packaging technology, inc

NFFSC – 8/30/2006

PACKAGING TECHNOLOGY, INC.

NFFSC – 8/30/2006


Rockville, MD August 30, 2006

Advanced Test ReactorAdvanced Test ReactorNew Fresh Fuel Shipping New Fresh Fuel Shipping

Container (NFFSC)Container (NFFSC)

Packaging Technology, Inc.under contract

Idaho National Laboratory

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NFFSC – 8/30/2006


ATR NFFSC

‣‣ ScopeScope�� Identify need for new ATR fresh fuel Identify need for new ATR fresh fuel

shipping containershipping container

�� Present NFFSC conceptual designPresent NFFSC conceptual design

�� Present preliminary analysis resultsPresent preliminary analysis results

�� Identify planned certification strategyIdentify planned certification strategy

�� Project Status and ScheduleProject Status and Schedule

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NFFSC – 8/30/2006


ATR NFFSC

NFFSC PurposeNFFSC Purpose‣‣ Existing packaging Certificate # Existing packaging Certificate #

USA/9099/B(U)FUSA/9099/B(U)F--8585

‣‣ Existing packagings are nearing end of useful Existing packagings are nearing end of useful lifelife

‣‣ 10CFR71.19(c)(1) preclude fabrication of new 10CFR71.19(c)(1) preclude fabrication of new USA/9099/B(U)FUSA/9099/B(U)F--8585’’ss

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NFFSC – 8/30/2006


ATR NFFSCConceptual DesignConceptual Design‣‣ Type AF PackageType AF Package‣‣ Transport by NNSA and commercial carrier Transport by NNSA and commercial carrier –– road road

transport onlytransport only�� Single package via commercial carrierSingle package via commercial carrier

�� Multiple packages via NNSA SSTMultiple packages via NNSA SST

‣‣ Two payloads currently consideredTwo payloads currently considered�� Advanced Test Reactor (ATR) Advanced Test Reactor (ATR) –– primary payloadprimary payload

•• Weight: 28 lbsWeight: 28 lbs•• Length: 66.19Length: 66.19”” min to 66.31min to 66.31”” maxmax•• Fissile content: 1,200 g UFissile content: 1,200 g U--235 max235 max•• ~60% of an A2~60% of an A2

�� Scrap fuel platesScrap fuel plates

‣‣ Potential future payloads Potential future payloads –– other research reactor fuelsother research reactor fuels

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NFFSC – 8/30/2006


ATR NFFSC

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Conceptual Design (cont)Conceptual Design (cont)

ATR Fuel Element

Top Support

Container Closure

Container Body

Support connecting bar

Bottom Support

NFFSC Package – Exploded View

NFFSC – 8/30/2006


ATR NFFSC

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NFFSC Package – Exploded ViewNFFSC Container – Closure Section View

TID

Closure Locking pins

NFFSC – 8/30/2006


ATR NFFSC

Conceptual Design (cont)Conceptual Design (cont)‣‣ Materials of construction (package)Materials of construction (package)

�� Type 304 Stainless steel (pipe, plate & mechanical Type 304 Stainless steel (pipe, plate & mechanical tubing)tubing)

�� Unifrax FiberfraxUnifrax Fiberfrax®® DurablanketDurablanket

““High temperature insulation blankets made from longHigh temperature insulation blankets made from long--staple, staple, inorganic spun fibersinorganic spun fibers””

‣‣ Materials of construction (Materials of construction (““fuel support structurefuel support structure””))�� For ATR fuel element: Aluminum & neopreneFor ATR fuel element: Aluminum & neoprene

�� For scrap fuel plates: 304 SST or Al (to be determined)For scrap fuel plates: 304 SST or Al (to be determined)

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NFFSC – 8/30/2006


ATR NFFSC

Conceptual Design (cont)Conceptual Design (cont)‣‣ DimensionsDimensions

�� Cavity: 5.29Cavity: 5.29”” ID (pipe, 5ID (pipe, 5”” schd 10) x 67.9schd 10) x 67.9”” longlong

�� Overall: 72Overall: 72”” long x 8long x 8”” squaresquare

‣‣ WeightWeight�� Empty ~280 lbsEmpty ~280 lbs

�� With ATR payload ~324 lbsWith ATR payload ~324 lbs

280 lb (container) + 28 lb (ATR) + 16 lb (280 lb (container) + 28 lb (ATR) + 16 lb (““basketbasket””))

‣‣ Tiedowns: No integral tiedown systemTiedowns: No integral tiedown system

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NFFSC – 8/30/2006


ATR NFFSC

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Shipping rack – NNSA SST Transport

NFFSC – 8/30/2006


ATR NFFSCConceptual Design (cont)Conceptual Design (cont)

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Shipping rack – Secured to NNSA SST conveyance

NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses -- CriticalityCriticality‣‣ Preliminary calculations have shown the reactivity to be Preliminary calculations have shown the reactivity to be

acceptable assuming the fuel remains intact under HAC.acceptable assuming the fuel remains intact under HAC.

‣‣ The testing program will utilize prototypic simulated fuel The testing program will utilize prototypic simulated fuel to verify robustness under accident conditions.to verify robustness under accident conditions.

‣‣ Scoping calculations conservatively assumed up to 48 Scoping calculations conservatively assumed up to 48 ATR fuel elements per conveyance (will be limited to 24 ATR fuel elements per conveyance (will be limited to 24 per conveyance)per conveyance)

‣‣ The maximum allowable CSI = 2.0 for exclusive useThe maximum allowable CSI = 2.0 for exclusive use (e.g., (e.g., 48*2.0 = 96 < 100).48*2.0 = 96 < 100).

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NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses –– Criticality Criticality (cont)(cont)

‣‣ To justify a CSI = 2.0, N = 25, and the NCT array must To justify a CSI = 2.0, N = 25, and the NCT array must contain at least 5N=125 packages, and the HAC array contain at least 5N=125 packages, and the HAC array must contain at least 2N=50 packages.must contain at least 2N=50 packages.

‣‣ Preliminary NCT array calculations utilized an 11x12x1 Preliminary NCT array calculations utilized an 11x12x1 array (132 packages)array (132 packages)

�� k ~ 0.7k ~ 0.7

‣‣ Preliminary HAC array calculations utilized a 7x8x1 array Preliminary HAC array calculations utilized a 7x8x1 array (56 packages)(56 packages)

�� k ~ 0.89k ~ 0.89

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NFFSC – 8/30/2006


ATR NFFSCPreliminary Analyses Preliminary Analyses –– Criticality Criticality

(cont)(cont)‣‣ The preliminary models do not include the square The preliminary models do not include the square

tube, which increases the distance between fuel tube, which increases the distance between fuel assemblies and further reduces the reactivity.assemblies and further reduces the reactivity.

‣‣ Models are fully flooded within the pipe and dry Models are fully flooded within the pipe and dry between the pipes, which maximizes the reactivity.between the pipes, which maximizes the reactivity.

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Water in pipe - green

Water between plates - gray HAC array

NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses -- ThermalThermal‣‣ Preliminary analysis based on quarter symmetry model Preliminary analysis based on quarter symmetry model

of NFFSC Package and ATR fuel assemblyof NFFSC Package and ATR fuel assembly

‣‣ Results for ATR fuel assembly are bounding for other Results for ATR fuel assembly are bounding for other potential payloads.potential payloads.

‣‣ Simulation of ATR fuel assembly geometry included the Simulation of ATR fuel assembly geometry included the 19 individual fuel plates & vented side plates.19 individual fuel plates & vented side plates.

‣‣ Approx. 5,200 nodes, 2,800 solids, and 2,200 planar Approx. 5,200 nodes, 2,800 solids, and 2,200 planar elements used in thermal model to provide thermal and elements used in thermal model to provide thermal and geometric resolution.geometric resolution.

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NFFSC – 8/30/2006


ATR NFFSCPreliminary Analyses Preliminary Analyses –– Thermal (cont)Thermal (cont)

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Thermal Model for Concept Design

NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses –– Thermal (cont)Thermal (cont)‣‣ Support ribs conservatively assumed to be welded to Support ribs conservatively assumed to be welded to

outer plates outer plates –– current design uncouples the ribs and the current design uncouples the ribs and the outer tube. outer tube.

‣‣ No significant damage to package geometry assumed No significant damage to package geometry assumed based on preliminary structural analysis.based on preliminary structural analysis.

‣‣ Fuel assembly end supports assumed to be FRFuel assembly end supports assumed to be FR--3700 3700 foam foam –– current design uses metallic support.current design uses metallic support.

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NFFSC – 8/30/2006


ATR NFFSCPreliminary Analyses Preliminary Analyses –– Thermal (cont)Thermal (cont)

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Peak ATR Temp. at 3.5 Min After Fire

NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses –– Thermal (cont)Thermal (cont)‣‣ Peak ATR fuel assembly temperature predicted to Peak ATR fuel assembly temperature predicted to

be 690F.be 690F.

‣‣ Incorporation of gap between support ribs and Incorporation of gap between support ribs and outer plates will increase the thermal margin.outer plates will increase the thermal margin.

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NFFSC – 8/30/2006


ATR NFFSC

Preliminary Analyses Preliminary Analyses -- StructuralStructural‣‣ Scoping calculations evaluated package performance Scoping calculations evaluated package performance

under crush test under crush test –– i.e., a 500i.e., a 500--kg (1100kg (1100--lb) mass falling 9 m lb) mass falling 9 m (30 ft) onto the specimen.(30 ft) onto the specimen.

‣‣ Ground support simulated with perfectly rigid surface.Ground support simulated with perfectly rigid surface.

‣‣ Preliminary structural analysis used quarter symmetry Preliminary structural analysis used quarter symmetry model.model.

�� Analysis assumes outer plates welded to support ribs.Analysis assumes outer plates welded to support ribs.

�� Rounded corners assumed on package.Rounded corners assumed on package.

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NFFSC – 8/30/2006

PACKAGING TECHNOLOGY, INC.24

ATR NFFSC

Preliminary Analyses Preliminary Analyses –– Structural (cont)Structural (cont)

Permanent Deformation – X Direction (inches)

NFFSC – 8/30/2006


ATR NFFSC

Permanent Deformation – Y Direction (inches)

Preliminary Analyses Preliminary Analyses –– Structural (cont)Structural (cont)

NFFSC – 8/30/2006


ATR NFFSCPreliminary Analyses Preliminary Analyses –– Structural (cont)Structural (cont)‣‣ Overall, package design is shown to be robust.Overall, package design is shown to be robust.

‣‣ Some decrease in package stiffness expected due Some decrease in package stiffness expected due to gap between support ribs and outer plates.to gap between support ribs and outer plates.

‣‣ Potential for buckling is very low.Potential for buckling is very low.

‣‣ Engineering tests plannedEngineering tests planned�� 30 foot free drop and puncture bar 30 foot free drop and puncture bar

�� Verify closure remains intactVerify closure remains intact

�� Verify ATR fuel assembly remains intactVerify ATR fuel assembly remains intact

�� Verify package geometry control Verify package geometry control

NFFSC – 8/30/2006


Certification PlansCertification Plans‣‣ 10CFR71.45 10CFR71.45 –– Lifting and tieLifting and tie--downdown

�� Lifting Lifting §§(a)(a)•• Lift points designed for weight of one packageLift points designed for weight of one package•• Compliance demonstrated by analysisCompliance demonstrated by analysis

�� TieTie--down down §§(b)(b)•• TieTie--downs are not structural part of package for either downs are not structural part of package for either

single or racked packagingssingle or racked packagings•• Lift points to be disabled during transportLift points to be disabled during transport•• Lift points subjected to 9 meter free drop and puncture Lift points subjected to 9 meter free drop and puncture

bar testsbar tests

ATR NFFSC

NFFSC – 8/30/2006


Certification PlansCertification Plans‣‣ 10CFR71.71, NCT 10CFR71.71, NCT –– demonstrated by ademonstrated by a combination ofcombination of test, test,

analysis, and reasoned argumentanalysis, and reasoned argument

‣‣ 10CFR71.73(c), HAC10CFR71.73(c), HAC�� Free drop Free drop §§(1) (1) –– by testby test

�� Crush Crush §§(2) (2) –– not applicablenot applicable

•• Mass <1,100 lb (~ 324 lb with payload)Mass <1,100 lb (~ 324 lb with payload)

•• Density > 62.4 lb/ftDensity > 62.4 lb/ft3 3 (~105 lb/ft(~105 lb/ft3 3 for empty package)for empty package)

�� Puncture Puncture §§(3) (3) –– by testby test

�� Thermal Thermal §§(4) (4) –– by analysisby analysis

�� Immersion Immersion §§(5) (5)

•• No seals, assumed to floodNo seals, assumed to flood

•• Annular space dry and floodedAnnular space dry and flooded

�� Immersion Immersion –– all packages all packages §§(6) (6) –– by analysisby analysis

ATR NFFSC

NFFSC – 8/30/2006


ATR NFFSC

Project Status & ScheduleProject Status & Schedule‣‣ StatusStatus�� Concept design developedConcept design developed

�� Full scale packaging mockups (5 each) in fabrication Full scale packaging mockups (5 each) in fabrication –– 9/29/06 9/29/06 deliverydelivery

•• Four packages for use in operations evaluationsFour packages for use in operations evaluations

•• One package for engineering testsOne package for engineering tests

�� Engineering test procedure prepared Engineering test procedure prepared –– tests scheduled for tests scheduled for midmid--OctoberOctober

NFFSC – 8/30/2006


ATR NFFSC

Project Status & Schedule (cont)Project Status & Schedule (cont)‣‣ ScheduleSchedule�� Concept briefing Concept briefing –– 8/30/068/30/06

�� Certification testCertification test•• Test plan briefing Test plan briefing –– 12/12/0612/12/06

•• CTU fabrication CTU fabrication –– December 2006December 2006

•• Perform certification tests Perform certification tests –– February 2007February 2007

�� Submit application Submit application –– 6/14/07 (anticipate 4 month review)6/14/07 (anticipate 4 month review)

�� Receive RAI Receive RAI –– 10/8/0710/8/07

�� Issue license Issue license –– December 2007December 2007

packaging technology, inc

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