69M44HICMN S01 SOW.pdf

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1/8/2021

STATEMENT OF WORK

FOR

HIGH INTEGRITY CONTAINER

Prepared by

PUGET SOUND NAVAL SHIPYARD &

INTERMEDIATE MAINTENANCE FACILITY

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CONTENTS

Section/Paragraph

1 Scope

2 Background

3 References

4 Requirements

4.1 General Requirements

4.2 Fabrication Requirements

4.3 Certification and Testing Requirements

5 Notice

6 Delivery

7 Government-Furnished Property

8 Security Requirement

9 Place of Performance/Delivery Address

10 Period of Performance

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1 Scope

1.1 The contractor shall fabricate and deliver one (1) each of a High Integrity Container (HIC) fully compliant with this Statement of Work (SOW).

2 Background

2.1 The HIC is required for use inside a government-owned Allied Technology Group (ATG)

14-210H Type A cask for support of government work.

3 References

3.1 A-A-59326D: Commercial Item Description – Coupling Halves, Quick-Disconnect, Cam-Locking Type, General Specification For; Revision D

3.2 WN-I019-2: State of Washington Radioactive Materials License; Amendment 40

3.3 RR-W-410H: Federal Specification – Wire Rope and Strand; Revision H

3.4 RR-C-271G: Federal Specification – Chains and Attachments, Carbon and Alloy Steel;

Revision G

3.5 ANSI N14.6-1993: Radioactive Materials – Special Lifting Devices for Shipping

Containers Weighing 10,000 Pounds (4,500 kg) or More; 1993 Edition

3.6 ASTM E208-06: Standard Test Method for Conducting Drop-Weight Test to Determine Nil-Ductility Transition Temperature of Ferritic Steels; Revision 06

3.7 ASTM A370-17: Standard Test Methods and Definitions for Mechanical Testing of Steel

Products; Revision 17

3.8 NAVSEA-T9074-AS-GIB-010/271: Requirements for Nondestructive Testing Methods;

2014 Edition

3.9 MIL-STD-2035A: Department of Defense Test Method – Nondestructive Testing Acceptance Criteria; Revision A

3.10 ASME B30.9-2018: Slings Standards; 2018 Edition

4 Requirements

4.1 General Requirements

4.1.1 The material required by this contract shall be manufactured and tested in accordance with this SOW.

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4.1.2 The contractor shall fabricate the HIC as listed in this SOW to meet the performance criteria specified by the references of paragraphs 3.1-3.5 and in accordance with the detailed requirements in paragraph 4.2 below.

4.1.3 The contractor shall test and certify the HIC as listed in this SOW to meet the testing criteria specified by the references of paragraphs 3.6-3.8 and in accordance with the detailed requirements in paragraph 4.3 below.

4.2 Fabrication Requirements

4.2.1 HIC Dimensions. The HIC, with certified lifting arrangement, shall be used inside of a government owned ATG 14-210H Type A Cask. The HIC shall have a maximum outside diameter of 77", a maximum overall height of 80" (not including lifting arrangement), and have a minimum wall thickness of 25/64". The HIC shall have a minimum useable volume of 900 gallons. Useable volume shall be defined as the volume of the HIC reduced by the volume of the closure pan and spray foam in the top of the HIC (i.e., the maximum volume of water that can be added to the HIC following fabrication and assembly without overflowing).

4.2.2 HIC Marking. The HIC serial number and gross empty weight shall be stenciled on the closure lid and the upper surface of the polyethylene HIC using 1" high letters and highly contrasting color paint. Ensure that serial numbers and gross empty weight are visible and can be read with the shielded shipping cask primary lid in place and the 29" diameter secondary lid removed on a government owned ATG 14- 210H cask.

4.2.3 Closure Pan Assembly:

4.2.3.1 Closure Pan. 3” thick steel plate with a maximum diameter of 18-3/4” to accept paragraph 4.2.3.2 through 4.2.3.10 items. The closure pan shall be centered on the tank top and attached to the HIC.

4.2.3.2 Media Inlet Connection. 2” IPS pipe (schedule 40, CRES) butt welded to a 2” cam-type connector (male adapter) and dust cap. The cam-type connectors shall adhere to the full requirements of reference 3.1 (Class SS, Style 1).

4.2.3.3 Vent Connection. 2” IPS pipe (schedule 40, CRES) with 2” cam-type connector

(male adapter) and dust cap. The cam-type connectors shall adhere to the full requirements of reference 3.1 (Type I, Class SS, Style 1). A splash shield shall be installed inside of the HIC to protect the vent outlet port from liquid.

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4.2.3.4 TV Camera Housing with TV Camera Viewing Port. TV camera shall have 3” sealed viewing port through the closure pan assembly. The TV camera housing shall be made out of 4” pipe (schedule 40, CRES) with a threaded 4” pipe cap (schedule 40, CRES). The TV camera housing shall be sized for a Mirion Tech Dotcam (1.14” x 4.3” long). The TV camera housing cap shall have two (2) ports for ½” male NPT couplings and shall have liquid tight connectors for ¼” - 3/8” cables. The TV camera and TV camera power cables shall be existing government equipment.

4.2.3.5 Light Housing for TV Camera. The light housing shall have a 3” sealed viewing port through the closure pan assembly. The light housing shall be made out of 4” pipe (schedule 40, CRES) with a threaded 4” pipe cap (schedule 40, CRES).

The light housing shall be sized for use with a Mirion Tech LED Light. The light housing cap shall have one (1) ½” male NPT coupling and shall have a liquid tight connector, for a ¼” -3/8” cable. The light and power cables shall be existing government equipment.

4.2.3.6 Flushing Fixture. The camera and light shall have a flushing fixture to flush/clean the sealed camera viewing and light ports inside of the HIC. The flushing fixture shall have a flush hose that is 6 ft. (+ ½”) long. The final flush hose connection shall be a ¼” (nom.) Hansen (Eaton Corporation) female socket quick-disconnect fitting (series 3RL, stainless steel construction) to connect to existing government equipment.

4.2.3.7 Dewatering Connection. 1-1/2” IPS pipe (schedule 40, CRES) with 1-1/2” cam-type connector (male adapter) and dust cap. The cam-type connectors shall adhere to the full requirements of reference 3.1 (Type I, Class SS, Style 1).

4.2.3.8 Tank Level Indication (TLI) Connection. There shall be a port through the closure pan, sized for the TLI instrument requested per paragraph 4.2.5.1.

4.2.3.9 Test Port. ¼” IPS pipe (schedule 40, CRES) with ¼” Hansen (Eaton Corporation) female quick disconnect and dust cap.

4.2.4 Internal Dewatering Assembly. The dewatering system shall be equipped with 5-micron panel filters. The filter assembly shall be used to dewater the container to meet disposal requirements of reference 3.2. All internal cam-type connectors shall be secured with arm ring tie-wraps.

4.2.5 Indication:

4.2.5.1 Level Indication. The vendor shall install a Siemens XPS-10 transducer for continuous level sensing. Transducer cable shall be 10 meters long and have a 3 contact male plug (Switchcraft P/N: SL403X). Vendor shall provide the following information of the Siemens XPS-10 transducer for input into the Siemens Multiranger:

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Dimension X - Empty Distance Dimension Y - Near Blanking Distance Dimension C - flag 3 (also see 4.2.5.2) Dimension D - flag 4 (also see 4.2.5.2) Flag 4 volume in gallons (also see 4.2.5.2)

4.2.5.2 Visual Indication. The HIC shall have four (4) visual indicator flags mounted inside of the HIC. The visual indicators shall be mounted in such a way that a TV camera installed in the TV camera housing can readily indicate the volume inside of the HIC. The vendor shall locate the visual level indicator flags as follows:

Dimension A – flag 1 at 30% of HIC usable volume +/- 1.5% Dimension B – flag 2 at 60% of HIC usable volume +/- 1.5% Dimension C – flag 3 at 80% of HIC usable volume +/- 1.5% Dimension D – flag 4 at 90% of HIC usable volume +/- 1.5%

4.2.6 Lifting Arrangement. The HIC lifting arrangement shall consist of a lifting liner bail, shackles, wire ropes, and a master link. The overall lifting arrangement height, including the HIC height, shall not exceed 152”. The integral liner bail shall be specifically sized to the HIC and designed for a four point lift. The weight of a full HIC and liner bail shall be distributed between the two wire rope pendants. The two wire rope pendants shall be in the upside down basket configuration and connected to the four liner bail pad eyes using shackles. The two wire rope pendants shall be placed through a forged master link, at the apex of the basket configuration, to allow the two wire rope pendants to load equalize. A final top wire rope pendant shall be connected to the master link for lifting the liner bail assembly and installed HIC.

Both end eyes of the top wire rope shall be directly swaged to the master link.

4.2.6.1 Wire Ropes. The wire ropes shall be free of all types of surface treatments such as paint, galvanization, or plating. The wire rope shall be thoroughly coated with a lubricant during process of manufacture. The vendor shall connect the lower wire rope pendants to the liner lifting bail pad eyes via 5/8” shackles, Crosby G- 209 or equal. The wire ropes shall be a minimum diameter of 5/8”, Type I, Class 2, 6 by 19, bright Extra Improved Plow Steel (EIPS), independent wire rope core (IWRC), and Construction 3 (Seale) or Construction 5 (Warrington- Seale) per reference 3.3. The top wire rope pendant connected to the 1" master link shall be a minimum diameter of 7/8”, Type I, Class 2, 6 by 19, bright EIPS, IWRC, and Construction 3 or Construction 5 per reference 3.3. Both ends of the pendant shall be directly swaged to the 1” master link. The length of the top wire rope while attached to the master link, in the basket configuration, shall be 36” (+ ½”).

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4.2.6.2 Master Link. 1” weldless master link, Crosby A-342 or equal, are to be forged and meet the material composition requirements for shackles per reference 3.4.

The master link shall be installed on the 5/8” wire rope to equalize loading. The 7/8” wire rope shall be permanently attached to the 1" master link through the swaged wire rope eyes.

4.2.6.3 Integral Lifting Attachments. The integral lifting attachments (pad eyes) shall meet the design and material requirements of reference 3.5. The pad eye design strength shall be 3:1 yield and 5:1 ultimate. The anticipated minimum service temperature for lifting the HIC is 0° F.

4.2.6.3.1 Lifting Liner Bail. The lifting liner bail for lifting the HIC shall meet the requirements of reference 3.5.

4.2.6.4 Lifting Shackles. Each forged shackle, Crosby G-209 or equal, are to meet the technical requirements of reference 3.4 for shackle material composition.

Shackle pins must be easy to disassemble/reassemble without tools.

4.3 Certification and Testing Requirements

4.3.1 Testing Procedures Expectations. Vendor shall provide drawings and procedures for inspection and testing of welded pads and lift slings for approval by the government, a minimum of one month prior to delivery of the HIC. The government shall provide comments within two weeks of receipt of procedures for inspection and testing procedures. The tests shall be conducted at the contractor's facilities or at an independent laboratory or commercial testing facility.

4.3.2 Pressure Test. The vendor shall hydrostatically/pneumatically test the HIC to 7 (+0, -

1) psig. Vendor shall provide certification and results of the hydrostatic/pneumatic testing.

4.3.3 Hydrostatic Test of Internal Hoses. The vendor shall hydrostatically test all hoses used in the HIC assembly to a minimum pressure of 225 psig, held for a minimum of 30 minutes with no leakage or deformation. Vendor shall supply certification and results of hydrostatic tests.

4.3.4 Lifting and Handling Tests and Inspections:

4.3.4.1 Breaking Strength. Vendor shall provide certification of the breaking strength of the wire ropes by obtaining breaking strength results from destructive testing of a sample from the originating wire rope reels.

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4.3.4.2 Integral Lifting Attachments Drop Weight Test. Vendor shall perform drop weight test per reference 3.6 or a Charpy impact test per reference 3.7 of material used for the integral lifting attachments (e.g. lifting lugs or pad eyes).

The anticipated minimum service temperature for the HIC is 0° F, therefore the nil ductility transition temperature shall be a minimum of -40° F. Vendor shall supply certification and results of drop weight test.

4.3.4.3 Lifting Liner Bail Drop Weight Test. Vendor shall perform drop weight test per reference 3.6 or a Charpy impact test per reference 3.7 of the material used for the lifting liner bail. The anticipated minimum service temperature for the HIC is 0° F, therefore the nil ductility transition temperature shall be a minimum of - 40° F. Vendor shall supply certification and results of drop weight test.

4.3.4.4 Prior to Load Test. Vendor shall perform a visual inspection of the liner bail and all rigging gear. No signs of nicks, gouges, cracks, breaks, wear, distortion, corrosion, deterioration, binding, loose parts, thread damage, or other defects that may reduce the load-bearing capability are allowed. There is to be no arc strikes, discoloration (burn marks), or other evidence of heat damage that may reduce the load-bearing capability. There is to be no deformation such as bending or twisting out of the natural plane of the gear. For the wire rope, no broken wires, wear, flattened sections, kinked, bird caged, dog legged crushed, high strands, corrosion, heat damage, inadequate end attachments, or any other damage resulting in distortion of the rope structure are allowed. For the shackles and master link, inspect for manufacturer’s identification and safe working load markings. Vendor shall provide certification of satisfactory pre-load test visual inspection.

4.3.4.5 Wire Ropes Load Test. Vendor shall perform load test of each of the wire ropes individually to twice their respective rated capacities/working load limits per reference 3.10. The maximum expected service load for this application is considered to be 12,200 lbs. Load test shall be held for a minimum of 10 minutes. Vendor shall provide certification and results of load testing.

4.3.4.6 Rigging Assembly Load Test. Vendor shall perform load test the entire rigging assembly (integral lifting attachments, wire ropes, shackles and master link) to 150% (+ 5%, -0 %) of the maximum expected service load. The maximum expected service load for this application is considered to be 12,200 lbs. Load test shall be held for a minimum of 10 minutes. Vendor shall provide certification and results of load testing.

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4.3.4.7 After Load Test Completion. Vendor shall perform a visual inspection of the liner bail and all rigging gear. No signs of nicks, gouges, cracks, breaks, wear, distortion, corrosion, deterioration, binding, loose parts, thread damage, or other defects that may reduce the load-bearing capability are allowed. There is to be no arc strikes, discoloration (burn marks), or other evidence of heat damage that may reduce the load-bearing capability. There is to be no deformation such as bending or twisting out of the natural plane of the gear. For the wire rope, no broken wires, wear, flattened sections, kinked, bird caged, dog legged crushed, high strands, corrosion, heat damage, inadequate end attachments, or any other damage resulting in distortion of the rope structure are allowed. For the shackles and master link, inspect for manufacturer’s identification and safe working load markings. Vendor shall provide certification of satisfactory post-load test visual

4.3.4.8 Lifting Shackles Magnetic Particle Inspection. After the load test is complete, vendor shall perform a magnetic particle inspection of the lifting shackles.

Magnetic particle inspection shall be performed in accordance with reference

3.8 with acceptance criteria to reference 3.9. Alternative inspection methods may be allowed provided they meet the following and has been submitted for review and approved for use by the government:

a. Magnetic particle inspections performed in accordance with ASTM

A275/A275M are acceptable provided that the following areas meet the requirements of reference 3.8:

(1) Inspection of welds, removal of arc strikes per paragraph 4.7 and tolerance on equipment ammeters per paragraph 4.3.1.7.1.

(2) Automated equipment per paragraph 4.3.3.2.2.

(3) Final surface inspection per paragraph 4.3.1.4.

Vendor shall provide certification and results of satisfactory magnetic particle

4.3.4.9 Integral Lifting Attachments Magnetic Particle Inspection. After the load test is complete, vendor shall perform a magnetic particle inspection of the integral lifting attachment (pad eyes), including the welds that attach the lifting pad eyes and the heat effected zone. Magnetic particle inspection shall be performed in accordance with reference 3.8 with acceptance criteria to reference 3.9 (Class 3 for welds). Alternative inspection methods may be allowed provided they meet the following and has been submitted for review and approved for use by the government:

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a. Magnetic particle inspections performed in accordance with ASTM A275/A275M are acceptable provided that the following areas meet the requirements of reference 3.8:

(1) Inspection of welds, removal of arc strikes per paragraph 4.7 and tolerance on equipment ammeters per paragraph 4.3.1.7.1.

4.3.4.10 Master Link Magnetic Particle Inspection. After the load test is complete, vendor shall perform a magnetic particle inspection of the master link. Magnetic particle inspection shall be performed in accordance with reference 3.8 with acceptance criteria to reference 3.9. Alternative inspection methods may be allowed provided they meet the following and has been submitted for review and approved for use by the government:

a. Magnetic particle inspections performed in accordance with ASTM

A275/A275M are acceptable provided that the following areas meet the requirements of reference 3.8:

(1) Inspection of welds, removal of arc strikes per paragraph 4.7 and tolerance on equipment ammeters per paragraph 4.3.1.7.1.

4.3.4.11 Rigging Assembly Labeling. Vendor shall tag rigging assembly components (e.g. pad eyes, wire ropes, etc.) with legible tags that state the working load limit, date of the test, test load and identification of tester.

4.3.4.12 Proper Installation. Vendor shall provide certification that the HIC lifting gear is properly fitted and securely installed.

4.3.5 Manufacturer’s Literature. Vendor shall provide operating manuals, as-built engineering drawings, and user handling and dewatering procedures for the HIC with applicable revision one month prior to delivery of the HIC.

4.3.6 Miscellaneous Requirements and Certifications.

4.3.6.1 Vendor shall provide, as a minimum, with quotation complete fabrication specifications, preliminary engineering drawings (including details of the filter assembly), and testing/inspection procedures to Puget Sound Naval Shipyard for evaluation and review.

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4.3.6.2 At the time of the delivery of the HIC, the vendor shall provide all certification data and the following additional certifications and information:

4.3.6.2.1 Certification and photographs that a visual inspection of the HIC internals reveals that the component parts are intact and the hardware inside the HIC is adequately secured.

4.3.6.2.2 Certification and photographs that a visual inspection of the HIC externals reveals no obvious flaws or defects.

4.3.6.2.3 Certification of the total usable volume of the HIC.

4.3.6.2.4 Certification of the fully assembled empty HIC weight.

4.3.6.2.5 Certification of the height (in inches) of each of the visual indicator flags from the bottom of the HIC.

4.3.6.2.6 Certification of the height (in inches) of the HIC from the bottom to the face of the Siemens Echomax XPS-10 transducer.

4.3.6.2.7 Certification of the height (in inches) of the distance from the face of the

Siemens Echomax XPS-10 transducer to where surface can be reliably measure (Near Blanking Distance).

4.3.6.2.8 Certification that the closure pan is centered on the tank top and attached to the HIC by a certified method.

4.3.6.2.9 Washington State Department of Health (DOH) approval of the HIC handling procedure and applicable revision.

4.3.6.2.10 Washington State DOH approval of the HIC drawing and applicable revision.

4.3.6.2.11 HIC Certificate of Compliance (COC) recognized by the Washington State DOH.

4.3.6.2.12 HIC licensing by the Washington State DOH for disposal at the US Ecology site.

4.3.7 Certificate of Compliance. Vendor shall provide a COC to confirm all design, performance, drawing, and test specifications required by this contract have been met.

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4.3.8 Vendor shall provide two complete sets of certification data. One set shall accompany the HIC and one set shall be forwarded to:

Victoria Johnson / Code 2380.2 / Bldg. 850 Puget Sound Naval Shipyard and IMF 1400 Farragut Ave. Stop 2077 Bremerton, WA 98314

5 Notice

5.1 The government reserves the right to witness, at any time, the fabrication and testing of the HIC.

6 Delivery

6.1 CDRLs A-001 through A-012 are included.

7 Government-Furnished Property – None

8 Security Requirement

8.1 UNCLASSIFIED

9 Place of Performance/Delivery Address

9.1 Vendor’s Facility/1400 Farragut Ave, Bremerton, WA 98314

10 Period of Performance

10.1 HIC shall be fabricated, tested, and delivered no later than January 10, 2021.