Attachement 1 - 9274V000-00646-Distro A Performance Specification Rev C cask.pdf

PSNS&IMF, Code 2310.3 Page 1 of 20 October 30, 2019 Rev. C

Statement of Work / Specification for

Shielded Shipping Containers (Casks)

Contract No: N4523A9078V000

October 30, 2019

Revision: C

Distribution Statement A: Approved for public release, distribution is unlimited.

PSNS&IMF, Code 2310.3 Page 2 of 20 October 30, 2019 Rev. C

TABLE OF CONTENTS

1. STATEMENT OF WORK:

2. APPLICABLE DOCUMENTS / SPECIFICATIONS

3. REQUIREMENTS

3.1 General

3.2 Technical Requirements

3.2.1 General Configuration / Design

3.2.2 Shipping Criteria

3.2.3 Dimensions

3.2.4 Gamma Radiation Attenuation

3.2.5 Weather Protection

3.2.6 Materials of Construction

3.2.7 Lifting & Handling

3.2.8 Painting

3.2.9 Labelling and Markings

4. QUALITY ASSURANCE

4.1 Welding Requirements

4.2 NDT Requirements

4.3 Gamma Radiation Attenuation

4.4 Inspections

4.5 Documentation and Certifications

PSNS&IMF, Code 2310.3 Page 3 of 20 October 30, 2019 Rev. C

1. STATEMENT OF WORK:

1.1 Provide the design for Shielded Shipping Containers (Casks) per the following requirements.

Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS&IMF) intends to use the casks as Type A packages or General Design packages in accordance with Title 49 of the

Code of Federal Regulations (49 CFR) for shipment of demineralizers and associated radioactive contents over public highways.

1.2 Fabricate, test and deliver an initial quantity of four (4) Shielded Shipping Containers (Casks) per the design of paragraph 1.1 above and the following requirements. It is the Government’s intent that a contract be awarded to a single primary contractor to deliver complete and usable items meeting the requirements stated herein.

1.3 Delivery Schedule: Initial delivery quantity is four (4) no later than 03/31/2020 and (2) no later than 09/30/2020, then PSNS&IMF shall have the option to purchase two (2) additional casks each year thereafter for additional 3 years. Schedule is summarized below:

Year Quantity Delivery Date

2020 4 EA 03/31/2020

2020 2 EA 09/30/2020

2021 2 EA 09/30/2021

2022 2 EA 09/30/2022

2023 2 EA 09/30/2023

Total: 12 EA

2. APPLICABLE DOCUMENTS / SPECIFICATIONS

2.1 Title 49 (Transportation) of the Code of Federal Regulations (49 CFR)

2.2 ANSI 14.6-1993; Radioactive Materials – Special Lifting Devices for Shipping Containers

Weighing 10,000 Pounds (4500 kg) or More

2.3 AWS D1.1/D1.1M; Structural Welding Code – Steel

2.4 NAVSEA Technical Publication TP T9074-AS-GIB-010/271 (TP-271); Requirements for Non-

Destructive Testing Methods

2.5 MIL-STD-2035A; Non-Destructive Testing (NDT) Acceptance Criteria

2.6 SSPC-SP 10/NACE NO.2; Joint Surface Preparation Standard, Near-White Metal Blast Cleaning

2.7 ASTM C1831; Standard Guide for Gamma Radiation Shielding Performance Testing

2.8 ASTM A36; Standard Specification for Carbon Structural Steel

2.9 ASTM A500; Standard Specification for Cold-Formed Welded and Seamless Carbon Steel

Structural Tubing in Rounds and Shapes

2.10 ASTM B29; Standard Specification for Refined Lead

2.11 ASTM A370; Standard Test Methods and Definitions for Mechanical Testing of Steel Products

2.12 ASTM E208; Standard Test Method for Conducting Drop-Weight Test to Determine Nil-

Ductility Transition Temperature of Ferritic Steels https://ewb.ihs.com/#/document/VJZNJFAAAAAAAAAA?qid=636706583079258000&sr=re-1-10&kbid=4%7C20027&docid=943287455 https://ewb.ihs.com/#/document/MLKRJFAAAAAAAAAA?qid=636706588478027800&sr=re-1-10&kbid=4%7C20027&docid=941851271 https://ewb.ihs.com/#/document/IMYXEGAAAAAAAAAA?qid=636706589778867800&sr=re-1-10&kbid=4%7C20027&docid=943507795 https://ewb.ihs.com/#/document/IMYXEGAAAAAAAAAA?qid=636706589778867800&sr=re-1-10&kbid=4%7C20027&docid=943507795

PSNS&IMF, Code 2310.3 Page 4 of 20 October 30, 2019 Rev. C

3. REQUIREMENTS

3.1 General

3.1.1 The design for the shielded shipping cask will be provided by the Contractor to the Government.

The Contractor will also be responsible for manufacturing, testing, delivery and off-loading of the casks at PSNS&IMF as follows:

3.1.1.1 The contractor shall fabricate, assemble, and test the shielded shipping casks at the Contractor’s facility prior to delivery.

3.1.1.2 The contractor shall deliver completed casks to PSNS&IMF, Bremerton, Washington.

3.1.1.3 The contractor shall perform final cleaning of the casks after offloading.

3.1.1.4 The contractor shall provide and submit a transportation, delivery, and offloading plan 60 days prior to delivery to PSNS&IMF. PSNS&IMF shall have 5 working days to review and approve the plan. The delivery plan shall conform to all state and local transportation requirements.

3.1.1.5 The delivered cask assemblies, including the pallets shall be free of corrosion.

3.1.2 Where MIL-Specs, Standards, or Technical Publications are referenced in this document, the latest revisions shall be used unless a specific revision is listed.

3.2 Technical Requirements

3.2.1 General Configuration / Design

3.2.1.1 The general configuration of the cask shall be a vertical cylinder with integral bottom/base and removable lid. Lid shall be able to be secured with fasteners to the cask body in a way that allows for transportation over public highway to meet 49 CFR requirements.

3.2.1.2 Each cask shall be designated with a unique serial number for identification during fabrication, testing and delivery. All certified records requested by this specification shall include the unique serial number for the cask being tested / documented. The convention shall be “PSNS SC-1”, “PSNS SC-2”, etc, in sequence. The serial number for each cask shall be clearly labeled on both the cask body and the lid. See Table 1. At final delivery, the cask lid number must match the cask body number.

3.2.1.3 A steel pallet shall be fabricated to be bolted onto the bottom of the cask body (baseplate) and shall be designed to lift the entire cask with a forklift. Pallet shall be removable. Pallet will remain attached to the bottom of the cask when lifting the cask via overhead crane.

3.2.1.4 All calculations required for the design of the casks shall be performed by a Structural Engineer and/or certified by a Professional Engineer.

3.2.1.5 Contractor shall provide a conceptual rendering, sketch, drawing, and/or photo of the design concept with the bid submittal. These submittals shall illustrate the general design intent to meet section 3.2.3 requirements, including proposed lifting padeye locations. Submittals shall also illustrate type/location of gamma radiation attenuation materials. Contractor shall also submit proof of past performance on similar products / fabrication processes with the bid submittal.

Submittals will be evaluated against these criteria and adherence will factor into the decision for which vendor is awarded the contract.

PSNS&IMF, Code 2310.3 Page 5 of 20 October 30, 2019 Rev. C

3.2.1.6 Contractor shall provide a user manual for the cask including complete instructions for assembling the cask lid to place package into shipping configuration. User manual shall be provided to PSNS&IMF at delivery.

3.2.1.7 A complete set of pre-fabrication drawings for the cask including materials of construction shall be provided to PSNS&IMF prior to the start of fabrication. PSNS&IMF shall have 10 working days to review the drawings and approve start of fabrication.

3.2.1.8 A complete set of final, as-built drawings for the cask shall be provided to PSNS&IMF at delivery including materials of construction.

3.2.1.9 PSNS&IMF shall have unlimited rights to the submitted drawings as defined in

DFARS 252.227-7013 (see http://farsite.hill.af.mil/vmdfara.htm)

PSNS&IMF, Code 2310.3 Page 6 of 20 October 30, 2019 Rev. C

3.2.2 Shipping Criteria

3.2.2.1 The casks shall be designed and fabricated for use as a Type A Package per 49 CFR.

3.2.2.2 Contractor shall submit proof of cask compliance with 49 CFR Part 173.412 for certification as a

Type A package. Results of testing per 49 CFR Part 173.465 and demonstration of compliance must be submitted to PSNS&IMF in a manner that satisfies 49 CFR Part 173.461. In addition, contractor shall supply documentation as referenced in 49 CFR Part 173.415(a) to PSNS&IMF so that PSNS&IMF may ship the casks as Type A containers. Contractor shall submit this documentation prior to shipment of casks to PSNS&IMF.

3.2.2.3 Contractor shall provide photos, sketches, schematics of testing to PSNS&IMF prior to shipment along with any calculations to meet 49 CFR Part 173.465 packaging tests.

3.2.2.4 The intended shipping contents of the cask will be a nine (9) cubic feet cylindrical pressure vessel

(demineralizer), 24 inch (+/-1/8 inch) diameter, no greater than 46 inches tall. Maximum weight of the demineralizer to be loaded into the shipping cask is expected to be 1,525 pounds, however, the cask must be certified for a gross weight to accept a 2,000 pound payload. Cask must be configured to allow for installation and removal of this pressure vessel. If contractor requires additional details for this pressure vessel, contact PSNS&IMF. PSNS&IMF shall have 5 working days to provide additional details of pressure vessel.

3.2.2.5 PSNS&IMF intends to shore the pressure vessel in four quadrants equally spaced between the pressure vessel and cask walls to prevent lateral movement of the vessel during shipment. The top of the pressure vessel will be shored to prevent vertical motion of the pressure vessel during shipment.

3.2.2.6 Any structural part of the cask which could be used to lift the package but is not designed to carry the entire package weight must be capable of being rendered inoperable before PSNS&IMF ships the container as required by 49 CFR Part 173.410(b). The cask lid padeye holes are intended to be rendered inoperable by PSNS&IMF during preparation for shipment.

3.2.2.7 The outside of the cask shall incorporate a feature such as a seal, that is not readily breakable, and that, while intact, is evidence that the package has not been opened as required by 49 CFR Part

173.412(a).

3.2.2.8 The cask must be marked legibly and durably with lettering at least 0.47 inches tall indicating

“Type A” and the international vehicle registration code of the country of origin of the design as required by 49 CFR Part 172.310(b) and (c) and shall also comply with the following:

3.2.2.8.1 Per 49 CFR Part 178.350, cask must be marked legibly and durably with “USA DOT 7A Type

A”. See Table 1.

3.2.3 Dimensions

3.2.3.1 The cask exterior shall be a vertical cylinder, nominally 60” tall and 36” diameter. Cask exterior dimensions in the shipping configuration shall not exceed 66” tall and 40” diameter (not including padeyes). See Figure 1 for a side view of the cask.

PSNS&IMF, Code 2310.3 Page 7 of 20 October 30, 2019 Rev. C

1 4 7 10 13 16 19 22 etc.

2 5 8 11 14 17 20 23 etc.

3 6 9 12 15 18 21 24 etc.

8"

8" typ.

typ.

8"

8" typ.

typ.

1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

Cask Lid Gridding 16 total grids expected (disregard partial grids: <50% by area)

Cask Body Gridding 42 total grids expected

O 24" u 1/8"

1 1/2" Min.

Demineralizer Vessel

Cask Wall

Annular Void Space

Pallet

24"

1 4 7 10 13 16 19 22

2 5 8 11 14 17 20 23

3 6 9 12 15 18 21 24

>1.9 tenth thickness

>1.425 tenth thickness

>1.425 tenth thickness

>1.9 tenth thickness

11"

CLEAR

OPENING

Cask LidCask Lid Padeye (typ) (2 EA)

Cask Body Padeye (typ) 3 EA Equally Spaced

Cask Pallet

36" +4" -0"

47" +3" -0"

27" +3" -0"

60 +6" -0"

Temporary Cradle

Chain Fall

Figure 1: Elevation View of the Cask

3.2.3.2 The cask body, when lid is removed, shall provide a clear vertical cylinder clearance of 27”

(diameter) minimum not to exceed 30” (diameter) for installation and removal of demineralizer.

Clear height inside container with lid installed shall be a minimum of 47” (to provide clearance for demineralizer fittings), but not to exceed 50”.

3.2.3.3 The cask must be configured to allow for shoring of the 24 inch (+/- 1/8 inch) outer diameter demineralizer. The annular gap between the demineralizer outer diameter and shipping cask inner diameter shall be 1-1/2 inches or greater to allow for insertion of radiation detection probes and shoring. See Figure 2.

2 5 8 11 14 17 20 23 etc.

3 6 9 12 15 18 21 24 etc.

8"

8" typ.

typ.

8"

8" typ.

typ.

1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

Cask Lid Gridding 16 total grids expected (disregard partial grids: <50% by area)

Cask Body Gridding 42 total grids expected

O 24" u 1/8"

1 1/2" Min.

Demineralizer Vessel

Cask Wall

Annular Void Space

Pallet

24"

1 4 7 10 13 16 19 22

2 5 8 11 14 17 20 23

3 6 9 12 15 18 21 24

>1.9 tenth thickness

>1.425 tenth thickness

>1.425 tenth thickness

>1.9 tenth thickness

11"

CLEAR

OPENING

Cask LidCask Lid Padeye (typ) (2 EA)

Cask Body Padeye (typ) 3 EA Equally Spaced

Cask Pallet

36" +4" -0"

47" +3" -0"

27" +3" -0"

60 +6" -0"

Temporary Cradle

Figure 2: Plan View of the Cask (lid removed)

PSNS&IMF, Code 2310.3 Page 8 of 20 October 30, 2019 Rev. C

3.2.3.4 The cask pallet size shall be 42 inches X 42-1/2 inches. The cask pallet shall be removable.

Required design for pallet is shown in Figure 3.

Figure 3: Cask Pallet Design

Material for Figure 3:

PC QTY DESCRIPTION MATL SPEC

1 6 CHANNEL, STRUCTURAL, C 4 X 5.4 X 42” LG ASTM A36

2 2 TUBING, RECTANGULAR, HSS 12 X 4 X ¼ X 42 ½” LG ASTM A500 GR B

NOTES:

Dimensional tolerance: ± 1/16".

Break all sharp edges to 1/32" (Min.)

chamfer. Remove all burrs.

PSNS&IMF, Code 2310.3 Page 9 of 20 October 30, 2019 Rev. C

3.2.3.5 The cask pallet shall be bolted to the baseplate of the cask. The cask baseplate may be either circular or rectangular and shall contain the bolt hole pattern of Figure 4. PSNS&IMF may authorize alternative bolting patterns if required for proper fit-up. Cask shall be bolted to the pallet using the fastener system of paragraph 3.2.6.6.

Figure 4: Cask Pallet Design

3.2.4 Gamma Radiation Attenuation

3.2.4.1 The walls, bottom, and lid of the cask when assembled in the shipping configuration shall provide gamma radiation attenuation equivalent to four inches of solid lead sheet for a Co60 source. The cask must be configured such that gamma rays emitted from a Co60 source placed in any location inside the cask are attenuated equivalent to four inches of solid lead sheet for a Co60 source (i.e.

no gaps allowing for radiation to escape attenuated below design thickness).

3.2.4.2 No areas of shielding are allowed to be less than 95% of design attenuation thickness stated in paragraph 3.2.4.1 (i.e. walls, bottom, and lid of cask must provide minimum shielding equivalent to 3.8 inches of solid lead sheet for a Co60 source). Cask walls and lid shall be gamma scanned per section 4.3 to validate this requirement. Measurements below these minimums are cause for rejection.

3.2.4.3 If lead or other molten materials are poured and used as the shielding material, the following techniques shall be utilized during the pouring process to ensure gamma radiation attenuation complies with paragraph 3.2.4.1 & 3.2.4.2:

3.2.4.3.1 Internal surfaces of the container shell shall be cleaned prior to pouring molten shielding to avoid creating unacceptable voids or defects.

3.2.4.3.2 A method shall be utilized to free trapped gases in molten materials (e.g. raking).

3.2.4.3.3 Stiffeners / spacers / brackets shall be temporarily installed to separate the walls of the container prior to pouring molten shielding and to reduce deformation of the container walls.

Resultant dimensions of container after pouring shielding materials must conform to Figure 1.

PSNS&IMF, Code 2310.3 Page 10 of 20 October 30, 2019 Rev. C

3.2.4.3.4 A method shall be utilized to cool molten shielding material in a slow, controlled manner to minimize shrinkage, creation of voids, and distortion to cask walls (e.g. use of zone heaters/torches, environmental controls). Solidification shall proceed from the bottom of the pour, upward.

3.2.4.3.5 If unacceptable voids are created during pouring which will not comply with paragraph 3.2.4.1, they must be repaired by excavation and local re-pouring / melting or re-fabricated and poured.

3.2.4.3.6 A total void percentage of 5% or less is required after molten shielding materials have cooled.

This shall be confirmed using volume / density calculations and the calculated void percentage shall be reported to PSNS&IMF at delivery for each cask.

3.2.4.4 If hazardous materials are to be used for gamma radiation attenuation (e.g. lead), the hazardous material must be encased so it is inaccessible to workers during normal operation and maintenance of the cask.

3.2.5 Weather Protection

3.2.5.1 It is critical that the cask be weather-tight when in the normal shipping configuration. Infiltration of rainwater, including wind driven rain, is unacceptable.

3.2.5.2 A gasket shall be used to install the cask lid and must provide weather protection and protection against release of contents as required by 49 CFR Part 173.412.(j).(1). Gasket shall be provided upon initial delivery of the cask. The specification, configuration and material for gasket shall be submitted to PSNS&IMF prior to fabrication and PSNS&IMF shall have 5 working days to review and approve. No hazardous gasket materials are allowed.

3.2.5.3 The lid/gasket configuration shall be designed such that use of a sealant or other consumable material (e.g. RTV) is not required to preclude the entrance of rain water into the cask interior during shipment.

3.2.5.4 Gasket must be removable to allow for inspection and periodic replacement.

3.2.6 Materials of Construction

3.2.6.1 The inside of the cask must be constructed with corrosion resistant material (e.g. 300 Series

Stainless Steel) or painted (minimum) ordinary strength steel. The bottom and sides of the cask interior shall be constructed to minimize crevices which can trap radioactive contamination. All joints must be seal welded. This ensures cask interior is easily decontaminated if required.

3.2.6.2 Structural Steel Framework (bar, tubing, angle, channel, plate, etc.) shall be constructed of ordinary strength steel meeting ASTM A36 or ASTM A500 Gr. B, as applicable, sized to meet the design criteria of this specification.

3.2.6.3 If lead is chosen as the shielding material, it shall conform with Federal Specification

QQ-L-171e, Grade C or pure lead per ASTM B29 unless otherwise authorized by PSNS&IMF.

3.2.6.4 No Resource Conservation and Recovery Act (RCRA) hazardous materials shall be accessible to workers during normal operation and maintenance of the cask.

3.2.6.5 Cask lid fasteners shall conform with the following:

3.2.6.5.1 Bolts - Standard bolts shall be regular hexagon head type, SAE J429 Grade 5, or better. Steel, zinc plated.

3.2.6.5.2 Washers - Per Federal Specification FF-W-92, Type A, Grade 1, Class B or better. Steel, zinc plated.

PSNS&IMF, Code 2310.3 Page 11 of 20 October 30, 2019 Rev. C

3.2.6.5.3 Nuts - Standard nuts shall be regular hexagon head type per SAE J995 Grade 5 or better. Steel, zinc plated.

3.2.6.6 Cask body to pallet bolts shall be as follows:

3.2.6.6.1 8 each cap screws, hexagon head, 7/8 inch nominal size X LG to suit, SAE J429 Grade 8 or better. Steel, zinc plated.

3.2.6.6.2 8 each washers per Federal Specification FF-W-92, Type A, Grade 1, Class B or better, 7/8 inch nominal size. Steel, zinc plated.

3.2.6.6.3 8 each nuts, plain, hexagon, 7/8 inch nominal size, SAE J995 Grade 5 or better. Steel, zinc plated.

3.2.7 Lifting & Handling

3.2.7.1 The cask body shall be designed with three permanent (not bolted on) padeyes capable of lifting the entire cask assembly (cask, lid, pallet) while containing the demineralizer of paragraph 3.2.2.4

(2,000 pound maximum payload). Each of the padeyes will be designed and then certified for a working load limit (WLL) that is one-third the max total weight possible (cask, lid, pallet, max payload, etc.), times 1.1 (+10% safety), and times 1.0353 (rigging at 15 degrees). The range of the rigging for each padeye is from vertical to 15 degrees inward. The rigging configuration for the cask is to have rigging coming from each of the three evenly spaced padeyes to a single point above the cask. The padeye design will review loading the padeye, with WLL, from vertical to bent in 15 degrees from vertical within the plane of the padeye. Padeyes are to be aligned so the rigging stays in the plane of the padeye no matter how long the rigging is. Lifting attachments must be compatible with standard rigging gear.

3.2.7.1.1 PSNS&IMF intends to choke around the cask body in two different positions to tip an empty cask (no lid installed) over on its side for routine maintenance. The first location would be just below the cask body padeye structure (as seen on Figure 1). The second location would be structure on the lower half of the cask or one of the fork lift pockets to rotate the cask to the horizontal position. Prior to shipment of casks, vendor shall provide proof that casks may be tipped over using one of the following methods: 1) Performance of tipping operation and submission of photos showing evolution including rigging gear. 2) Calculations showing cask structure is adequate for tipping evaluation described above. 3) Written authorization from

Structural Engineer for location and method of tipping (as described above) stating that cask structure is adequate for tipping.

3.2.7.2 The cask lid shall contain two permanent (not bolted on) lifting padeyes. Each of the padeyes will be designed and then certified for a working load limit (WLL) that is the max lid weight possible times 1.1 (+10% safety). Each padeye will be designed to withstand WLL in any direction. Normal lifting of the lid will be by using both padeyes at the same time. Padeyes are to be aligned so the rigging stays in the plane of the padeye no matter how long the rigging is.

PSNS&IMF intends to lift the cask assembly and cask lid using an overhead crane or a forklift.

Lifting attachments must be compatible with standard rigging gear.

3.2.7.3 All lifting padeyes and associated attachment welds shall be designed with a minimum Safety

Factor of 10:1 where the maximum Von Mises stress (using WLL) of the worst configuration is less than 1/10th of the weakest material’s yield strength (the weaker of the weld or base material).

Possible configurations are defined in paragraphs 3.2.7.1 and 3.2.7.2.

PSNS&IMF, Code 2310.3 Page 12 of 20 October 30, 2019 Rev. C

3.2.7.4 The allowable bearing design strength for the lifting attachments shall be based on 1/10 of the yield strength of the padeye material.

3.2.7.5 The padeye base material shall meet the material requirements of ANSI N14.6-1993. This requires a drop weight test per ASTM E208 or a Charpy impact test per ASTM A370-77 of the base material as specified in paragraph 4.2.6 of ANSI N14.6-1993. The anticipated minimum service temperature for the cask is 20 deg. F, therefore, the nil ductility transition temperature shall be a minimum of -20 deg F. Contractor shall submit certified documentation of satisfactory results for all padeye base material.

3.2.7.6 The contractor or subcontractor shall conduct NDT of accessible surfaces of the padeyes, including attachment welds and heat effected zone (1 inch) of the metal the padeye is attached to using an NDT program that meets NAVSEA Technical Publication TP T9074-AS-GIB-010/271.

3.2.7.7 Prior to the start of fabrication, contractor shall provide design and calculations required for the design of the padeyes. Calculations shall be performed by a Structural Engineer and/or certified by a Professional Engineer. Lifting padeyes shall be designed/oriented such that all load bearing welds are accessible for future Magnetic Particle Testing (MT) inspections. PSNS&IMF shall have 15 working days to review and approve the design and authorize fabrication.

3.2.7.8 The contractor shall provide a lift sketch detailing the recommended rigging configuration, rigging gear and associated capacities to lift the cask assembly and lid at least 30 days prior to delivery. PSNS&IMF shall have 10 working days to review and approve.

3.2.7.9 The structure supporting the lifting attachments shall be designed to sustain the various lateral loads that will be imparted by the lifting attachments during lifting including the loads induced by sling and rigging attached at various angles. The adequacy of the structure shall be shown by an analysis that can be done in accordance with AISC Steel Construction Manual using Allowable

Strength Design or other accepted engineering analysis methods and must include buckling where appropriate. This analysis performed by a Structural Engineer is to be submitted prior to fabrication and PSNS&IMF shall have 15 working days to review.

3.2.7.10 All welding and weld visual inspection of the padeyes shall be in accordance with AWS D1.1.

These welds shall meet the Workmanship requirements of AWS D1.1 and shall be full-sized as specified by the design engineer. Surface finish of these welds shall be suitable for Magnetic

Particle Testing (MT) with acceptance criteria per MIL-STD 2035A Class 3.

3.2.7.11 The contractor shall perform visual inspections, NDT and proof load testing of each padeye in accordance with the following:

3.2.7.11.1 Following fabrication, the contractor shall perform a pre-load test visual inspection of the welds. Visually inspect the welds associated with the padeyes and accessible load bearing members per AWS D1.1 to ensure that there are no signs of cracked, broken, worn, distorted, corroded, binding, or loose parts. There should be no splatter. Verify welds are the required size. A certified report is required with reference to the requirements, extent of the inspection, and the results of the inspection.

3.2.7.11.2 Pre-load test visual inspection: Perform a visual inspection of the padeyes, adjacent structure

(within 1” of the toe of the weld), and welds (padeye and accessible load bearing member).

There shall be no apparent deformation or apparent damage such as cracked, broken, worn, distorted, corroded, binding, loose parts, bending, twisting, elongation, or excessive wear. A certified report is required with reference to the requirements, extent of the inspection and the results of the inspection.

PSNS&IMF, Code 2310.3 Page 13 of 20 October 30, 2019 Rev. C

3.2.7.11.3 Following the visual inspections above, the contractor shall subject the load bearing welds including the heat affected zone of each lifting attachment and accessible load bearing members to Magnetic Particle testing in accordance with NAVSEA Technical Publication TP

T9074-AS-GIB-010/271. The acceptance criteria for welds shall be MIL-STD 2035A, Class

3. In addition, all accessible surfaces of the lifting padeyes shall be Magnetic Particle tested in accordance with NAVSEA Technical Publication TP T9074-AS-GGIB-010/271. The acceptance criteria for MT of these surfaces shall be MIL-STD 2035A, for wrought material.

3.2.7.11.4 Following acceptance of the pre-load test MT above, the contractor shall subject each lifting attachment to a proof load test for a minimum of ten minutes. The test value shall be 155 %

+5%,-0 % of the padeye WLL. For the cask padeyes, the test load will be in the direction of the highest stresses as shown by the calculation package within the plane of the padeye. For the lid padeyes 2 load tests are required where one is the worst case in plane loading and the other is the worst case out of plane loading. Contractor shall submit photographs showing the configuration for the load tests. A certified report is required with reference to the requirements, extent of the test (load configuration, load applied, time tested), and the results of the test.

3.2.7.11.5 Post load test visual inspection: Perform a visual inspection of the padeyes, adjacent structure

(within 1” of the toe of the weld), and welds (padeye and accessible load bearing member).

There shall be no apparent deformation or apparent damage such as cracked, broken, worn, distorted, corroded, binding, loose parts, bending, twisting, elongation, or excessive wear. A certified report is required with reference to the requirements, extent of the inspection, and the results of the inspection.

3.2.7.11.6 Post load test inspection of welds: Perform a post load test visual inspection of the welds.

Visually inspect the welds associated with the padeyes and accessible load bearing members per AWS D1.1 to ensure that there are no signs of cracked, broken, worn, distorted, corroded, binding, or loose parts. There should be no splatter. Verify welds are the required size. A certified report is required with reference to the requirements, extent of the inspection, and the results of the inspection.

3.2.7.11.7 Following the proof load test and visual inspections above, the contractor shall subject the load bearing welds including the heat affected zone of each lifting attachment and accessible load bearing members to Magnetic Particle testing in accordance with NAVSEA Technical

Publication TP T9074-AS-GIB-010/271. The acceptance criteria for welds shall be MIL-STD

2035A, Class 3. In addition, all accessible surfaces of the padeyes shall be Magnetic Particle tested in accordance with NAVSEA Technical Publication TP T9074-AS-GIB-010/271. The acceptance criteria for MT of these surfaces shall be MIL-STD 2035A, for wrought material. A certified report is required with reference to the requirements, extent of the inspection, and the results of the inspection.

PSNS&IMF, Code 2310.3 Page 14 of 20 October 30, 2019 Rev. C

3.2.7.11.8 Following satisfactory completion of the above tests, mark each padeye with a laser etched stainless steel label plate with the information below. Attach label plates to structure adjacent to the padeyes using permanent industrial adhesive. See Table 1.

For the cask padeyes:

SPS PADEYE

ID NO: (PSNS SC-X) cask serial # per paragraph 3.2.1.2

SPS CAPACITY: (WLL of paragraph 3.2.7.1) LBS PER PADEYE

MAX 15 DEG. FROM VERTICAL

TEST DATE: (date above tests are completed)

CERT EXPIRATION DATE: NA, SF >10:1

NO LIFTING BELOW 20°F

For the lid padeyes:

SPS PADEYE

ID NO: (PSNS SC-X) cask serial # per paragraph 3.2.1.2

SPS CAPACITY: (WLL of paragraph 3.2.7.2) LBS PER PADEYE

TEST DATE: (date above tests are completed)

CERT EXPIRATION DATE: NA, SF >10:1

NO LIFTING BELOW 20°F

3.2.7.11.9 The deliverables of this section (3.2.7.11) shall be sent to PSNS&IMF 30 days prior to shipment.

3.2.7.12 The cask assembly (cask, lid, pallet) must be weighed after all work is complete, including painting and outfitting. A calibrated instrument shall be used in weighing the cask. Proof of calibration shall be provided. The final weight of the cask (rounded up to the next 100 pounds) must be recorded (do not include the weight of the rigging gear in the final weight). The final recorded weight and a copy of the weighing instrument certification of calibration papers shall be forwarded to PSNS&IMF 10 days prior to delivery. Label the actual cask assembly weight

(cask, lid, pallet) and max gross weight (cask, lid, pallet, max payload) on the side. Marking requirements are contained in 49 CFR Part 172.310(a). See Table 1.

3.2.8 Painting

3.2.8.1 General Paint Requirements:

3.2.8.1.1 Paint shall not contain lead, chromates, or other heavy metals above RCRA limits. Paint shall contain no hazardous constituents in the dried form.

3.2.8.1.2 Prior to painting, clean all exposed ferrous surfaces and blast to near white metal per NACE

No. 2/SSPC-SP 10 and immediately coat per manufacturer’s instructions and paragraph 3.2.8.2 of this specification.

PSNS&IMF, Code 2310.3 Page 15 of 20 October 30, 2019 Rev. C

3.2.8.1.3 Ambient or space temperature at the time of paint application and curing shall be maintained between 50° and 95° F and at a minimum of 5° F above the dew point during coating application.

3.2.8.1.4 The dry film thickness, drying time between coats, etc., shall conform to the paint manufacturer's recommendations. Measure dry film thickness of surface coating system with elcometer or similar device.

3.2.8.1.5 The finished coating system shall have a continuous surface, smooth, easy to clean, free of pits, voids, cracks or other surface discontinuations. The coating shall show no signs of chalking, crinkling, peeling, delaminating, blistering, entrained dirt particles or wrinkling.

3.2.8.1.6 Do not blast or paint stainless steel (if used). For any welded joints where stainless steel and carbon steel are joined, paint the carbon steel up to and including the weld and heat affected zone. Stainless steel surfaces shall be protected during coating processes. All over spray shall be removed.

3.2.8.2 Coating System:

3.2.8.2.1 Prime paint all carbon steel surfaces with an epoxy primer compatible with chosen topcoat per manufacturer’s guidance. Primer must be Formula 150 Green epoxy primer per

MIL-DTL-24441 unless otherwise authorized by PSNS&IMF. Equivalent paint per

MIL-PRF-23236 may be used.

3.2.8.2.2 Topcoat paint all EXTERIOR primed carbon steel surfaces with a gray epoxy topcoat, Formula 151 per MIL-DTL-24441 unless otherwise authorized by PSNS&IMF. Equivalent paint per MIL-PRF-23236 may be used.

3.2.8.2.3 Topcoat paint all INTERIOR primed carbon steel surfaces with a white epoxy topcoat, Formula 152 per MIL-DTL-24441 unless otherwise authorized by PSNS&IMF. Equivalent paint per MIL-PRF-23236 may be used.

3.2.8.2.4 Topcoat lifting padeyes for the lid and cask body with International Orange enamel paint per

MIL-E-24635, TY-2, CL-1.

3.2.8.2.5 Paint a lid “matchmark” using red epoxy paint showing the as-installed orientation of the cask lid to cask body. Mark shall be approximately 1” wide by 2” tall on cask lid and cask body.

3.2.8.2.6 Any painted-on text labels applied to the cask shall be stenciled, legible, and applied with black epoxy paint. See Table 1 for additional labelling requirements.

PSNS&IMF, Code 2310.3 Page 16 of 20 October 30, 2019 Rev. C

3.2.9 Labelling and Markings

Table 1: Summary of Labelling and Marking Requirements for this Specification

Paragraph #: Description: Size Location Color

3.2.1.2

Cask serial numbers on body of cask

(e.g. PSNS SC-1)

4 inch Tall

Lettering

Two places, 180o apart, centered vertically on cask exterior

Black

3.2.1.2 Cask serial numbers on cask lid

(e.g. PSNS SC-1)

2 inch Tall

Lettering

One place on top of

Lid Black

3.2.2.8

Shipping markings

“USA DOT 7A Type A”

1 inch Tall

Lettering

(0.47 inch min)

Two places, 180o apart, on side of cask exterior

Black

3.2.7.11.8 Lifting and handling certification

and testing Legible

Structure adjacent to padeyes

NA /

laser etched

3.2.7.12 Cask actual weight and maximum

gross weight (lbs.)

1 inch Tall

Lettering

Two places, 180o apart, on side of cask exterior

Black

PSNS&IMF, Code 2310.3 Page 17 of 20 October 30, 2019 Rev. C

4. QUALITY ASSURANCE

4.1 Welding Requirements

4.1.1 All welding of this specification shall be performed to AWS D1.1 (or AWS D1.6 if stainless steel is used) by AWS qualified welders.

4.1.2 Prior to award of the contract, the vendor shall provide their AWS compliant welding procedure for review.

4.1.3 The weld procedure and procedure qualification test shall be submitted to the Government and approved in writing by the Government prior to any production welding being performed in accordance with that procedure.

4.1.4 Welder qualification reports shall be submitted to the Government and approved in writing prior to any production welding being performed.

4.1.5 A minimum of 5 working days shall be allowed for PSNS&IMF to review these submissions.

4.2 NDT Requirements

4.2.1 Prior to award of the contract, the vendor shall submit the following documents to PSNS&IMF for review, demonstrating compliance with NAVSEA Technical Publication TP T9074-AS-GIB-

010/271: NDT Written Practice, MT procedure, and the MT procedure qualification.

4.2.2 All Visual Inspections are per AWS D1.1. Prior to performing any visual inspections, the vendor shall submit copies of AWS inspector certification(s) for the inspector(s) who will be performing the visual inspections.

4.2.3 Prior to performing any NDT, the vendor shall submit for review copies of MT inspector certification(s) for the inspector(s) who will be performing the NDT.

4.2.4 A minimum of 5 working days shall be allowed for PSNS&IMF to review these submissions.

4.3 Gamma Radiation Attenuation

4.3.1 Vendor shall verify by shielding performance testing per ASTM C1831 that the minimum shielding requirements of paragraph 3.2.4.1 have been met.

4.3.1.1 Scanning shall be performed in 8 inch by 8 inch (max size) grids. Grid 1 shall be documented with a physical reference point on the cask geometry for later reference. See Figure 6 for required grids. The grids for cask body and lid shall be differentiated using a unique identifier (prefix or other method).

4.3.1.2 Results of shielding performance testing as required by ASTM C1831 shall be submitted to

PSNS&IMF at delivery.

PSNS&IMF, Code 2310.3 Page 18 of 20 October 30, 2019 Rev. C

2 5 8 11 14 17 20 23 etc.

3 6 9 12 15 18 21 24 etc.

8"

8" typ.

typ.

8"

8" typ.

typ.

1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

Cask Lid Gridding 16 total grids expected (disregard partial grids: <50% by area)

Cask Body Gridding 42 total grids expected

O 24" u 1/8"

1 1/2" Min.

Demineralizer Vessel

Cask Wall

Annular Void Space

Pallet

24"

1 4 7 10 13 16 19 22

2 5 8 11 14 17 20 23

3 6 9 12 15 18 21 24

Sheilding Equivalent to:

4" Solid Lead Sheet for Co60 Source

11"

CLEAR

OPENING

Cask LidCask Lid Padeye (typ) (2 EA)

Cask Body Padeye (typ) 3 EA Equally Spaced

Cask Pallet

36" +4" -0"

47" +3" -0"

27" +3" -0"

60 +6" -0"

Temporary Cradle

Figure 6: Gamma Scan / Probe Required Grids

4.4 Inspections

4.4.1 Final acceptance of the cask shall be made at destination by PSNS&IMF within 10 working days after receipt. Acceptance shall be based on satisfactory examination of the physical items (casks) and of submitted documentation / deliverables.

4.4.2 PSNS&IMF shall have the right to send a technical representative to the vendor site to perform an inspection of the fabrication process at any time prior to shipment of casks to PSNS&IMF.

4.5 Documentation and Certifications

4.5.1 The contractor shall certify, by signature of the contractor's QC manager, that the specific submittals / approvals / requirements of this specification have been met. This certification shall be via signature on a letter or form supplied by the contractor and shall refer to this contract and identify the item/component to which that certification applies. Signature may be made based on his/her personal observation or his/her review of the required documentation. All signatures shall include the full name, title, and date.

4.5.2 A Certificate of Compliance is required to be submitted at delivery verifying compliance with the requirements of this specification.

PSNS&IMF, Code 2310.3 Page 19 of 20 October 30, 2019 Rev. C

Table 2: Summary of Deliverables for this Specification

Paragraph: Deliverable Description: Submission Time:

PSNS&IMF

Review Time

3.2.1.5

Conceptual rendering, sketches, photos or technical drawings of the proposed design showing:

1) General design intent to meet section 3.2.3.

2) Type/location of gamma radiation attenuation materials to meet section 3.2.4.1.

4) Proof of past performance / prior similar products

With bid submittal NA

4.1.2 AWS compliant welding procedure.

Prior to award of the contract 5 Working Days

4.2.1

NDT written practice, MT procedure, and the MT procedure qualification demonstrating compliance with

NAVSEA Technical Publication TP

T9074-AS-GIB-010/271

Prior to award of the contract 5 Working Days

3.2.5.2 The specification, configuration and

material for cask lid gasket.

Prior to Fabrication 5 Working Days

3.2.1.7 Pre-fabrication drawings for the cask

including materials of construction Prior to Fabrication 10 Working Days

3.2.7.7 Design and calculations for cask lifting

attachments.

Prior to Fabrication 15 Working Days

3.2.7.9 Stress analysis of structure supporting

the lifting attachments.

Prior to Fabrication 15 Working Days

4.1.3 & 4.1.4

Weld procedure, procedure qualification test, and welder qualification reports.

Prior to Welding during

Fabrication 5 Working Days

4.2.2

AWS inspector certification(s) for the inspector(s) who will be performing the visual inspections.

Prior to performing any

Visual Inspections per

AWS D1.1.

5 Working Days

4.2.3

MT inspector certification(s) for the inspector(s) who will be performing the

NDT

Prior to performing any

NDT.

5 Working Days

3.1.1.4

Transportation and delivery plan to ship, offload, and perform final cleaning of casks.

60 Days Prior to Delivery 5 Working Days

PSNS&IMF, Code 2310.3 Page 20 of 20 October 30, 2019 Rev. C

(CONT) Table 2: Summary of Deliverables for this Specification

Paragraph: Deliverable Description: Submission Time:

PSNS&IMF

Review Time

3.2.7.8

Lift sketch detailing the recommended rigging configuration, rigging gear and associated capacities.

30 Days Prior to Delivery 10 Working Days

3.2.7.12

The final recorded cask weight and a copy of the weighing instrument certification of calibration papers

10 Days Prior to Delivery NA

3.2.7.11.1 &

3.2.7.11.2

Pre-Load Test visual inspections of lifting attachments.

30 Days Prior to Shipment 10 Working Days

3.2.7.11.3 Pre-Load Test MT 30 Days Prior to Shipment 10 Working Days

3.2.7.11.4

Lifting attachments load test photographs and certification of satisfactory result.

30 Days Prior to Shipment 10 Working Days

3.2.7.11.5 &

3.2.7.11.6

Post-Load Test visual inspections of lifting attachments.

30 Days Prior to Shipment 10 Working Days

3.2.7.11.7 Post-Load Test MT 30 Days Prior to Shipment 10 Working Days

3.2.2.2

Conformance to 49 CFR Part 173.412.

Results of package testing as required by 49 CFR, Part 173.465. Submittals satisfying 49 CFR Part 173.461 and

49 CFR Part 173.415(a).

Prior to Shipment NA

3.2.2.3

Photos, sketches, schematics, calculations, testing to meet 49 CFR

Part 173.465 requirements.

Prior to Shipment NA

3.2.7.1.1 Proof of cask tipping evolution. Prior to Shipment NA

3.2.1.6 Cask User Manual (lid assembly /

prepare for shipping procedure) At Delivery NA

3.2.1.8 Final as-built drawings for the cask

including materials of construction At Delivery NA

3.2.4.3.6 Total calculated void space in shielding

materials (shall be < 5%) At Delivery NA

4.3.1.2 Results of shielding performance testing At Delivery NA

4.5.2 Certificate of Compliance At Delivery NA