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TEST AND EVALUATION DOCUMENT FOR U.S. DOT SPECIFICATION 7A TYPE A PACKAGING Volume 2

Figure 3-2: TRUPACT-II Standard Waste Box, Bolted Closure.

3.2.1 Package Description

The Standard Waste Box (SWB) was originally tested and evaluated by Mound in 1988 and 1989. Westinghouse Hanford Company (WHC) evaluated and approved a design change that incorporated a lid lift nut under Docket 89-07-7A in 1989. Historical information on these designs may be found in DOE/RL 1996, Vol. 1. The SWB design underwent evaluation in 1999 by Waste Management Federal Services, Inc., Northwest Operations (WMNW) under Docket 98-45-7A. Changes are minor and consist of better identification of the materials of construction as used and applied in commercial practice. Evaluation of the approved SWB design under Docket 98-45-7A includes the following:

• Westinghouse Waste Isolation division Drawing No. 165-F-001-W, Revisions F through K.

• Westinghouse Electric Company, Waste Isolation Division, Specification E-I-343, Revision 3, Specification for the TRUPACT-II Standard Waste Box (WEC 1999).

The lid and body are made of 10 gauge carbon steel. The lid incorporates a lid lift nut that may be used for lifting the lid only. The gasket assembly is made of closed cell rubber, and is cut with a knife die. Forty-two, ½" – 13 UNC x 1¾" socket flat head cap screws secure the lid to the body. The cap screws are secured by applying a non-locking liquid anaerobic thread sealant prior to placing into position. The cap screws are threaded into rivets that are installed in the body tube. The rivets may be manufactured or can be supplied off-the-shelf. The rivets may be procured from RIVNUT Engineered Products. The SWB has two flat sides that each incorporate three lift clips (six total) on the upper-most portion of the box body. The ends of the container are rounded and each incorporate two body bumpers (four total). The body bumpers are located on the upper and lower portion of the body. The box body contains four recessed NPT, ¾" pipe couplings. Two couplings are located on each of the flat sides of the box. A maximum of two commercial quality ¾" pipe plugs (NPTF or PTF) are installed in the pipe couplings; and a minimum of two NucFil-013, ¾" NPT filters are installed in the pipe couplings. Thread tape is used prior to installing the plugs or filters. The SWB is painted according to the user’s specifications.

Table 3.2-1. Dimensions

Table 3.2-2. Materials/Method of Construction.

Table 3.2-3. Packaging Weights.

3.2.2 Authorized Contents

The shipper must determine that the actual contents are closely simulated by the test contents. If they are not, testing/analysis must be conducted and documented to demonstrate DOT-7A compliance with the actual contents.

3.2.2.1 Physical Form and Maximum Gross Weight

Liquids. Not authorized.

Gases. Not authorized.

Solids. Five forms are authorized. Each shipper must determine the most appropriate form for the particular contents to be shipped, and comply with any special requirements.

• Material Form No. 1: Solids—any particle size.

• Material Form No. 2: Solids—large particle size only (e.g., sand, concrete, debris, soil, etc.).

• Material Form No. 3: Solids—objects with no significant dispersible or removable contamination. (For definition, see 49 CFR 173.443, Contamination control.)

• Material Form No. 4: Solids as described in Form No. 3 above, including large, bulky, dense objects with sharp and obtrusive members or components, but having Form No. 1 and/or No. 2 as dispersible contaminates associated with the material (e.g., steel plates, motors, valves, steel pipes, concrete blocks).

• Material Form No. 5: Solids—four 208 L (55 gal) drums [in any arrangement not exceeding 453.592 kg (1,000 lb) per drum] and overpacked within the SWB.

Maximum Gross Weight. All forms 1814.369 kg (4000 lb).

3.2.2.2 Chemical Form

The shipper must evaluate and ensure chemical compatibility of the material to be shipped with the materials of the packaging in contact with the payload.

3.2.2.3 Radiological

Testing Damage. Drop testing conducted by Mound in 1988 and 1989 is as identified in Table F-9. Following is a summary of the damage that occurred to the test units during the 1.2-m (4-ft) drop test, that could impact the radiological evaluation of the performance of the package. A dent [approximately 10.16 cm (4 in.)] resulted from the 1.2-m (4-ft) drop test onto the bottom edge.

3.2.2.4 Simulated Payload

The simulated payload used during testing that was conducted by Mound in 1988 and 1989 was represented as follows:

• Flour, fluorescein, and sand to a weight of 1832.513 kg (4040 lb) to represent Material Form Nos. 1 and 2.

• Flour, fluorescein, and debris to a weight of 1856.1 kg (4092 lb) to represent Material Form Nos. 1, 3, and 4.

• Flour, fluorescein, and four steel drums to a weight of 1859.729 kg (4100 lb) to represent Material Form Nos. 1 and 5.

3.2.3 Restrictions/Specifications

1. The SWB shall be operated in accordance with the Westinghouse Electric Company, Waste Isolation Division, Specification for the TRUPACT-II Standard Waste Box, E-I-343, Revision 3 (WEC 1999), and Westinghouse Waste Isolation Division Drawing Number 165-F-001-W, Revisions F through K.

2. Inspect rivets for damaged threads and loose fit. If any rivets require adjustment or replacement, follow the guidance provided in WEC 1999.

3. Install a minimum of two NucFil-013 filters in any of the four filter mounting locations. Filters shall be installed by first applying thread sealant tape or compound to the filter body pipe threads. Next, insert the filters into the filter mounting locations and tighten to a final torque of 13.56 ±6.78 N-m (10 ±5 ft-lb).

   NOTE: Users may have difficulty installing the filter as it is a straight thread and the coupling is a tapered thread. This may be corrected by using a ¾-in. NPT tap in the coupling prior to installing the filter.

   NOTE: The rubber gasket supplied with the filter can be removed at the user’s option prior to installation of the filter. The SWB relies on the mechanical interface of the pipe threads with thread sealant to generate a leak-tight joint.

4. Install a maximum of two pipe plugs in any remaining open mounting locations. Plugs shall be installed by first applying thread sealant tape or compound to the plug pipe threads. Next, insert the plugs into the mounting locations and tighten to a final torque of 13.56 ±6.78 N-m (10 ±5 ft-lb).

5. Ensure that the gasket assembly is not ripped or torn. Wipe the gasket sealing surface of the body and lid to remove any loose debris. Install the gasket according to WID 1999. The gasket material must have an operating range of -40° C to +70° C (-40° F to +158° F).

6. A lifting attachment point is located in the center of the lid and will accept a ¼-in.–20 UNC lifting eye. The lid lifting point is for the lid only!

7. Coat all lid screw threads with a non-locking liquid anaerobic thread sealant prior to placing into position. Install a screw in each corner of the lid, approximately ¼-in. or 3 to 4 turns. Install the four corner screws. Install the middle screws on the straight sides. Install the middle screws on the curved ends. Install the remaining screws in any sequence. Using a calibrated torque wrench, pre-torque all screws in a crisscrossing pattern to 40.68 (-0, +13.56) N-m [30 (-0, +10) ft-lb]. Torque all screws in a crisscrossing pattern to a final torque of 67.8 (-0, +13.56) N-m [50 (-0, +10) ft-lb].

   NOTE: If needed, a lineup bar may be used to pull the lid into position with the body. Be careful not to damage the rivet threads. If the threads are damaged, repair as stated in WEC 1999.

8. For heavy, bulky materials (e.g., concrete chunks, motors, pumps, etc.), equipment or materials with sharp corners or protrusions, or material/containment geometries that could result in highly localized forces, the shipper must ensure that the contents are securely fastened/positioned within the package.

9. The shipper shall ensure that the amount of radiation at any surface would not increase by more than 20% [IAEA 1996, Paragraph 646(b)].

3.2.4 49 CFR 178.2(c) Notification

At the time of testing and evaluation, the specific organization taking on the responsibility of manufacturer is unknown. Note that neither the organization that fabricates the packaging nor the organization that tests the packaging is by the DOT definition necessarily the manufacturer. In 49 CFR 178.2(e) the manufacturer is defined by the DOT as follows: "Manufacturer means the person whose name and address or symbol appears as part of the specification markings required by this part or, for a packaging marked with the symbol of an approval agency, the person on whose behalf the approval agency certifies the packaging." The specification marking is defined as, "Specification markings mean the packaging identification markings required by this part (49 CFR 178) including, where applicable, the name and address or symbol of the packaging manufacturer or approval agency." In this particular case, it is assumed in this document that the shipper will assume the responsibility of manufacturer.

The Type A packaging evaluated is the result in a sharing of responsibilities. The packaging was designed to meet the Type A packaging requirements when loaded and used as described in this document. The design was developed by the Waste Isolation Pilot Plant (WIPP), Carlsbad, NM. Test units were prepared by a fabricator (unidentified) and tested in the DOE’s DOT-7A Type A Packaging Test and Evaluation Program by Mound Laboratory to show that when loaded as described they would meet the physical test requirements. Design changes were evaluated in the DOE’s DOT-7A Type A Test and Evaluation Program by WHC under Docket 89-07-7A and WMNW under Docket 98-45-7A to show that the identified package designs meet the identified requirements. As part of the evaluation process, those requirements not demonstrated as being met are identified as the responsibility of the shipper.

This document, in conjunction with the design drawings and packaging specification, identify the requirements for Type A packaging that are met and those requirements that remain to be completed (i.e., identified as shipper is to ensure…). It can therefore serve as a starting point for the notification required by this section. Any organization having packages fabricated should, before using or supplying the packagings to others, prepare a notification that updates the information. The notification should be supplied with the packagings.

3.2.5 49 CFR 178.350 Regulatory Requirements

Table 3.2-4. Regulatory Compliance Assessment.

3.2.6 Quality Control

Table 3.2-5. Packaging/Acceptance/Use Criteria.

3.2.7 Additional Information

Evaluation of the SWB design was performed by WMNW and took place at Hanford in June 1999 under Docket Number 98-45-7A. Historical information on previous designs tested and evaluated by Mound and WHC may be found in DOE/RL 1996, Vol. 1. Complete evaluation reports are available upon request from one of the DOT-7A Program technical contacts listed in Section 1.1.2.

3.2.7.1 Primary Users

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