LPRCT Ordering Specs Attachment A (Revised 1-13-22).docx

Revised 1/13/22

Statement of Work Low Pressure Resin Catch Tank Revised 1/13/22 Statement of Work Low Pressure Resin Catch Tank

1. Scope. This statement of work covers a Low Pressure Resin Catch Tank (LPRCT) used in the disposal of waste from submarines and Navy prototype reactors. These tanks receive radioactive waste from the reactor, and are used to safely transport the waste to a processing site or to a low level radioactive waste disposal site where the tank will be buried.

2. Applicable Documents.

2.1 A-A-59326D, Coupling Halves, Quick-Disconnect, Cam-Locking Type

2.2 NAVSEA Technical Publication T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods

2.3 MIL STD-2035A, Nondestructive Testing Acceptance Criteria

2.4 ASME B30.9, Slings

2.5 ANSI N14.6-1993, Special Lifting Devices for Shipping Containers Weighing 10,000 Pounds (4500 kg) or More

3. Requirements.

3.1 General Requirements.

3.1.1 The contractor shall have and maintain a quality assurance (QA) program approved by the Nuclear Regulatory Commission or by an agreement state.

3.1.2 The contractor shall store the LPRCT in a secure facility from the completion of fabrication until the LPRCT is used by the Navy. Storage period may be as long as twelve months. The Navy will provide at least one week notice prior to use.

3.1.3 Cam type connectors shall be stainless steel and shall adhere to the requirements of paragraph 2.1. Attached parts (rings and pins) shall not be zinc plated or cadmium plated.

3.1.4 Norfolk Naval Shipyard (NNSY) reserves the right to witness the fabrication and testing of the LPRCT, and to inspect the LPRCT for damage or defect after storage and prior to use.

3.2 Specific Requirements.

3.2.1 The contractor shall provide a LPRCT with the following characteristics:

3.2.1.1 The LPRCT shall be capable of receiving media at 140 degrees F and have a capacity of at least 650 gallons.

3.2.1.2 The LPRCT shall be a High Integrity Container (HIC) accepted by the State of Washington Department of Health (WDH) for disposal as a stable waste container at the Hanford Disposal Site when used in conjunction with approved Washington engineered concrete barriers, at the Containerized Waste Disposal Facility in Clive, Utah, and at the Barnwell Disposal Site in Barnwell, South Carolina in accordance with the South Carolina Department of Health and Environmental Control (SCDHEC) requirements. The contractor shall provide a Certification of Compliance that the HIC is acceptable for disposal in accordance with Exhibit A (CDRL A001).

3.2.1.3 Dimensions: (a) Prior to installation of the HIC into its steel shell, the contractor shall verify that the HIC dimensions are as follows: (1) Outside diameter, 64 inches (+0/-1 1/2 inches); (2) External height to tank shoulder, 65 inches (+0/-1 1/2 inches); and (3) Overall height, 70 inches (+0/-1 1/2 inches). (b) The LPRCT shall have overall finished dimensions of 70 1/2 inches (+0/-1 1/2 inches) high and 65 inches (+0/- 1/8 inch) outside diameter in order to fit into 10-160B and 14-195H shielded shipping containers.

3.2.1.4 The LPRCT shall be marked on the top and side using one inch high (minimum) letters and highly contrasting color paint, providing the LPRCT serial number and maximum gross weight. Marking on top shall be located so that it is visible when the LPRCT is in a shielded shipping container with the primary lid installed and the secondary lid removed.

3.2.1.5 The LPRCT shall have a 3 inch thick closure pan for shielding. The closure pan shall be centered on top of the tank and attached to the HIC by a method that will withstand the pressure test required by paragraph 3.2.1.22 as well as 1,000 pound of direct weight. A 1000 pound weight test is not required if the method of attachment was validated to support this weight or more under a previous contract/drawing. Horizontal supports inside the tank shall be rolled flat bar to improve visibility of level flags (see paragraph 3.2.1.17). Configuration of the closure pan shall be as described in paragraphs 3.2.1.6 through 3.2.1.13 and shall be similar to the following figure.

3.2.1.6 The LPRCT shall have a media inlet connection consisting of 3 inch IPS pipe with a 3 inch cam type connector (male adapter) and EZLinkTM armless dust cap (Dixon part number EZL300-DC-SS).

3.2.1.7 The LPRCT shall have a vent connection consisting of 2 inch IPS pipe with a 2 inch cam type connector (male adapter) and EZLinkTM armless dust cap (Dixon part number EZL200-DC-SS).

A cyclonic separator shall be installed on the internal side of the closure pan to prevent entrained water from passing out of the vent connection. The cyclonic separator shall be centered under the vent connection with an outside diameter as large as possible without interfering with the ultrasonic transducer signal. Hoses used to drain the cyclonic separator shall be routed and secured outside of the transducer signal and secured to internal support structure.

3.2.1.8 The LPRCT shall have a dewatering connection consisting of 1-1/2 inch IPS pipe with a 1-1/2 inch cam type connector (male adapter) and EZLinkTM armless dust cap (Dixon part number EZL150-DC-SS).

3.2.1.9 The LPRCT shall have a verification dewatering connection consisting of 1/2 inch IPS pipe with a 1/2 inch cam type connector (male adapter) and dust cap.

3.2.1.10 The LPRCT shall have camera and light ports with Pyrex viewing windows on the underside of the closure pan. The windows shall be sealed with rubber gaskets to withstand the pressure test of paragraph 3.2.1.22. The diameter of the openings in the closure pan shall be minimized to promote radiation shielding but have dimensions to accommodate a cylindrical camera and light, each having dimensions of approximately 1.14 inches in diameter by 4.57 inches long. Cameras and lights shall be provided separately by the government. The configuration of the camera and light ports shall be identical. No air cooling or exhaust connections shall be installed. The camera and light ports shall include the capacity to be externally sealed when not in use, using 1-1/2 inch cam type connectors (male adapters) and EZLinkTM armless dust cap (Dixon part number EZL150-DC-SS). These two dust caps shall not be in place during the pressure test of paragraph 3.2.1.22.

3.2.1.11 The LPRCT shall have an air purge line to allow clearing of condensation on the inner surface of the camera and light port viewing windows. The underside of the closure pan shall be equipped with two 0.117 inch inside diameter nozzles, one directed at each window. The nozzles shall be connected to a single external connection on the top surface of the closure pan. The external connection shall be equipped with a stainless steel ¼ male NPT by ¼ inch female self-sealing quick disconnect, Dixon 2FM2-S.

3.2.1.12 The LPRCT shall be equipped with a Siemens Echomax XPS-10 ultrasonic transducer, mounted to the closure pan via a three inch IPS flanged port. The transducer shall be equipped with a vendor-installed four foot long (minimum) cable, which shall be provided with a Switchcraft SL403MX (or equal) connector. The connector shall be wired as follows: shield to pin 1; white to pin 2; and black to pin 3. The contractor shall provide one equivalently wired 50 foot extension cable with a Switchcraft SL413FX (or equal) connector on the upstream end and with a Switchcraft SL403MX (or equal) connector on the downstream end. All connectors shall be attached using solder and heat shrink wrap.

3.2.1.13 All closure pan connections except the ultrasonic transducer of paragraph 3.2.1.12 shall be appropriately marked as follows: INLET, VENT, DEWATER, VERIF, LIGHT, CAMERA, and AIR.

3.2.1.14 The LPRCT shall have an internal dewatering assembly consisting of twenty 1-micron cartridge style filters (Graver MBF or equal). The filters shall be secured to the bottom of the HIC to ensure that individual filters do not float when the LPRCT is filled with water. Internal cam type connectors shall be secured with tie-wraps. Internal hose barb connections shall be secured using double hose clamps where space allows (all vertical runs of dewatering hoses). For hose barb connections where space is limited (between filters), single hose clamps are acceptable. The contractor shall provide a Certification of Compliance that the internal dewatering assembly consists of twenty 1-micron cartridge style filters in accordance with Exhibit A (CDRL A001).

3.2.1.15 The verification dewatering filter rating shall be 1 micron. The contractor shall provide a Certification of Compliance that the verification dewatering filter rating is 1 micron in accordance with Exhibit A (CDRL A001).

3.2.1.16 Each component of the internal dewatering assembly (including filters, PVC fittings, hoses, hose clamps, and dewatering verification filter/tubing) shall be individually inspected (1X visual inspection of external and accessible internal surfaces) prior to installation into the system. The acceptance criteria shall be no signs of cuts, cracks, nicks, permanent distortion or other damage. Upon completion of assembly and installation into the tank, a visual inspection of accessible external surfaces shall be conducted utilizing the same acceptance criteria. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002).

3.2.1.17 The LPRCT shall have internal level markers (flags) labeled “1”, “2”, “3”, and “4” located as follows: Flags 1, 2, and 3 shall be attached to the support leg closest to the light port; flags 2, 3, and 4 shall be attached to the support leg closest to the camera port. (Note: flags 2 and 3 are duplicated on each support leg.) Flags 3 and 4 on the support leg closest to the camera shall be attached via opposite sides of the flag (i.e., attachment ring on the right side of flag 3 and left side of flag 4). All flags shall be positioned such that they are visible to the camera, illuminated by the light, and in a location that will not interfere with the ultrasonic transducer signal. Flag numbers shall be white in color on a flat black background and a minimum of 1-1/2 inch in height. The attachment rings for flag 3 shall be painted white; all others shall be black. The four support legs shall be black except for the area between the top of flag 2 and the top of flag 3, which shall be white. Horizontal supports (rolled flat bar) between flags 2 and 3 shall be white. The top of each marker shall correspond to the following set points: Flag 1 – approximately 20 percent of usable volume; Flag 2 – approximately 40 percent of usable volume; Flag 3 – approximately 60 percent of usable volume; Flag 4 – 514 gallons (+/- 25 gallons). Location and visibility of the flags shall be confirmed by operational testing, adding water to the LPRCT and verifying gallon levels associated with each flag using the ultrasonic level indicator described in paragraph 3.2.1.12. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002).

3.2.1.18 The HIC shall be contained in an ASTM A-36 steel welded shell with ¼ inch thick wall and ½ inch thick bottom plate. The steel shell shall be fabricated using all-welded construction, including welding of the top to the shell.

3.2.1.19 The LPRCT shall have four welded padeyes. Each welded padeye shall be designed to carry one-half the maximum loaded weight of 8,750 lbs. and account for a lift angle of 30 degrees from vertical. The design strength of the padeyes shall be a minimum safety factor of 10 to 1 based on the minimum yield strength. The contractor shall supply written verification that each padeye has been load tested to 150% of its rated capacity for a minimum of 10 minutes. The container integral attachments are to meet the design requirements of paragraph 2.5. Non-destructive testing (NDT) shall be performed after the load test(s). NDT shall be per paragraph 2.2 or a magnetic particle inspection procedure approved by the government. Acceptance criteria shall be in accordance with paragraph 2.3, Class 3. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002) referencing the LPRCT by its identification number.

3.2.1.20 The LPRCT lift sling assembly shall consist of two 5/8” dia. 6 X 19 independent wire rope core (IWRC) cables with a swaged eye at each end and have a minimum working load limit of 7,800 lbs. Two pairs of slings (four slings total) shall be provided. One pair of wire ropes shall have a finished length of 126” ± 1" each. The other two wire ropes shall have a finished length of 168" ± 1" each. The shorter pair of slings shall be installed on the LPRCT and the longer pair shall be provided separately. The load test shall be 11,700 (+585, -0) lbs for a minimum of 10 minutes. The visual inspection criteria shall be per paragraph 2.4 with the following six additional requirements as cause for rejection: 1. Two or more broken wires within 1 lay length of an end connection. 2. A reduction 3/64” or more of the nominal diameter in the straight run of the sling. 3. One completely broken or torn strand in any wire rope. 4. Wear exceeding one-third of the original diameter of outside individual wires. 5. Flattened sections where the diameter across the flat is less than 5/6 of the nominal diameter (does not apply to runs around eyes, thimbles, or shackles). 6. High strand (a strand that is not tightly twisted around the axis of the wire rope) where the height exceeds 10 percent of the nominal diameter. Slings shall have permanent tags attached providing sling identification number, sling capacity, and date that the certification is completed. The minimum safety factor shall be 5 to 1 based on wire rope certified breaking strength and downgrades. Vendor must provide the following information: 1. Actual breaking strength of the wire rope in pounds. 2. Wire rope manufacturer’s name. 3. Master reel number. 4. Breaking strength data must be traceable to the master reel number and to the qty of wire rope specified on this order. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002) referencing the identification tagging on each sling.

3.2.1.21 The contractor shall provide four one-inch shackles. Shackles shall be self-colored bolt type anchor shackles with a minimum capacity of 8.5 tons (e.g., Crosby S-2130). Shackles shall be load tested to 25,500 (+1275, -0) lbs for a minimum of ten minutes. NDT shall be performed after the load test(s). NDT shall be per paragraph 2.2 or a magnetic particle inspection procedure approved by the government. Acceptance criteria shall be in accordance with paragraph 2.3, Class 3. Shackles shall have permanent tags attached providing a shackle identification number, shackle capacity (if the shackle is not already so marked), and date that the certification is completed. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002) referencing the identification tagging on each shackle.

3.2.1.22 The HIC shall be pressure tested to 7.5 psig (+ 0.5 psig, -0.5 psig) as an integral unit consisting of the HIC liner, closure pan assembly, HIC liner shell, and an approved pressure test rig. The contractor shall provide a test/inspection report in accordance with Exhibit B (CDRL A002) referencing the LPRCT by its identification number.

3.2.1.23 The contractor shall provide two LPRCT closure lid gasket (primary plus one spare gasket).

3.2.2 The LPRCT shall be delivered to the Energy Solutions Barnwell Logistics Facility in Barnwell, South Carolina.

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