-Driscopipe's patented hard t o o l i n g polyethylene extrusion process, and each can be manufactured using the same manufacturing equipment. The mater ia ls d i f f e r on ly i n the ASTM spec i f i ca t ions t o which they are c e r t i f i e d . intended f o r use i n the d i s t r i b u t i o n sf natural gas must be manufactured i n accordance w i t h the requirements o f ASTM 02513. This i s a requirement o f Part 192 o f the Federal Minimum Safety Code f o r Transportat ion o f Natural and Other Gases by Pipel ine, as administered by the DOT. and i n d u s t r i a l appl icat ions are manufactured i n accordance w i t h the requirements o f ASTM F714. I n the areas where the speci f icat ions d i f f e r , ASTM D2513 i s the more s t r ingent o f the two. per ASTM D2513 equals o r exceeds a l l requirements o f ASTM F714.

Polyethylene p i p i n g products

Piping produced f o r municipal

Therefore, the product manufactured

2-1

WHC-SD-TP-OTR-002. Revision 0

Form No. 1 - Solids of any particulate size.

A packaging certified for these contents is expected to contain radioactive contents of any representative particulate form.

Form No. 2 - Solids of large particulate size only (cement grade sand or 1 arger) . Contents of a corresponding particulate size, such as soil or construction debris. particulate available for dispersion would not fit this category and would require a packaging certified for fine particulate, Form No. 1.)

Form No. 3 - Solid material with no removable or dispersible contamination. (For definition, see 49 CFR 173.443, "Contamination Control . ")

1. Metals with activation products;

2.

3.

(Glass or plastic labware having fine

Forms of metals/alloys/compounds o f uranium, thorium;

Solid materials with the radioactive material firmly fixed in place, possibly by the application of a fixing media (paint, etc.);

4. Solidified material.

NOTE: This is an example only and each form must be analyzed for compliance with the "no removable or dispersible contamination" criterion found in 40 CFR 173.443. Additional restrictions on contents can be found in Section 6.0 of this report.

The simulated payload used in two test units was clean, noncontaminated, and taped lead bricks. Carbon steel shot was added as a filler material. It was estimated that the lead bricks made up 65% of the content fill weight (314.3-kg [693.0-lb]), and the steel shot made up 35% of the content fill weight (169.2-kg [373.0-lb]). Fluorescein was added as a tracer material. The third test unit was basically empty, and fluorescein was added as a tracer material. The maximum gross weight of the tested packaging is 519.82 kg (1146-lb).


This page in tent iona l ly l e f t blank.

3-2


4. D i s t o r t i o n o f features.

b.

E.

d.

There were no observable d i s to r t i ons o f features.

Any deviat ion found under paragraph (a) o f t h i s sect ion from t h e spec i f ied design sha l l be corrected o r su i tab l y taken i n t o account i n t h e subsequent evaluation.

As s tated i n paragraph (a) o f t h i s section, the o r i g i n a l packaging design was modified p r i o r t o tes t ing . one end o f the end caps was taken i n t o account during test ing, and had no negative impact o r e f f e c t on the performance o f the t e s t u n i t s o r on the tes t i ng conducted.

The modif ied length o f the end caps and pipe/tube had no negative impact o r e f f e c t on the performance o f the t e s t un i t s o r on the t e s t i n g conducted.

The containment system o f t h e packaging sha l l be c l e a r l y specif ied.

Primary containment i s provided by the permanent fus ion o f t he c y l i n d r i c a l pipe/tube t o the two end caps.

The add i t ion o f the plugs t o

The external features o f t he packaging sha l l be c l e a r l y i d e n t i f i e d so t h a t reference may be made t o any p a r t o f it.

The external features o f the packaging are c l e a r l y i d e n t i f i a b l e . External features consist o f the cy1 i n d r i c a l tube/pipe, two domed end caps, and t w o fus ion j o i n t s .

4.2 TEST CONTENTS

The simulated payload used i n two t e s t u n i t s was clean, noncontaminated, and taped lead br icks. Carbon s tee l shot was added as a f i l l e r mater ia l . It was estimated tha t the lead br icks made up 65% o f the content f i l l weight (314.3-kg [693.0-1b]), and the s tee l shot made up 35% o f the content f i l l weight (169.2-kg [373.0-1b]). The t h i r d t e s t u n i t was bas ica l l y empty, and f luorescein was added as a t race r mater ia l . The maximum gross weight o f the tested packaging i s 519.82 kg

Fluorescein was added as a t race r mater ia l .

(1146-1 b) .

4.3 LOADING, ASSEMBLY, AND CLOSURE

Appendix A, Figure A-1, o f t h i s repor t . The packagings were assembled, loaded, and closed i n accordance w i th the ins t ruc t ions as ou t l ined i n Appendix B o f t h i s repor t .

A diagram o f the as-tested packaging conf igurat ion i s provided i n

The ARROW-PAK packaging system, consis t ing o f a Marlex M-8000 Driscopipe, Series 8000 (gas) o r Series 8600 ( i n d u s t r i a l ) r e s i n pipe, i s sealed w i t h dome- shaped end caps manufactured f r o m the same materials. permanently fused and sealed t o the p ipe body. This process involves the use

The two end caps are

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5.0 PACKASINS EVALUATION RESULTS

The fo l lowing l i s t shows the primary sections o f 49 CFR appl icable t o

NOTE: This l i s t h igh l igh ts the performance requirements and i s not intended t o present an all-encompassing l i s t .

Type A packaging:

173.24

173.24a

173.24b

173.411

173.412

173.415(a)

173.442

173.461

173.462

173.463

173.465

173.474

173.475

178.3

178.350

178.608

General Requirements f o r Packagings and Packages

Addit ional General Requirements f o r Non-Bul k Packagings and Packages

Addit ional General Requirements f o r Bulk Packagings

General Design Requirements

Addit ional Design Requirements f o r Type A Packages

Authorized Type A Packages

Thermal Limitat ions

Demonstration o f Cornpl iance w i th Tests

Preparations o f Specimens f o r Testing

Packaging and Shielding - Testing f o r I n t e g r i t y

Type A Packaging Tests

Q u a l i t y Control for Construction o f Packaging

Q u a l i t y Control Requirements Pr io r t o Each Shipment o f Radioactive Material

Marking o f Packagings

Speci f icat ion 7A; General Packaging, Type A

Vibrat ion Standard

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5.1 DESIGN EVALUATION

NOTE: out l ined i n 49 CFR.

The bolded t e x t i d e n t i f i e s the applicable Type A regulat ions

Following i s an evaluation o f the a b i l i t y o f the packaging conf igurat ion t o meet performance-related regulat ions. Compliance w i th a l l the indicated regulat ions w i l l s i g n i f y t ha t the packagings have met the design and performance tes t i ng requirements f o r a DOT-7A Type A packaging.

5.1.1 49 CFR 173.24 - General Requirements f o r Packages and Packagings

a. App l icab i l i t y . Except as otherwise provided i n t h i s subchapter, t he provisions o f t h i s sect ion apply to--

(1) Bulk and non-bulk packagings; (2) New packagings and packagings which are reused; and (3 ) Speci f icat ion and non-specif icat ion packagings.

The packaging conf igurat ion has been tested and/or evaluated by WHC and meets DOT-7A Type A packaging c r i t e r i a .

b. Each package used f o r shipment o f hazardous mater ia ls under t h i s subchapter sha l l be designed, constructed, maintained, f i l l e d , i t s contents so l imi ted, and closed so t h a t under condit ions normally inc ident t o transportat ion--

Except as otherwise provided i n t h i s subchapter, there w i l l be no i d e n t i f i a b l e (without the use o f i n s t r u e n t s ) release o f hazardous materi a1 s t o the environment;

The packaging conf igurat ion meets the i n ten t o f t h i s requirement as demonstrated by meeting the more severe Type A packaging requirements o f 49 CFR 173.411, .412, and .465 as demonstrated i n t h i s repor t .

The effect iveness o f the package w i l l no t be subs tan t ia l l y reduced; f o r example, impact resistance, strength, packaging compat ib i l i ty , etc. must be maintained f o r the minimum and maximum temperatures encountered during t ransportat ion;

The packaging conf igurat ion meets the i n ten t o f t h i s requirement as demonstrated by meeting the more severe Type A packaging requirements o f 49 CFR 173.411, .412, and .465 as demonstrated i n t h i s report .

There w i l l be no mixture o f gases o r vapors i n the package which could, through any credib le spontaneous increase o f heat o r pressure, s i g n i f i c a n t l y reduce the effect iveness o f the packaging .

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It i s the r e s p o n s i b i l i t y o f the shipper t o ensure t h a t the payload w i l l remain s tab le during t ranspor t . The shipper i s responsible t o ensure t h a t there w i l l be no mixture o f gasses o r vapors i n the package which could, through any c red ib le spontaneous increase o f heat o r pressure, s i g n i f i c a n t l y reduce the effect iveness o f the packaging.

The ARROW-PAK's containment system was tested t o ensure t h a t i t could withstand a pressure d i f f e r e n t i a l o f 77.2 kPa (11.2 p s i ) .

A hydrostat ic pressure t e s t was conducted t o simulate reduction i n ambient (external) pressure t o 24.1 kPa (3.5 ps ia ) . Test u n i t 40-TU-03, which was bas ica l l y an empty packaging, was used f o r t h i s v e r i f i c a t i o n process. a half-cup o f f luorescein, and then underwent the water spray tes t , penetrat ion bar drop, and compression tes t . Upon completion o f these tes ts , t h i s t e s t u n i t was then f i l l e d completely w i th water. The external surface was cleaned and checked w i th a black l i g h t f o r o f any t race o f f luorescent dye. Compressed n i t rogen gas was used t o pressurize the i n te rna l cav i t y o f the packaging t o 80.66 kPa (11.7 ps ig ) . This pressure was held f o r 15 minutes. No leakage o f water o r f luorescent dye was observed under visual and black l i g h t inspection.

This t e s t u n i t was f i l l e d w i t h

c. Authorized packagings. A packaging i s authorized f o r a hazardous mater ia l on ly if--

(1) The packaging i s prescribed or permitted f o r t he hazardous mater ia l i n a packaging sect ion spec i f ied f o r t h a t mater ia l i n Column 8 o f the sect ion 172.101 Table and conforms t o appl icable requirements i n the special Brovisions o f Column 7 o f the sect ion 172.101 Table and, f o r spec i f i ca t i on packagings ( inc lud ing U.N. standard packagings), t he spec i f i ca t i on requirements i n par ts 178 and 179 o f t h i s subchapter; o r

(2) The packaging i s permitted under, and conforms to, prov is ions contained i n sections 171.11, 171.12, 171.12a, 173.3, 173.4, 173.5, 173.7, 173.27, or 176.11 o f t h i s subchapter.

The packaging configuration, as documented herein, has been q u a l i f i e d t o meet Spec i f i ca t ion 7A packaging requirements i n accordance w i th 49 CFR 178.350. shipper t o ensure t h a t the packagings used are i n compliance w i t h the design discussed i n t h i s repor t .

It i s the r e s p o n s i b i l i t y o f the

d. DOT spec i f i ca t i on and U.N. standard packagings. For DOT spec i f i ca t i on packagings ( inc lud ing U.N. standard packagings, conformance t o the appl icable speci f icat ions i n par ts 178 and 179 o f t h i s subchapter i s required i n a l l de ta i l s . For perfornance- or iented packagings covered by subpart L o f p a r t 178 o f t h i s subchapter, each packaging must be capable o f meeting the performance t e s t requirements spec i f ied i n subpart M o f p a r t 178 o f

5-3


The packaging conf igurat ion described and tested i s not authorized for t ranspor tat ion o f 1 iquids.

The packaging conf igurat ion described and tested w i l l not t ransport compressed gasses or cryogenic 1 iquids.

by a i r c r a f t must conform t o the general requirements f o r t ranspor tat ion by a i r c r a f t i n 173.27, except as provided i n 171.11 o f t h i s subchapter.

The packaging conf igurat ion described and tested was not evaluated f o r t ransportat ion by a i r c r a f t .

i . A i r transportat ion. Packages of fered or intended f o r t ranspor tat ion

5.1.2 49 CFR 173.24a - Addit ional General Requirements fo r Non-Bul k Packagings and Packages

a. Packaging design. Except as provided i n sect ion 172.312 o f t h i s subchapter:

(1) Inner packaging closures. A Combination packaging containing l i q u i d hazardous mater ia ls must be packed so t h a t closures on inner packagings are upr ight .

The packaging conf igurat ion described and tested does not incorporate any inner packaging closures, and l i q u i d s are not authorized f o r use i n the ARROW-PAK.

(2) f r i c t i o n . The nature and thickness o f the outer packaging must be such t h a t f r i c t i o n dur ing t ranspor tat ion i s no t l i k e l y t o generate an amount o f heat s u f f i c i e n t t o a l t e r dangerously the chemical s t a b i l i t y o f the contents.

The nature and thickness o f the packaging conf igurat ion i s such tha t f r i c t i o n during t ransport w i l l not generate any heating tha t would adversely a f fec t the contents.

(3) Securing and cushioning. Inner packagings o f combination packagings must be so packed, secured and cushioned t o prevent t h e i r breakage or leakage and t o control t h e i r movement within the outer packaging under condit ions normally incident t o transportat ion. Cushioning material must no t be capable o f react ing dangerously w i t h the contents o f the inner packagings.

The ARROW-PAK i s intended t o ship rad ioact ive ly contaminated lead. Simulated contents used during tes t i ng were wrapped lead br icks and steel shot. The lead br icks were t i g h t l y packed w i th in the cav i ty o f the ARROW-PAK. Steel shot was f i l l e d i n the void space around the br icks. Refer t o Appendix B o f t h i s repor t f o r a descr ip t ion as t o how the t e s t un i ts were assembled, loaded, and closed f o r test ing.

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The shipper i s responsible t o ensure tha t the in te rna l contents do not s h i f t such tha t an increase i n rad ia t ion o f 20 percent o r more i s encountered (IAEA, 1985). It i s the respons ib i l i t y o f the shipper t o ensure tha t cushioning mater ia l i s compatible w i th contents.

(4) Me ta l l i c devices. Nails, staples and other m e t a l l i c devices sha l l not protrude i n t o the i n t e r i o r o f t he outer packaging i n such a manner as t o be l i k e l y t o damage inner packagings or receptacles.

There are no me ta l l i c devices o r protrusions t h a t could cause fa i l u res .

withstanding, without rupture or leakage, the v ib ra t i on t e s t procedure speci f ied i n sect ion 178.608 o f t h i s subchapter.

The approved packaging conf igurat ion was judged t o pass t h i s requirement. Type A packagings are required " t o withstand the e f fec ts o f any acceleration, v ibrat ion, o r v ib ra t ion resonance tha t may ar ise during normal t ransportat ion" [see 49 CFR 173.412 (e)] . The t e s t i d e n t i f i e d i n t h i s sect ion was applied t o support the a b i l i t y o f the packaging t o meet the requirement. Visual examination o f the packaging i d e n t i f i e d no rupture o r leakage.

(5) Vibrat ion. Each non-bulk package must be capable o f

The cy l i nd r i ca l tube/pipe and end caps are closed and sealed v i a a patented process developed by Arrow. This process involves the use o f e l e c t r i c a l energy t o heat opposing faces o f the pipe and end caps, and hydraul ic rams t o press the heated surfaces together. The r e s u l t i s a homogeneous bonding o f the end cap t o the pipe, w i th no in ternal evidence o f a seam between components.

V ibrat ion tes t i ng was conducted as described i n Section 5.2.3 o f t h i s report . Damage received by the packaging as a r e s u l t from t h i s tes t i ng are described i n Section 5.2.3.c o f t h i s report . A f te r the v ib ra t ion tes t , the packagings underwent a "soap bubble" t e s t and were checked v i sua l l y and under black l i g h t inspection. None were observed t o have leakage o f simulated contents.

b. Non-bulk packaging f i l l i n g l i m i t s .

(1) A s ing le or composite non-bulk packaging may be f i l l e d with a l i q u i d hazardous mater ia l on ly when the spec i f i c g rav i t y o f the mater ia l does not exceed t h a t marked on t he packaging, or a spec i f i c g rav i ty o f 1.2 i f not marked, except as follows:

(i) A Packing Group I packaging may be used for a Packing Group I1 mater ia l w i th a spec i f i c g rav i t y no t exceeding the greater o f 1.8, or 1.5 times the spec i f i c g rav i t y marked on the packaging, provided a l l the performance

5-9


(iii) A s ing le o r composite non-bulk packaging which i s tested and marked f o r Packing Group I1 l i q u i d hazardous mater ia ls may be f i l l e d w i th a s o l i d Packing Group I11 hazardous mater ia l t o a gross mass, i n kilograms, no t exceeding the rated capacity o f t he packaging i n l i t e r s , m u l t i p l i e d by 1.5, mu l t i p l i ed by the spec i f i c g rav i t y marked on the packaging, o f 1.2 i f not marked.

This i s not appl icable t o a Type A packaging as Type A packaging does not incorporate packing groups. authorized f o r use i n the ARROW-PAK. The s o l i d mater ia ls intended f o r shipment a r e l i m i t e d i n weight, t o the as-tested weight i d e n t i f i e d during tes t i ng (Section 2.1, Table 2-1).

(4) Packagings tested as prescribed i n sect ion 178.605 o f t h i s subchapter and marked w i t h the hydrostat ic t e s t pressure as prescribed i n sect ion 178.503(a)(5) o f t h i s subchapter may be used f o r l i q u i d s only when the vapor pressure o f the l i q u i d conforms t o one o f the fol lowing:

Liquids are not

(i) The vapor pressure must be such t h a t the t o t a l pressure i n the packaging [i.e., the vapor pressure o f the l i q u i d plus the p a r t i a l pressure o f a i r o r other i n e r t gases, less 100 kPa (15 ps i ) a t 55 "C (131 O F ) , determined on the basis o f a maximum degree o f f i l l i n g i n accordance with paragraph (b ) ( l ) o f t h i s section and a f i l l i n g temperature o f 15 'C (59 O F ) ] , w i l l not exceed two-thirds o f t he marked t e s t pressure;

ii) The vapor pressure a t 50 'C (122 'F) must be less than four-sevenths o f the sum o f the marked t e s t pressure plus 100 kPa (15 psi) ; o r

ii) The vapor pressure a t 55 'C (131 'F) must be less than two-thirds o f the sum o f the marked t e s t pressure plus 100 kPa (15 psi) .

This i s not appl icable t o Type A packaging as Section 178.605 does not per ta in t o speci f icat ion packagings. The packaging conf igurat ion described and tested i s authorized f o r t ransportat ion o f radioact ive s o l i d materials.

The ARROW-PAK's containment system was tested t o ensure tha t i t could withstand a pressure d i f f e r e n t i a l o f 77.2 kPa (11.2 p s i ) .

(5) No hazardous mater ia l may remain on the outside o f a package a f t e r f i l l i n g .

The leve l o f non-fixed (removable) radioact ive contamination on the external surfaces o f each package of fered f o r shipment sha l l be kept as low as pract icable (49 CFR 173.443). the respons ib i l i t y o f the shipper t o ensure compliance w i th t h i s requirement.

It i s

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c. Hixed contents.

(1) An outer non-bulk packaging may contain more than one hazardous mater ia l only when--

(i) The inner and outer packagings used f o r each hazardous mater ia l conform t o the relevant packaging sections o f t h i s pa r t appl icable t o t h a t hazardous mater ia l ;

(ii) The package as prepared f o r shipment meets the performance tes ts prescribed i n pa r t 178 of t h i s subchapter f o r t he packing group ind ica t ing the highest order o f hazard f o r the hazardous mater ia ls contained i n the package;

packed i n securely closed inner receptacles before packing i n outer packagings; and

does no t exceed the lowest permitted maximum net quant i t y per package as shown i n Column 9a or 9b, as appropriate, o f the sect ion 172.101 Table. The permitted maximum net quant i t y must be calculated i n kilograms i f a package contains both a l i q u i d and a so l id .

(iii) Corrosive mater ia ls (except OM-D) i n bo t t l es are fu r the r

( i v ) For t ranspor tat ion by a i r c r a f t , the t o t a l net quant i t y

(2) A packaging containing inner packagings o f D iv is ion 6.2 mater ia ls may no t contain other hazardous materials, except d ry ice.

The package i s designed and tested f o r Type A radioact ive mater ia l shipments only. It i s the respons ib i l i t y o f the shipper t o ensure tha t react ive hazardous components are not shipped together i n a packaging, and tha t the package i s i n compliance w i th the above requirements.

d. Liquids must not completely f i l l a receptacle a t a temperature o f 55 'C (131 O F ) or less.

Liquids are not authorized f o r t ransport i n the packaging conf igurat ion described i n t h i s report .

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This requirement i s met as the packaging conf igura t ion tested has a gross weight o f more than 50 kg (110 l b ) . Handling o f the ARROW-PAK sha l l be done i n such a manner t h a t it i s not damaged by dragging over sharp objects o r cu t by chokers o r l i f t i n g equipment. o r cable-type chokers must be avoided. This packaging conf igura t ion may be eas i l y l i f t e d and handled v i a the use o f a f o r k l i f t o r nylon s l ings .

Chains

d. Each l i f t i n g attachment on the package, when used i n t h e intended manner, w i t h a minimum safe ty fac to r o f three, does no t impose an unsafe s t ress on the s t ruc tu re o f t he package. l i f t i n g attachment sha l l be so designed t h a t f a i l u r e under excessive load would no t impair t he a b i l i t y o f t he package t o meet a l l other requirements o f t h i s subpart. Each attachment o r other fea ture on the outer surface o f the packaging t h a t could be used t o l i f t the package must be removable or otherwise capable or being made inoperable f o r transport, or sha l l be designed w i t h s t rength equivalent t o t h a t required f o r l i f t i n g attachments;

I n addit ion, t he

There are no l i f t i n g attachments; therefore, t h i s requirement i s not applicable.

e. The external surface, as f a r as practicable, may be e a s i l y decontaminated;

The packaging conf igurat ion tested meets the i n t e n t o f t h i s requirement. The ex te r io r surface o f the ARROW-PAK i s made o f HDPE mater ia l . This material i s used throughout indust ry f o r rad ioac t ive and hazardous material shipments, and may be eas i l y decontaminated i f no degradation o f the mater ia l has occurred due t o exposure t o incompatible materials.

Protrusions and crevices e x i s t on the ARROW-PAK ar.ound the two fus ion j o i n t areas; however, the surface i s smooth and t h i s area can eas i l y be decontaminated. t o ensure tha t materials shipped i n the container are compatible w i t h each other and the container.

It i s the r e s p o n s i b i l i t y o f the shipper

f. The outer layer o f packaging w i l l avoid, as f a r as practicable, pockets or crevices where water might co l l ec t ; and

The ex te r io r o f the packaging i s HDPE pipe tha t has thermally fused end caps. The seal ing process resu l t s i n a homogeneous bonding o f the end caps t o the pipe. ARROW-PAK around the two fus ion j o i n t areas; however, the external fus ion r i ngs are s l i g h t , and such tha t water w i l l no t c o l l e c t .

Test u n i t 40-TU-03 was subjected t o the water spray condit ions f o r one hour w i th no adverse e f f e c t o r loss o f contents.

Protrusions and crevices e x i s t on the

5-15.


polyethylene m a t e r i a l used i s d u c t i l e t o -118°C (-180°F). The Marlex 8000 r e s i n i s capable o f enduring exposure t o 70°C (158°F) f o r an i n d e f i n i t e time per iod without thermal degradation.

e. It i s able t o withstand the e f f e c t s o f any acceleration, v ib ra t ion , o r v i b ra t i on resonance t h a t may a r i se dur ing normal t ranspor tat ion, wi thout any de te r io ra t i on o f the effect iveness o f c los ing devices o r o f t he i n t e g r i t y o f the package as a whole and wi thout loosening or un intent ional release of nuts, bo l ts , o r other securing devices even a f t e r repeated use;

The packaging conf igurat ion was judged t o pass t h i s requirement. The t e s t i d e n t i f i e d i n 49 CFR 178.608 was applied t o two packages t o support the a b i l i t y of the packaging t o meet the requirement. Visual examination o f the packaging i d e n t i f i e d no rupture o r 1 eakage.

The c y l i n d r i c a l tube/pipe and end caps are closed and sealed v i a a patented process developed by Arrow. This process involves the use o f e l e c t r i c a l energy t o heat opposing faces o f the pipe and end caps, and hydraul ic rams t o press the heated surfaces together. The r e s u l t i s a homogeneous bonding o f the end cap t o the pipe, w i th no i n te rna l evidence o f a seam between components.

V ib ra t ion t e s t i n g was conducted as described i n Section 5.2.3 o f t h i s repor t . Damage received by the packaging as a r e s u l t from t h i s t e s t i n g are described i n Section 5.2.3.c o f t h i s repor t . A f t e r the v i b r a t i o n tes t , the packagings underwent a "soap bubble" t e s t and were checked v i s u a l l y and under black l i g h t inspection. None were observed t o have leakage o f simulated contents.

It includes a containment system securely closed by a p o s i t i v e fasten ing device t h a t cannot be opened un in ten t i ona l l y o r by pressure t h a t may a r i se w i t h i n the package during normal t ranspor t . Special form, as demonstrated i n accordance w i t h Paragraph 173.469 may be considered as a component o f the containment system;

The c y l i n d r i c a l tube/pipe and end caps are closed and sealed v i a a patented process developed by Arrow. This process involves the use o f e l e c t r i c a l energy t o heat opposing faces o f the pipe and end caps, and hydraul ic rams t o press the heated surfaces together. The r e s u l t i s a homogeneous bonding o f the end cap t o the pipe, w i th no i n te rna l evidence o f a seam between components. The only method o f opening the ARROW-PAK i s t o cu t it open.

The ARROW-PAK's containment system was tested t o ensure t h a t i t could withstand a pressure d i f f e r e n t i a l o f 77.2 kPa (11.2 ps i ) .

A hydrostat ic pressure t e s t was conducted t o simulate reduction i n ambient (external ) pressure t o 24.1 kPa (3.5 psia). Test u n i t 40-TU-03, which was bas i ca l l y an empty packaging, was used f o r t h i s v e r i f i c a t i o n process. This t e s t u n i t was f i l l e d w i th a half-cup o f f luorescein, and then underwent the water spray tes t , penetrat ion bar drop, and compression t e s t .

f.

-

Upon completion o f these tests ,

5-17


t h i s t e s t u n i t was t h e m f i l l e d completely w i th water. The external surface was cleaned and checked w i th a black l i g h t f o r any t race o f f luorescent dye. i n te rna l cav i t y o f the packaging t o 80.66 kPa (11.7 psig). This pressure was held f o r 15 minutes. No leakage o f water o r f luorescent dye was observed under v isual and black l i g h t inspection.

Compressed n i t rogen gas was used t o pressurize the

g. The mater ia ls o f t he packaging and any components or st ructures are phys i ca l l y and chemically compatible w i t h each other and w i t h the contents, tak ing i n t o account the behavior o f each under i r r a d i a t i o n ;

The mater ia ls o f the packaging conf igurat ion are phys ica l l y and chemically compatible w i th each other. the shipper t o ensure tha t the contents are compatible w i t h the packaging.

HDPE mater ia l has been used as construction mater ia l f o r piping, containers, and l i n i n g o f s tee l containers. HDPE mater ia l has been tested and i s s t r u c t u r a l l y and environmentally su i tab le f o r commercial appl icat ions. HDPE packagings are used i n the management o f wastes f o r transport ing, storing, and/or disposing o f rad ioact ive, mixed radioactive-hazardous, and hazardous wastes. The advantage o f HDPE packagings i s a marked resistance t o leaking, leaching, and corrosion (Farnsworth, 1994).

It i s the r e s p o n s i b i l i t y o f

' S ign i f i can t data ex is ts on HDPE damage from i r r a d i a t i o n and corros ive chemicals. The i r r a d i a t i o n data have showed t h a t HDPE ( i n general) and Ph i l1 ips-Driscopipe ( i n pa r t i cu la r ) have been res i s tan t t o gamma i r r a d i a t i o n leve ls o f up t o 39 Mrad (Phil l ips-Driscopipe) and 100 Mrad ( a l l HDPEs). No spec i f i c t es t i ng has been performed f o r P h i l l i p s ' Marlex resin. The chemical corrosion data from Ph i l 1 ips-Dri scopipe showed t h a t Ph i l 1 ips ' M a r l ex r e s i n i s res i s tan t t o near ly a l l forms o f chemicals, w i th the exception o f extremely concentrated acids (Farnsworth, 1994).

For each component o f the containment system account i s taken, where applicable, o f r a d i o l y t i c decomposition o f mater ia ls and the generation o f gas by chemical react ion and rad io lys is ;

h.

It i s the r e s p o n s i b i l i t y o f the shipper t o ensure t h a t the e f f e c t s o f rad ia t i on from the payload w i l l not degrade the performance o f the packaging through gas generation, chemical reaction, o r rad io l ys i s .

i. The Containment system w i l l r e t a i n i t s rad ioac t ive contents under t h e reduct ion o f ambient pressure t o .25 kilograms per square centimeter (3.5 pounds per square inch);

The ARROW-PAK packaging provides primary containment v i a the permanent fus ion o f the c y l i n d r i c a l pipe/tube and two end caps.

5-18


The packaging described i n t h i s repor t passed the required pressure condit ions. The ARROW-PAK's containment system was tested t o ensure t h a t i t could withstand a pressure d i f f e r e n t i a l o f 77.2 kPa (11.2 ps i ) .

A hydrostat ic pressure t e s t was conducted t o simulate reduct ion i n ambient (external) pressure t o 24.1 kPa (3.5 ps ia ) . 40-TU-03, which was bas i ca l l y an empty packaging, was used f o r t h i s v e r i f i c a t i o n process. This t e s t u n i t was f i l l e d w i th a half-cup o f f luorescein, and then underwent the water spray tes t , penetrat ion bar drop, and compression t e s t . Upon completion o f these tests , t h i s t e s t u n i t was then f i l l e d completely w i t h water. The external surface was cleaned o f any t race o f f luorescent dye, and checked w i th a black l i g h t . Compressed n i t rogen gas was used t o pressurize the i n te rna l cav i t y o f the packaging t o 80.66 kPa (11.7 psig). This pressure was held f o r 15 minutes. No leakage o f water o r f luorescent dye was observed under v isual and black l i g h t inspection.

Test u n i t

j. Each valve through which the rad ioact ive contents could otherwise escape i s protected against damage and unauthorized operation and, except f o r a pressure r e l i e f device, has an enclosure t o r e t a i n any 1 eakage;

There are no valves used i n t h i s packaging configuration; therefore, t h i s requirement i s not applicable.

Any r a d i a t i o n sh ie ld t h a t encloses a component o f t h e packaging spec i f i ed as p a r t o f the containment systuin w i l l prevent the unintent ional escape o f t h a t component from the shield;

k.

Shielding i s not a component o f t h i s packaging system; therefore, t h i s requirement i s not appl icable. The ARROW-PAK packaging provides primary containment v i a the permanent fus ion o f the c y l i n d r i c a l pipe/tube and two end caps.

Fa i l u re o f any t i e down attachment o f t he packaging under excessive load w i l l no t impair t he a b i l i t y o f the package t o meet other requirements o f t h i s subpart;

There are no tie-down attachments on the packagings; therefore, t h i s requirement i s not appl icable.

1.

m. When subjected t o the t e s t s spec i f ied i n Paragraph 173.465 or evaluated against these t e s t s by any o f t he nethods authorized by Paragraph 173.461(a), t he packaging w i l l prevent:

(1) Loss o r dispersal o f t h e rad ioac t ive contents; and

(2) Any s i g n i f i c a n t increase i n the rad ia t i on l eve l s recorded or calcu lated a t t he external surfaces f o r t he cond i t ion before the tes t .

5-19


(3 )

I f an ind ica t ion o f the name o f the manufacturer or other i d e n t i f i c a t i o n o f the packaging as speci f ied by the competent au thor i ty i s required, t he name and address o r symbol o f t he person making the mark sha l l be entered. Symbols, i f used, must be reg is tered w i th the Associate Administrator f o r hazardous Material Safety. Dupl i ca te symbols are no t authorized.

Packagings manufactured t o UN standards i n accordance w i th t h i s subchapter sha l l be marked as prescrf bed i n paragraph 178.503 o f t h i s par t .

c. Where a packaging conforms t o more than one UN standard or DOT speci f icat ion, the packaging nay bear more than one marking, provided the packaging w e t s a l l the requirements o f each standard o r spec i f icat ion. Where more than one marking appears on a packaging, each marking must appear i n i t s en t i re ty .

It i s the respons ib i l i t y o f the shipper t o ensure tha t the above requirements have been properly addressed by providing assurance tha t the packagings have been cor rec t ly marked as a Type A packaging, inc lud ing i d e n t i f i c a t i o n o f the manufacturer.

The ARROW-PAK packaging was tested only t o DOT-7A Type A packaging requirements, as i s t o be used only f o r radioact ive mater ia l t ransportat ion. The use o f any addi t ional markings would requi re addi t ional t es t i ng o f the packaging t o ensure the packaging met tha t standard/specif icat ion.

5.2 COMPLIANCE TEST EVALUATION

5.2.1 49 CFR 173.465 - Type A Packaging Tests

a. The proposed packaging w i th proposed contents must be capable o f withstanding the tes ts prescribed i n t h i s section. One prototype may be used f o r a l l tes ts i f the requirements o f paragraph (b) o f t h i s sect ion are complied with.

Water Spray Test. The water spray t e s t must precede each t e s t or t e s t sequence prescribed i n t h i s section. The water spray t e s t sha l l simulate exposure t o r a i n f a l l o f approximately 5 centimeters (2 inches) per hour f o r a t l eas t one hour. The t ime in te rva l between the end o f the water spray t e s t and the beginning o f the next t e s t sha l l be such t h a t the water has soaked-in t o the maximum extent wi thout appreciable dry ing o f the ex te r io r o f the specimen. I n the absence o f evidence t o the contrary, t h i s i n te rva l may be assumed t o be two hours i f the water spray i s appl ied from four d i f f e r e n t d i rec t ions simultaneously. However, no t ime in te rva l may elapse i f the water spray i s appl ied from each o f the four d i r e c t i ons consecutively .

b.

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POUNDS >11,000 TO 22,000 ... >22,000 TO 33,000.. . More than 33,000.. .

The water spray t e s t was successful ly conducted on t e s t u n i t 40-TU-03 (Series 8600 pipe) . f i l l e d w i th a half-cup o f f luorescein. the water spray condit ions f o r 1 hour wi th no negative e f fec t on the packaging. absorption o f water nor loss o f contents.

This was bas ica l l y an empty t e s t u n i t t ha t had been The t e s t u n i t was subjected t o

No fu r ther water spray tes ts were conducted as there was no

FEET 3

2 1

c. Free Drop Test. The f ree drop t e s t consists o f a f a l l onto the ta rge t i n a manner t h a t causes maximum damage t o the safety features being tested, and:

1. For packages weighing 5,000 kilograms (11,000 pounds) or less, the distance o f the f a l l measured from the lowest po in t o f the packaging t o the upper surface o f the ta rge t sha l l not be less than 1.2 meters (4 feet).

For packages weighing more than 5,000 kilograms (11,000 pounds), the distance o f the f a l l sha l l no t be less than the distance speci f ied i n Table 11, f o r the applicable packaging weight:

2.

TABLE 11: FREE-FALL DISTANCE FOR PACKAGING WEIGHING MORE THAN 5,000 KILOGRAMS.

PACKAGING W E I M I FREE-FALL DISTANCE I KILOGRAMS

>5,000 TO 10,000.. . >10,000 TO 15,000.. . More than 15,000.. .

METERS

0.3

The v ib ra t i on t e s t was conducted on t e s t un i ts 40-TU-01 and 40-TU-02 p r i o r t o the 1.2-m (4- f t ) drop tes t . The water spray t e s t was conducted on t e s t u n i t 40-TU-03 p r i o r t o the 1 . 2 4 (4 - f t ) drop t e s t . As the water spray t e s t had no negative e f fec t on the tested packaging configuration, the water spray t e s t was not conducted on the two t e s t un i ts (40-TU-01 and 40-TU-02) used f o r the drop tes ts described below.

Test u n i t 40-TU-01 was made from Series 8000 pipe, and t e s t u n i t 40-TU-02 was made from Series 8600 pipe. The packagings shown i n Table 5-1 were subjected t o drop tes ts from a height o f 1.2 m (4 ft).


40-TU-01

40-TU-01

Table 5-1. Drop Tests - 1.2 m (4 ft).

_ . .

519.8 (1146) without plugs 519.8 (1146) w a l l o f the packaging

Ver t ica l , t o impact f l a t onto the end cap

Horizontal, t o impact f l a t onto the side

507.6 (1119) 507.6 (1119) 507.6 (1119) 507.6 11119)

I Center o f g rav i ty (CG), t o impact the edge I 40-TU-01 I o f the end cap without plugs

Ver t ica l , t o impact f l a t onto the end cap without plugs Horizontal, t o impact f l a t onto the side wall o f the packaging CG, t o impact the edge o f the end cap without plugs CG, t o impact the edge o f the end cap w i th 01 uas

I Ver t ica l , t o impact f l a t onto the end cap I 40-TU-01 I w i th plugs

40-TU-02

40-TU-02

40-TU-02

40-TU-02

Results:

noncontaminated, wrapped lead br icks and steel shot, and contained two plywood spacers ( re fe r t o Appendix B f o r assembly, loading, and closure procedure used f o r test ing) . Fluorescein was added f o r leak detect ion purposes. This t e s t u n i t measured a t o t a l length o f 187.96-cm (74-in). The gross weight o f t h i s t e s t u n i t was 519.8 kg (1146 lb ) . This t e s t u n i t underwent and passed a t o t a l o f four drops.

- - : This t e s t u n i t was loaded w i th simulated contents o f

DroD #1 - t h i s o r ien ta t ion was ve r t i ca l t o impact f l a t onto the end cap without plugs. Minor damage resul ted i n s l i g h t scarr ing o f the HDPE mater ia l on the end cap a t the po in t o f impact. The impact po in t and fusion j o i n t s were checked v i sua l l y and under black l i g h t condit ions. There was no ind ica t ion o f leakage o f simulated contents.

DroD #Z - t h i s o r ien ta t ion was CG (10' angle), t o impact the edge o f the end cap without plugs. Damage resul ted i n a s l i g h t c i r c u l a r f l a t t e n i n g a t the area o f impact on the edge o f the end cap, and having a diameter o f 5.08-cm (2-in). No damage resul ted from the slap-down. The impact po in t and fusion j o i n t s were checked v i sua l l y and under black l i g h t condit ions. There was no ind ica t ion o f leakage o f simulated contents.

Proo #3 - t h i s o r ien ta t ion was hor izontal , t o impact f l a t onto the side w a l l o f the package. Damage resul ted i n s l i g h t f l a t ten ing o f the beaded

5-24


edge along the fus ion j o i n t s . The beaded edge o f the fus ion j o i n t , near the end cap without the plugs, f la t tened s l i g h t l y over a length o f 7.62-cm (3- in) . The beaded edge o f the fus ion j o i n t , near the end cap w i th the plugs, f l a t tened s l i g h t l y over a length o f 6.99-cm (2.75-in). There was no f l a t t e n i n g o f the pipe o r end caps. The fus ion j o i n t s were checked v i s u a l l y and under black l i g h t conditions. There was no i nd i ca t i on o f 1 eakage o f simulated contents.

A f t e r the t h i r d drop, a soap bubble t e s t was conducted t o v e r i f y the containment o f t h i s t e s t u n i t p r i o r t o conducting the fou r th drop. The center p lug was removed from the end cap, and compressed n i t rogen gas was connected t o t e s t u n i t 40-TU-01. The in te rna l pressure was increased t o 27.6 kPa (4 p s i ) , and held f o r 15 minutes. A low-v iscos i ty soap bubble so lu t ion (i .e., "Snoop") was coated around the connections, plug, c y l i n d r i c a l side, and area where the end caps are fused t o the c y l i n d r i c a l wal l of the packaging. No bubbles o r foam were detected. The area was also checked w i th a black l i g h t f o r detect ion o f f luorescent dye. No i nd i ca t i on o f leakage was detected. The fou r th drop was then conducted.

Proo #4 - t h i s o r i en ta t i on was v e r t i c a l t o impact f l a t onto the end cap w i th the plugs. The t e s t u n i t impacted f l a t onto the designated end cap, the package pivoted, and slapped down onto the edge o f the drop pad. The package then r o l l e d o f f the drop pad. Damage resu l ted i n a minor scratch measuring 39.37-cm (15.5-in), diagonal, along the sidewall o f the c y l i n d r i c a l pipepube, and near the center o f the package. One o f the end caps received a minor gouge when it h i t an un iden t i f i ed object when the packaging r o l l e d o f f the t e s t pad. incorporates a f l a t , c i r c u l a r base piece, measuring 6.35-cm (2.50-in) i n diameter, and located a t the center axis o f the packaging's domed end. This base piece i s ra ised s l i g h t l y from the domed end, and i s a r e s u l t o f the process used by the manufacturer i n molding t h i s component. The f l a t base piece pu l led outward s l i g h t l y , around the e n t i r e circumference o f the base piece. A l l noted damaged areas were checked under black l i g h t condit ions. There was no i nd i ca t i on o f leakage o f simulated contents. The fus ion j o i n t s were checked v i s u a l l y and under black l i g h t condit ions. There was no ind ica t ion o f leakage o f simulated contents.

Each dome-shaped end cap

A f t e r the fou r th drop, a soap bubble t e s t was conducted t o v e r i f y the containment o f t h i s t e s t un i t . The center p lug was removed from the end cap, and compressed nitrogen gas was connected t o t e s t u n i t 40-TU-01. The in te rna l pressure was increased t o 27.6 kPa (4 p s i ) , and held f o r 15 minutes. A low-viscosity soap bubble so lut ion (i.e., "Snoop") was coated around the connections, plugs, c y l i n d r i c a l side, and area where the end caps are fused t o the c y l i n d r i c a l wall o f the packaging. The area o f the end cap containing the 6.35-cm (2.50-in) f l a t base piece was coated w i th "Snoop." No bubbles o r foam were detected from any o f the spec i f ied locat ions. These areas were also checked w i th a black l i g h t f o r detect ion o f f luorescent dye. No ind ica t ion o f leakage was detected.

Test Un i t 40-TU-02: This t e s t u n i t was loaded w i th simulated contents o f noncontaminated, wrapped lead b r i cks and s tee l shot, and contained two plywood spacers ( r e f e r t o Appendix B f o r assembly, loading, and closure

5-25


procedure used f o r t es t i ng ) . purposes. The gross weight o f t h i s t e s t u n i t was 507.6 kg (1119 l b ) . This t e s t u n i t underwent and passed a t o t a l o f four drops.

Fluorescein was added f o r leak detect ion This t e s t u n i t measured a t o t a l length o f 184.15-cm (72.5-in).

OroD #1 - t h i s o r i en ta t i on was v e r t i c a l t o impact f l a t onto the end cap without plugs. The t e s t u n i t impacted f l a t onto the designated end cap, the package pivoted and f e l l against a turnbuckle and beam located near one edge o f the drop pad, then slapped down onto the edge o f the drop pad. The package then r o l l e d o f f the drop pad. One o f the end caps was gouged s l i g h t l y from s t r i k i n g the turnbuckle. Minor damage resu l ted i n s l i g h t scarr ing o f the HDPE mater ia l from the package r o l l i n g o f f the t e s t pad. beaded edge o f the fus ion j o i n t , which had s l i g h t f l a t t e n i n g over a length o f 5.08-cm (2-in). A l l noted and damaged areas were checked v i s u a l l y and under black l i g h t conditions. checked v i s u a l l y and under black l i g h t condit ions. There was no i nd i ca t i on o f 1 eakage o f simulated contents.

Damage r e s u l t i n g from the slap-down was v i s i b l e along the

The fus ion j o i n t s were

Oroo #2 - t h i s o r i en ta t i on was CG (10" angle), t o impact the edge o f the end cap without plugs. Damage resu l ted i n a s l i g h t dimpling o f the HDPE mater ia l having a diameter o f 2.54-cm (1-in) a t the area o f impact on the edge o f t he end cap. No damage resu l ted f r o m the slap-down. The impact po in t and fus ion j o i n t s were checked v i s u a l l y and under black l i g h t condit ions. There was no i nd i ca t i on o f leakage o f simulated contents.

Oroo #3 - t h i s o r i en ta t i on was hor izonta l , t o impact f l a t onto the side w a l l o f the package. edge o f the fus ion j o i n t . f l a t t ened a length o f 6.35-cm (2.50-in). pipe o r end caps. black l i g h t condit ions. contents.

A f t e r the t h i r d drop, a soap bubble t e s t was conducted t o v e r i f y t he containment o f t h i s t e s t u n i t p r i o r t o conducting the fou r th drop. The center p lug was removed from the end cap, and compressed n i t rogen gas was connected t o t e s t u n i t 40-TU-02. The in te rna l pressure was increased t o 27.6 kPa (4 ps i ) , and held f o r 15 minutes. A low-viscosity soap bubble so lu t ion ( i .e., "Snoop") was coated around the connections, plugs, c y l i n d r i c a l side, and area where the end caps are fused t o the c y l i n d r i c a l wal l o f the packaging. The area was also checked w i th a black l i g h t f o r detect ion o f f luorescent dye. conducted.

Damage resu l ted i n s l i g h t f l a t t e n i n g o f the beaded

There was no f l a t t e n i n g o f the

There was no i nd i ca t i on o f leakage o f simulated

Each beaded edge o f the fus ion j o i n t s

The fus ion j o i n t s were checked v i s u a l l y and under

No bubbles o r foam were detected.

No i nd i ca t i on o f leakage was detected. The fou r th drop was then

ProD x4 end cap O f 2.54-

- t h i s o r i en ta t i on was CG (10" angle) t o impact the edge o f the w i t h the plugs. Damage resu l ted i n a s l i g h t dimpling (diameter

-cm [ I - i n ] ) o f the HDPE material a t the area o f impact on the edge o f the end cap. No damage resu l ted f r o m the slap-down. Each dome-shaped end cap incorporates a f l a t , c i r c u l a r base piece, measuring 6.35-cm (2.50-in) i n diameter, and located a t t he center axis of t he packaging's domed end. This base piece i s ra ised s l i g h t l y from the domed end, and i s a r e s u l t o f the process used by the manufacturer i n molding t h i s

5- 26


2. The distance o f the f a l l o f the bar measured from i t s lower end t o the upper surface o f the packaging specimen sha l l n o t be less than 1 meter (3.3 feet) .

The penetrat ion t e s t was successful ly conducted on t e s t u n i t 40-TU-03 (Series 8600 pipe). This was bas ica l l y an empty packaging; a half-cup o f f luorescein was added f o r leak detect ion purposes.

The water spray t e s t was conducted on t h i s t e s t u n i t p r i o r t o conducting the penetrat ion t e s t . Immediately a f t e r the water spray t e s t was conducted and before the packaging could dry, the subject t e s t u n i t underwent the 1 m (3.3 ft) penetrat ion tes t . The package was l a i d hor izon ta l l y onto i t s side, and the penetrat ion bar was dropped t o h i t the cy l i nd r i ca l tube/pipe, a t the center o f the package. The po in t o f impact caused the HDPE mater ia l t o dimple s l i g h t l y , and measured 1.27-cm (0.50-in) across. This minor damage was observed under a black l i g h t , and no leakage o f simulated contents was detected.

5.2.2 49 CFR 173.466 - Addit ional Tests f o r Type A Packagings Designed f o r Liquids and Gases

In addi t ion t o the tes ts prescribed i n 173.465, Type A packaging designed f o r l i q u i d s and gases sha l l be capable o f Withstanding the fo l lowing tests:

1. Free Drop Test. The packaging specimen sha l l f a l l onto the ta rge t i n a manner which w i l l cause i t t o su f fe r the maximum damage t o i t s containment. The distance o f the f a l l measured from the lowest p a r t o f the packaging specimen sha l l no t be less than 9 meters (30 feet).

This packaging i s not authorized f o r t ransport o f l i q u i d s and/or gases; therefore, t h i s t e s t i s not required.

Penetration Test. The specimen must be subjected t o the t e s t spec i f ied i n 173.465(e) except t h a t the distance o f the f a l l sha l l be 1.7 meters (5.5 feet).

2.

This packaging i s not authorized f o r t ransport o f l i q u i d s and/or gases; therefore, t h i s t e s t i s not required.

5.2.3 49 CFR 178.608 - Vibrat ion Standard

a.

b. Test method.

Each packaging must be capable o f withstanding, wi thout rupture or leakage, the v ib ra t i on t e s t procedure out l ined in t h i s section.

(1) Three sample packagings must be f i l l e d and closed as f o r s h i pment .

(2) The three samples must be placed on a v ib ra t i ng p la t form t h a t has a ve r t i ca l o r r o t a r y double-amp1 i tude (peak-to-peak

5-29

WHC-SO-TP-OTR-007. Revision 0


5-32


7.0 QUALITY ASSURANCE PROGRAH

The q u a l i t y assurance program implemented by the shipper 's organization must implement act ions t o provide adequate confidence tha t the shipment w i l l comply w i th the regulat ions. q u a l i t y cont ro l appl icable t o Type A packaging.

qua l i t y cont ro l elements prescribed i n 49 CFR. These requirements must be met f o r a l l shipments.

173.474. Q u a l i t y Control f o r Construction o f Packaging ,

The fo l lowing regulatory requirements address

Paragraphs 173.474 and 173.475 t ha t a r e restated below provide the

a. P r io r t o the f i r s t use o f any packaging f o r the shiplnent o f rad ioact ive material, the shipper sha l l determine that:

1.

2.

The packaging meets the q u a l i t y o f design and construct ion requirements as speci f ied i n t h i s subchapter; and

The effect iveness o f t he shielding, containment, and, when required heat t ransfer character is t ics o f the package, are w i t h i n the l i m i t s speci f ied f o r the package design.

173.475. Q u a l i t y Control Requirements Pr io r t o Each Shipment o f Radioactive Hater i a1 s

Before each shipment o f any rad ioact ive mater ia ls package, the shipper sha l l ensure by examination or appropriate tests, that :

a.

b.

C.

d.

e.

f.

9.

The packaging i s proper f o r the contents t o be shipped;

The packaging i s i n unimpaired physical condition, except f o r superf i c i a1 marks;

Each closure device o f the packaging, inc lud ing any required gasket, i s proper ly insta l led, secured, and f ree o f defects;

For f i s s i l e material, each moderator and neutron absorber, i f required, i s present and i n proper condition;

Each special i ns t ruc t i on f o r f i l l i n g , closing, and preparation o f the packaging f o r shipment has been followed;

Each closure, valve, or other opening o f the containment system through which the rad ioact ive content might escape i s proper ly closed and sealed;

Each packaging containing l i q u i d i n excess o f an A quant i t y and intended f o r a i r s h i p n t has been tested t o show t h a t i t w i l l no t leak under an ambient atmospheric pressure o f no t more than 0.25 atmosphere, absolute, (0.25 kilograms per square centimeter or 3.6 pisa). The t e s t must be conducted on the e n t i r e containment

7-1


This page intent ional ly l e f t blank.

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9.0 REFERENCES

49 CFR, “Transportation,” P a r t s 100 t o 177 and Parts 178 t o 199, Code o f Federal Regulations, as amended.

Cruse, J. M., 1992, Test and Evaluation Document f o r DOT Speci f icat ion 7A Type A Packaging, WHC-EP-0558, Rev. 2, Westinghouse Hanford Company, Richl and, Washington.

DOE, 1985, Safety Requirements f o r the Packaging and Transportation o f Hazardous Materials, Hazardous Substances, and Hazardous Wastes, DOE Order 5480.3, U.S. Department o f Energy, Washington, D.C.

Construction’s ARROW-PAK as an A1 ternat ive macro and Improved Container f o r Mixed Waste Storage, EGG-WTD-11240, Idaho National Engineering Laboratory, EG&G Idaho, Inc., Idaho F a l l s , Idaho.

Farnsworth, R. K., (e t a l . ) , 1994, Demonstration and Evaluation o f Arrow

IAEA, 1985, IAEA Safety Standards, Safety Series No. 6, 1985 edi t ion, Regulations f o r the Safe Transport o f Radioactive Material, In ternat ional Atomic Energy Agency, Vienna, Austr ia.

Kel ly , 0. L., 1995a, DOT-7A Type A Packaging Design Guide, WHC-SD-TP-RPT-017, Rev. 0, Westinghouse Hanford Company, Richland, Washington.

Kel ly , 0. L., 1995b, Test Plan f o r Lockheed Idaho Technologies Company ARROW-PAK Packaging, Docket 95-40-7A, Type A Container, WHC-SO-TP-OTP-002, Rev. 0, Westinghouse Hanford Company, Richl and, Washington.

Kel ly, 0. L., 1995c, DOT-7A Packaging Test Procedure, WHC-SO-TP-RPT-018, Rev. 0, Westinghouse Hanford Company, Richland, Washington.

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This page intentionally left b l a n k .

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WHC-SD-TP-OTR-002 Revis.ion 0

APPENDIX B

ASSEMBLY, LOADING, AND CLOSURE FOR TESTING PURPOSES

B1.0 GENERAL INFORMATION

Refer t o Appendix A o f t h e Tes t P lan ( K e l l y , 1995b) f o r a ske tch o f t h e ARROW-PAK c o n f i g u r a t i o n be ing t e s t e d . o f a M a r l e x - r e s i n p i p e manufactured by P h i l l i p s - D r i s c o p i p e , I n c . , and i s sea led w i t h end caps manufactured f r o m t h e same m a t e r i a l s v i a a pa ten ted process developed by Arrow Cons t ruc t i on , , I n c . The pa ten ted process i n v o l v e s t h e use o f e l e c t r i c a l energy t o heat opposing faces o f t h e p i p e and end caps, and h y d r a u l i c rams t o p ress t h e heated sur faces t o g e t h e r . The r e s u l t i s a homogeneous bonding o f t h e end cap t o t h e p ipe .

The ARROW-PAK packaging system c o n s i s t s

82.0 INSTRUCTIONS

NOTE: Due t o the complexity o f the thermal seal ing process and t h e machinery involved, the t e s t u n i t s w i l l be p a r t i a l l y f i l l e d w i t h simulated contents and sealed a t BOH Brothers Construction Company, Inc.? New Orleans, Louisiana. The WHC t e s t and/or p ro jec t engineer(s) w i l l witness the loading and seal ing process p r i o r t o test ing. responsible f o r ensuring t h a t a l l three t e s t u n i t s are sound and do n o t leak p r i o r t o shipment t o the DOE-approved t e s t f a c i l i t y f o r Type A tes t ing . The remaining simulated contents, a t racer mater ia l used f o r leak tes t ing , w i l l be added a t the DOE-approved t e s t f a c i l i t y .

The sponsor i s

Three t e s t u n i t s w i l l be s u p p l i e d f o r t e s t i n g purposes. Two 25.4-cm ( 1 0 - i n ) d iameter ARROW-PAKs w i l l be f i l l l e d w i t h s imu la ted con ten ts o f c lean , noncontaminated, taped l e a d b r i c k s . Carbon s t e e l sho t w i l l be added as a f i l l e r m a t e r i a l .

NOTE: The sponsor i s responsible f o r d r i l l i n g and tapping two holes i n t o the center o f one end cap, on each o f these t e s t un i t s . The sponsor i s responsible f o r p lac ing a su i tab le hex-socket plug i n t o each o f the holes. It is suggested t h a t the hex-socket plugs be 1/2-inch normal pipe thread (NPT), and be f l u s h o r below the surface o f the end caps. Refer t o Figure B-1 f o r diagram o f hole placement on these two t e s t un i ts .

A t h i r d ARROW-PAK w i l l be l e f t empty.

NOTE: one end cap. socket p lug i n t o the hole. 1/2-inch NPT, and be f l u s h o r below the surface o f the end cap. Figure B-1 f o r diagram o f hole placement on t h i s t e s t u n i t .

The sponsor i s responsible f o r d r i l l i n g and tapping a hole i n t o The sponsor i s responsible f o r p lac ing a su i tab le hex-

It i s suggested t h a t the hex-socket plugs be Refer t o

' P h i l l i p s - D r i s c o p i p e , Inc . , i s a s u b s i d i a r y o f P h i l l i p s Petro leum Company.

E- 1

WHC-SD-TP-OTR-002 R e v i s i o n 0

r NOTE: The spacer needs t o f i t down snugly onto the layer o f bricks and shot. It may be necessary t o wrap the outside edge o f t h i s spacer with several layers o f tape so tha t the spacer does not move and s h i f t .

83.0 ASSEMBLY

1.

2.

1.

2.

3 .

4.

F o l l o w t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r f u s i o n u n i t setup, c a l i b r a t i o n , l o a d i n g o f t u b i n g on to t h e f u s i o n u n i t , f ac ing , h e a t i n g , f u s i n g , and un load ing o f t h e packaging assembly f rom t h e f u s i o n u n i t . F o l l o w t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r a p p r o p r i a t e coo l down p e r i o d . ( I n f o r m a t i o n on t h i s process has been inc luded a t t h e end o f t h i s Appendix.)

Fuse one o f t h e end caps t h a t has had t h e a p p r o p r i a t e h o l e ( s ) d r i l l e d and tapped i n t o i t ( f o r t e s t i n g purposes o n l y ) , t o t h e p i p e . Remove t h i s p a r t i a l assembly f rom t h e f u s i o n u n i t .

B4.0 LOADING CONTENTS

NOTE: 5xlOx20-cm (2x4x8- in ) .

Load l e a d b r i c k s i n t o t h e f i r s t end cap. About f o u r l e a d b r i c k s w i l l f i t i n t o an end cap.

Load l e a d b r i c k s , v e r t i c a l l y , i n t o t h e c y l i n d r i c a l tube. The b r i c k s should f i t snug ly i n t o t h e packaging. across t h e d iameter o f t h e ARROW-PAK cy1 i n d r i c a l tube.

The dimensions o f t h e l ead b r i c k s used d u r i n g t e s t i n g a re

Four l e a d b r i c k s should f i t snug ly

Cont inue t o f i l l t h e c y l i n d r i c a l tube w i t h l e a d b r i c k s . Leave an e s t i m a t e d 5.08-cm (2 - in ) space between t h e l a s t l e v e l o f b r i c k s and t h e t o p o f t h e tube.

F i l l t h e v o i d space w i t h i n c y l i n d r i c a l tube and f i r s t end cap with s t e e l sho t . Leave an es t imated 5.08-cm ( 2 - i n ) space between t h e s t e e l sho t and t h e t o p o f t h e tube.

NOTE: t o al low f o r fusion o f the second end cap t o the cy l indr ica l tube.

Place a plywood spacer on t o p o f t h e s imu la ted l oad . down i n t o t h e tube about 5.08-cm ( :?- in) , u n t i l i t i s t o u c h i n g t h e s i m u l a t e d con ten ts . l o a d i n p l a c e w h i l e t h e second end cap i s fused on to t h e c y l i n d r i c a l tube.

Adequate space i s required for the placement o f a wooden spacer and

5. Pound t h e spacer

The purpose o f t h i s spacer i s t o keep t h e s i m u l a t e d

6. Load l e a d b r i c k s i n t o t h e second end cap. f i t i n t o an end cap. b r i c k s and t h e t o p o f t h e second end cap.

About f o u r l e a d b r i c k s w i l l Leave an es t imated 5.08-cm ( 2 - i n ) space between t h e

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7 . Fill the void space within the second end cap with steel shot. Leave an estimated 5.08-cm (2-in) space between the steel shot and the top of the tube.

NOTE: to allow for fusion of the second end cap to the cylindrical tube.

Place a plywood spacer on top of the simulated load. down into the tube about 5.08-cm (%-in), until it is touching the simulated contents. load in place while the second end cap is fused onto the cylindrical tube.

Adequate space is required for the placement of a wooden spacer and

8. Pound the spacer

The purpose of' this spacer is to keep the simulated

NOTE: The spacer needs to fit down snugly onto the layer of bricks and shot. It may be necessary to wrap the outside edge of this spacer with several layers o f tape so that the spacer does not move and shift.

1.

1 .

2.

3 .

4 .

95.0 CLOSURE

Follow the manufacturer's instructions for fusion unit setup, calibration, loading of tubing onto the fusion unit, facing, heating, fusing, and unloading of the packaging assembly from the fusion unit. Follow the manufacturer's instructions for appropriate cool down period. (Information on this process has been included at the end of this Appendix.)

96.0 ADDITION OF TRACER MATERIAL

Prior to testing at the approved DOE-test facility, tracer material for leak detection purposes will be added to the test units.

The tracer material will be added by removing one of the plugs that is located on an end cap from each test unit.

Tracer material used will be as follows:

Fluorescein will be added to the two test units containing the simulated contents of lead bricks and steel shot.

The third, empty, test unit, will be filled with about 1/2 cup of

Secure the plug, once the tracer material has been added.

Note: applied to the thread plugs to assure that there is no leakage in this area during testing.

fl uorescei n .

An appropriate thread sealer, such as Teflon tape, may need to be

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WHC-SO-TP-OTR-002 Revis ion 0

TIM pipe s l d contain no nxycIed compound except that getmated h the mmufacturu's own plant from reshi of the same specification h m the Same raw mat&. The pipe slatdl be hotnogenous throughout and ffee of visible cracks, holes, voids, &r&n Inclusions, or other deleterious dekcts arid shall be identical m color, density, melt index and 0 t h physical properties Ulmughout.

&Kk?Z&mQB l i ~ pipe sllall be in wniplisnce with the phydcal and Paformance requirements of Section UI of this specification. SpecUlcally, the pipe will be extnrded Rom ruin meeting spaciflcations of A S I U D3350 with a cell classification of PE 355434C and ASTM I11248 pipe pad6 n d n type 111. Class C, Category 5, grade P34 polyethylene compound. The pipe shdl &bit the short term tensile and compressive physical properties listed in Section IlI. And the pipe shall provide the long tenn endurance oharacteristlcs recogtJzed by: the compnssed pipe h g stress crack resistance greats than 1000 b u n : the slow wok growth r e 8 i $ t ~ ~ e wet than 32 days; and the linpact strength (toughness) gresttr than 84 in-IWin notch.

r- The standard HDPE fittings shall be standard commercial products u~~~~ufhctured by lnjedion molding or by extmsion and machining, or, shall be fabricated horn PB pipe conFonning to this 8yecification. The fitting shall be hlly pressure rated by the manufhcturer to provide a workiq ptessure equal to the pipe for 50 years of service at 73.4 degrees F with an included 2:l s&y factor. The fittings shall be manufactured fim the same w i n type, grade and crll dasdEcation BJ the pipe itself. The manuIhcture of the fittings shall be in accordaqc with good commercial practice to prodde fittings homogeneous throughout and h e &om crack, boles, tbnign Inclusions, voids or other Injurious defects. The fining s M 1 be as unlbrm as commeroidly practicable in color. opacity, density and other physical properties. Ihc mlnimum "quick-burst" stmgtli of tlie flttings sllall not be less than that of the pipa with which the Wing is to be used.

VI. JOINlNG Sections of polyethylene pipe should be joined into continuow lengths on the job site above ground. The joltring ntethod shall be the butt hslon method and shall be paformed in strict accordance with the pipe manufacturer's recommendations. The butt tirslon equipment used In the joidng ptocedures should be capable of meeting all conditions recommended by the pipe manufacturer, includillg, but not limited to, temperature requirements of 500 degrees F, alignment and 150 psi lriterfncial W o n pressure.

Butt fusiot! joltling shall be 100% eficient offering a joint weld strength equal to or greater than the t e t d e strength of the pipe. Socket Iirsion shdl not be used. Extnrmon welding or hot gas welding of IlDPE shall not be used for pnssun p i p appUcations nor in fabrications where shear or structural stresigth is important. Flanges, unions, tratuitlon fittings and some mdianlcal couplers IMY be used io mechanically connect HDPE pipe without butt htsioa. Refk to the manufactuier's recomfiendations.


3.2.2 FlcE l r o v Fus l o n U n l t De s c r l p t 1 ont

As p r e v l o u s l y s ta ted , two d l f f e r e n t McElroy f u s l o n machlnes w l l l be used t o per form t h e f u s i o n opera t l ons . The McElroy No. 412 w i l l be used t o fuse t h e 6 - i n . and IO- ln. dlameter c o n t a l n e r s and t h e No. 1236 w l l l be used t o fuse t h e 28-111. diameter c o n t a i n e r s . The d i f f e r e n c e between t h e two machines 1 s t h a t t h e No. 1236 uses automated h y d r a u l l c c y l i n d e r s t o p o s l t l o n t h e h e a t e r p l a t e , t u b l n g clamps and f a c e r , whereas these f u n c t i o n s are per formed manual ly on t h e No. 412 . D e t a l l e d s tep -by -s tep procedures f o r o p e r a t l n g t h e McElroy No. 412 opera t l ons and 1136 f u s l o n machines are p resen ted I n Appendix A .

The h y d r a u l l c pump f o r t h e McElroy No. 412 I s powered b y a g a s o l i n e

A l l t h e s e l tems a r e mounted on t h e Power f o r t h e No. 1236’s e l e c t r l c a l l y d r l v e n

englne t h a t is a l s o connected t o a 220 V , 60 Hz, s i n g l e phase, 3.0 kW c a p a c i t y a l t e r n a t o r t o power t h e h e a t e r p l a t e . chass l s o f t h e f u s l o n u n i t . h y d r a u l l c pump and hea te r p l a t e is p r o v i d e d by a separate, s tand a lone gaso l l ne powered generator t h a t p rov ldes 230 V, 60 c y c l e , 3-phase power w l th a r a t l n g o f 30 KVA. D e t a i l s o f t h e o p e r a t i o n o f each Fuslon U n i t a r e desc r lbed below.

3.2.2.1. FlcElrov No. 412 Fusion U n l t Opera t l o nt:

SETUP I The u n i t 1s p o s l t i o n e d o u t s l d e o f t h e warehouse, i n an area f r e e f rom

hazardous vapors. It 1s then secured i n p lace by s e t t l n g t h e break p r o v l d e d on t h e r e a r l e f t t l r e , and chock lng t h e t l r e s . The g a s o l i n e engine i s s t a r t e d t o p r o v i d e power t o t h e h y d r a u l l c pump and e l e c t r i c a l power t o t h e h e a t e r p l a t e .

1 CALIBRATION I Whl le t h e h e a t e r p l a t e 1s comlng up t o o p e r a t i o n a l temperature (41D.F

f o r t h e 6-111. MACRO, S00.F f o r t h e 1 0 - l n . MACRO), t h e p ressu re r e g u l a t o r s used t o c o n t r o l t h e f a c i n g pressure, h e a t l n g pressure, and f u s i n g pressure a re ad jus ted t o t h e approp r la te s e t t l n g by t h e operator . It takes approx lmate ly 20 t o 2 5 minutes f o r t h e hea te r p l a t e t o reach o p e r a t i o n a l temperature. The temperature i s d l s p l a y e d by a d l a l thermometer l o c a t e d on t h e p e r l m e t e r o f t h e h e a t e r p l a t e . The h e a t e r p l a t e r e s i d e s I n an i n s u l a t e d c r a d l e when n o t I n use.

I LOADING I The HOPE t u b l n g i s loaded l n t o t h e double c lamshe l l clamps l o c a t e d on

t h e l e f t s l d e o f t h e m,;iline f a c l n g t h e c o n t r o l s . The end cap I s p l a c e d I n t h e s i n g l e c lamshe l l on t h e r i g h t s l d e o f t h e machlne. The clamps are secured by manual screw j a c k s . A f t e r t h e f i r s t end c a p - t o - s l e e v e f u s l o n 1s completed, t h e l o a d l n g o f l e a d o r l e a d f l l l e d c o n t a i n e r s w l l l be accompllshed u s l n g a

8-13


combination of manual labor and lifting slings. each container is expected t o be approximately 6 5 w t X lead brlcks (2-in. x 4- in. x 8-in.) and 3 5 w t X lead shot.

I F A C I N G 1

The lead that i s placed in

The facer is then rotated lnto posltion between the two pleces t o be fused. hydraulic cylinders applying a sllght pressure. hydraulically and rotates at approximately 30 RPM. are simultaneously planed establishing clean and parallel surfaces for fusing. After the two matlng surfaces have been sufficiently planed, the alignment of the two surfaces is checked and, If necessary, reface until proper alignment is achieved.

H E A T I N G I After the two mating surfaces have been planed, the facer Is manually

rotated out of position and is manually replaced by the heating plate. The two surfaces t o be fused are hydraulically brought in contact wlth the heater plate under light pressure (close t o zero). After a bead of heated material measuring 3/16- t o 1/4-in. thick is formed at the circumference of each HDPE plece, the hydraulic pressure is released and the hot plate is manually removed.

The facer is sandwlched between the two pieces by activating a set of The facer i s operated

The surfaces t o be fused

I F U S I N G 1 After the heater plate is removed, the hydraulic cylinders are actuated

'Thls ensures a single monolithic bond of

brlnglng the two heated surfaces together under a compressive load. The surfaces are held under sustained hydraulic pressure and allowed t o cool f o r a perlod of approxlmately 35 mlnutes. fused materlal.

I U N L O A D I N G 1 The fused pleces are then removed from the machine by releasing the

screw jacks securing clamshell clamps. If the fusion is only on the first end cap-to-sleeve, there i s no need for any special handling equipment (due t o the lightness of the material). However, after completing the second fusion on both the 6-in. and 10-in. MACROS, special handling procedures shall be used t o safely remove the completed HAZ-PAKs from the fusion machine. The special handling procedures are needed due t o the 200-500 l b of lead that are t o be in each MACRO. For the demonstration at IDAHO FALLS a forklift wlth a sling system wlll be used t o load and unload the HDPE pieces.

B- 14


I SUBSE(1UENT FUSING 1 I n t h e event of subsequent f u s i n g , t h e same opera t i ons a r e f o l l o w e d t o

fuse o t h e r s e c t i o n s o f t h e HDPE sleeves. i n t e r n a l Jaw i n s e r t s on each c lamshe l l clamp a re r e p l a c e d w i t h Jaw i n s e r t s conforming t o t h e new d iameter . f u s i n g i s t h e n repeated.

T o f u s e a d i f f e r e n t d iameter , t h e

The process of l oad ing , f a c i n g , h e a t i n g , and

1 SHUTDOWN

Upon complet ion o f t h e f u s i n g process, t h e g a s o l i n e engine on t h e No. 412 Fusion U n i t w i l l be t u r n e d o f f removing h y d r a u l i c p ressu re t o t h e c y l i n d e r s and power t o t h e hea te r p l a t e . t h e area.

Th is w i l l be f o l l o w e d by c leanup o f

3.2.2.2. McElrov No. 1236 Fusion U n i t ODerations:

I SETUP I The u n i t I s p o s i t i o n e d i n an area f r e e f rom hazardous vapors, and t h e n

secured in p l a c e by s e t t i n g t h e brake p r o v i d e d on t h e l e f t r e a r wheel, and chock ing t h e wheels. The generator u n i t I s t h e n p o s i t i o n e d o u t s i d e o f t h e warehouse, b u t near t h e No. 1236 U n i t , a t a d i s tance t h a t w i l l a l l o w adequate work ing space around t h e fus ion u n i t . Considerat ion shou ld be given, where t h e placement o f t h e generator i s concerned, t o r o u t e t h e power c o r d i n a manner t o p reven t it from b e i n g d r i v e n over by t h e f o r k l i f t and ou t o f t h e opera to r ' s way.

I ALIGNMENT/CALIBRATION I Dur ing t h e IDAHO FALLS demonstrat ion t h e end cap holder /a l ignment

Upon

f i x t u r e w i l l be p o s i t i o n e d in t h e f u s i o n u n i t and t h e n secured u s i n g t h e h y d r a u l i c clamps. The end cap w i l l be p laced on t h e f i x t u r e t h e n cen te red wi th t h e mat ing p i e c e u s i n g t h e a d j u s t i n g screws f o r p roper a l ignment . complet ion o f t h e l oad ing , t h e generator u n i t i s s t a r t e d , p r o v i d i n g e l e c t r i c a l power t o operate t h e h y d r a u l i c pump and t h e hea te r p l a t e . pressure r e g u l a t o r s , used t o c o n t r o l t h e f a c i n g pressure, h e a t i n g pressure, and f u s i n g pressure, a re then a d j u s t e d acco rd ing l y .

The h y d r a u l i c

I LOADING 1

and spreader bars. A f t e r t h e end cap has been loaded and p o s i t i o n e d , a 28-ln. diameter x 6 0 - i n . s e c t i o n o f HOPE s leeve w i l l be loaded i n t o t h e No. 1236 u s i n g a f o r k l i f t and m a t e r i a l h a n d l i n g equipment. The HOPE i s t h e n secured i n p l a c e u s i n g t h e h y d r a u l i c clamps. Once t h e HOPE has been fused t o form t h e

HDPE sleeves are e a s i l y handled wi th f o r k l i f t s , s y n t h e t i c web s l i n g s ,

12

8-15


HAZ-PAK, it will be removed from the fusion unit. equipment and a forklift, an empty 55 gallon drum will then be loaded into the HAZ - PAK .

Using material handling

1 F A C I N G Facing of the two surfaces t o be mated is accomplished by hydraulically

posltloning the facer between the section of HDPE sleeve and the end cap, applying a slight hydraulic pressure t o maintain the two surfaces in contact wlth the facer, and turning on the facer which rotates at approximately 30 RPM. The surfaces t o be fused are slmultaneously planed establishing a clean and parallel surface for fusing. After the two mating surfaces have been sufflctently planed, the facer 1s then hydraulically rotated out of position. Alignment of the two surfaces is checked and, if necessary, refaced until proper alignment is achieved.

The heater plate takes approximately 30 t o 45 minutes t o reach proper operating temperature (410.F). When the heater plate has reached aperating temperature, it Is hydraulically rotated into position. The surfaces t o be fused are then hydraulically positioned against the heater plate under light pressure (close t o zero). The HDPE pleces are heated until a 3/16- t o 1/4-ln. wide uniform bead forms around the circumference of the two sections.

[ F U S I N G 1 Upon completion of the heating sequence, the heater plate is

hydraulically rotated out of position and the two surfaces are compressed together under sustained hydraulic pressure and allowed t o cool for approximately 3 5 minutes. material.

This ensures a single monolithic bond of fused HDPE

LSUBSEPUENT F U S I N G I In the event of subsequent fusings, as in the case of a sleeve to

sleeve fuse, during the Pre-Operational Test, the newly fused HDPE can be removed from the No. 1236, as mentioned in "LOADING", and cut uslng a band saw of hot wire. The process of loading, facing, heating, and fusing is then simply repeated.

[ S H U T D O W N 1 Upon completion o f the Pre-Operational Demonstration, the No. 1236

Fusion Unit will be shutdown by releaslng all hydraulic pressure and turning off the heater plate. The electrical generator may then be turned off and clean-up of the area initiated.

13

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WHC-SD-TP-OTR-002 Rev is - ion 0

Page L of 9

ncELROY NO. 618 HYDRAULIC FUSION UNIT INSTRUCTION HANUAL

GENERA L DESCRIPTION OF UNIT

The McElroy 618 Fusion Unit is a self-contained unit designed to butt fuse polyolefin pipe from 6" IPS (6 S f 8 " OD) minimum to 18" IPS (18" OD) maximum.

Weight is 1200 lbs. Overall dimensions are 46" wide x 51" high x 8 2 " long. With reasonable maintenance and care, this machine will give years of satisfactory service. Although all parts are designed for and protected against the elements, inside storage is preferable. The McElroy shipping and Storage container also provides an inventory control of auxiliary parts.

PESCRIPTION OT COMPONENTS

clamping unit

While on the wagon, the clamping unit consists of two fixed jaws and two hydraulically operated movable jaws bolted to the frame.

The tvo hydraulic jaws and the inner fixed jaw are attached together, and can be unbolted from the wagon frame and removed for remote operation. For this we gffer optional hydraulic extension hoses.

For hazardous environments the jaw works must be removed from the cart. There must be sufficient hose and cable length for the cart to remain in a safe location.

Wagon

This cpmpaCt an6 self-contained fusion system is mounted pn a four-wheel wagon for mobility and movement along a pipe line. The front axle has an automotive spindle-type steering, controlled by the

so that the unit may be conveniently maneuvered at the job site. The cart is not designed for over-road towing.

'tongue. The tongue has a ring on the end tp slip over a ball hitch

' !!! WARNING !!!

TOKING AT SPEEDS GREATER THAN 5 npx CAN RESULT IN XACHINE

FLATBED TRUCK OR s I n I m HEANS. DAMAGE AB lELL AB INJURY. ALWAYS TRANSPORT THE HACHINE BY

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Engine

A 16 HP Kohler."Cast Iron" electric-start, industrial quality, gasoline engine drives the hydraulic pump for fusion force and power of the facer motor, and a 3 . 0 KWI220V (1) Phase, 60 Hr, alternator to power the heater plate.

The oil Gear pressure compensated pump should be set at 1100 PSI and 5.5 GPH.

The reservoir is incorporated in the wagon frame. The oil level should remain visible in the sight gauge in the side of the filler spout. Never allov dirt or other foreian matter to enter the oven t.n*. Use Sunmark 2105 or equivalent. Refer to Hydraulic Flvi'ds Recommendations included with this manual.

Filter

'This unit is equipped with a 10 Hicron Filter on the suction side of the pump. Replace filter and oil approximately every 500 hours of operation.

Wydraylic Manifold Blpck

Hounted on this block are (1) carriage control valve, (1) selector valve, ( 3 ) pressure valves and (1) 1500 PSI gauge. The carriage control valve is mounted on top with the gauge. The selector valve, mounted on the front, selects a reduced pressure from one of the pressure reducing valves. Each pressure reducing valve is labeled with a different function; top for facing pressure, middle for heating pressure and bottom for fusion pressure.

Lift Roller Control

The control valve is located under the inner fixed jaw. Pull to lift and push to lower the pipe lift cylinder.

Hydraulic -1ind.r~

The tvo carriage cylinders and the lift cylinder have air bleed screws and must be bled if the system ever runs low on oil or leaks air on suction side of pump. l-sted below:

1.

The bleeding procedure for this unit is

Tilt unit so the fixed jaw end is higher than the opposite end. -

2 . Shift the directional control and move the carriage to thc fixed jaw end. Adjust the pressure to approximately 50-11. PSI before proceeding to step 3 . _.

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Pipe Support Btands

For fixed fusion inst allat ion, install pipe support stands about 2 0 ’ in front and behind the unit, and adjust to proper height.

When movina the unit from ioint to ioint, an optional pipe support trailer is available. It is pulled behind the unit, and incorporates a jack to obtain the proper height.

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XC ELROY NO. 618 HYDRAULIC FUSION UNIT INSTRUCTION W U A L

9PERATING INSTRUCTIONS

!!! VAIINING !!!

KEEP CLEAR OF JAW AREA. UNIT OPERATES UNDER PRESSURF AND CAN CRUSH HANDS, ARUS, OR OTHER BODY PARTS. BE AWARE OF YOURSELF AN0 OTHERS WHEN OPERATING THIS UNIT.

Before starting unit, the following checkout and lubrication should be performed to insure trouble-free operation and optimum life of the unit.

1. ma ine Oil L eve1 D ~ D St ick - Do not screw in for proper reading; (Refer to'engine manual for further instructions.)

2. Hvdraul ic Fluid Level - Check for oil in sight gauge on filler spout and add if necessary. Use Sunmark 2105 or equivalent oil.

nonhazardous area. 3 . Fuel - Fill the tank with unleaded gasoline in a

!!! DANGER !!!

SPARKS COULD IGNITE GASOLINE, CAUSING EXPLOSION AND DEATH. DO NOT SMOKE OR OPERATE UNIT WHEN FILLING WITH GAS.

-

4 . Grease all terk fittings one shot each yeek.

Start-up Procedvre

1! ! PANGER !!!

E ENGINE I N A K A Z ARDOUS E NVIROHHENT. THE EXt3IXX SEOOLD ALWAYS REMAIN IN A SAFE LOCATION. REUOVE FACER AwD TOP KORKS AND ATTACH HOSES.

1. pisconnect heater plug and open facer operating valve before starting engine.

2. TQ start engine, close choke (move lever avay from engine), turn svitch to "ON** , and press starter button.

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3 .

4 .

5 .

open choke as engine warms LIP. Engine speed is governor controlled and has been factory set to obtain 255 no load Volts, or 230 full load Volts from the alternator. DO NOT EXCEED 2 5 5 NO & O W VOLTS.

close facer operating vaive.

Plug in heater in a NONHAZARDOWB environment. Allow unit to run long enough to bring heater to temperature before attempting to fuse pipe.

Check Hydraulic Pressur.

The pressure gauge indicates the pressure at the carriage control valve. How much pressure depends on the positiqn of the selector valve and the pressure set on the (3) pressure reducing valves. With the selector valve up, the facing pressure can be set ( 8 0 - 100 PSI). Shift the selector valve to center and the heating pressure can be set. If heating pressure is not required, set the pressure reducing valve at its lowest setting. With the selector valve down, the fusion pressure can be set. The heating and fusion pressures can'be calculated using the enclosed nomogram.

The hydraulic pump is set at 1100 PSI from the plant. When facing SDR 11 and thicker vall pipe, it is necessary to increase the pump pressure to 1400-1500 PBI. To increase the pressure, shift the selector valve to the down (fusion) position and screw the bottom pressure reducing valve "IN" as far as it will go. The actual pump pressure should be shown on the pressure gauge at the manifold block.

With the pump running and the system deadheading with no motion occurring, loosen the locknut on the pressure adjusting screw (see pump specification sheet for location) and turn it clockwise to increase the pressure. Watch the pressure gauge on the manifold block and retighten the locknut on the adjusting screw when the desired pressure is reached. Then back off the lower pressure reducing valve tp the required fusion pressure.

Butt Fusion Procedure

1. Opan upper jaws and insert pipe in each pair of jaws with a m i c a b l e inserts installed. Let end of pipe protrude a k w t If" - 2" past face of jaw.

2. W v e r facer into place.

3. With the carriage control valve lever, move the carriage toward the fixed clamps, while watching the gap at each end of the facer rest buttons. When the pipe is in contact with the facer, this gap indicates the amount of material that will be trimmed from the pipe end.

4. Tighten the clamp screw knobs on the outside clamps.

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16.

17.

18.

19.

2 0 .

Hove the carriage to the left, bringing the heater into contact with both pipe ends.

Hove selector valve is not required, qu neutral position.

to center position. If heating pressure ckly return carriage control valve to

After following the pipe manufacturer's suggested heating procedure, shift ca rlage control valve to neutral position and then the selector valve down to fusion position.

Hove the carriage to the right just enough to remove the heater. Remove the heater.

Quickly move the carriage to the left, bringing the pipe ends together under the pipe manufacturerls recommended pressure. pipe manufacturer's recommendations. hazardous environment,, plug the heater into power source outside gf hazardous environment between joints to maintain operating temperature.

Allow joint to cool under pressure according tp If working in a

- !!! CAUTION !!!

FAILURE TO FOLLOW PIPE MANUFACTURER'S HEATING AND COOLING PRESSURE, TEMPERATURE, ANLI TIME RECOHHENDATIONS, CAN RESULT IN BAD JOINTS.

2 1 .

2 2 .

2 3 .

2 4 .

2 5 .

2 6 .

Shift the carriage control valve to the neutral positipn.

Loosen clamp screws on movable jaws and move carriage to the right enoygh to open the jaw to the left of the facer.

LQosen clamp crews on fixed jaws and open jaws.

Rqise pipe with hydravlic lift.

Mpve wit to end pf pipe or pull pipe to rear through the jawa until t h e end of the pipe is protryding l+" - 2" past the jaw face.

Inmert new joint of pipe in movable jaws and repeat procedure, starting with Step 1.

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APPENDIX C

PHOTOGRAPHS

c-1

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T h i s page i n t e n t i o n a l l y l e f t b lank .

c -2


Photo C-4. Compress ion T e s t (40-TU-03)

C-6

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Photo C-8. 1.2-si ( 4 - f t ) Drop T e s t . (40-TU-02, CG on to Corne r o f End Cap w i t h P lugs)

c - L O

WHC-SD~-TF'-OTR-002 R e v i s i o n 0

Photo C-12 . 1.2-m ( 4 - f t ) Drop Tes t . (40-TU-02, F l a t on to H o r i z o n t a l Side)

C-14

DISTRIBUTION SHEET

Name

To D i s tri but i on

~ ~~~ ~ ~~

Text Text Only Attach./ EDT/ECN MSlN With All Appendix Only

Attach. Only

From Packaging Operations and DeveloDment

Project Title/Work Order 1 EDT No. 611189 Final Evaluation Report f o r Lockheed Idaho Technologies Company, ARROW-PAK Packaging, Docket 95-40-7A, Type A Container

84400/TH540 I

C . R. Hoover D. L. K e l l y D. L. McCall D. W . McNally J . H. O'Brien Central F i l e s (o r ig . +1) DOT-7A F i l e

62-02 62-02 62-02 62-02 62-02 A3-88 62-02

X

A-6000-135 (01193) UEF067

RMIS View/Print Document Cover Sheet/67531/metadc682990/m2/1/high_re… · "" RMIS View/Print Document Cover Sheet"" This document was retrieved from the Documentation and Records

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