N39040Q4312V106 Attachment 1 4312V106 DEMINERALIZER SPEC SOW.pdf

DEMINERALIZER SPECIFICATIONS

The contractor shall furnish demineralizer assemblies that conform to the following design and specification requirements:

1) Pressure Vessel

Design Pressure:150 PSI and 29” Hg Vacuum.

Design Temperature: 140oF.

Design Flow Rate: 25 GPM.

Design size: 7 cubic feet of resin/media volume

Design Dimensions: 24” OD, Max height with fittings 45.25” Plus 0” Minus 1/8”

Lifting Attachments: Two ½”-13 UNC 2B tapped lifting holes with a minimum usable depth of 7/8”. Additional requirements as stated in Appendix 1.

Weight: Maximum gross weight shall be 2,500 pounds

2) Overpack/HIC Container

Dimensions: Diameter:33” Plus ¼” maximum OD

Height: 57” Plus 0” maximum

Lifting Attachments: Four lifting points with shackles rated to 10:1 safety factor based on material yield strength. The lifting points shall be designed that two attachments carry the load. Additional requirements as stated in Appendix 1.

Weight: The weight shall account for the max gross pressure vessel weight plus the weight of the Overpack/HIC Container.

3) The pressure vessel shall be fabricated and inspected to ASME BPVC-VIII, DIV I (latest Ed.) (U stamp). Code calculations shall be available upon request.

4) The contractor shall provide a drawing that specifies the specific manufacturing/assembly details of the demineralizer incorporating the requirements of this specification. The contractor shall obtain approval of the drawing(s) from Portsmouth Naval Shipyard, Code 2310.3 prior to fabrication of the demineralizer assembly.

5) The demineralizer shall be furnished filled with 3.5 cubic feet of activated carbon and

3.5 cubic feet of HOH resin

3.5 cubic feet of newly manufactured 20x50 US Sieve Series mesh, granulated, activated, coal or coconut based carbon. The carbon shall be loaded last. Granulated Activated Carbon shall meet the specifications of AWWA B604-18 at a minimum.

3.5 cubic feet of newly manufactured resin. Resin shall conform to O-I-1279, Class 3, FEDERAL SPECIFICATION ION EXCHANGE RESINS, or HOH resin that conforms to MIL- DTL-24119D Class 6. Rohm and Haas Amberlite IRN150, Amberlite MB20 or Ionac Chemical Company IONAC NM-60 are acceptable for use. The resin shall be loaded first.

6) The contractor shall hydrostatically test each demineralizer to a minimum of 135% of the design pressure (203 psig) for 30 minutes prior to installation into the High Integrity Container (HIC) or steel overpack. The acceptance criteria are no leakage and no visible permanent deformation of pressure boundary parts. The demineralizer shall be blown down of free-standing liquid after the hydrostatic test and prior to shipment.

7) A copy of hydrostatic test certification papers shall be provided for each demineralizer with the hydrostatic test pressure and documented proof of duration of test.

8) The demineralizer shall be braced and secure within the overpack to prevent movement or damage.

9) The overpack shall be designed such that the pressure vessel is removable from the overpack container.

10) Exposed surfaces of the demineralizer and associated components accessible under the HIC cover or overpack lid shall be coated with a non-porous substance, as necessary, to provide for easy decontamination of all accessible interior surfaces of the HIC or overpack lid.

11) Carbon steel surfaces shall be painted with coatings that do not have any heavy metal constituents.

12) The contractor shall provide written storage requirements for the as shipped condition of the demineralizer and how time will affect the resin for the following conditions; as shipped, filled with water and partially dewatered after use.

Absence of the documents listed above shall be cause for rejection.

13) Inlet, outlet and vent connections shall be 1” NPT connections with male camlok CRES fittings with mating CRES caps. The inlet, outlet, and vent connections shall be labeled.

The inlet piping shall be located in the center of the top shield to provide uniform flow distribution over the media bed.

14) The top of the demineralizer (below the fittings) shall be shielded with six (6) inches of steel or equivalent shielding.

15) To minimize backflow of media, the demineralizer inlet distribution nozzle shall be located as close as possible to the underside of the top shield to maximize the distance between the media bed and the nozzle. It shall incorporate a screen/retention element sized appropriately to prevent backflow.

16) The internal vent pipe through the top shield shall be installed flush or recessed into the underside of the top shield to eliminate a void space when filling the demineralizer.

17) The demineralizer shall be able to be dewatered to less than 0.5 % of the volume of the waste as specified in 10CFR61.56. A certified dewatering procedure shall be provided with the demineralizer.

18) The demineralizer shall be installed in a steel overpack container/HIC prior to shipment to Portsmouth.

19) There shall be minimum six (6) inches of clearance between the top of the demineralizer and the overpack lid seal.

20) The demineralizer shall be secured within the overpack to hold the demineralizer in place, i.e. shoring provided.

21) Additional shielding shall be installed as necessary to prevent streaming of radiation between the top six (6) inch steel shield and the circumference of the HIC or overpack.

22) The HIC/overpack shall be provided with a gasketed cover that has ASME B30 compliant rigging points, unless authorized below. The weight of the cover shall be less than 100 lbs with included rigging points. Each rigging point shall be rated for a minimum capacity of 200 lbs. If custom rigging points are utilized, the rigging points shall meet the design requirements of ANSI N14.6-1993. This requires a drop weight test per ASTM E 208-20 or a Charpy impact test per ASTM A 370-24 of the base material as specified in paragraph 4.2.6 of ANSI N14.6-1993. The anticipated minimum service temperature for lifting the demineralizer vessel is 20 deg. F, therefore, the nil ductility transition temperature shall be a minimum of -20 deg. F. The cover shall be labeled with the weight.

23) The HIC/overpack basket lifting equipment shall be field replaceable.

24) A list of all material used in the fabrication of the demineralizer and HIC/overpack assembly shall be provided.

25) All applicable warning/caution labels shall be affixed onto the top shield of the demineralizer assembly. These labels shall be visible upon removal of HIC cover or overpack lid.

26) All caution/warning signs shall be affixed to the HIC/overpack in a location that is easily readable.

27) Contractor shall arrange for the transportation company to protect the demineralizer from freezing during shipment. Contractor shall label the shipping container (crate, etc.) with the following statement in large, legible font: “Provide Freeze Protection”.

28) All Certifications and Tests for individual Demineralizers and associated parts are required to be sent to Code 2310.3 prior to shipping each Demineralizer.

Appendix 1 HIC/OVERPACK LIFT GEAR and SHACKLE

SPECIFICATIONS/PROCUREMENT REQUIREMENTS

1) The HIC lifting basket or overpack lifting gear must meet the requirements of NAVSEA 0989-030-7000, Rev 13 (or later), LIFTING STANDARD as specified below.

a. All welding shall be in accordance with AWS D1.1/D1/1M:2020.

b. The lifting basket lifting points shall meet the design requirements of ANSI N14.6-1993.

This requires a drop weight test per ASTM E 208-20 or a Charpy impact test per ASTM A 370-24 of the base material as specified in paragraph 4.2.6 of ANSI N14.6-1993. The anticipated minimum service temperature for lifting the overpack/HIC is 20 deg. F, therefore, the nil ductility transition temperature shall be a minimum of -20 deg. F. A certification of design requirements in accordance with ANSI N14.6-1993 for the lifting point is required.

c. The lifting basket lifting points and shackles must be designed to a safety factor of 10:1 based on material yield strength (must support ten times the maximum gross weight of the entire package). The lifting points shall be designed to account for two points carry the load and a minimum sling angle of 60 degrees from horizontal. A certification of compliance is required.

d. Before load test of paragraph 1.d), the lifting basket lifting points shall be visually inspected to the maximum extent practical for cracks, crushed threads, gouges and other deficiencies that would affect load bearing capability. Proof of completion of the visual inspection prior to load test must be submitted to the Shipyard for each lifting point.

e. A load test shall be performed to 150% (+5%, -0%) of the working load limit (i.e. if the working load limit of the attachment is 2500 lbs, load test is to 3750 lbs - 3937 lbs) at an angle of 60 (+5, -0) degrees from horizontal. Certification of load test for the lifting points and shackles is required.

f. After load test of paragraph 1.d), the lifting basket lifting points shall be visually inspected to the maximum extent practical for cracks, crushed threads, gouges and other deficiencies that would affect load bearing capability. Proof of completion of the visual inspection following load test must be submitted to the Shipyard for each lifting point.

g. After load testing of paragraph 1.d), a Magnetic Particle inspection shall be performed on each lifting point, the weld, the area surrounding each lifting point (heat affected zone), and each shackle. This shall be performed in accordance with NAVSEA Technical Publication TP T9074-AS-GIB-010/271. The acceptance criteria for the Magnetic Particle inspection shall be MIL-STD 2035A, for wrought material. The vendor shall submit documentation of satisfactory results of all Magnetic Particle tests prior to shipment of the demineralizer. (Certification of satisfactory test results is required.

h. In addition to the above, the shackles must meet the following:

i. Minimum breaking strength must be five (5) times the manufacturer’s rated safe working load. The working load limit of the shackles shall be reduced to account for the safety factor of 10:1 based on material yield strength.

ii. The material composition must meet the technical requirements of Fed. Spec. RR-C- 271H (grade A or B) for carbon and alloy steel or ASTM A314-23 for stainless steel.

Certification that the material composition meets RR-C-271H or ASTM A314-23 is required.

iii. The shackles must have a bolt type pin and nut to form a positive means of securing (similar to Crosby G-2130 or S-280). Snap ring pins thru the shackle pin are not authorized. Shackles shall be free of paint or other coatings. The bolt threads must extend past the nut when fully engaged.

i. After satisfactory load test and non-destructive testing, a metal tag or stencil shall be applied to the overpack/HIC with the following minimum information:

“Working load limit: __________ (combined)” ; “Test Load: _______” ; “Test Date: _______” ; “Minimum service temperature: 20 deg. F” “ Gross Weight ___________”, “Minimum Sling length ____________”

2) Summary of Certification of Compliance required:

(1) DESIGN REQUIREMENT CERTIFICATION TO ANSI N14.6-1993

(2) 10:1 SAFETY FACTOR

(3) LOAD TEST

(4) SATISFACTORY TEST RESULTS OF MAGNETIC PARTICLE TEST.

(5) MATERIAL COMPOSITION OF SHACKLE

DEMINERALIZER/PRESSURE VESSEL LIFTING POINT CERTIFICATION

3) The two integral tapped lifting holes must meet the requirements of NAVSEA 0989-030-

7000, Rev 13 (or later), LIFTING STANDARD as specified below:

a) Two 1/2”-13UNC-2B tapped lifting holes must be drilled and tapped into the six-inch shielding material. The holes must be tapped to a usable depth of 7/8” (minimum) and must be drilled 180 degrees apart on a 18-1/2” DBC. An area one inch in all directions from the center of each tapped lifting hole must be flat to allow 360 deg.

contact of the safety hoist ring bushing. An area two inches in all directions from the center of each tapped lifting hole must be clear of obstructions that would restrict free movement of the safety hoist ring. The minimum yield strength of the six-inch shielding material must be 36,000 PSI.

b) The tapped lifting holes shall meet the design requirements of ANSI N14.6-1993.

This requires a drop weight test per ASTM E 208-20 or a Charpy impact test per ASTM A 370-24 of the base material as specified in paragraph 4.2.6 of ANSI N14.6-1993.

The anticipated minimum service temperature for lifting the demineralizer vessel is 20 deg. F, therefore, the nil ductility transition temperature shall be a minimum of - 20 deg. F. A certification of design requirements in accordance with ANSI N14.6- 1993 for the lifting hole is required.

c) Before load test of paragraph 3.d), the tapped lifting holes shall be visually inspected to the maximum extent practical for cracks, crushed threads, gouges and other deficiencies that would affect load bearing capability. Proof of completion of the visual inspection prior to load test must be submitted to the Shipyard for each tapped lifting hole.

d) A load test shall be performed on the tapped lifting holes of paragraph b) with the test load applied in the same direction the demineralizer is lifted, not to exceed 10.6 deg. from vertical. The load test shall be 150% (+5%, -0%) of the Working Load Limit (i.e., if the Working Load Limit is 2500 lbs, the test is 3,750 lbs (+187 lbs, -0 lbs) applied equally between the two tapped lifting holes. The load test shall be held for a minimum of 10 minutes.

e) After load test of paragraph 3.d), the tapped lifting holes shall be visually inspected to the maximum extent practical for cracks, crushed threads, gouges and other deficiencies that would affect load bearing capability and shall be inspected using GO, NO-GO gages. Proof of completion of the visual inspection following load test must be submitted to the Shipyard for each lifting hole.

f) After load testing of paragraph 3.d), a Magnetic Particle inspection shall be performed on the base material around the tapped lifting holes, beginning at the edge of the hole and extending out ½ inch. This shall be performed in accordance with NAVSEA Technical Publication TP T9074-AS-GIB-010/271. The acceptance criteria for the Magnetic Particle inspection shall be MIL-STD 2035A, for wrought material. The vendor shall submit documentation of satisfactory results of all Magnetic Particle tests prior to shipment of the demineralizer.

g) After satisfactory load test and non-destructive testing, a metal tag or stencil shall be applied to the vessel head with the following minimum information:

“Working load limit: 2500 lbs (combined)” ; “Test Load: _______” ; “Test Date: _______” ;

“Minimum service temperature: 20 deg. F” “ Gross Weight ___________”, “Minimum Sling length

h) Proof of the tapped lifting hole certification must be submitted to the Shipyard for each tapped lifting hole. A copy of all load test certification papers, results of visual inspections, results of magnetic particle inspections, design requirement certifications to ANSI N14.6-1993, and results of gage inspections shall be sent to the Shipyard before delivery. Absence of these documents shall be cause for rejection.

i) The tapped holes shall have threaded plugs installed, after testing and inspection, to protect the internal threads. The tapped holes must be free of paint, lubrication and debris.

4) Summary of Certification of Compliance required:

(1) DESIGN REQUIREMENT CERTIFICATION TO ANSI N14.6-1993

(2) PROOF OF COMPLETION OF VISUAL INSPECTION PRIOR TO AND AFTER

LOAD TEST

(3) LOAD TEST

(4) SATISFACTORY TEST RESULTS OF MAGNETIC PARTICLE TEST