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{{#Wiki_filter:TS:23:03017 UFC: 5822.00 Mining Contractors April 27, 2023 ATTN: Document Control Desk Director, Spent Fuel Project Office Office of Nuclear Material Safety and Safeguards U. S. Nuclear Regulatory Commission Washington, DC 20555-0001
{{#Wiki_filter:}}
 
==Subject:==
RESPONSE TO REQUEST FOR ADDITIONAL INFORMATION ON THE HalfPACT DOCKET NO. 71-9279, REQUEST FOR AUTHORIZATION OF ONE-TIME SHIPMENT OF MODEL NO. HalfPACT CREDITING THE OUTER CONFINEMENT VESSEL AS THE CONTAINMENT BOUNDARY (EPID L-2023-LLA-0030)
 
==References:==
: 1. Letter from T. E. Sellmer to Document Control Desk dated February 23, 2003, subject: HalfPACT Docket No. 71-9279, Request for Authorization of One-Time Shipment of Model No.
HalfPACT Crediting the Outer Confinement Vessel as the Containment Boundary
: 2. Letter from N. Garcia Santos (NRC) to T. E. Sellmer dated April 17, 2023, subject: Application for the Model No. HalfPACT Transport Package - Request for Additional Information (EPID L-2023-LLA-0030)
 
==Dear Ms. Diaz-Sanabria:==
 
Salado Isolation Mining Contractors (SIMCO) LLC, on behalf of the U. S. Department of Energy Carlsbad Field Office (DOE/CBFO), hereby submits an amendment to the request for the authorization for a one-time shipment of a single HalfPACT package crediting the outer confinement vessel (OCV) as the containment boundary instead of the inner containment vessel (ICV) as outlined in Reference 1. This amendment is in response to the Request for Additional Information (RAI) (Reference 2).
The following documents are attached to support this request:
x  Attachment A - Responses to NRC RAI on HalfPACT Docket No. 71-9279, Request for Authorization of One-Time Shipment of Model No. HalfPACT Crediting the Outer Confinement Vessel as the Containment Boundary x  Attachment B - HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation, Revision 1 P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083
 
Document Control Desk                                                                  TS:23:03017 x  Attachment C - Section 3.1.4, Payload Container (PT03) Requirements (Balance of Plant), of Packaging and Transportations System (PT00) System Design Description (SDD) (SDD PT00), Revision 13 x  Attachment D - WIPP Container Data Report SWD12275 and WIPP Payload Data Report SRE033 x  Attachment E - HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506, Revision 2 x  Attachment F - HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Revision 2 As stated in Reference 1, DOE/CBFO is requesting the authorization for this one-time shipment from the Commission on or before May 17, 2023.
If you have any questions or require additional information regarding this request, please contact me at (575) 234-7396 or via cell phone at (575) 302-7583.
Sincerely, TODD SELLMER              Digitally signed by TODD SELLMER (Affiliate)
(Affiliate)              Date: 2023.04.26 16:26:21 -06'00' T. E. Sellmer, Manager Packaging and Information Systems TES:clm cc: D. Bamper, CBFO                                              M. Budney, SRS M. Bollinger, CBFO                                          H. Crapse, DOE/SRS D. C. Gadbury, CBFO                                          K. Crawford, SRS K. E. Princen, CBFO                                          M. Garrett, SRS D. M. Smith, CBFO                                            V. Kay, NNSS/SRS D. L. Standiford, CBFO                                      P. Kilroy, SRS M. Toothman, CBFO                                            M. Maxted, NNSA/SRS J. A. Walker, CBFO                                          S. Protzman, SRS J. Shuler, EM-4.24                                          Y. K. Diaz-Sanabria, USNRC J. Shenk, EM-4.24                                            N. Garcia Santos, USNRC L. F. Gelder, SRRC                                          B. H. White, USNRC M. Bowers, SRS P.O. Box 2078 z Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200 z Fax: (575) 234-7083
 
Document Control Desk                                                                  TS:23:03017 The following table summarizes the components of this submittal. No deviations occur from the NRC-prescribed PDF formatting for the submitted files. Please contact Ms. C. L. Morrison at (505) 350-3693 or cindy.morrison@wipp.ws to resolve any discrepancies in this submittal.
File Release    Submittal File Name                                                                Size Level      Type (MB) 001 RAI Response - Request for One-Time                                        Publicly 36.6                EIE Shipment.pdf                                                                    Available P.O. Box 2078  Carlsbad, New Mexico USA 88221-2078 Phone: (575) 234-7200  Fax: (575) 234-7083
 
ATTACHMENT A - Responses to RAI Responses to NRC Request for Additional Information (RAI) on HalfPACT Docket No. 71-9279, Request for Authorization of One-Time Shipment of Model No.
HalfPACT Crediting the Outer Confinement Vessel as the Containment Boundary STRUCTURAL EVALUATION (St)
RAI-St-1    Provide the information listed below to supplement appendix F, report No.
HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation, submitted as part of the application:
: a. Include the pertinent information from section 3.1.4 of PDD PT00 in report No. HPT-CAL-0001. Document PDD PT00 is mentioned on the cover sheet of the report but is not referenced.
: b. Justify the exclusion of normal conditions of transport (NCT) effects of decay heat, environmental thermal, and internal pressure for the structural evaluation of internal containment vessel (ICV) lid lifting sockets and pins during transfer lift conditions.
: c. Provide a description of the anticipated location and ambient conditions during the transfer lift of the ICV from the old outer confinement vessel (OCV) to the new one.
: d. Justify the use of Type 304 stainless steel material properties in the transfer lift evaluation, which appears to have been taken from the 70°F entry on table 2.3-1 of the safety analysis report (SAR),
revision 9.
: e. Provide a reference for the ICV 506 payload weight and include it in the report.
: f. Justify the addition of the simulated ICV payload weight of a 5,485 pounds (lbs.) to the ICV self-weight of 2,215 lbs. to determine the gross allowable lifting capacity of 7,700 lbs.
: g. Include the pertinent information from report reference No. 10 in Report No. HPT-CAL-0001 as part of the report content: Washington TRU Solutions 412-L-082, Revision E, Adjustable Center of Gravity Lift Fixture (ACGLF) Leg Weldment & Miscellaneous Details; Lift Leg Weldment.
: h. Identify the source of the lifting pin groove locations and widths, as well as pin minimum through-thickness at these locations.
 
ATTACHMENT A - Responses to RAI The staff notes that the guidance in section 2.4.10 of NUREG-2216 notes that copies of applicable references, if not generally available to the viewer, should be included in the review package. The staff is not familiar with PDD PT00 or the Washington TRU Solutions document 12-L-082.
The latter is needed to verify the method of loading assumed for the lifting pins. In addition, a source for the payload weight of the ICV should be cited in the report to allow verification of a key input parameter for the lifting condition evaluation. The staff notes that revision No. 9 of the table 2.2-1 of the SAR provides the ICV self-weight; cite as a reference.
The ICV is sealed and contains a payload of radioactive material. The staff expects that some decay heat and internal pressure are present at the time of the ICV lift and transfer from the old to the new OCV.
Nevertheless, the application does not include a description of the anticipated location and ambient conditions during the transfer. Therefore, the applicant must justify the omission of decay heat, environmental thermal effects, operating pressure, and use of material properties associated with 70°F in the evaluation of the lid stress during lifting.
An outdoor transfer may present environmental conditions such as increased ambient temperature and insolation. Per section 3.0 of the SAR, revision 9, the maximum ICV decay heat is 30 watts and per section 3.4.4.3, the ICV maximum normal operating pressure is 50 pounds force per square inch gauge (psig). Maximum temperatures for the ICV determined from the thermal analysis of decay heat and insolation conditions are shown in table 3.1-1 of the SAR, rev. 9. [S]ection 2.1.2 of the SAR indicates that container allowable stresses are determined employing the load combination guidance of Regulatory Guide 7.8, Load Combinations for the Structural Analysis of Shipping Casks for Radioactive Material.
In report section 3.2, the allowable OCV lid stress during lifting conditions is determined to be 10,000 psi. The applicant needs to justify the determination of allowable lifting load capacity in report section 4.2.1 as the addition of the self-weight of 2,215 lbs. (resulting in a Von Mises stress of over 2,800 psi, per figure 6) and the payload weight of 5,485 lbs. (resulting in a Von Mises stress of almost 10,000 psi, per figure 7).
Report No. HPT-CAL-0001, section 4.2.2 presents a finite element analysis (FEA) of an individual lifting pin based on its geometry and assumed load application points. From Drawing No. 707-SAR, revision 12, the staff is unable to determine the exact location, width, and depth of the grooves on the lifting pins as stated in this report section and reflected in the FEA. Therefore, the applicant must provide references for this geometrical information. Since the locations of load application to the
 
ATTACHMENT A - Responses to RAI pin are stated in the report as being based on information for the ICV lift fixture presented in Washington TRU Solutions, 412-L-082, Revision E, the applicant also needs to provide the pertinent portions of this reference in the report.
This information is necessary to demonstrate compliance with the regulatory requirements in 10 CFR Parts 71.43(f), 71.45(a), and 71.51(a).
 
===Response===
HPT-CAL-0001 of the application is revised (from Revision 0 to Revision 1) to address items included in the RAI (see Attachment B).
: a. PDD PT00 is referenced in the RAI; however SDD PT00 is the applicable document as referenced in HPT-CAL-0001. The pertinent information from Section 3.1.4 of SDD PT00 is that the payload container lift fixtures meet the design requirements of ASME B30.20.
Section 3.2 of HPT-CAL-0001 addresses ASME B30.20. Section 3.1.4 of SDD PT00 is included as Attachment C of this RAI response submittal. For this one-time shipment, the lifting features on ICV 506 may be treated as a payload container lifting device subject to the requirements of SDD PT00 Section 3.1.4.
: b. NCT effects of decay heat and environmental temperatures were excluded from the structural evaluation of ICV lid lifting sockets and pins during transfer lift conditions. The use of room-temperature material properties is justified as follows:
: i. The loading process will be performed inside the WIPP Waste Handling Building, a temperature and radiologically controlled environment.
ii. The certified payload decay heat plus error (0.02206 watt) is very low per page 2 of WIPP Container Data Report SWD12275, and page 3 of WIPP Payload Data Report SRE033 (see Attachment D).
iii. The ICV lid lifting sockets and pins are Type 304 stainless steel.
Table Y-1 in Section II, Part D, of the ASME Boiler and Pressure Vessel Code specifies the yield strength of SA-240, Type 304, stainless steel plate as 30,000 psi for -20°F to 100°F.
Given the room temperature controlled environment, very low decay heat, and material properties that are constant up to 100°F, the use of 30,000 psi for the stainless steel materials yield strength is justifiable.
HPT-CAL-0001 has been revised to account for internal pressure.
 
ATTACHMENT A - Responses to RAI
: c. The transfer lift of the ICV from the old OCV to the new one will occur in the WIPP Waste Handling Building. The WIPP Waste Handling Building is a steel-frame structure with insulated steel siding. The ventilation systems for the WHB consist of filters, cooling coils, heating elements, fans with associated ductwork, and controls to condition the supply air, maintaining the design temperature between 40°F and 80°F during winter and summer.
: d. The ICV lid lifting sockets and pins are Type 304 stainless steel. The ASME Boiler and Pressure Vessel Code evaluation (see response to RAI St-1(b), above) of this material at room temperature is applicable to the transfer lift of the ICV 506 from the old OCV to the new one in the temperature-controlled WIPP Waste Handling Building.
: e. The payload weight for ICV 506 is 409.3 kilograms (902.35 pounds),
including uncertainty, per page 2 of WIPP Container Data Report SWD12275 (see Attachment D). HPT-CAL-0001 has been revised to add a reference to WIPP Container Data Report SWD12275 in the determination of Section 4.1.1, ICV and Payload Weights.
: f. HPT-CAL-0001 has been revised to replace the simulated ICV payload weight value with the actual measured payload weight. The empty weight of the ICV assembly is 2,250 pounds per Table 2.2-1 of the HalfPACT SAR. The payload weight for ICV 506 is 409.3 kilograms (902.35 pounds), including uncertainty, per page 2 of WIPP Container Data Report SWD12275 (see Attachment D), for a total gross lifting weight of 2,250 + 902.35 = 3,152.35 pounds.
: g. HPT-CAL-0001 has been revised to include the drawing, Washington TRU Solutions, 412-L-082, Rev. E, Adjustable Center of Gravity Lift Fixture (ACGLF) Leg Weldment & Miscellaneous Details; Lift Leg Weldment, in Section 6.1.
: h. The source of the lifting pin groove locations and widths is Sheet 8 of HalfPACT SAR drawing 707-SAR. As shown in Section AT-AT on Sheet 8 of HalfPACT SAR drawing 707-SAR, the lift pocket lift pin is a 7/8-inch diameter round bar with two, 1/8-inch wide x 0.470/0.460-inch diameter radial reliefs spaced 3.563 inches apart; the radial reliefs are designed to be the overload failure point rather than the containment boundary structure.
OPERATING PROCEDURES OP-7-1    Clarify in the application section 7.4.4.1, step 2; section 7.4.4.2, step 2; section 8.1.3.5, step 3; section 8.1.3.6, step 2; section 8.1.3.7, step 2; and
 
ATTACHMENT A - Responses to RAI section 8.2.4.3 that, in addition to the assembly requirements as shown in appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR, the O-ring seals must meet the requirements of section 4.1.1.1 of this application.
Specifically, section 4.1.1.1 of the application describes requirements for the innermost main O-ring seal of the OCV and the OCV vent port plug O-ring seal that are in addition to the requirements in appendix 1.3.1 of the HalfPACT SAR. Both O-ring seals must be important-to-safety Category A butyl rubber.
This information is needed to determine compliance with the regulatory requirements in 10 CFR 71.87 and 71.51.
 
===Response===
Section 7.4.4.1, step 2; section 7.4.4.2, step 2; section 8.1.3.5, step 3; section 8.1.3.6, step 2; section 8.1.3.7, step 2; and section 8.2.4.3 are implemented by HPT-PRO-0001 and HPT-PRO-0002. HPT-PRO-0001 and HPT-PRO-0002 have been revised to include a general reference to HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506, to direct the required use of Category A butyl rubber O-ring seals.
The reference to HPT-PRO-0003 has been added to page 4 of HPT-PRO-0001, and pages 3 and 25 of HPT-PRO-0002 (see Attachments E and F).
 
Attachment B HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation, Revision 1
 
Calculation Cover Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                              3. Document Revision:                      4. Page:
HPT-CAL-0001          I                                1        I            1 of 23
: 5. Summary Description This calculation evaluates a loaded HalfPACT inner containment vessel (ICV) to the requirements of 49 CFR §173.410(b), and as specified in Section 3.1.4 of SDD PT00, to determine stresses in the ICV lid for a one-time shipment supporting ICV 506. These requirements are consistent with the lifting requirements specified in 10 CFR §71.45(a).
: 6. Software Usage Software Name                                                                                      Version
: 1. ANSYS                                                                                          2022 R2.03 2.
3.
4.
5.
: 7. Preparer Name          Signature                                                                          Date Digitally signed by STEVEN PORTER (Affiliate)
Steve Porter        STEVEN PORTER (Affiliate)                Date: 2023.04.24 14:51:15 -07'00'
: 8. Independent Reviewer(s)
Name          Signature                                                                          Date Kyle Moyant          KYLE MOYANT (Affiliate) Digitally                  signed by KYLE MOYANT (Affiliate)
Date: 2023.04.24 16:01:47 -06'00'
: 9. Project Representative Name          Signature                                                                          Date Digitally signed by ROBERT BURNS (Affiliate)
Scott Burns
                                          ~                            Date: 2023.04.24 16:28:49 -06'00'
: 10. QA Representative Name          Signature                                                                          Date Steve Tanner        David S. Tanner Digitally                              signed by David S. Tanner Date: 2023.04.25 10:40:05 -06'00'
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                                3. Document Revision:                                  4. Page:
HPT-CAL-0001                      I                                        1            I                  2 of 23 TABLE OF CONTENTS
 
==1.0 INTRODUCTION==
................................................................................................................... 4 2.0 DESIGN DESCRIPTION ...................................................................................................... 4 3.0 ALLOWABLE STRESSES ................................................................................................... 6 3.1 Material Properties ................................................................................................................. 6 3.2 Design Criteria ....................................................................................................................... 6 4.0 STRUCTURAL EVALUATION ........................................................................................... 8 4.1 Loads ...................................................................................................................................... 8 4.1.1 ICV and Payload Weights ................................................................................................ 8 4.1.2 Internal Pressure............................................................................................................... 8 4.2 Evaluations ........................................................................................................................... 12 4.2.1 ICV Lift Pocket Region Evaluation ............................................................................... 12 4.2.2 ICV Lift Pin Evaluation ................................................................................................. 17 4.2.3 ICV Lift Overload Evaluation ....................................................................................... 19 5.0
 
==SUMMARY==
........................................................................................................................... 19 6.0 ATTACHMENTS ................................................................................................................. 20 6.1 WTS Drawing 412-L-082, Rev. E ....................................................................................... 20 LIST OF TABLES Table 1 - Material Properties for Structural Components ...............................................................6 Table 2 gallon Drum in HalfPACT, Concentrated Decay Heat (from Table 3.4-2 of HalfPACT SAR) ....................................................................................................................10 Table 3 - Saturation Properties of Water .......................................................................................11 LIST OF FIGURES Figure 1 - HalfPACT ICV Section View ........................................................................................5 Figure 2 - HalfPACT ICV Lid Lift Pocket Detail (Upper Honeycomb Spacer Removed for Clarity) ...............................................................................................................................5 Figure 3 - Overall ICV Structural Model ......................................................................................13 Figure 4 - ICV Lift Pocket Detail..................................................................................................14
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                  3. Document Revision:                                  4. Page:
HPT-CAL-0001                I                                        1            I                  3 of 23 Figure 5 - Lift Pocket Region Equivalent Stress - Empty ICV - No Internal Pressure ...............15 Figure 6 - Lift Pocket Region Equivalent Stress - Empty ICV - with Internal Pressure .............15 Figure 7 - Lift Pocket Region Equivalent Stress - Loaded ICV - with Internal Pressure ............16 Figure 8 - Lift Pin Reaction Force - Loaded ICV - with Internal Pressure .................................16 Figure 9 - ICV Lift Pin Model ......................................................................................................17 Figure 10 - ICV Lift Pin Equivalent Stress Results ......................................................................18 Figure 11 - ICV Lift Pin Linearized Equivalent Stress Results ....................................................18 TABLE OF REVISIONS Revision            Pages Number            Affected                                    Revision Description 0              All              New Issue 1              All              Revised to address NRC Request for Additional Information (RAI), dated 04/17/2023
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                    3. Document Revision:                4. Page:
HPT-CAL-0001            I                            1      I              4 of 23
 
==1.0 INTRODUCTION==
 
As discussed in Section 2.5.1, Lifting, of the HalfPACT Safety Analysis Report, 1 the three lift pockets in the HalfPACT inner containment vessel (ICV) lid are designed for lifting either the ICV lid or empty ICV assembly (i.e., lid and body with upper and lower aluminum honeycomb spacers installed).
The lift pockets and surrounding structural components are evaluated to determine the maximum allowable gross weight (i.e., ICV weight plus payload weight) while meeting the requirements of 49 CFR §173.410(b) 2 for DOT Type A packages. These requirements are consistent with the lifting requirements specified in 10 CFR §71.45(a). 3 2.0 DESIGN DESCRIPTION As depicted in Figure 1 and Figure 2, and in Section X-X on Sheet 8 of HalfPACT SAR drawing 707-SAR,1 the ICV lid lift pockets are comprised of a 4-inch, Schedule 80, pipe (4.500-inch outside diameter x 3.826-inch inside diameter; 4.163-inch mean diameter), a 1/4-inch thick x 41/2-inch outside diameter bottom plate, and a 3/8-inch thick x 8-inch outside diameter doubler plate. As shown in Section AT-AT on Sheet 8 of HalfPACT SAR drawing 707-SAR, the lift pocket lift pin is a 7/8-inch diameter round bar with two, 1/8-inch wide x 0.470/0.460-inch diameter radial reliefs spaced 3.563 inches apart; the radial reliefs are designed to be the overload failure point rather than the containment boundary structure.
The empty weight of an ICV is 2,250 pounds per Table 2.2-1 of the HalfPACT SAR.
1 U.S. Department of Energy (DOE), Safety Analysis Report for the HalfPACT Package, USNRC Certificate of Compliance 71-9279, Current Revision, U.S. Department of Energy, Carlsbad Field Office, Carlsbad, New Mexico.
2 Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers - General Requirements for Shipments and Packagings, 10-01-20 Edition.
3 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 10-01-20 Edition.
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                        3. Document Revision:    4. Page:
HPT-CAL-0001                            1          5 of 23 Figure 1 - HalfPACT ICV Section View Figure 2 - HalfPACT ICV Lid Lift Pocket Detail (Upper Honeycomb Spacer Removed for Clarity)
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                  3. Document Revision:                  4. Page:
HPT-CAL-0001            I                              1        I            6 of 23 3.0 ALLOWABLE STRESSES 3.1 Material Properties The ICV is fabricated entirely of ASTM A240, 4 ASTM A312, 5 ASTM A376, 6 or ASTM A479, 7 Type 304, stainless steel plate, pipe, and bar stock. Room-temperature material properties are correspondingly delineated in Table 1 as taken from Section 2.5 of the HalfPACT SAR.1 Table 1 - Material Properties for Structural Components Elastic              Yield            Ultimate Poissons          Modulus            Strength            Strength Material                  Ratio              (psi)              (psi)              (psi)
Type 304 Stainless Steel                0.3            28,300,000          30,000              70,000 The reasons for using room-temperature material properties are threefold:
: 1. The loading process will be performed inside the WIPP Facilitys Waste Handling Building, a temperature and radiologically controlled environment.
: 2. The payload decay heat was determined to be 0.02206 watts, including uncertainty, per page 2 of WIPP Container Data Report SWD12275. 8
: 3. Table Y-1 in Section II, Part D, of the ASME Boiler and Pressure Vessel Code specifies the yield strength of SA-240, Type 304, stainless steel plate as 30,000 psi for -20 °F to 100 °F.
Given the room temperature controlled environment, very low decay heat, and material properties that are constant up to 100 °F, the use of 30,000 psi for the materials yield strength is justifiable.
3.2 Design Criteria The ICV lift pockets are evaluated to the requirements of 49 CFR §173.410(b)2 for DOT Type A packages, and is consistent with the lifting requirements specified in 10 CFR §71.45(a).3 4
ASTM A240, Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications, ASTM International, West Conshohocken, PA.
5 ASTM A312, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes, ASTM International, West Conshohocken, PA.
6 ASTM A376, Standard Specification for Seamless Austenitic Steel Pipe for High-Temperature Service, ASTM International, West Conshohocken, PA.
7 ASTM A479, Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels, ASTM International, West Conshohocken, PA.
8 Waste Data System, Waste Isolation Pilot Plant Container Data Report for Container Number SWD12275, Report Version 3.1, generated on October 3, 2022.
 
Calculation Continuation Sheet
: 1. Document
 
==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                              3. Document Revision:                4. Page:
HPT-CAL-0001            I                          1        I            7 of 23 Section 20-1.2.2 of ASME B30.20 9 requires that structural and mechanical lifting devices be designed in accordance with ASME BTH-1. Per Section 2-3 of ASME BTH-1, 10 Service Class 0, applies for 1 to 20,000 load cycles over the life of a lifting device. Analyzing for fatigue is not required for a Service Class 0 lifting device and not deemed necessary here since ICV 506 will only be lifted once (or twice) to satisfy its safe return for disposition via the one-time shipment that is requested. Therefore, determination of the maximum load capacity of the ICV lifting components shall be based on combined membrane-plus-bending stresses that are limited to one-third of the materials yield strength, i.e., 30,000/3 = 10,000 psi.
Equivalent stress results are determined by combining stresses based on the distortion-energy (von Mises-Hencky) theory and compared to the allowable stress limit of 10,000 psi.
9 ASME B30.20-2021, Below-The-Hook Lifting Devices, American Society of Mechanical Engineers, Two Park Avenue, New York, NY, November 2021.
10 ASME BTH-1-2020, Design of Below-The-Hook Lifting Devices, American Society of Mechanical Engineers, Two Park Avenue, New York, NY, June 2021.
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001            I                        1        I            8 of 23 4.0 STRUCTURAL EVALUATION 4.1 Loads 4.1.1 ICV and Payload Weights The empty weight of the ICV assembly is 2,250 pounds per Table 2.2-1 of the HalfPACT SAR.1 The material density for the analysis models used an adjusted value resulting in a lift interface reaction force that equals 2,250 pounds.
The payload weight for ICV 506 is 409.3 kilograms (902.35 pounds), including uncertainty, per page 2 of WIPP Container Data Report SWD12275,8 for a total gross lifting weight of 2,250 +
902.35 = 3,152.35 pounds.
To determine the maximum load capacity of the ICV lift pockets, a downward force is applied at the lower edge of the bodys cylindrical shell transition to simulate the payload weight.
4.1.2 Internal Pressure The HalfPACT ICV gauge pressure, pmax (psig), at the end of a maximum sealed duration of 110,480 days, 11 which corresponds to the maximum time that HalfPACT payload SRE033 can be sealed with the flammable gas concentration remaining below the lower flammability limit of 5%
per Section 5.2.3 of CH-TRAMPAC 12 is determined by the following equation:
p max  p rg  p hu  p wv  p a where:
p rg = pressure due to radiolytic gas generation p hu = presssure due to heat-up of gas p wv = water vapor pressure p a = ambient atmospheric pressure The pressure due to radiolytic gas generation is determined as a function of the flammable gas generation rate (FGGR) via the methodology outlined in Section 5.2.5.3.3 of CH-TRAMPAC.
The pressure increase due to radiolytic gas generation, prg (psia), is defined by the ratio of the volume of gas generated and heated to the average ICV gas temperature over the sealed duration, Vrg (liters), to the void volume within the ICV, Vicv = 1,496 liters (per Table 3.4-4 of HalfPACT SAR), as follows:
11 Day, B.A., Flammable Gas Concentration Evaluation for HalfPACT Payload SRE033, Rev. 1, January 2023, Nuclear Waste Partnership LLC, Carlsbad, New Mexico.
12 U.S. Department of Energy (DOE), CH-TRAMPAC, Rev. 6, February 2022, U.S. Department of Energy, Carlsbad Field Office, Carlsbad, New Mexico.
 
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                                3. Document Revision:            4. Page:
HPT-CAL-0001                        I                              1 I        9 of 23
                                                                  § Vrg
* p rg        p a ¨ - ¸ 2.81 psia
                                                                  © Vicv ¹ The heated volume of radiolytic gas, Vrg (liters), is corrected from the volume of radiolytic gas determined at STP conditions, VR (liters @ STP), to the average ICV gas temperature as follows:
                                                    § Ticvavg  460 qR
* Vrg      VR ¨                              ¸    286.22 liters
                                                    © 32 qF  460 qR ¹ The average ICV gas temperature, Ticvavg = 115.2 qF, average payload contents temperature, Tpayavg = 115.3 qF, and minimum ICV wall temperature, Ticvmin = 115.2 qF, for the SRE033 standard waste box (SWB) payload within the HalfPACT packaging is given as a function of decay heat, as summarized in Table 2. The temperature results used to represent the SWB payload in a HalfPACT are conservatively based on the 55-gallon drum concentrated decay heat thermal analysis results. All temperature results are linearly interpolated based on the decay heat plus error value of 2.206E-2 watts within the SWB payload. 13,14 The total number of liters of radiolytic gases that are generated, VR (liters), when corrected from moles to liters at STP (32 qF and 1 atmosphere pressure) over the maximum sealed duration is calculated using the following equation:
VR    [n gen ](110,480 days){conversion factors}
[n gen ](110,480 days)^(86,400sec/day) 22.4 liters/mole `
244.82 liters The number of moles per second of total gas generated by radiolysis can be calculated as follows:
                                  § G eff _ net (Tpayavg )
* n gen    ¨¨                      ¸¸ u FGGR u N = 1.145E-9 mol/sec
                                  ©        G              ¹ where ngen is the rate of radiolytic gas generation (moles/sec), Geff_net(Tpayavg) is the temperature-corrected effective net gas G value (total number of molecules of gas generated per 100 eV of energy emitted (molecules/100 eV) at the temperature of the target material), G = 3.4 molecules/100eV is the flammable gas G value for waste material type III.1, FGGR = 3.6553E-10 mol/sec is the flammable gas generation rate per container (moles/sec/container) 11, and N = 1 is the number of payload containers in the package (# containers). As discussed in Appendix 3.2 of the CH-TRU Payload Appendices,15 the effective net gas G value provided at room temperature (RT) is a function of temperature based on the activation energy (Ea) for the material. The effective net gas G value used in 13 Waste Data System, Waste Isolation Pilot Plant Payload Data Report for Payload Number SRE033, Report Version 3.1, generated on October 3, 2022.
14 Waste Data System, Waste Isolation Pilot Plant Container Data Report for Container Number SWD12275, Report Version 3.1, generated on October 3, 2022.
15 U.S. Department of Energy (DOE), CH-TRU Payload Appendices, Rev. 5, February 2022, U.S. Department of Energy, Carlsbad Field Office, Carlsbad, New Mexico.
 
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
: 2. Document Number:                                                      3. Document Revision:                    4. Page:
HPT-CAL-0001                            I                                  1    I            10 of 23 the calculation for pressure increase in the ICV is corrected to the average contents temperature using the activation energy provided in Appendix 3.2 of the CH-TRU Payload Appendices.
The temperature-corrected effective net gas G value is calculated using the following equation:
                                                                  § -E a *§ Tpayavg  TRT *
                                                                  ¨ R ¸¨¨ (T              ¸
                                                                  © ¹© payavg )(TRT ) ¸¹ G eff _ net (Tpayavg )  G eff _ net (TRT ) e                              10.65 molecules/100 eV where Geff_net(TRT) = 8.4 molecules/100 eV is the effective net gas G value at room temperature, Ea
= 2.1 kcal/g-mole is the activation energy for the target material, the ideal gas constant R =
1.99(10)-3 kcal/g-mole-K, Tpayavg = 115.3 qF is the temperature of the target material (qF), and the room temperature is TRT = 25 qC = 298 K.
The pressure due to heat-up of gas is given as a function of the assumed ambient atmospheric pressure, pa = 14.7 psia, and a ratio of the average ICV gas temperature, Ticvavg = 115.2 qF, under normal conditions of transport (NCT) to the assumed ICV average gas temperature, Ta = 70 qF, at the time of closing the ICV as follows:
                                                                § Ticvavg  460 qR
* p hu      14.7 psia ¨                                      ¸  15.95 psia
                                                                © Ta  460 qR ¹ The pressure due to water vapor within the ICV, pwv (psia), is based on the temperature of the coolest or condensing surface of the ICV and obtained by linearly interpolating the saturation properties of water data listed in Table 3, and converting to psia pressure units as follows.
                                                                        § 14.7 psia
* p wv    (10.2 kPa)¨                                  ¸  1.48 psia
                                                                        © 101.325 kPa ¹ Therefore, the ICV gauge pressure at the end of a 110,480-day sealed duration for HalfPACT payload SRE033 is as follows:
p max    2.81  15.95  1.48  14.7 = 5.54 psig Table 2 gallon Drum in HalfPACT, Concentrated Decay Heat (from Table 3.4-2 of HalfPACT SAR)
Average Payload                              Average ICV Gas          Minimum ICV Wall Decay Heat                        Temperature,                                  Temperature,            Temperature, (watts)                          Tpayavg, (qqF)                                Ticvavg, (qqF)        Ticvmin, (qqF) 0                              115.2                                        115.2                  115.2 10                              163.9                                        127.4                  125.8 20                              209.5                                        139.5                  135.7 30                              251.9                                        150.9                  144.9
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001              I                            1  I          11 of 23 Table 3 - Saturation Properties of Water 16 Minimum ICV Wall              Water Vapor              Minimum ICV Wall        Water Vapor Temperature,              Pressure, pwv,                Temperature,        Pressure, pwv, Ticvmin, (qqC)                  (kPa)                      Ticvmin, (qqC)          (kPa) 40                      7.385                            47              10.627 41                      7.788                            48              11.177 42                      8.210                            49              11.752 43                      8.651                            50              12.352 44                      9.112 45                      9.595 46                    10.099 16 NIST web: http://webbook.nist.gov/chemistry/fluid)
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001            I                              1        I          12 of 23 4.2 Evaluations Two ANSYS 17 finite element analysis (FEA) models are utilized to determine the maximum load capacity of the ICV lift pockets.
The first FEA model of the ICV lift pocket region evaluates the components in the load path beyond the ICV lift pin, i.e., the lift pocket, lift pocket doubler, and torispherical head structure.
The second FEA model of the ICV lift pin is a highly refined model that includes the two radial grooves that are used to limit stresses by being the shear-failure point in an excessive overload condition. Each FEA model is discussed in more detail below.
4.2.1 ICV Lift Pocket Region Evaluation As shown in Figure 3 and Figure 4, the overall ICV structural model accurately depicts the entire ICV structure without its internal components such as the aluminum honeycomb end spacers and pallet. The ICV structural model is a 1/6 representation of the entire ICV, and uses symmetry boundary conditions along its radial cut edges for continuity.
The entire ICV lid structure, including the lift pocket, is comprised of solid elements. Given the relatively thin shell structures, quadratic elements are used to ensure accurate results for shell bending stresses. The ICV seal flanges and locking ring are also solid elements. The ICV body cylindrical shell and torispherical head are modeled using shell elements.
With one exception, all parts of the model are bonded together. The lift pocket doubler plate is bonded at its edges: the inside edge to the lift pocket to simulate the full penetration weld, and the outside edge to the torispherical head dome to simulate the fillet weld. The interface between the top surface of the doubler plate and bottom surface of the head dome is set to frictionless which allows the surfaces to move relative to each other.
Although the lift pin is included in the model, its only purpose is to provide the load path to the remainder of the model. Each of the ICVs three lift fixture leg weldments 18 have a locking bar that engages the lift pin at a 3.00-inch diameter and provide for a straight vertical lift. Given the locking bars relatively greater strength and rigidity compared to the lift pin, the lift pin may be reasonably evaluated having two concentrated loads spaced 3.00 inches apart.
17 ANSYS Simulation Software, Version 2022 R2.03, Ansys, Inc., Canonsburg, PA.
18 Washington TRU Solutions, 412-L-082, Rev. E, Adjustable Center of Gravity Lift Fixture (ACGLF) Leg Weldment
& Miscellaneous Details; Lift Leg Weldment.
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                                1            13 of 23 z
0.00                                                            50.00 (in) 12.50                                  37.50 Figure 3 - Overall ICV Structural Model
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                                      1                  14 of 23 Figure 4 - ICV Lift Pocket Detail For this model, the lift pin is restrained in the vertical (Z) direction 1.50 inches inward from the axisymmetric cut plane, and gravity is applied to the model to determine stresses both empty and when loaded to its maximum capacity. Payload weight is simulated by applying a downward vertical force around the periphery of the ICV bodys cylindrical-to-torispherical shell interface.
With reference to Figure 5, the maximum equivalent stress for an empty, unpressurized ICV structure is 2,897 psi, and occurs at the outside surface of the lids torispherical dome at the outside edge of the lift pocket doubler plate.
With reference to Figure 6, the maximum equivalent stress for an empty, pressurized ICV structure is 5,131 psi, and occurs at the inside surface of the lids torispherical knuckle.
With reference to Figure 7, the maximum equivalent stress for a loaded, pressurized ICV structure is 6,045 psi, and once again occurs at the inside surface of the lids torispherical knuckle.
Figure 8 illustrates the reaction force vector in the vertical direction for the final analysis case with a loaded, pressurized ICV (525.4-pound reaction force; multiply by six to get the total reaction load, i.e., 6 x 525.4 = 3,152.4 pounds).
Given an allowable sWUHVVa = 10,000 psi, for the Type 304 stainless steel material, the design margin for lift pocket region, DMLPR, is:
Va        10, 000 DM LPR          1               1 0.65 Veq        6, 045
 
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                          1          15 of 23 A:.H.alfPACTICVUftl"9Ew*l..,_lion*EMplylCV
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                          1          16 of 23 A:.H.alfPACTICVUftl"9Ew*l..,_lion
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411l/20236:28PM Figure 8 - Lift Pin Reaction Force - Loaded ICV - with Internal Pressure
 
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                                      1                    17 of 23 4.2.2 ICV Lift Pin Evaluation As discussed in Section 4.2.1, ICV Lift Pocket Region Evaluation, the lift pin is subject to bending and shear loads due to the vertical load applied by ICVs lift fixture.18 Thus, the lift pin is evaluated by applying two concentrated loads of 525.4 pounds spaced 3.00 inches apart.
Since the lift pin is fully welded into the lift pocket, the lift pin may be treated as a fixed-fixed cylindrical beam in bending and shear, with the beams length based on the inside diameter of the lift pockets 4-inch, Schedule 80, pipe (4.500-inch outside diameter x 3.826-inch inside diameter).
To perform this evaluation, a high-resolution ANSYS FEA model of the lift pin is used. The lift pins geometry, as shown in Figure 9, includes its two 1/8-inch wide radial grooves with a full 1/16-inch bottom radius per Section AT-AT on Sheet 8 of HalfPACT SAR drawing 707-SAR.1 Figure 10 presents the equivalent stress results by combining stresses based on the distortion-energy (von Mises-Hencky) theory. The resulting maximum stress of 11,971 psi occurs at the surface of the 1/16-inch radius in the grooves. Since the stress distribution through the pins thickness clearly shows these stresses in the grooves to be peak stresses, the center section through the groove was linearized to separate primary membrane-plus-bending stresses from peak stresses, given that the peak stresses are only important from a fatigue failure standpoint. As said earlier, since only one (or two) lifts will be performed, evaluating for fatigue is not required.
As shown in Figure 11, the resulting maximum equivalent stresseq, for membrane-plus-bending is 6,639 psi. *LYHQDQDOORZDEOHVWUHVVa = 10,000 psi, for the Type 304 stainless steel lift pin material, the design margin for each lift pocket lift pin, DMLP, is:
Va        10, 000 DM LP          1             1 0.51 Veq        6, 639 Figure 9 - ICV Lift Pin Model
 
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==Title:==
Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001                            1          18 of 23 A=~ltY . . . . . . . . . . . ....,. . . . . . . ltY Typt; ........ (llon-Mls.s)S-..
r...., 1, 4114/ZOZ311::Z7AM 9310.6 Figure 10 - ICV Lift Pin Equivalent Stress Results
                                                                        ..        o.soo
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                  ~=--=--
Figure 11 - ICV Lift Pin Linearized Equivalent Stress Results
 
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Loaded HalfPACT ICV Lifting Evaluation
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HPT-CAL-0001          I                            1        I          19 of 23 4.2.3 ICV Lift Overload Evaluation Since the materials of construction are identical for all of the ICV structural components, and since the design margin for the ICV lift pocket region (+0.65) exceeds the design margin for the lift pin (+0.51), overload failure will occur in the lift pins radial grooves, as intended, before ICV containment integrity is compromised due to failure of any other components in the lift pocket region that comprise the inner containment vessel structure.
5.0
 
==SUMMARY==
 
The minimum lifting design margin for this payload is 51%. Furthermore, per Section 8.1.2.1 of the HalfPACT SAR,1 the bounding design load of the ICV lifting sockets is 5,000 pounds, and load testing to 7,500 pounds is required. Successful load testing and post-test non-destructive testing, coupled with the validation of this evaluation, ensures that the ICV lifting features will operate safely as designed for the loaded ICV 506.
 
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HPT-CAL-0001          I                      1    I          20 of 23 6.0 ATTACHMENTS 6.1 WTS Drawing 412-L-082, Rev. E Washington TRU Solutions, 412-L-082, Rev. E, Adjustable Center of Gravity Lift Fixture (ACGLF) Leg Weldment & Miscellaneous Details, is attached for reference (three sheets total).
Refer to Item 2 on Sheet 2 for relevant lift bar details.
 
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                                                                                                                                -~Jf-:-f WELDMENT    (As NaTEDl WELDMENT @  (As N111ED)
CIWl1/ll :!:1J11                          c_j
                                                                                                                                                              =
X45'lYP2X                                                      ALLNICUND                R.!IO
                                                                                                                                                ,.oo
                                                                ~~i/11                                                                              C-C
                                                                                                                                                                                                                                  ;,)(2PLCS) 0  BAR V1EW WELDMENT    @
                                                                                                          ~A L
                                                                                                                  ...,. " ,.., ,,,t.:.C."* *"""
I.
                                                                                                            ~
                                                                                                            ~
                                                                                                            @ Ill>  SPUR GEAR
_.__.,;.  -          W, TRIJ SOlunons
                                                                                                                                                                                                                        --l'lllll'lont              --
                                                                                                                                                                                      .==,
DII.NICIDWI.O.    -
A I                                                                                                                                                                              (
111. l'I.B 11.
ADJUSTABLE CENTER OF GRAVITY LIFT FIXl\JRE (ACGLF)
A I;jfiJ'1 !/i'21il .:...~ -=- =:;;*~-                n El~:--:--IOI-
::~;~~ "'~~;ET;~ le
                                                                                                                                                                                                                                          &L a                      I            7                    I  s                    I            s        f                        4                  I        3        I                      2
 
412-L-082-W3
      ~--\m '~--
          ..... -.\~~,,,_....,..,.
[!J>
r""7
                                                          *f I    @Ul>
I+                  .......
TABLE 1
                                                                                                                                                      *w~-
UO 4 Pl.CS EO. SP. 0N 1.00 DIA.B.C.COUNIER80RE*.38X SCALE:1/1                              SCALE*1/1                                                                                                                                                                    .20DEEPltaSIDE.
                                                                                                                                                                                              ,.204F'UICESEll.!IP.DN1.DO DII\.B.C.ROOOED45'FROII 0RlllW..H01..ESCCJUNIER90RE lt.31lC.20DEEPCA'O!iflESIDE lr "'"'*          71.75 r----=k:~*'""
L A
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MIN.MD.,-
Ll,..j 'v EQ.SP.ON1.250B.C.
WELDMENT  @      (!J>
                                                                                                                                                                                                                                            @)[!l>
SECTION 8-8 (llEU)MENTM) 0Ul>
ENCODERMDUNTINGIANOL.EIIRIICKrTS,SHDRTa.TALI.
l/1B"WIJE~-~~
i.ro.~~=11 e/11-111UNC-2B 1---.
SECTION    A-A                                                                                                      5.M(IE,IIEYB)
                                  """""'"'                                                                                                        -~ ""['._llli_l I
i--- ...,      ::::::;7 / ..."  -                                    0(ASN01ED) 0 ... .,,.,,
A L
(WELDNENTM)
B L
('IELl)MENTM)
AO ~r4DJ 1v I I
r3/4~
WEI..DMENT    @ (AS NO'IED) fij>
WELDMENT      @ (AS NOTED) [ii>-                                            0Ul>
A                                                                                                                                                                                                          .=~
a1111C1DWLO.      -II.A-      ADJUSTABLE CENlER OF GRAVITY      A 1J.r1t:c1 !iYihi                -=- ___,_,.
1111. 11. *
                                                                                                                                                                                                                ~
l'I.
                                                                                                                                                                                                                                            ~*  LIFT FDCnJRE (ACGLF)
WELD.::E:T & MISC. DETAILS _
                                                                                                                                                                                                                                  - - -
* E WH02 412-L-082-W3              B a                                        1                    s                                        s                          ,
 
Attachment C Section 3.1.4, Payload Container (PT03) Requirements (Balance of Plant), of Packaging and Transportations System (PT00)
System Design Description (SDD)
(SDD PT00), Revision 13
 
ISSUED SDD:        PT00 Revision Number:    13 Revision Date: 02/14/2023 ECN Number:      14731 U.S. DEPARTMENT OF ENERGY WASTE ISOLATION PILOT PLANT PACKAGING AND TRANSPORTATIONS SYSTEM (PT00)
SYSTEM DESIGN DESCRIPTION (SDD)
SDD PT00 Prepared by WASTE ISOLATION PILOT PLANT Carlsbad, New Mexico For U. S. Department of Energy Cognizant Individual:  S.V. McGonagill                  01/31/23 Approved for Use                      Date Cognizant Individual:  Tony Donner                      01/31/23 Approved for Use                      Date Cognizant Manager:      Todd Sellmer                      02/19/23 Approved for Use                      Date
 
ISSUED SDD PT00                                                              February 14, 2023 3.0  REQUIREMENTS AND BASES 3.1  Requirements 3.1.1 Wherever possible, commercially available equipment, components, and tools are utilized. The equipment is purchased per the equipment specification and modified as necessary to meet the specific needs of the WIPP program.
3.1.2 Contact-Handled TRU Waste Packaging (PT01) Requirements (Safety Significant) 3.1.2.1    Packaging systems will be NRC-certified as meeting the requirements set forth in 10 CFR Part 71, "Packaging and Transportation of Radioactive Material" with the issuance of a Certificate of Compliance (C of C) for Radioactive Materials Packages.
3.1.2.2    Packaging systems will be designed to be transported without requiring special state or Federal permits when practical.
3.1.2.3    The materials and dimensions of the tools must be compatible with the equipment with which they are used.
3.1.3 Remote-Handled TRU Waste Packaging (PT02) Requirements (Safety Significant) 3.1.3.1    Packaging systems will be NRC-certified as meeting the requirements set forth in 10 CFR Part 71 with the issuance of a C of C.
3.1.3.2    Packaging systems will be designed to be transported without requiring special state or Federal permits when practical.
3.1.3.3    The materials and dimensions of the tools must be compatible with the equipment with which they are used.
3.1.4 Payload Container (PT03) Requirements (Balance of Plant) 3.1.4.1    Payload containers will either be DOT Type A or NRC-certified packaging. All payload container lift fixtures meet the design requirements of ASME B30.20, Below-the-Hook Lifting Devices.
3.1.5 Transport Trailer (PT04) Requirements (Balance of Plant) 3.1.5.1    Trailers will meet the design requirements of ANSI N14.30, Nuclear Materials - Semi-Trailers Employed in the Highway Transport of Weight-Concentrated Radioactive Loads, and/or DOT requirements for over-the-road trailers.
SDD PT00                                      14                                Rev. 13
 
Attachment D WIPP Container Data Report SWD12275 and WIPP Payload Data Report SRE033
 
~WDS                      Waste Isolation Pilot Plant
. WASTE DATASYSm~
Container Data Report              Page 1 of 9 Report Statistics Report Version:  3.1 WDS Instance:    prd05.wipp.carlsbad.nm.us Generated on:    October 03, 2022 10:31 AM Generated by:    MOYANT, KYLE Total Pages:    9 Selection Criteria Container Number:  SWD12275
 
~WDS                                                              Waste Isolation Pilot Plant                                                        MOYANT, KYLE
-        ~STEDATASYSTEfA                                                                                                                    October 03, 2022 10:31 AM Container Data Report Page 2 of 9 I Container:        SWD12275                  Extended Status:          APPROVED CERT RECEIVED Type: 2- SWB I    Container Status:          CERTIFICATION DATA APPROVED                                Waste Handling Code:      CH Certification Date:        06/13/2013                                                Disposal Date:
Latest DA Approval Date:  06/13/2013 Current Location Site:    WI                  Neutron Dose Rate (mrem/hr):        2.0                    FGE (g):                          6.19E-03 Generator Site:          SR                  Beta Gamma Dose Rate (mrem/hr): 1.0                        FGE Uncertainty (g):              6.17E-04 Destination Site ID:      WI                  Total Dose Rate (mrem/hr):          3.0 Gross Weight (kg):                393.00 Certification Program ID: C1                                                                              Gross Weight Uncert (kg):        16.30 Shipping Program ID:      C1 Decay Heat (W):                  1.9E-02 Decay Heat Uncertainty (W): 3.06E-03 Shipment Data Payload ID:            SRE033              Assembly ID: SR 179698          Payload Complete?        Y Shipment Number:        SR220010 Scheduled Send Date:    08/25/2022          Send Date:      08/25/2022      Receipt Date:    08/26/2022 Shipment Status:        SHIPMENT RECEIVED AT DESTINATION Certification Data Values                                          ~    Transportation Data Values Waste Stream Profile Code:    SR-SWMF-HET-A Closure Date:        03/20/2013          Shipment
 
==Purpose:==
DISPOSAL Waste Type Code:              MTRU Vent Date:            03/20/2013          Machine Compacted?          N IDC Code:                    NONE Process Knowledge? N                      Puck Drum Waste?
Waste Matrix Code:            S5400 Plastic <= 2kg?
WAC Revision Number:          7.4 TRUCON Code:          SR225C              Liner Exists?              N Fill Factor(%):              85.00 Waste Stream BIR ID :        SR-SWMF-HET-A                                Shipping Category:    3003400041          Liner Hole Size(mm):
Waste Stream MWIR ID:                                                      Aspiration Method :  3                  Liner Lid Present?
NONE CCEM Revision:                SR-SWMF-HET-A CCE10 - Rev 0                                                            Layers of Packaging        1 Aqueous Material?            N AK Assessment Date:          06/23/2022 AK Assessment Date Verification Date:    07/26/2022 Gas Generation Data Values IWMDL Date:
Measured FGGR  Measured TGRR  Truncated FGGR    Truncated FGGR BOK Evaluation Acceptance: Y                                                      (molls)        (molls)      Test (YIN)    Test Period (days)
BOK Eval Acceptance Verification Date: 07/19/2022
 
~WDS                                                                Waste Isolation Pilot Plant                                                                  MOYANT, KYLE
-      W~ST&#xa3; DATASYSTEM                                                                                                                          October 03, 2022 10:31 AM Container Data Report Page 3 of 9 IContainer:          SWD12275 I
Extended Status:
Container Status:
APPROVED CERT RECEIVED CERTIFICATION DATA APPROVED                                      Waste Handling Code:      CH Type:2-SWB                                    Certification Date:        06/13/2013                                                        Disposal Date:
Latest DA Approval Date:  06/13/2013 TRU Alpha Activity (Ci):                                  5.72E-01 TRU Alpha Activity Uncertainty (Ci):                      9.24E-02 TRU Alpha Activity Concentration (Ci/g):                  5.55E-06            Filters Product Container Assembly Approved?
Filter Model Number    Filter Diffusivity (mol/s/mf) Quantity        Install Date PU-239 Equivalent Activity (PE-Ci):                      5.25E-01 Alpha Surface Contamination (dpm/cm 11 2):                19.0                        NF019D                      1.85E-05                        03/20/2013 Beta/Gamma Surface Contamination (dpm/cm 11 2):          199.0 PCB Waste?                      N PCB Mass (kg):
PCB Concentration (ppm):
PCB Out of Service Date:
Be Present?                      Y Be <= 1% by weight?              Y Be mass <= 100kg?                Y Separation OK?
Packing Fraction (compaction level):              non-compacted Certification Comments Radionuclides Radionuclide            Activity (Ci)        Activity Uncert (Ci)  Mass (g)                Mass Uncert (g)
AM-241                    6.060E-02            3.860E-03              1.746E-02                1.135E-03 CS-137                    3.390E-07            5.240E-08              3.852E-09                6.076E-10 NP-237                    1.200E-04            6.080E-06              1.683E-01                8.701 E-03 PU-238                    5.110E-01            9.230E-02              2.954E-02                5.444E-03 PU-239                    <LLD                <LLD                  <LLD                    <LLD PU-240                    <LLD                <LLD                  <LLD                    <LLD
 
~W D S                                                                  Waste Isolation Pilot Plant                                              MOYANT, KYLE
.      Vl\dSTE DATASYSTEf~                                                                                                            October 03, 2022 10:31 AM Container Data Report Page 4 of 9
                                                            &#xa9; IContainer:          SWD12275                    Extended Status:          APPROVED CERT RECEIVED I      Container Status:          CERTIFICATION DATA APPROVED                      Waste Handling Code:    CH Type:2-SWB                                      Certification Date:        06/13/2013                                        Disposal Date:
Latest DA Approval Date:  06/13/2013 Radionuclides Radionuclide              Activity (Ci)        Activity Uncert (Ci)  Mass (g)            Mass Uncert (g)
PU-241                      .000E00                .000E00              .000E00              .000E00 PU-242                    1.560E-07            2.820E-08              3.929E-05            7.248E-06 SR-90                      3.390E-07              5.240E-08            2.457E-09            3.875E-10 U-233                        <LLD                  <LLD                  <LLD                <LLD U-234                      9.030E-05              1.630E-05            1.429E-02            2.632E-03 U-235                      .000E00                .000E00              .000E00              .000E00 U-238                        <LLD                  <LLD                  <LLD                <LLD Samples Sample Type                                                                                    Layer Sample ID                            Sample Type Description / Purpose                                Sample Date Code                                                                                    Sampled H-SWD12275                  HGHM-T    HEADSPACE GAS HYDROGEN AND METHANE                                05/28/2013      0 T - TRANSPORTATION Unique Samples Concentration                                    Reporting CAS Number        Analyte Description                                              Analysis Date  Analysis Method (ppm)                                            Flags 1333-74-0      HYDROGEN                                                8.21      05/28/2013        1HG2              NA 74-82-8      METHANE                                                6.85      05/28/2013        1HG2                u
 
~WDS                                                                Waste Isolation Pilot Plant                                          MOYANT, KYLE
.      Wo.STE DATA SYSTEM                                                                                                    October 03, 2022 10:31 AM Container Data Report Page 5 of 9 n
IContainer:          SWD12275                Extended Status:        APPROVED CERT RECEIVED CERTIFICATION DATA APPROVED                    Waste Handling Code:
Container Status:                                                                                CH Type:2- SWB                                  Certification Date:      06/13/2013                                      Disposal Date:
Latest DA Approval Date: 06/13/2013 Samples Sample Type                                                                              Layer Sample ID                          Sample Type Description / Purpose                            Sample Date Code                                                                                Sampled SWD12275                HGVO-T    HEADSPACE GAS        voe                                      05/28/2013      0 T- TRANSPORTATION Unique Samples Concentration                                    Reporting CAS Number    Analyte Description                                          Analysis Date  Analysis Method (ppm)                                          Flags 100-41-4    ETHYL BENZENE                                        2.32      05/28/2013        1HG2              u 107-06-2    1,2-DICHLOROETHANE                                  1.09      05/28/2013        1HG2              u 108-10-1    METHYL ISOBUTYL KETONE                              2.28      05/28/2013        1HG2              u 108-67-8    1,3,5-TRIMETHYLBENZENE                              5.36      05/28/2013        1HG2              u 108-88-3    TOLUENE                                              2.43      05/28/2013        1HG2              u 108-90-7    CHLOROBENZENE                                        2.15      05/28/2013        1HG2              u 108383/106423  M,P-XYLENE                                          1.24      05/28/2013        1HG2              u 110-82-7    CYCLOHEXANE                                          3.54      05/28/2013        1HG2              u 156-59-2    CIS-1,2-DICHLOROETHYLENE                            0.31      05/28/2013        1HG2              u 60-29-7      ETHYL ETHER                                          0.82      05/28/2013        1HG2              u 67-56-1      METHANOL                                              9.6      05/28/2013        1HG2              u 67-64-1      ACETONE                                              7.2      05/28/2013        1HG2              u 71-36-3      BUTANOL                                              0.98      05/28/2013        1HG2              u 71-43-2      BENZENE                                              0.61      05/28/2013        1HG2              u 75-34-3      1,1-DICHLOROETHANE                                  2.84      05/28/2013        1HG2              u 75-35-4      1, 1-DICHLOROETHYLENE                                2.92      05/28/2013        1HG2              u
 
~WDS                                                                  Waste Isolation Pilot Plant                                                MOYANT, KYLE
~      Vl~STEDATASYSTEM                                                                                                                October 03, 2022 10:31 AM Container Data Report Page 6 of 9 i  li'    s IContainer:        SWD12275 I
Extended Status:
Container Status:
APPROVED CERT RECEIVED CERTIFICATION DATA APPROVED                        Waste Handling Code:    CH Type:2-SWB                                      Certification Date :      06/13/2013                                          Disposal Date:
Latest DA Approval Date:  06/13/2013 Samples Sample Type                                                                                          Layer Sample ID                            Sample Type Description / Purpose                                  Sample Date Code                                                                                          Sampled SWD12275                HGVO-T        HEADSPACE GAS      voe                                              05/28/2013      0 T - TRANSPORTATION Unique Samples Concentration                                        Reporting CAS Number          Analyte Description                                                Analysis Date  Analysis Method (ppm)                                              Flags 78-93-3          METHYL ETHYL KETONE                                    3.21          05/28/2013        1HG2              u 95-47-6          O-XYLENE                                              1.68          05/28/2013        1HG2              u 95-63-6          1,2,4-TRIMETHYLBENZENE                                6.75          05/28/2013        1HG2              u Material Parameters Material Parameter    Description                                                              Weight (kg)
IRON BASE METAL ALLOYS                                                        64.00 4            OTHER INORGANIC MATERIALS                                                        1.00 7            RUBBER                                                                          1.30 8            PLASTICS                                                                      36.70 13          STEEL CONTAINER MATERIALS                                                    290.00 Waste Weight:          103.oo  11 Packaging Weight:          290.00  11 Total Material Weight:        393 .oo 11 Hazardous Waste Numbers Hazardous Waste Number        Description
 
~\NOS                                                          Waste Isolation Pilot Plant                            MOYANT, KYLE
~      WASTEDATASYSTE,A                                                                                    October 03, 2022 10:31 AM Container Data Report Page 7 of 9 IContainer:        SWD12275                Extended Status:
Container Status:
APPROVED CERT RECEIVED Waste Handling Code:
CERTIFICATION DATA APPROVED                              CH Type:2- SWB                              Certification Date:      06/13/2013                        Disposal Date:
Latest DA Approval Date: 06/13/2013 Hazardous Waste Numbers Hazardous Waste Number      Description 0008            LEAD F001            SPENT HALOGENATED SOLVENTS F002            SPENT HALOGENATED SOL VENTS F004            SPENT NONHALOGENATED SOLVENTS F005            SPENT NON-HALOGENATED SOLVENTS FOO?            SPENT CYANIDE PLATING BATH F009            SPENT STRIPPING SOLUTION U133            HYDRAZINE U151            MERCURY Assay Methods Assay Method      Description                                                              Assay Date 1NABC1          NOA BOX COUNTER                                                          06/03/2013 Non-Destructive Examination (NDE)
Examination NOE Method        Description Date 1LCNDE          REAL-TIME RADIOGRAPHY                                                    05/23/2013 Edit Limit Check Results Evaluation Date: 06/13/2013 13:25:41      Overall Status:  PASS Evaluation Code              Status            Return Code          Detailed Description DI_CERT_ALL                PASS
 
~VVDS                                                        Waste Isolation Pilot Plant                                                                    MOYANT, KYLE
'fll1 \11\dSTE DATASYSTEM                                      Container Data Report October 03, 2022 10:31 AM Page 8 of 9 IContainer:          SWD12275          Extended Status:          APPROVED CERT RECEIVED Type:2- SWB I Container Status:        CERTIFICATION DATA APPROVED                                              Waste Handling Code:    CH Certification Date:      06/13/2013                                                              Disposal Date:
Latest DA Approval Date:  06/13/2013 Edit L1m1t Check Results
                                                                                ~*--.- .. --- . - .,._,, ---* ...... --- -- ....._ ...... -~                        -.--.-
Evaluation Date: 06/13/2013 13:25:41    Overall Status:  PASS Evaluation Code              Status DI_CERT_BE                  PASS DI_CERT_CERT                PASS DI_CERT_CHARZ                PASS DI_CERT_ED                  PASS DI_CERT_EPA                  PASS DI_CERT_PCB                  PASS DI_CERT_PERC                PASS DI_CERT_TRAMPAC              PASS DSA                          PASS WAC                          PASS WAP CERT                    PASS TRAMPAC Evaluation Results Evaluation Date: 06/13/2013 13:25:43    Overall Status:  PASS Evaluation Code              Status        Return Code          Detailed Description CE_ACT                      PASS CE ALL                      PASS CE ASP                      PASS CE_DDH                      PASS CE_FGE                      PASS CE_FIL                      PASS CE_GVE                      PASS CE RDR                      PASS CE_TRU                      PASS
 
~V\/DS                                                            Waste Isolation Pilot Plant                                            MOYANT, KYLE
-      Vl~STEDATA SYSTEM                                                                                                      October 03, 2022 10:31 AM Container Data Report Page 9 of 9
[
IContainer:          SWD12275                Extended Status:          APPROVED CERT RECEIVED Type:2- SWB I  Container Status:          CERTIFICATION DATA APPROVED                      Waste Handling Code:    CH Certification Date:        06/13/2013                                      Disposal Date:
Latest DA Approval Date:  06/13/2013 TRAMPAC Evaluation Results Evaluation Date: 06/13/2013 13:25:43          Overall Status:  PASS Evaluation Code              Status CE WGT                        PASS Details Matrix Depleted Shipping Category:                                    Compliance Method :              ANALYTICAL Decay Heat Limit (w):                0.346084648493543 76              FGE Limit (g):                  325 FGGR (molls):                        6. 695656995 79552E-9            FGGR Limit (molls) :            1.2195121951219514E-7 Volume Model :                                                        Required Aspiration Time (days):
Total Headspace voes (ppm):          57.33 Sample-Vent Time (days):            69                                CM Lookup Time Applied (days):
TFGVC in ICL (mol fr) :                                                MLEL (mol fr):                  0.05 History Event Date/Time        Container Number          Event Description                              Reason 06/13/2013 13:25:43      SWD12275                  INSERT DATA INTO THE DATABASE 06/13/2013 13:25:43      SWD12275                  SUCCESSFUL SUBMISSION FOR CERT 06/13/2013 13:26:35      SWD12275                  APPROVED FOR CERT 08/15/2022 15:03: 11      SWD12275                  ASSIGNED TO PAYLOAD
 
~WDS                          Waste Isolation Pilot Plant
* \/\~STEDATA SYSTEM Payload Data Report                Page 1 of 3 Report Statistics Report Version:  2.8.6 WDS Instance:    prd05.wipp.carlsbad.nm.us Generated on:    October 03, 2022 10:32 AM Generated by:    MOYANT, KYLE Total Pages:    3 Selection Criteria Payload Number:      SRE033
 
r.;J.\Vvos                                                          Waste Isolation Pilot Plant                                                    MOYANT, KYLE
.      WASTE DATA SYSTEM                                                                                                                October 03, 2022 10:32 AM Payload Data Report Page 2 of 3 IPayload Number:      SRE033 Package Type:        HALFPACT Current Location Site:    WI                Surface Dose Rate (mrem/hr):      9.5            ICV/IV Closure Date:                  08/23/2022 08:25 Destination Site ID:      WI                Dose Rate @1m(mrem/hr):            2.5            Package Vent Date:
Shipping Program ID:      C1                Dose Rate @2m(mrem/hr):            1.1            OCA/OC Lid Number:                    506 Package Number:            506                Alpha Surface Contamination                        Handling Material Weight (kg):        94.60 Payload Complete:          true              (dpm/cm"2):                        19.0 Handling Material Weight Uncert (kg):
Payload Type:              HALFPACT-1        Beta Gamma Surface                                Radionuclide Reportable Quantity:      y SWB                Contamination (dpm/cm"2):          199.0 Radionuclide Highway Route Controlled Quantity:                              N DOT
 
== Description:==
RQ, UN2916, WASTE RADIOACTIVE MATERIAL, TYPE B(U) PACKAGE, 7 Shipment Number:          SR220010        Send Date:    08/25/2022 08:11 :00      Receipt Date:  08/26/2022 14:34:00 Shipment Status: SHIPMENT RECEIVED AT DESTINATION Assembly Number                                            Containers in Assembly SR179698                                        TRUCON        Shipping      Shipping    Gross Weight    FGE + 2x Container Number                                                      + Error        Error Code        Category        Period SWD12275                SR225C      3003400041        60          409.30      7.424E-03 Edit Limit Check Results Evaluation Date: Mon, Aug 15 202215:03:11                      Overall Status:  PASS Evaluation Code        Status      Return Code    Detailed Description PAY ALL                      PASS PAY_DSA_FGE                  PASS PAY DSA MAR                  PASS PAY EAK                      PASS
 
~WDS                                                          Waste Isolation Pilot Plant                                      MOYANT, KYLE
-      ~TEDATASYSTEM                                                                                                October 03, 2022 10:32 AM Payload Data Report Page 3 of 3 IPayload Number:    SRE033 Package Type:      HALFPACT TRAMPAC Evaluation Results Evaluation Date: Mon, Aug 15 202215:03:11                Overall Status: PASS Evaluation Code        Status  Return Code  Detailed Description PA ACT                      PASS PA ALL                      PASS PA CFG                      PASS PA DOH                      PASS PA FGE                      PASS PA GVE                      PASS PA SHIP PA TGRR                      PASS PA WGT                      PASS CHTES Results Governing Shipping Period :            60 Gross Weight +Gross Weight Error:      503 .90 FGE + 2xFGE Error:                    7.424E-3 FGE Limit:                            325 Decay Heat + Decay Heat Error:        2.206E-2 Container Number            Compliance Method        FGGR (molls)      FGGR Limit (molls) Flammability Index            AFGC SWD12275                  ANALYTICAL                6.6957E-9          1.2382E-7            2704                      0.0500
 
Attachment E HPT-PRO-0001, Operating Procedures for One-Time Shipment Supporting ICV 506, Revision 2
 
Operating Procedures for One-Time Shipment Supporting ICV 506 Prepared by:
                                ~I~ttgm Mining Contractors Prepared for:
SIMCO Transportation Packaging Group Document Number:
HPT-PRO-0001, Rev. 2 April 2023 Digitally signed by ROBERT Document Preparer      R. S. Burns                ~              -
BURNS (Affiliate)
Date: 2023.04.17 07:17:20 -06'00' Signature                                    Date Digitally signed by STEVEN PORTER STEVEN PORTER (Affiliate)  (Affiliate)
Independent Reviewer    S. A. Porter                                  Date: 2023.04.17 12:26:38 -07'00' Signature                                    Date Digitally signed by TODD SELLMER TODD SELLMER (Affiliate)  (Affiliate)
Cognizant Manager      T. E. Sellmer                                Date: 2023.04.18 12:39:00 -06'00' Signature                                    Date Quality Assurance    D. S. Tanner David S. Tanner Digitally              signed by David S. Tanner Date: 2023.04.18 09:50:13 -06'00' Signature                                    Date
 
This page intentionally left blank to facilitate duplex printing
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 TABLE OF CONTENTS
 
==1.0 INTRODUCTION==
................................................................................................................... 1 1.1    Purpose ........................................................................................................................... 1 1.2    Background .................................................................................................................... 1 1.3    Format ............................................................................................................................ 1
7.0 OPERATING PROCEDURES ............................................................................................ 2
7.1 Procedures for Loading the Package .............................................................................. 2
7.1.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar ........... 2
7.1.2 Outer Confinement Assembly (OCA) Lid Removal .......................................... 2
7.1.3 Inner Containment Vessel (ICV) Lid Removal .................................................. 3
7.1.4 Loading the Payload into the HalfPACT Package ............................................. 3
7.1.5 Inner Containment Vessel (ICV) Lid Installation .............................................. 3
7.1.6 Outer Confinement Assembly (OCA) Lid Installation ...................................... 4
7.1.7 Final Package Preparations for Transport (Loaded)........................................... 5
7.2 Procedures for Unloading the Package .......................................................................... 7
7.2.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar ........... 7
7.2.2 Outer Confinement Assembly (OCA) Lid Removal .......................................... 7
7.2.3 Inner Containment Vessel (ICV) Lid Removal .................................................. 8
7.2.4 Unloading the Payload from the HalfPACT Package ........................................ 8
7.2.5 Inner Containment Vessel (ICV) Lid Installation .............................................. 8
7.2.6 Outer Confinement Assembly (OCA) Lid Installation ...................................... 9
7.2.7 Final Package Preparations for Transport (Unloaded) ..................................... 10
7.3 Preparation of an Empty Package for Transport .......................................................... 11
7.4 Preshipment Leakage Rate Test ................................................................................... 12
7.4.1 Gas Pressure Rise Leakage Rate Test Acceptance Criteria.............................. 12
7.4.2 Determining the Test Volume and Test Time .................................................. 12
7.4.3 Performing the Gas Pressure Rise Leakage Rate Test ..................................... 12
7.4.4 Preshipment Leakage Rate Test for One-Time Shipment of ICV 506 ............. 12
i
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 TABLE OF REVISIONS Revision Number          Pages Affected                    Revision Description 0                All                                New issue.
1          1, 3, 4, and 12 Revised to clarify footnote references and a few additional minor editorials.
2                  4        Revised to clarify that the O-ring seals shall meet the requirements of HPT-PRO-0003, Section 4.1.1.1.
ii
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
 
==1.0 INTRODUCTION==
 
1.1 Purpose The purpose of this procedure is to support transferring Inner Containment Vessel (ICV) 506, containing Payload SRE033, to a different Outer Confinement Vessel (OCV)/Outer Confinement Assembly (OCA) and preparing the HalfPACT package for a one-time shipment by performing a helium leak test on the OCV.
The OCV shall serve as the containment boundary for this one-time shipment.
 
===1.2 Background===
HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP)
(Shipment SR220010). During the processing of the package, which includes venting and sampling of the ICV headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded because its mandatory 5-year maintenance certification expired on September 1, 2022, such that the unit is out of compliance with Certificate of Compliance (CofC) No. 9279.
In order to return ICV 506 with its payload to SRS, the loaded ICV 506 will be transferred from HalfPACT 506 OCA to a different HalfPACT OCA. Use of an alternate HalfPACT OCA is supported through the application of targeted acceptance tests, maintenance activities, and operating procedures to credit the OCAs OCV as the containment boundary for this one-time shipment.
1.3 Format The format of this document will utilize a format similar to Chapter 7.0, Operating Procedures, of the HalfPACT Safety Analysis Report (SAR) including identical section numbering to facilitate ease of review. Sections that may not be applicable due to the situation of this one-time shipment are noted accordingly. Change bars are included for information that is different than the currently approved HalfPACT SAR, Revision 9, but specific to this one-time shipment authorization.
1
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.0 OPERATING PROCEDURES 7.1 Procedures for Loading the Package This section delineates the procedures for loading a payload into the HalfPACT packaging, and leakage rate testing the outer confinement vessel (OCV). Hereafter, reference to specific HalfPACT packaging components may be found in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
The loading operation shall be performed in a dry environment. In the event of precipitation during outdoor loading operations, precautions, such as covering the OCV cavity shall be implemented to prevent water or precipitation from entering the cavity. If precipitation enters the cavity, the free-standing water shall be removed prior to loading the payload.
Based on the current configuration of the HalfPACT packaging when preparing for loading, begin at the section applicable to the following criteria:
x If the HalfPACT package will be loaded while on the transport trailer or railcar, proceed directly to Section 7.1.2, Outer Confinement Assembly (OCA) Lid Removal.
x If the outer confinement assembly (OCA) lid has already been removed, proceed directly to Section 7.1.3, Inner Containment Vessel (ICV) Lid Removal.
x If the OCA lid has already been removed, proceed directly to Section 7.1.4, Loading the Payload into the HalfPACT Package.
7.1.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar
: 1. Uncover the forklift pockets located at the base of the OCA body.
: 2. Disengage each of the four (4) tie-down devices on the transport trailer or railcar from the corresponding tie-down lugs on the package.
CAUTION: Failure to disengage the tie-down devices may cause damage to the packaging and/or transport trailer/railcar.
: 3. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.
: 4. Lift the package from the transport trailer or railcar and move the package to the loading station.
: 5. Place the package in the loading station and remove the forklift.
7.1.2 Outer Confinement Assembly (OCA) Lid Removal
: 1. If necessary, clean the surfaces around the joint between the OCA lid and body as required.
: 2. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug.
: 3. Remove the OCV vent port access plug, OCV vent port thermal plug, and OCV vent port cover.
: 4. Remove the OCV vent port plug to vent the OCV cavity to ambient atmospheric pressure.
2
 
  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 5. Remove the six 1/2-inch lock bolts (socket head cap screws) from the exterior of the OCA thermal shield.
: 6. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10&#xba; counterclockwise until the exterior alignment mark indicates the unlocked position. If used, disconnect the vacuum system and equalize pressure to the OCV cavity.
: 7. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and remove the OCA lid from the OCA body. Store the OCA lid in a manner such that potential damage to the OCA lids sealing region is minimized.
7.1.3 Inner Containment Vessel (ICV) Lid Removal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, shipped from SRS on August 25, 2022, and received at WIPP on August 26, 2022. Because potential for airborne contamination was identified during the venting of the unit upon receipt at WIPP, ICV 506 was re-sealed for temporary storage and remains sealed.
7.1.4 Loading the Payload into the HalfPACT Package ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. ICV 506 with Payload SRE033 remains sealed. This section describes the procedures for transferring the loaded ICV 506 into an OCV capable of serving as a containment boundary.
HPT-CAL-00011 documents the lifting analysis performed to ensure the as-loaded ICV can be lifted and placed into an alternate OCV. The original fabrication traveler required a load test be performed on the ICV lids with the requirement of 7500 pounds, +1000/-0.
: 1. Connect an appropriate lifting device to ICV 506.
: 2. Balance the ICV to ensure it does not damage the OCV sealing region during the loading operation.
: 3. Lower the ICV into the OCV cavity; disconnect and remove the lifting device.
7.1.5 Inner Containment Vessel (ICV) Lid Installation Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, shipped from SRS on August 25, 2022, and received at WIPP on August 26, 2022. Because potential for airborne contamination was identified during the venting of the unit upon receipt at WIPP, ICV 506 was re-sealed for temporary storage and remains sealed.
1 HPT-CAL-0001, Loaded HalfPACT ICV Lifting Evaluation, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM, February 2023.
3
 
  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.1.6 Outer Confinement Assembly (OCA) Lid Installation
: 1. Visually inspect each of the following OCA components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: a. OCV seal test port plug and the accompanying O-ring seal
: b. OCV vent port cover and the accompanying O-ring seal
: c. Lock bolts
: 2. Ensure the O-ring seals used for this one-time shipment meet the requirements of Section 4.1.1.1, Outer Confinement Assembly (Primary Containment), of HPT-PRO-0003.2
: 3. Visually inspect both OCV main O-ring seals. If necessary, remove the O-ring seal(s) and clean the seal(s) and sealing surface(s) on the OCA lid and body to remove contamination.
If, during the visual examination, it is determined that damage to the O-ring seal(s) and/or sealing surface(s) is sufficient to impair OCV containment integrity, replace the damaged seal(s) and/or repair the damaged sealing surface(s) per Section 8.2.3.3.1, Seal Area Routine Inspection and Repair, of HPT-PRO-00023.
: 4. Visually inspect the O-ring seal on the OCV vent port plug. If necessary, remove the O-ring seal and clean the seal and sealing surfaces on the OCV vent port plug and in the OCV vent port to remove contamination. If, during the visual examination, it is determined that damage to the O-ring seal and/or sealing surface(s) is sufficient to impair OCV containment integrity, replace the damaged seal and/or repair the damaged sealing surface(s) per Section 8.2.3.3.1, Seal Area Routine Inspection and Repair, of HPT-PRO-00023.
: 5. As an option, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the OCV body, OCV seal test port plug, and OCV vent port plug.
: 6. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and install the OCA lid onto the OCA body. Remove the lift fixture.
: 7. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10&#xba; clockwise until the alignment mark indicates the locked position. After rotating the OCV locking ring, disconnect the vacuum system and equalize pressure to the OCV cavity.
: 8. Install the six 1/2-inch lock bolts (socket head cap screws) through the cutouts in the OCA outer thermal shield to secure the OCV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.
2 HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM.
3 HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM.
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  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 9. Leakage rate testing of the OCV main O-ring seal shall be performed based on the following criteria:
: a. Perform preshipment leakage rate testing per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506.
: 10. Install the OCV seal test port plug; tighten to 55 - 65 lb-in torque. Install the OCV seal test port thermal plug and the OCV seal test port access plug; tighten to 28 - 32 lb-ft torque.
: 11. Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.
: 12. Leakage rate testing of the OCV vent port plug O-ring seal shall be performed based on the following criteria:
: a. Perform preshipment leakage rate testing per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506.
: 13. Install the OCV vent port cover; tighten to 55 - 65 lb-in torque.
: 14. Install the OCV vent port thermal plug and the OCV vent port access plug; tighten to 28 - 32 lb-ft torque.
7.1.7 Final Package Preparations for Transport (Loaded)
: 1. Install the two tamper-indicating devices (security seals). One security seal is located at the OCA vent port access plug; the second is located at an OCA lock bolt.
: 2. If the HalfPACT package is not already loaded onto the transport trailer or railcar, perform the following steps:
: a. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.
: b. Lift the loaded HalfPACT package, aligning the packaging over the tie-down points on the transport trailer or railcar.
: c. Secure the loaded HalfPACT package to the transport trailer or railcar using the appropriate tie-down devices.
: d. Load as many as three HalfPACT packages per transport trailer or up to seven HalfPACT packages per railcar.
: e. Install forklift pocket covers over the four forklift pockets located at the base of the OCA body.
: 3. Monitor external radiation for each loaded HalfPACT package per the guidelines of 49 CFR
    &sect;173.441 4. 146F
: 4. Determine that surface contamination levels for each loaded HalfPACT package are per the guidelines of 49 CFR &sect;173.443.
: 5. Determine the shielding Transport Index (TI) for each loaded HalfPACT package per the guidelines of 49 CFR &sect;173.403.
4 Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers-General Requirements for Shipments and Packagings, Current Version.
5
 
  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 6. Complete all necessary shipping papers in accordance with Subpart C of 49 CFR 172 5.                147F 6
: 7. HalfPACT package marking shall be in accordance with 10 CFR &sect;71.85(c) and Subpart D      148F of 49 CFR 172. Package labeling shall be in accordance with Subpart E of 49 CFR 172.
Package placarding shall be in accordance with Subpart F of 49 CFR 172.
5 Title 49, Code of Federal Regulations, Part 172 (49 CFR 172), Hazardous Materials Tables and Hazardous Communications Regulations, Current Version.
6 Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.
6
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.2 Procedures for Unloading the Package This section delineates the procedures for unloading a payload from the HalfPACT packaging.
Hereafter, reference to specific HalfPACT packaging components may be found in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
The unloading operation shall be performed in a dry environment. In the event of precipitation during outdoor unloading operations, precautions, such as covering the outer confinement vessel (OCV) and inner containment vessel (ICV) cavities shall be implemented to prevent water or precipitation from entering the cavities. If precipitation enters the cavities, the free-standing water shall be removed prior to installing the lids.
x If the HalfPACT package will be unloaded while on the transport trailer or railcar, proceed directly to Section 7.2.2, Outer Confinement Assembly (OCA) Lid Removal.
7.2.1 Removal of the HalfPACT Package from the Transport Trailer/Railcar
: 1. Uncover the forklift pockets located at the base of the OCA body.
: 2. Disengage each of the four (4) tie-down devices on the transport trailer or railcar from the corresponding tie-down lugs on the package.
CAUTION: Failure to disengage the tie-down devices may cause damage to the packaging and/or transport trailer/railcar.
: 3. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.
: 4. Lift the package from the transport trailer or railcar and move the package to the loading station.
: 5. Place the package in the loading station and remove the forklift.
7.2.2 Outer Confinement Assembly (OCA) Lid Removal
: 1. If necessary, clean the surfaces around the joint between the OCA lid and body as required.
: 2. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug.
: 3. Remove the OCV vent port access plug, OCV vent port thermal plug, and OCV vent port cover.
: 4. Remove the OCV vent port plug to vent the OCV cavity to ambient atmospheric pressure.
: 5. Remove the six 1/2-inch lock bolts (socket head cap screws) from the exterior of the OCA thermal shield.
: 6. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10&#xba; counterclockwise until the exterior alignment mark indicates the unlocked position. If used, disconnect the vacuum system and equalize pressure to the OCV cavity.
7
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 7. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and remove the OCA lid from the OCA body. Store the OCA lid in a manner such that potential damage to the OCA lids sealing region is minimized.
7.2.3 Inner Containment Vessel (ICV) Lid Removal
: 1. Remove the ICV vent port cover, the ICV outer vent port plug, and ICV inner vent port plug to vent the ICV cavity to ambient atmospheric pressure.
: 2. Remove the ICV seal test port plug.
: 3. Remove the three 1/2-inch lock bolts (socket head cap screws) from the exterior of the ICV locking ring.
: 4. Install a vacuum pump to the ICV vent port and evacuate the ICV cavity sufficiently to allow the ICV locking ring to freely rotate. Rotate the ICV locking ring approximately 10&#xba; counterclockwise until the alignment mark indicates the unlocked position. Disconnect the vacuum system and equalize pressure to the ICV cavity.
: 5. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the ICV lid. Engage the lift fixture and remove the ICV lid from the ICV body. Store the ICV lid in a manner such that potential damage to the ICV lids sealing region and ICV upper aluminum honeycomb spacer assembly is minimized.
7.2.4 Unloading the Payload from the HalfPACT Package
: 1. Connect an appropriate lifting device to the payload assembly.
: 2. Balance the payload assembly sufficiently to ensure the payload does not damage either the ICV or the OCV sealing regions during the unloading operation.
: 3. Remove the payload assembly from the ICV cavity; disconnect and remove the lifting device.
7.2.5 Inner Containment Vessel (ICV) Lid Installation
: 1. Visually inspect each of the following ICV components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: a. ICV debris shield
: b. ICV wiper O-ring seal and wiper O-ring holder
: c. ICV main O-ring seals and sealing surfaces
: d. ICV seal test port plug and accompanying O-ring seal
: e. ICV inner and outer vent port plugs and accompanying O-ring seals
: f. ICV vent port cover and accompanying seal (O-ring or gasket)
: g. Lock bolts 8
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 2. As an option, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the ICV body, ICV seal test port and vent port plugs.
: 3. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the ICV lid. Engage the lift fixture and install the ICV lid onto the ICV body. Remove the lift fixture.
: 4. Install a vacuum pump to the ICV vent port and evacuate the ICV cavity sufficiently to allow the ICV locking ring to freely rotate. Rotate the ICV locking ring approximately 10&#xba; clockwise until the alignment mark indicates the locked position. After rotating the ICV locking ring, disconnect the vacuum system and equalize pressure to the ICV cavity.
: 5. Install the three 1/2-inch lock bolts (socket head cap screws) through the cutouts in the ICV locking ring to secure the ICV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.
: 6. Install the ICV seal test port plug; tighten to 55 - 65 lb-in torque.
: 7. Install the ICV inner and outer vent port plugs, followed by the ICV vent port cover; tighten each to 55 - 65 lb-in torque.
7.2.6 Outer Confinement Assembly (OCA) Lid Installation
: 1. Visually inspect each of the following OCA components for wear or damage that could impair their function and, if necessary, replace or repair per the requirements of the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: a. OCV main O-ring seals, if used, and sealing surfaces
: b. OCV seal test port plug and, if used, the accompanying O-ring seal
: c. OCV vent port plug and, if used, the accompanying O-ring seal
: d. OCV vent port cover and, if used, the accompanying O-ring seal
: e. Lock bolts
: 2. As an option and if O-ring seals are used, sparingly apply vacuum grease to the O-ring seals and install into the appropriate O-ring seal grooves in the OCV body, OCV seal test port and vent port plugs.
: 3. Rig an overhead crane, or equivalent, with an appropriate lift fixture capable of handling the OCA lid. Engage the lift fixture and install the OCA lid onto the OCA body. Remove the lift fixture.
: 4. Optionally install a vacuum pump to the OCV vent port and evacuate the OCV cavity sufficiently to allow the OCV locking ring to freely rotate. Rotate the OCV locking ring approximately 10&#xba; clockwise until the alignment mark indicates the locked position. After rotating the OCV locking ring, disconnect the vacuum system and equalize pressure to the OCV cavity.
: 5. Install the six 1/2-inch lock bolts (socket head cap screws) through the cutouts in the OCA outer thermal shield to secure the OCV locking ring in the locked position. Tighten the lock bolts to 28 - 32 lb-ft torque, lubricated.
9
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
: 6. Install the OCV seal test port plug; tighten to 55 - 65 lb-in torque. Install the OCV seal test port thermal plug and the OCV seal test port access plug; tighten to 28 - 32 lb-ft torque.
: 7. Install the OCV vent port plug and OCV vent port cover; tighten each to 55 - 65 lb-in torque.
Install the OCV vent port thermal plug and the OCV vent port access plug; tighten to 28 - 32 lb-ft torque.
7.2.7 Final Package Preparations for Transport (Unloaded)
: 1. If the HalfPACT package is not already loaded onto the transport trailer or railcar, perform the following steps:
: a. Using a forklift of appropriate size, position the forklifts forks inside the forklift pockets.
: b. Lift the HalfPACT package, aligning the packaging over the tie-down points on the transport trailer or railcar.
: c. Secure the HalfPACT package to the transport trailer or railcar using the appropriate tie-down devices.
: d. Load as many as three HalfPACT packages per transport trailer or up to seven HalfPACT packages per railcar.
: e. Install forklift pocket covers over the four forklift pockets located at the base of the OCA body.
: 2. Transport the HalfPACT package in accordance with Section 7.3, Preparation of an Empty Package for Transport.
10
 
  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.3 Preparation of an Empty Package for Transport Previously used and empty HalfPACT packagings shall be prepared and transported per the requirements of 49 CFR &sect;173.428 1.      149F 1
Title 49, Code of Federal Regulations, Part 173 (49 CFR 173), Shippers-General Requirements for Shipments and Packagings, Current Version.
11
 
  ~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.4 Preshipment Leakage Rate Test After the HalfPACT package is assembled and prior to shipment, leakage rate testing shall be performed to confirm proper assembly of the package following the guidelines of Section 7.6, Preshipment Leakage Rate Test, and Appendix A.5.2, Gas Pressure Rise, of ANSI N14.51.          150F The leak test for this one-time shipment shall confirm the OCV can serve as the containment boundary.
7.4.1 Gas Pressure Rise Leakage Rate Test Acceptance Criteria Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required.
7.4.2 Determining the Test Volume and Test Time Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required.
7.4.3 Performing the Gas Pressure Rise Leakage Rate Test Section not applicable. A helium leak test per Section 7.4.4, Preshipment Leakage Rate Test for One-Time Shipment of ICV 506, is required .
7.4.4 Preshipment Leakage Rate Test for One-Time Shipment of ICV 506 Section 8.2.2, Maintenance/Periodic Leakage Rate Tests, of HPT-PRO-00022, shall be performed on the OCV. Section 7.4.4.1, Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity, and Section 7.4.4.2, Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity, provide the requirements from Section 8.1.3.6, Helium Leakage Rate Testing the OCV Main O-ring Seal integrity, and Section 8.1.3.7, Helium Leakage Rate Testing of the OCV Vent Port Plug O-ring Seal Integrity, of HPT-PRO-00023, for preshipment leak testing required for this one-time
shipment.
7.4.4.1 Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity
: 1. The fabrication leakage rate test of the OCV main O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.
: 2. The OCA shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
1 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).
2 HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors LLC, Carlsbad, NM.
12
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023
 Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and
OCV vent port plug.
 Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum
or better (i.e., d10% ambient atmospheric pressure).
 Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal
test port plug, and install a helium mass spectrometer leak detector to the OCV seal test port.
Evacuate through the OCV seal test port until the vacuum is sufficient to operate the helium
mass spectrometer leak detector.
 Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a
pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).
 Perform the helium leakage rate test to the requirements of Section 7.4.4.3, Fabrication
Leakage Rate Test Acceptance Criteria, below. If, after repeated attempts, the OCV main 2ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the
leak path and repeating the leakage rate test, record on a nonconformance report and
disposition prior to final acceptance in accordance with the cognizant quality assurance
program.
7.4.4.2 Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity
 The fabrication leakage rate test of the OCV vent port plug O-ring seal shall be performed
following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI
N14.5.
 The OCV shall be assembled with both main O-ring seals installed into the OCV lower seal
flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings,
of the HalfPACT SAR.
 Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and
OCV vent port plug.
 Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum
or better (i.e., d10% ambient atmospheric pressure).
 Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a
pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).
 Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.
 Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the
OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak
detector.
 Perform the helium leakage rate test to the requirements of Section 7.4.4.3, Fabrication
Leakage Rate Test Acceptance Criteria, below. If, after repeated attempts, the OCV vent port
plug O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the
leak path and repeating the leakage rate test, record on a nonconformance report and disposition
prior to final acceptance in accordance with the cognizant quality assurance program.
13
 
~I~I[gm Mining Contractors HPT-PRO-0001, Rev. 2 April 2023 7.4.4.3        Fabrication Leakage Rate Test Acceptance Criteria
: 1. To be acceptable, each leakage rate test shall demonstrate a leaktight leakage rate of 1 x 10-7 reference cubic centimeters per second (scc/s), air, or less, per Section 6.3, Application of Referenced Air Leakage Rate (LR), of ANSI N14.5.
: 2. In order to demonstrate a leaktight leakage rate, the sensitivity of the leakage rate test procedure shall be 5 x 10-8 scc/s, air, or less, per Section 8.4, Sensitivity, of ANSI N14.5.
14
 
Attachment F HPT-PRO-0002, Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506, Revision 2
 
Acceptance Tests and Maintenance Program for One-Time Shipment Supporting ICV 506 Prepared by:
Mining Contractors Prepared for:
U.S. DEPARTMENT OF ENERGY SIMCO Transportation Packaging Group Document Number:
HPT-PRO-0002, Rev. 2 April 2023 Digitally signed by ROBERT Document Preparer      R. S. Burns                ~                      BURNS (Affiliate)
Date: 2023.04.18 08:44:45 -06'00' Signature                                  Date Digitally signed by STEVEN PORTER STEVEN PORTER (Affiliate)  (Affiliate)
S. A. Porter                                Date: 2023.04.18 09:33:13 -07'00' Independent Reviewer Signature                                    Date Digitally signed by TODD SELLMER TODD SELLMER (Affiliate)  (Affiliate)
Cognizant Manager      T. E. Sellmer                              Date: 2023.04.18 12:43:54 -06'00' Signature                                    Date Quality Assurance    D. S. Tanner David S. Tanner Digitally              signed by David S. Tanner Date: 2023.04.18 11:09:40 -06'00' Signature                                    Date
 
This page intentionally left blank to facilitate duplex printing HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                                            April 2023 TABLE OF CONTENTS 1.0 INTRODUCTION ................................................................................................................. 1
1.1 Purpose ........................................................................................................................... 1
1.2 Background .................................................................................................................... 1
1.3 Format ............................................................................................................................ 1
8.0 ACCEPTANCE TESTS AND MAINTENANCE PROGRAM ........................................ 2
8.1 Acceptance Tests ............................................................................................................ 2
8.1.1 Visual Inspection ................................................................................................ 2
8.1.2 Structural and Pressure Tests ............................................................................. 2
8.1.3 Fabrication Leakage Rate Tests ......................................................................... 3
8.1.4 Component Tests ................................................................................................ 6
8.1.5 Tests for Shielding Integrity ............................................................................. 19
8.1.6 Thermal Acceptance Test ................................................................................. 20
8.2 Maintenance Program................................................................................................... 21
8.2.1 Structural and Pressure Tests ........................................................................... 21
8.2.2 Maintenance/Periodic Leakage Rate Tests....................................................... 21
8.2.3 Subsystems Maintenance ................................................................................. 22
8.2.4 Valves, Rupture Discs, and Gaskets ................................................................. 25
8.2.5 Shielding ........................................................................................................... 25
8.2.6 Thermal ............................................................................................................ 25
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                      April 2023 TABLE OF REVISIONS Revision Number          Pages Affected                      Revision Description 0                All                                  New issue.
1        1, 3, 4, 19, 20, 21 Revised to clarify leakage rate testing on the OCV in Section 8.2.1.1 and a few additional minor editorials.
2                3, 25        Revised to clarify that the O-ring seals shall meet the requirements of HPT-PRO-0003, Section 4.1.1.1.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                    April 2023
 
==1.0 INTRODUCTION==
 
1.1 Purpose The purpose of this document is to discuss the acceptance tests and maintenance program required to be implemented on the HalfPACT packaging prior to the one-time shipment supporting ICV 506.
 
===1.2 Background===
HalfPACT 506 with Payload SRE033 was sent from the Savannah River Site (SRS) on August 25, 2022, and received on August 26, 2022, at the Waste Isolation Pilot Plant (WIPP)
(Shipment SR220010). During the processing of the package, which includes venting and sampling of the inner containment vessel (ICV) headspace prior to ICV lid removal, internal airborne plutonium-238 and americium-241 contamination was detected. WIPP safety protocol prevents opening the potentially contaminated ICV and dictates its return to SRS for investigation into the possible contamination source. The ability to return HalfPACT 506 is currently precluded because its mandatory 5-year maintenance certification expired on September 1, 2022 such that the unit is out of compliance with Certificate of Compliance (CofC)
No. 9279.
In order to return ICV 506 with its payload to SRS, the loaded ICV 506 will be transferred from HalfPACT 506 OCA to a different HalfPACT OCA. Use of an alternate HalfPACT OCA is supported through the application of targeted acceptance tests, maintenance activities, and operating procedures to credit the OCAs OCV as the containment boundary for this one-time shipment.
1.3 Format The format of this document will utilize a format similar to Chapter 8.0, Acceptance Tests and Maintenance Program, of the HalfPACT Safety Analysis Report (SAR), including section numbers, to facilitate ease of review. Sections that may not be applicable due to the situation of this one-time shipment are noted accordingly. Change bars are included for information that is different than the currently approved HalfPACT SAR, Revision 9, but specific to this one-time shipment authorization.
1
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                April 2023 8.0 ACCEPTANCE TESTS AND MAINTENANCE PROGRAM 8.1 Acceptance Tests Per the requirements of 10 CFR &sect;71.85 1, this section discusses the inspections and tests to be 15F performed on the HalfPACT packaging prior to the one-time shipment supporting ICV 506.
8.1.1 Visual Inspection All HalfPACT packaging materials of construction and welds shall be examined in accordance with requirements delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR, per the requirements of 10 CFR &sect;71.85(a).
Furthermore, the inspections and tests of Section 8.2.3.3, Seal Areas and Grooves, shall be performed prior to pressure and leakage rate testing.
8.1.2 Structural and Pressure Tests 8.1.2.1 Lifting Device Load Testing The bounding design load of the outer confinement assembly (OCA) lid lifting devices is 7,500 pounds total, or 2,500 pounds per lifting point. Load test each set of OCA lid lifting devices to 150% of their bounding design load, 11,250 pounds total, or 3,750 pounds per lifting point.
Perform load testing of the OCA lid lifting devices prior to polyurethane foam installation.
Following OCA load testing, all accessible base material and welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to OCA load testing shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code, Section V 2, Article 6, and ASME Boiler and Pressure Vessel 152F Code, Section III 3, Division 1, Subsection NF, Article NF-5000. Indications of cracking or 153F distortion shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.
The bounding design load of the inner containment vessel (ICV) lifting sockets is 5,000 pounds total, or 1,667 pounds per lifting socket. Load test each set of ICV lifting sockets to 150% of their bounding design load, 7,500 pounds total, or 2,500 pounds per lifting socket.
Following ICV load testing, all accessible base material and welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to ICV load testing shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code, Section V2, Article 6, and ASME Boiler and Pressure Vessel Code, Section III3, Division 1, Subsection NB, Article NB-5000. Indications of cracking or distortion 1
Title 10, Code of Federal Regulations, Part 71 (10 CFR 71), Packaging and Transportation of Radioactive Material, 01-01-19 Edition.
2 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section V, Nondestructive Examination, 1995 Edition, 1997 Addenda.
3 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Rules for Construction of Nuclear Power Plant Components, 1995 Edition, 1997 Addenda.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                            April 2023 shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.
8.1.2.2 Pressure Testing The outer confinement vessel (OCV) shall be pressure tested to 150% of the maximum normal operating pressure (MNOP) to verify structural integrity. The MNOP of the OCV is equal to the 50 psig design pressure. Thus, the OCV shall be pressure tested to 50 x 1.5 = 75 psig.
Following OCV pressure testing, all accessible welds and adjacent base metal (minimum 1/2 inch on each side of the weld) directly related to the pressure testing of the OCV shall be visually inspected for plastic deformation or cracking, and liquid penetrant inspected per ASME Boiler and Pressure Vessel Code, Section V, Article 6, and ASME Boiler and Pressure Vessel Code, Section III, Division 1, Subsection NF, Article NF-5000, as delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR. Indications of cracking or distortion shall be recorded on a nonconformance report and dispositioned prior to final acceptance in accordance with the cognizant quality assurance program.
Leakage rate testing per Section 8.1.3, Fabrication Leakage Rate Tests, shall be performed on the OCV after completion of pressure testing to verify package configuration and performance to design criteria.
8.1.3 Fabrication Leakage Rate Tests This section provides the generalized procedure for fabrication leakage rate testing of the containment vessel boundary and penetrations following the completion of fabrication.
Fabrication leakage rate testing shall follow the guidelines of Section 7.3, Fabrication Leakage Rate Test, of ANSI N14.5 4. 154F Prior to leakage rate testing, internal components such as the payload and spacer pallets, ICV aluminum honeycomb spacer assemblies, etc., shall be removed. For ease of leakage rate testing, each vessel should be thoroughly cleaned.
Fabrication leakage rate testing shall be performed on the OCV. Three separate tests comprise the series of tests on the OCV. Each test shall meet the acceptance criteria delineated in Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria.
The O-ring seals used during these maintenance activities to support this one-time shipment shall meet the requirements of Section 4.1.1.1, Outer Confinement Assembly (Primary Containment),
of HPT-PRO-0003.5 8.1.3.1 Fabrication Leakage Rate Test Acceptance Criteria
: 1. To be acceptable, each leakage rate test shall demonstrate a leaktight leakage rate of 1 x 10-7 reference cubic centimeters per second (scc/s), air, or less, per Section 6.3, Application of Referenced Air Leakage Rate (LR), of ANSI N14.5.
4 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).
5 HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors, Carlsbad, NM.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                          April 2023
: 2. In order to demonstrate a leaktight leakage rate, the sensitivity of the leakage rate test procedure shall be 5 x 10-8 scc/s, air, or less, per Section 8.4, Sensitivity, of ANSI N14.5.
8.1.3.2 Helium Leakage Rate Testing the ICV Structure Integrity Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.
8.1.3.3 Helium Leakage Rate Testing the ICV Main O-ring Seal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.
8.1.3.4 Helium Leakage Rate Testing the ICV Outer Vent Port Plug O-ring Seal Section not applicable. ICV 506 was loaded with Payload SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.
8.1.3.5 Helium Leakage Rate Testing the OCV Structure Integrity
: 1. The fabrication leakage rate test of the OCV structure shall be performed following the guidelines of Section A.5.3, Gas Filled Envelope - Gas Detector, of ANSI N14.5.
: 2. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.
: 3. Install the OCV lid with both main O-ring seals installed into the OCV lower seal flange. As an option, an assembled ICV may be placed within the OCV cavity for volume reduction.
Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: 4. Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.
: 5. Surround the assembled OCV with an envelope filled with helium.
: 6. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV structure fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.
8.1.3.6 Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity
: 1. The fabrication leakage rate test of the OCV main O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                April 2023
: 2. The OCA shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: 3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.
: 4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).
: 5. Remove the OCV seal test port access plug, OCV seal test port thermal plug, and OCV seal test port plug and install a helium mass spectrometer leak detector to the OCV seal test port.
Evacuate through the OCV seal test port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.
: 6. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).
: 7. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV main O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.
8.1.3.7 Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity
: 1. The fabrication leakage rate test of the OCV vent port plug O-ring seal shall be performed following the guidelines of Section A.5.4, Evacuated Envelope - Gas Detector, of ANSI N14.5.
: 2. The OCV shall be assembled with both main O-ring seals installed into the OCV lower seal flange. Assembly is as shown in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR.
: 3. Remove the OCV vent port access plug, OCV vent port thermal plug, OCV vent port cover, and OCV vent port plug.
: 4. Connect a vacuum pump to the OCV vent port and evacuate the OCV cavity to 90% vacuum or better (i.e., d10% ambient atmospheric pressure).
: 5. Provide a helium atmosphere inside the OCV cavity by backfilling with helium gas to a pressure slightly greater than atmospheric pressure (+1 psi, -0 psi).
: 6. Install the OCV vent port plug; tighten to 55 - 65 lb-in torque.
: 7. Install a helium mass spectrometer leak detector to the OCV vent port. Evacuate through the OCV vent port until the vacuum is sufficient to operate the helium mass spectrometer leak detector.
: 8. Perform the helium leakage rate test to the requirements of Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria. If, after repeated attempts, the OCV vent port plug O-ring seal fails to pass the leakage rate test, isolate the leak path and, prior to repairing the leak path and 5
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                    April 2023 repeating the leakage rate test, record on a nonconformance report and disposition prior to final acceptance in accordance with the cognizant quality assurance program.
8.1.4 Component Tests 8.1.4.1 Polyurethane Foam This section establishes the requirements and acceptance criteria for installation, inspection, and testing of rigid, closed-cell, polyurethane foam utilized within the HalfPACT packaging.
8.1.4.1.1 Introduction and General Requirements The polyurethane foam used within the HalfPACT packaging is comprised of a specific formulation of foam constituents that, when properly apportioned, mixed, and reacted, produce a polyurethane foam material with physical characteristics consistent with the requirements given in this section. In practice, the chemical constituents are batched into multiple parts (e.g.,
parts A and B) for later mixing in accordance with a formulation. Therefore, a foam batch is considered to be a specific grouping and apportionment of chemical constituents into separate and controlled vats or bins for each foam formulation part. Portions from each batch part are combined in accordance with the foam formulation requirements to produce the liquid foam material for pouring into a component. Thus, a foam pour is defined as apportioning and mixing the batch parts into a desired quantity for subsequent installation (pouring).
The following sections describe the general requirements for chemical composition, constituent storage, foamed component preparation, foam material installation, and foam pour and test data records.
8.1.4.1.1.1 Polyurethane Foam Chemical Composition The foam supplier shall certify that the chemical composition of the polyurethane foam is as delineated below, with the chemical component weight percents falling within the specified ranges. In addition, the foam supplier shall certify that the finished (cured) polyurethane foam does not contain halogen-type flame retardants or trichloromonofluoromethane (Freon 11).
Carbon ....................... 50% - 70%          Phosphorus .................... 0% - 2%
Oxygen ...................... 14% - 34%          Silicon ................................. < 1%
Nitrogen ...................... 4% - 12%          Chlorine............................... < 1%
Hydrogen..................... 4% - 10%            Other ................................... < 1%
8.1.4.1.1.2 Polyurethane Foam Constituent Storage The foam supplier shall certify that the polyurethane foam constituents have been properly stored prior to use, and that the polyurethane foam constituents have been used within their shelf life.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                              April 2023 8.1.4.1.1.3 Foamed Component Preparation Prior to polyurethane foam installation, the foam supplier shall visually verify to the extent possible (i.e., looking through the foam fill ports) that the ceramic fiber insulation is still attached to the component shell interior surfaces. In addition, due to the internal pressures generated during the foam pouring/curing process, the foam supplier shall visually verify that adequate bracing/shoring of the component shells is provided to maintain the dimensional configuration throughout the foam pouring/curing process.
8.1.4.1.1.4 Polyurethane Foam Installation As illustrated in the accompanying illustration, OCA LID OUTER FOAM FILL PORT the direction of foam rise shall be vertically                CENTER FOAM FILL PORT (TYP. 4 PLCS) aligned with the shell component axis.
FOAM RISE The surrounding walls of the component shell                                              DI RECTION where the liquid foam material is to be installed shall be between 55 &#xba;F and 95 &#xba;F prior to foam installation. Measure and record the component shell temperature to an accuracy of +/-2 &#xba;F prior to foam installation.
In the case of multiple pours into a single I                                                                  I foamed component, the cured level of each pour shall be measured and recorded to an accuracy                                      OCA BODY of +/-1 inch.
Measure and record the weight of liquid foam material installed during each pour to an accuracy of +/-10 pounds.
All test samples shall be poured into disposable containers at the same time as the actual pour it represents, clearly marking the test sample container with the pour date and a unique pour identification number. All test samples shall be cut from a larger block to obtain freshly cut faces. Prior to physical testing, each test sample shall be cleaned of superfluous foam dust.
8.1.4.1.1.5 Polyurethane Foam Pour and Test Data Records A production pour and testing record shall be compiled by the foam supplier during the foam pouring operation and subsequent physical testing. Upon completion of production and testing, the foam supplier shall issue certification referencing the production record data and test data pertaining to each foamed component. At a minimum, relevant pour and test data shall include:
x  formulation, batch, and pour numbers, with foam material traceability, and pour date, x  foamed component description, part number, and serial number, x  instrumentation description, serial number, and calibration due date, 7
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                      April 2023 x  pour and test data (e.g., date, temperature, dimensional, and/or weight measurements, compressive modulus, thermal conductivity, compressive stress, etc., as applicable), and x  technician and Quality Assurance/Quality Control (QA/QC) sign-off.
8.1.4.1.2 Physical Characteristics The following subsections define the required physical characteristics of the polyurethane foam material used for the HalfPACT packaging design.
Testing for the various polyurethane foam physical characteristics is based on a formulation, batch, or pour, as appropriate, as defined in Section 8.1.4.1.1, Introduction and General Requirements. The physical characteristics determined for a specific foam formulation are relatively insensitive to small variations in chemical constituents and/or environmental conditions, and therefore include physical testing for compressive modulus, Poissons ratio, thermal expansion coefficient, thermal conductivity, and specific heat. Similarly, the physical characteristics determined for a batch are only slightly sensitive to small changes in formulation and/or environmental conditions during batch mixing, and therefore include physical testing for flame retardancy, intumescence, and leachable chlorides. Finally, the physical characteristics determined for a pour are also only slightly sensitive to small changes in formulation and slightly more sensitive to variations in environmental conditions during pour mixing, and therefore include physical testing for density and compressive stress.
8.1.4.1.2.1 Physical Characteristics Determined for a Foam Formulation Foam material physical characteristics for the following parameters shall be determined once for a particular foam formulation. If multiple components are to be foamed utilizing a specific foam formulation, then additional physical testing, as defined below, need not be performed.
8.1.4.1.2.1.1 Parallel-to-Rise Compressive Modulus
: 1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be in the parallel-to-rise direction.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.
: 4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).
: 5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                                                  April 2023
: 6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until the compressive stress somewhat exceeds the elastic range of the foam material (i.e., the elastic range is typically Linear  Yield Region  Region 0% - 6% strain). Plot the compressive stress versus          300 strain for each test sample.
: 7. Determine and record the parallel-to-rise compressive                                    250
                                                                                                                                              /
                                                                                                                                                  ,~
I--.
modulus, E, of each test sample by computing the slope                                                                                I                                ,.__
I in the linear region of the elastic range of the stress-strain curve, where Hi and Hj, and Vi and Vj are the strain                              200 I
l -llD--llD-
                                                                                                  ~          -
and compressive stress at two selected points i and j, Compressive Stress (psi)
Vj respectively, in the linear region of the stress-strain                                  150 curve (see example curve to right) as follows:
ill--UD--llD-
                                                                                                  ~          -
V j  Vi                                                                                              V j  Vi E              , psi                                                100 i
H j  Hi
: 8. Determine and record the average parallel-to-rise compressive modulus of the three test samples. The 50 Vi    ~
I l
                                                                                                              ~~
t f
l I
I
                                                                                                                          ~-.l H j  Hi numerically averaged, parallel-to-rise compressive                                                I V
modulus of the three test samples shall be 6,810 psi                                      0 0
Hi            Hj              5    Strain (%)          10          15
  +/-20% (i.e., within the range of 5,448 to 8,172 psi).
9
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                                                          April 2023 8.1.4.1.2.1.2        Perpendicular-to-Rise Compressive Modulus
: 1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be in the perpendicular-to-rise direction.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.
: 4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).
: 5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.
: 6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until the compressive stress somewhat exceeds the elastic range of the foam material (i.e., the elastic range is typically 0% - 6% strain). Plot the compressive stress versus strain for each test sample.
Linear Yield Region            Region mr
: 7. Determine and record the perpendicular-to-rise                                          300 compressive modulus, E, of each test sample by computing the slope in the linear region of the elastic range of the stress-strain curve, where Hi and Hj, and Vi 250                mt and Vj are the strain and compressive stress at two selected points i and j, respectively, in the linear region                              200
                                                                                                                /IIIT      ii I
I                        L I I  I
                                                                                                            -Ji--llD--llD-of the stress-strain curve (see example curve to right) as                                              -
Compressive Stress (psi) follows:                                                                                Vj V j  Vi                                                      150 E
H j  Hi
                                        , psi
: 8. Determine and record the average perpendicular-to-rise 100 L;      V j  Vi
                                                                                                                                        ]_D--llD-compressive modulus of the three test samples. The numerically averaged, perpendicular-to-rise compressive modulus of the three test samples shall be 4,773 psi 50 Vi in=## ##
                                                                                                  ~
I
                                                                                                          ~__J__-.l H j  Hi
  +/-20% (i.e., within the range of 3,818 to 5,728 psi).                                                I 0
V 0
Hi        Hj                5                10              15 Strain (%)
10
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                            April 2023 8.1.4.1.2.1.3      Poissons Ratio
: 1. Three (3) test samples shall be taken from the sample pour.
Each test sample shall be a rectangular prism with nominal dimensions of 2.0 inches thick (T) u 2.0 inches wide (W)                    COM PRESSIVE LOADING u 2.0 inches long (L). The thickness dimension shall be in                  DIRECTION the parallel-to-rise direction.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.
: 4. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.
: 5. As illustrated below, place two orthogonally oriented dial indicators at the mid-plane of one width face and one length face of the test sample to record the lateral deflections. The dial indicators shall be capable of measuring to an accuracy of +/-0.001 inches.
: 6. Apply a compressive load to each test sample so that the strain remains within the elastic range of the material, as determined in Section 8.1.4.1.2.1.1, Parallel-to-Rise Compressive Modulus. Record the axial crosshead displacement (GT) and both dial indicator displacements (GW and GL) at one strain point within the elastic range for each test sample.
COMPRESSIVE LOAD TEST SAMPLE
: 7. Determine and record Poissons ratio of each test sample as follows:
GW I W  GL I L P
GT I T 11
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                          April 2023
: 8. Determine and record the average Poissons ratio of the three test samples. The numerically averaged Poissons ratio of the three test samples shall be 0.33 +/-20% (i.e., within the range of 0.26 to 0.40).
8.1.4.1.2.1.4 Thermal Expansion Coefficient
: 1. Three (3) test samples shall be taken from the sample pour. Each test sample shall be a rectangular prism with a nominal cross-section of 1.0 inch square and a nominal length of 6.0 inches.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature (TRT) to an accuracy of r2 &#xba;F.
: 3. Measure and record the room temperature length (LRT) of each test sample to an accuracy of
    +/-0.001 inches.
: 4. Place the test samples in a -40 &#xba;F to -60 &#xba;F cold environment for a minimum of three hours.
Measure and record the cold environment temperature (TC) to an accuracy of r2 &#xba;F.
: 5. Measure and record the cold environment length (LC) of each test sample to an accuracy of
    +/-0.001 inches.
: 6. Determine and record the cold environment thermal expansion coefficient for each test sample as follows:
LC  LRT DC                    , in/in/o F LRT TC  TRT
: 7. Place the test samples in a 180 &#xba;F to 200 &#xba;F hot environment for a minimum of three hours.
Measure and record the hot environment temperature (TH) to an accuracy of r2 &#xba;F.
: 8. Measure and record the hot environment length (LH) of each test sample to an accuracy of
    +/-0.001 inches.
: 9. Determine and record the hot environment thermal expansion coefficient for each test sample as follows:
LH  LRT DH                    , in/in/o F LRT TH  TRT
: 10. Determine and record the average thermal expansion coefficient of each test sample as follows:
DC  D H D            , in/in/ o F 2
: 11. Determine and record the average thermal expansion coefficient of the three test samples. The numerically averaged thermal expansion coefficient of the three test samples shall be 3.5 x 10-5 in/in/&#xba;F +/-20% (i.e., within the range of 2.8 x 10-5 to 4.2 x 10-5 in/in/&#xba;F).
8.1.4.1.2.1.5 Thermal Conductivity
: 1. The thermal conductivity test shall be performed using a heat flux meter (HFM) apparatus.
The HFM establishes steady state unidirectional heat flux through a test specimen between 12
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                              April 2023 two parallel plates at constant but different temperatures. By measurement of the plate temperatures and plate separation, Fouriers law of heat conduction is used by the HFM to automatically calculate thermal conductivity. Description of a typical HFM is provided in ASTM C518 6. The HFM shall be calibrated against a traceable reference specimen per the 15F HFM manufacturer's operating instructions.
: 2. Three (3) test samples shall be taken from the sample pour. Each test sample shall be of sufficient size to enable testing per the HFM manufacturer's operating instructions.
: 3. Measure and record the necessary test sample parameters as input data to the HFM per the HFM manufacturer's operating instructions.
: 4. Perform thermal conductivity testing and record the measured thermal conductivity for each test sample following the HFM manufacturer's operating instructions.
: 5. Determine and record the average thermal conductivity of the three test samples. The numerically averaged thermal conductivity of the three test samples shall be 0.230 Btu-in/hr-ft2-&#xba;F +/-20% (i.e., within the range of 0.184 to 0.276 Btu-in/hr-ft2-&#xba;F).
8.1.4.1.2.1.6 Specific Heat
: 1. The specific heat test shall be performed using a differential scanning calorimeter (DSC) apparatus. The DSC establishes a constant heating rate and measures the differential heat flow into both a test specimen and a reference specimen. Description of a typical DSC is provided in ASTM E1269 7. The DSC shall be calibrated against a traceable reference 156F specimen per the DSC manufacturer's operating instructions.
: 2. Three (3) test samples shall be taken from the sample pour. Each test sample shall be of sufficient size to enable testing per the DSC manufacturer's operating instructions.
: 3. Measure and record the necessary test sample parameters as input data to the DSC per the DSC manufacturer's operating instructions.
: 4. Perform specific heat testing and record the measured specific heat for each test sample following the DSC manufacturer's operating instructions.
: 5. Determine and record the average specific heat of the three test specimens. The numerically averaged specific heat at 77 &#xba;F of the three test samples shall be 0.30 Btu/lb-&#xba;F +/-20% (i.e.,
within the range of 0.24 to 0.36 Btu/lb-&#xba;F).
8.1.4.1.2.2 Physical Characteristics Determined for a Foam Batch Foam material physical characteristics for the following parameters shall be determined once for a particular foam batch based on the batch definition from Section 8.1.4.1.1, Introduction and General Requirements. If a single or multiple components are to be poured utilizing multiple pours from a single foam batch, then additional physical testing, as defined below, need not be performed for each foam pour.
6 ASTM C518, Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flux Meter Apparatus, American Society of Testing and Materials (ASTM).
7 ASTM E1269, Standard Test Method for Determining Specific Heat Capacity by Differential Scanning Calorimetry, American Society of Testing and Materials (ASTM).
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                          April 2023 8.1.4.1.2.2.1 Flame Retardancy
: 1. Three (3) test samples shall be taken from a pour from each foam batch. Each test sample shall be a rectangular prism with nominal dimensions of 0.5 inches thick, 3.0 inches wide, and a minimum length of 6.0 inches. In addition, individual sample lengths must not be less than the total burn length observed for the sample when tested.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85
    &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the length of each test sample to an accuracy of +/-0.1 inches.
: 4. Install a &#xd8;3/8 inches (10 mm), or larger, Bunsen or Tirrill burner inside an enclosure of sufficient size to perform flame retardancy testing. Adjust the burner flame height to                FRON T VIEW          SIDE VIEW 11/2 r1/8 inches. Verify that the burner flame temperature is 1,550 &#xba;F, minimum.
: 5. Support the test sample with the long axis oriented vertically within the enclosure such that the test samples bottom edge will be 3/4 r1/16 inches above the top edge of the burner.
: 6. Move the burner flame under the test sample for an elapsed time of 60 r2 seconds. As illustrated, align the burner flame with the front edge of the test sample thickness and the center of the test sample width.
: 7. Immediately after removal of the test sample from the burner flame, measure and record the following data:
: a. Measure and record, to the nearest second, the elapsed time until flames from the test sample extinguish.
: b. Measure and record, to the nearest second, the elapsed time from the occurrence of drips, if any, until drips from the test sample extinguish.
: c. Measure and record, to the nearest 0.1 inches, the burn length following cessation of all visible burning and smoking.
: 8. Flame retardancy testing acceptance is based on the following criteria:
: a. The numerically averaged flame extinguishment time of the three test samples shall not exceed fifteen (15) seconds.
: b. The numerically averaged flame extinguishment time of drips from the three test samples shall not exceed three (3) seconds.
: c. The numerically averaged burn length of the three test samples shall not exceed six (6) inches.
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HPT-PRO-0002, Rev. 2 Mining Contractors                                                                            April 2023 8.1.4.1.2.2.2 Intumescence
: 1. Three (3) test samples shall be taken from a pour from each foam batch. Each test sample shall be a cube with nominal dimensions of 2.0 inches.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Preheat a furnace to 1,475 &#xba;F r18 &#xba;F.
: 4. Identify two opposite faces on each test sample as the thickness direction. The thickness dimension shall be in the parallel-WIRE to-rise direction. Measure and record the                                                  FIBERBOARD initial thickness (ti) of each test sample to an accuracy of +/-0.01 inches.
: 5. Mount a test sample onto a fire resistant fiberboard, with one face of the thickness direction contacting to the board. As illustrated above, the test samples may be mounted by installing onto a 12 to 16 gauge wire (&#xd8;0.105 to &#xd8;0.063 inches, respectively) of sufficient length, oriented perpendicular to the fiberboard face. The test samples may be pre-drilled with an undersized hole to allow installation onto the wire.
: 6. Locate the test sample/fiberboard assembly over the opening of the pre-heated furnace for a 90 r3 second duration. After removal of the test sample/fiberboard assembly from the furnace, gently extinguish any remaining flames and allow the test sample to cool.
: 7. Measure and record the final thickness (tf) of the test sample to an accuracy of +/-0.1 inches.
: 8. For each sample tested, determine and record the intumescence, I, as a percentage of the original sample length as follows:
                                                  &sect;t t
* I = &#xa8;&#xa8; f i &#xb8;&#xb8; u 100
                                                  &#xa9; ti &#xb9;
: 9. Determine and record the average intumescence of the three test samples. The numerically averaged intumescence of the three test samples shall be a minimum of 50%.
8.1.4.1.2.2.3 Leachable Chlorides
: 1. The leachable chlorides test shall be performed using an ion chromatograph (IC) apparatus.
The IC measures inorganic anions of interest (i.e., chlorides) in water. Description of a typical IC is provided in EPA Method 300.0 8. The IC shall be calibrated against a traceable 157F reference specimen per the IC manufacturer's operating instructions.
: 2. One (1) test sample shall be taken from the sample pour. The test sample shall be a cube with dimensions of 2.00 r0.03 inches.
8 EPA Method 300.0, Determination of Inorganic Anions in Water by Ion Chromatography, U.S. Environmental Protection Agency.
15
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                        April 2023
: 3. Place the test sample in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test sample. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 4. Measure and record the thickness, width, and length of each test sample to an accuracy of
    +/-0.001 inches.
: 5. Obtain a minimum of 550 ml of distilled or de-ionized water for testing. The test water shall be from a single source to ensure consistent anionic properties for testing control.
: 6. Obtain a 400 ml, or larger, contaminant free container that is capable of being sealed. Fill the container with 262 r3 ml of test water. Fully immerse the test sample inside the container for a duration of 72 r3 hours. If necessary, use an inert standoff to ensure the test sample is completely immersed for the full test duration. Seal the container prior to the 72 hour duration.
: 7. Obtain a second, identical container to use as a control. Fill the control container with 262 r3 ml of the same test water. Seal the control container for a 72 +/-3 hour duration.
: 8. At the end of the test period, measure and record the leachable chlorides in the test water per the IC manufacturer's operating instructions. The leachable chlorides in the test water shall not exceed one part per million (1 ppm).
: 9. Should leachable chlorides in the test water exceed 1 ppm, measure and record the leachable chlorides in the test water from the control container. The difference in leachable chlorides from the test water and control water sample shall not exceed 1 ppm.
8.1.4.1.2.3 Physical Characteristics Determined for a Foam Pour Foam material physical characteristics for the following parameters shall be determined for each foam pour based on the pour definition from Section 8.1.4.1.1, Introduction and General Requirements.
8.1.4.1.2.3.1 Density
: 1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L).
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the weight of each test sample to an accuracy of +/-0.01 grams.
: 4. Measure and record the thickness, width, and length of each test sample to an accuracy of
    +/-0.001 inches.
: 5. Determine and record the room temperature density of each test sample utilizing the following formula:
Weight, g 1,728 in 3 /ft 3 Ufoam              u              , pcf 453.6 g/lb T u W u L in 3 16
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                        April 2023
: 6. Determine and record the average density of the three test samples. The numerically averaged density of the three test samples shall be 81/4 pcf +/-15% (i.e., within the range of 7 to 91/2 pcf).
8.1.4.1.2.3.2 Parallel-to-Rise Compressive Stress
: 1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be the parallel-to-rise direction.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.
: 4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).
: 5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.
: 6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until a strain of 70%, or greater, is achieved. For each test sample, plot the compressive stress versus strain and record the compressive stress at strains of 10%, 40%, and 70%.
: 7. Determine and record the average parallel-to-rise compressive stress of the three test samples from each pour. As delineated in Table 8.1-1, the average parallel-to-rise compressive stress for each pour shall be the nominal compressive stress +/-20% at strains of 10%, 40%, and 70%.
: 8. Determine and record the average parallel-to-rise compressive stress of all test samples from each foamed component. As delineated in Table 8.1-1, the average parallel-to-rise compressive stress for a foamed component shall be the nominal compressive stress +/-15% at strains of 10%, 40%, and 70%.
17
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                        April 2023 8.1.4.1.2.3.3 Perpendicular-to-Rise Compressive Stress
: 1. Three (3) test samples shall be taken from the foam pour. Each test sample shall be a rectangular prism with nominal dimensions of 1.0 inch thick (T) u 2.0 inches wide (W) u 2.0 inches long (L). The thickness dimension shall be the perpendicular-to-rise direction.
: 2. Place the test samples in a room (ambient) temperature environment (i.e., 65 &#xba;F to 85 &#xba;F) for sufficient time to thermally stabilize the test samples. Measure and record the room temperature to an accuracy of r2 &#xba;F.
: 3. Measure and record the thickness, width, and length of each test sample to an accuracy of +/-0.001 inches.
: 4. Compute and record the surface area of each test sample by multiplying the width by the length (i.e., W u L).
: 5. Place a test sample in a Universal Testing Machine. Lower the machines crosshead until it touches the test sample. Set the machines parameters for the thickness of the test sample.
: 6. Apply a compressive load to each test sample at a rate of 0.10 r0.05 inches/minute until a strain of 70%, or greater, is achieved. For each test sample, plot the compressive stress versus strain and record the compressive stress at strains of 10%, 40%, and 70%.
: 7. Determine and record the average perpendicular-to-rise compressive stress of the three test samples from each pour. As delineated in Table 8.1-1, the average perpendicular-to-rise compressive stress for each pour shall be the nominal compressive stress +/-20% at strains of 10%, 40%, and 70%.
: 8. Determine and record the average perpendicular-to-rise compressive stress of all test samples from each foamed component. As delineated in Table 8.1-1, the average perpendicular-to-rise compressive stress for a foamed component shall be the nominal compressive stress
    +/-15% at strains of 10%, 40%, and 70%.
Table 8.1 Acceptable Compressive Stress Ranges for Foam (psi)
Parallel-to-Rise at Strain, H//    Perpendicular-to-Rise at Strain, HA Sample Range            H=10%        H=40%        H=70%      H=10%        H=40%        H=70%
Nominal -20%            188          216          544        156          188          536 Nominal -15%            200          230          578        166          200          570 Nominal            235          270          680        195          235          670 Nominal +15%            270          311          782        224          270          771 Nominal +20%            282          324          816        234          282          804 18
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                April 2023 8.1.5 Tests for Shielding Integrity Section not applicable. The HalfPACT packaging does not contain any biological shielding.
ICV 506 does not contain a shielded container. It was loaded with Payload SRE033, comprised of one standard waste box, in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022.
19
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                      April 2023 8.1.6 Thermal Acceptance Test Material properties utilized in Chapter 3.0, Thermal Evaluation, of the HalfPACT SAR are consistently conservative for the normal conditions of transport (NCT) and hypothetical accident condition (HAC) thermal analyses performed. In addition, HAC fire certification testing of the HalfPACT package (see Appendix 2.10.3, Certification Tests, of the HalfPACT SAR) served to verify material performance in the HAC thermal environment. As such, with the exception of the tests required for polyurethane foam, as shown in Section 8.1.4, Component Tests, specific acceptance tests for material thermal properties are not performed.
20
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                            April 2023 8.2 Maintenance Program This section describes the maintenance program used to ensure continued performance of the HalfPACT package.
8.2.1 Structural and Pressure Tests 8.2.1.1 Pressure Testing Perform structural pressure testing on the outer confinement vessel (OCV) per the requirements of Section 8.1.2.2, Pressure Testing, once every five years. Upon completing the structural pressure test, perform leakage rate testing on the OCV per the requirements of Section 8.1.3, Fabrication Leakage Rate Tests.
8.2.1.2 ICV Interior Surfaces Inspection Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on 08/23/2022 and received at WIPP on 08/26/2022. Credit will not be taken for containment provided by the ICV.
8.2.2 Maintenance/Periodic Leakage Rate Tests This section provides the generalized procedure for maintenance and periodic leakage rate testing of the vessel penetrations during routine maintenance, or at the time of seal replacement or seal area repair. Maintenance/periodic leakage rate testing shall follow the guidelines of Section 7.4, Maintenance Leakage Rate Test, and Section 7.5, Periodic Leakage Rate Test, of ANSI N14.51.            160F Leakage rate testing of the outer confinement vessel (OCV) main O-ring seal and OCV vent port plug shall be performed in accordance with Section 8.1.3.6, Helium Leakage Rate Testing the OCV Main O-ring Seal Integrity, and Section 8.1.3.7, Helium Leakage Rate Testing the OCV Vent Port Plug O-ring Seal Integrity. Each leakage rate test shall meet the acceptance criteria delineated in Section 8.2.2.1, Maintenance/Periodic Leakage Rate Test Acceptance Criteria.
8.2.2.1 Maintenance/Periodic Leakage Rate Test Acceptance Criteria Maintenance/periodic leakage rate test acceptance criteria are identical to the criteria delineated in Section 8.1.3.1, Fabrication Leakage Rate Test Acceptance Criteria.
8.2.2.2 Helium Leakage Rate Testing the ICV Main O-ring Seal Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.
1 ANSI N14.5-1997, American National Standard for Radioactive Materials - Leakage Tests on Packages for Shipment, American National Standards Institute, Inc. (ANSI).
21
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                      April 2023 8.2.2.3 Helium Leakage Rate Testing the ICV Outer Vent Port Plug O-ring Seal Section not applicable. ICV 506 was loaded with Payload Assembly SRE033 in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022. Credit will not be taken for containment provided by the ICV.
8.2.3 Subsystems Maintenance 8.2.3.1 Fasteners All threaded components shall be inspected annually for deformed or stripped threads. Damaged components shall be repaired or replaced prior to further use. The threaded components to be visually inspected include the lock bolts, the OCV and ICV seal test port and vent port plugs, the OCV and ICV vent port covers, and OCV access plugs.
8.2.3.2 Locking Rings Before each use, inspect the OCV and ICV locking ring assemblies for restrained motion. Any motion-impairing components shall be corrected prior to further use.
8.2.3.3 Seal Areas and Grooves 8.2.3.3.1 Seal Area Routine Inspection and Repair Before each use and at the time of seal replacement, the OCV sealing surfaces shall be visually inspected for damage that could impair the sealing capabilities of the HalfPACT packaging.
Damage shall be corrected prior to further use (e.g., using emery cloth restore sealing surfaces) to the surface finish specified in Section 8.2.3.3.2.4, Surface Finish of Sealing Areas.
Upon completion of OCV seal area repairs, verify depth of O-ring groove does not exceed the value in Section 8.2.3.3.2.5, O-ring Groove Depth, when repairs are in the O-ring groove; perform leakage rate test per the applicable section of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.
8.2.3.3.2 Annual Seal Area Dimensional Inspection In order to demonstrate compliance of the OCV main O-ring seal regions, annual inspection of sealing area dimensions and surface finishes shall be performed as defined in Section 8.2.3.3.2.1, Groove Widths, through Section 8.2.3.3.2.5, O-ring Groove Depth.
Allowable OCV measurements for these dimensions are based on a minimum O-ring compression of 10.73%, which will ensure leaktight seals are maintained (see calculation in Appendix 2.10.2, Elastomer O-ring Seal Performance Tests, of the HalfPACT SAR, for the ICV seal flanges; this calculation is also applicable to the OCV seal flanges since their cross-sectional geometry is intentionally identical).
All OCV measurement results shall be recorded and retained as part of the overall inspection record for the HalfPACT package. OCV measurements not in compliance with the following dimensional requirements require repairs. Upon completion of OCV repairs, perform a maintenance/periodic leakage rate test per the applicable section of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.
22
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                      April 2023 8.2.3.3.2.1 Groove Widths The method of measuring the OCV upper (lid) seal flange groove width is illustrated in Figure 8.2-1. As an option, the lid may be inverted to facilitate the measurement process. The measuring equipment includes a &#xd8;0.560 +/-0.001 inch pin gauge of any convenient length, and a
&#xd8;0.250 +/-0.001 inch ball. With reference to Figure 8.2-1, the pin gauge is aligned parallel with the inner lip of the upper seal flange. Acceptability is based on the following conditions:
x  Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the upper seal flange groove width is acceptable.
x  Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the upper seal flange groove width is unacceptable.
The method of measuring the OCV lower (body) seal flange groove width is illustrated in Figure 8.2-2. The measuring equipment includes a &#xd8;0.273 +/-0.001 inch pin gauge of any convenient length, and a &#xd8;0.250 +/-0.001 inch ball. With reference to Figure 8.2-2, the pin gauge is aligned parallel with the outer lip of the lower seal flange. Acceptability is based on the following conditions:
x  Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the lower seal flange groove width is acceptable.
x  Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the lower seal flange groove width is unacceptable.
Groove width measurements shall be taken and recorded at six equally spaced locations around the circumference of the seal flanges.
8.2.3.3.2.2 Tab Widths The method of measuring the OCV upper (lid) seal flange tab width is illustrated in Figure 8.2-3.
As an option, the lid may be inverted to facilitate the measurement process. The measuring device is a tab width gauge of any convenient size, with a 0.234 +/-0.001 inch inside width u 0.428 +/-0.001 inch inside height u 0.375 +/-0.005 inch thickness. With reference to Figure 8.2-3, the tab width gauge is aligned parallel with the lowermost lip of the upper seal flange.
Acceptability is based on the following conditions:
x  Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the upper seal flange tab width is acceptable.
x  Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the upper seal flange tab width is unacceptable.
The method of measuring the OCV lower (body) seal flange tab width is illustrated in Figure 8.2-4. The measuring device is a 0.494 +/-0.001 inch inside width u 0.250 +/-0.001 inch inside height u 0.375 +/-0.005 inch thick tab width gauge of any convenient size. With reference to Figure 8.2-4, the tab width gauge is aligned parallel with the uppermost lip of the lower seal flange.
Acceptability is based on the following conditions:
x  Having contact at location c-c and a gap at location d-d is a NO-GO condition indicating that the lower seal flange tab width is acceptable.
23
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                        April 2023 x  Having contact or a gap at location c-c and contact at location d-d is a GO condition indicating that the lower seal flange tab width is unacceptable.
Tab width measurements shall be taken and recorded at six equally spaced locations around the circumference of the seal flanges.
8.2.3.3.2.3 Axial Play Measurement of axial play shall be performed to ensure that O-ring compression is sufficient to maintain package configuration and performance to design criteria. Axial play is the maximum axial distance that a lid can move relative to a body. Because the seal flange sealing surfaces are tapered, any axial movement where the lid moves away from the body results in a separation of the sealing surfaces and a slight reduction in O-ring compression. The procedure for measuring OCV axial play is as follows:
: 1. Remove the vent port access plug (OCV only), vent port thermal plug (OCV only), vent port cover, and vent port plug(s).
: 2. Assemble the lid onto the body.
: 3. Locate a minimum of six equally spaced locations around the exterior circumference of the lid and body. At each location, place vertically aligned temporary reference marks on the lid and body.
: 4. Install a vacuum pump to the vent port and evacuate the vessel sufficiently to fully compress the upper seal flange to the lower seal flange.
: 5. At each location, scribe a horizontal mark that intersects both the lid and the body vertical marks.
: 6. Install a source of pressure to the vent port and pressurize the vessel sufficiently to fully separate the upper seal flange from the lower seal flange.
: 7. At each location, scribe a second horizontal mark that intersects either the lid or the body vertical mark (select either the lid or body mark as a base point).
: 8. Measure and record the difference between the initial and final horizontal marks at each location. The maximum acceptable axial play at any location is 0.153 inch.
: 9. Other measuring devices, such as dial indicators, digital calipers, etc., may be used in lieu of the reference marking method, provided that the axial play is measured at a minimum of six equally spaced locations.
8.2.3.3.2.4 Surface Finish of Sealing Areas The surface finish in the OCV main O-ring sealing regions shall be a 125 micro-inch finish, or better, to maintain package configuration and performance to design criteria. Perform OCV surface finish inspections for the bottom of the grooves on the lower seal flange and the mating sealing surfaces on the upper seal flange. If the OCV surface condition is determined to exceed 125 micro-inch, repair the surface per the requirements of Section 8.2.3.3.1, Seal Area Routine Inspection and Repair.
24
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                            April 2023 8.2.3.3.2.5 O-ring Groove Depth Verify the OCV O-ring groove depth to be less than 0.253 inches at six equally spaced locations around the circumference of the seal flanges.
8.2.4 Valves, Rupture Discs, and Gaskets 8.2.4.1 Valves The HalfPACT packaging does not contain any valves.
8.2.4.2 Rupture Discs The HalfPACT packaging does not contain any rupture discs.
8.2.4.3 Gaskets The O-ring seals used during these maintenance activities to support this one-time shipment shall meet the requirements of Section 4.1.1.1, Outer Confinement Assembly (Primary Containment),
of HPT-PRO-0003.2 OCV containment boundary O-ring seals shall be replaced within the 12-month period prior to shipment or when damaged (whichever is sooner), per the size and material requirements delineated on the drawings in Appendix 1.3.1, Packaging General Arrangement Drawings, of the HalfPACT SAR. Following OCV containment O-ring seal replacement and prior to a loaded shipment, the new seals shall be leakage rate tested to the requirements of Section 8.2.2, Maintenance/Periodic Leakage Rate Tests.
8.2.5 Shielding The HalfPACT packaging does not contain any biological shielding. ICV 506 does not contain a shielded container. It was loaded with Payload SRE033, comprised of one standard waste box, in compliance with CofC 9279 on August 23, 2022, and received at WIPP on August 26, 2022.
8.2.6 Thermal No thermal tests are necessary to ensure continued performance of the HalfPACT packaging.
2 HPT-PRO-0003, Containment for One-Time Shipment Supporting ICV 506, Current Revision, Salado Isolation Mining Contractors, Carlsbad, NM.
25
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                          April 2023
                                                                            ' \
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                                                                                \
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                                        ---'-\--+-----<
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            &#xa2;.250 BALL LID PIN GAUGE UPPER SEAL FLANGE
                      &#xa2;.560D LOCKING RING Figure 8.2 Method of Measuring Upper Seal Flange Groove Widths 26
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                    April 2023 I
                                  -\                \
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                                              ''                        BODY PIN GAUGE
                                                \
                                                                        &#xa2;.250 BALL LOWER SEAL FLANGE Figure 8.2 Method of Measuring Lower Seal Flange Groove Widths 27
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                            April 2023 UPPER SEAL FLANGE LOCKING RING LID TAB GAUGE
(.375 +/-.005 THK)
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                                      .......----, \
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I                    >----++-;),--- MAINTAIN PARALLEL CONTACT
      .428+/-.001    \                                1 AT THIS INTERFACE
                                          .234+/-.001 Figure 8.2 Method of Measuring Upper Seal Flange Tab Widths 28
 
HPT-PRO-0002, Rev. 2 Mining Contractors                                                                    April 2023
                                                        .494+/-.001
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I BODY TAB GAUGE
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LOWER SEAL FLANGE Figure 8.2 Method of Measuring Lower Seal Flange Tab Widths 29}}

Revision as of 19:12, 14 November 2024

Response to Request for Additional Information on the Halfpact Docket No. 71-9279, Request for Authorization of One-Time Shipment of Model No. Crediting the Outer Confinement Vessel as the Containment
ML23117A072
Person / Time
Site: 07109279
Issue date: 04/27/2023
From: Sellmer T
Salado Isolation Mining Contractors (SIMCO) LLC
To: Yoira Diaz-Sanabria
Office of Nuclear Material Safety and Safeguards, Document Control Desk
References
TS:23:03017
Download: ML23117A072 (1)
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