no.: ej bitten/bc cornwell cvi/67531/metadc674899/... · k distribution 5. proj./prog./dept./div.:...

96
k Distribution 5. Proj./Prog./Dept./Div.: Advance Fuel Facilities Transition, BWHC 6. Design Authority/ Design Agent/Cog. 19110 The enclosed report contains a physical, chemical, and radiological characterization of the 309 Fuel Examination Facility (FEF). The Report contains photos of the cell equipment, cell air characterization including oxygen levels, and radiological monitoring measurements. 11. Receiver Remarks: 11A. Design Baseline Document? Yes [] No Engr.: EJ Bitten/BC Cornwell IAI Item NO. IE) Title or Description of Data Transmined IC) ID) 161 DocumentlDrawing No. Sheet Rev. NO. NO. IC YC" 1 4. Related ED1 No.: na HNF-SD-NEL-ER-007 0 "Characterization of the 309 Fuel Examination Facility 7. Purchase Order No.: na Appr~vsl Designator IF) :, S, Q, D or NIA see WHGCM-3-5, iec.12.71 ~ 9. Equip./Component NO.: CVI 15449 10. System/Bldg./Faci l i t y : FEF/309/300 12. Major Assm. Dug. No.: Disposition IH) & 11) Reason for Transmittal IG) 1. Approved 4. Reviewed nolcomment 1. Approval 4. Review 2. Release 5. Post-Review 2. Approved wlcomment 5. Reviewed wlcomment 3. Information 6. Oist. (Receipt Acknow. Required) 3. Disapproved wlcomment 6. Receipt acknowledged na 13. PermitlPermit Application No.: na 6/25/97 14. Required Response Date: Approval Reason Drigi- Receiv- natar Trans- Dispo- Dispo- mind eition sition 112 I I I I safety I 20. 21. DOE APPROVAL (if required) Ctrl. No. Cognizant Manager ED-7400-172-2 (05/96) GEF097

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Page 1: No.: EJ Bitten/BC Cornwell CVI/67531/metadc674899/... · k Distribution 5. Proj./Prog./Dept./Div.: Advance Fuel Facilities Transition, BWHC 6. Design Authority/ Agent/Cog. 19110 The

k

Distribution

5. Proj./Prog./Dept./Div.:

Advance Fuel Facilities Transition, BWHC 6 . Design Authority/ Design Agent/Cog.

19110

The enclosed report contains a physical, chemical, and radiological characterization o f the 309 Fuel Examination Facility (FEF). The Report contains photos o f the cell equipment, cell air characterization including oxygen levels, and radiological monitoring measurements. 11. Receiver Remarks: 11A. Design Baseline Document? Yes [ ] No

Engr.: EJ Bitten/BC Cornwell

IAI Item NO.

IE) Title or Description of Data Transmined

IC) ID) 161 DocumentlDrawing No. Sheet Rev.

NO. NO.

I C YC"

1

4. Related E D 1 No.: na

HNF-SD-NEL-ER-007 0 "Characterization of the 309 Fuel Examination Facility

7. Purchase Order No.:

na

Appr~vsl Designator IF) :, S, Q, D or NIA see WHGCM-3-5, iec.12.71

~

9. Equip./Component NO.:

CVI 15449

10. System/Bldg./Faci l i t y :

FEF/309/300

12. Major Assm. Dug. No.:

Disposition IH) & 11) Reason for Transmittal IG)

1. Approved 4. Reviewed nolcomment 1. Approval 4. Review 2. Release 5. Post-Review 2. Approved wlcomment 5. Reviewed wlcomment 3. Information 6. Oist. (Receipt Acknow. Required) 3. Disapproved wlcomment 6. Receipt acknowledged

na 13. PermitlPermit Application No.:

na

6/25/97 14. Required Response Date:

Approval Reason Drigi- Receiv-

natar Trans- Dispo- Dispo- mind eition sition

112

I I I I safety I

20. 21. DOE APPROVAL ( i f required) C t r l . No.

Cognizant Manager

ED-7400-172-2 (05 /96) GEF097

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@ HNF-SD-NEL-ER-007, Rev. 0

Characterization of the 309 Fuel Examination Facility

W. 0. Greenhalgh SGN Eurisys Services Corporation Richland, WA 99352-0840

B. C. Cornwell B&W Hanford Company; Rich1 and, Washington 99352 U.S. Department of Energy Contract DE-AC06-96RL13200

EDT/ECN: 605787 UC: 510 Org Code: 19110 Charge Code: 87006 B&R Code: EX7003000 Total Pages: 9 p

Key Words: 309 Building, Fuel Examination Facility, Transition, Plutonium Recycle Test Reactor, PRTR, Characterization, Radiation

Abstract: This document identifies radiological, chemical and physical conditions inside the Fuel Examination Facility. It is located inside the Plutonium Recycle Test Reactor containment structure (309 Building.) The facility was a hot cell used for examination of PRTR fuel and equipment during the 1960's. Located inside the cell is a PRTR shim rod assembly, reported are radiological conditions of the sample. The conditions were assessed as part of overall 309 Building transition.

TRADEMARK DISCLAIMER. Reference herein t o any spec i f i c comnercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily cons t i t u te or imply i t s endorsement, recommendation, or favoring by the United States Government or any agency thereof o r i t s contractors o r subcontractors.

Pr inted i n the United States of America. To obtain copies of t h i s document, contact: Document Control Services, P.O. Box 950, Mailstop H6-08, Richland WA 99352, Phone (509) 372-2420; Fax (509) 376-4989.

- - M ,A-

elease Approval 4 Date Release Stamp

Approved for Public Release

A-6400-073 (01/97) GEF321

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HNF-SD-NEL-ER-007, Rev. 0

CHARACTERISTICS OF THE 309 FUEL EXAMINATION FACILITY

EXECUTIVE SUMMARY

The Fuel Examination Facility (FEF), located inside the Plutonium Recycle Test

Reactor (PRTR) containment has been characterized in order to meet 309 Building needs for

transition to the Environmental Restoration Contractor. The assessment concludes that the

FEF is stable and does not appear to be changing. Additional stabilization work inside the

FEF is not needed to meet facility transition requirements. Minor work is required in

plugging a drain into B-Cell sump from FEF.

In a period of 10 to 20 years radiological conditions will allow for additional cleanout

of the facility with low worker radiological exposure. The peak dose in the FEF is 6.7 Whr

from an activated PRTR shim rod assembly, which contains an estimated 0.9 Ci of Corn.

Dose from the 23.3 pCi total smearable contamination is negligible in comparison. The

smearable content is 99.9% betalgamma. Neutron counts inside the FEF are consistent with

background, implying no transuranic (TRU) material. The shim rod assembly did have an

estimated 48 pCi of smearable TRU.

Lead (est. 2,680 kg {5,910 lbs}) in the FEF is the only known regulated material.

Lubricating oils in the fuel manipulator may also be regulated. Air quality in the cell was

found to be near normal.

The FEF Cell remains essentially the same as when it was operational, except for

some removed equipment. FEF equipment which was original on the containment floor and

in the B-Cell have been removed. The main FEF control console outside the cell is

completely removed. The periscope viewing equipment is gone. Ventilation equipment is no

longer operable, external fans and ducting has been removed. Lighting equipment is intact,

but is not powered. Cooling water sprays headers have no water supply, and the B-Cell

sump pump has been removed. The fuel manipulator appears to be intact, as well as the

water spray risers and the lighting banks. Mounted in the manipulator is a portion of a

PRTR Shim Rod Assembly. Observations show the cell has a dried material on the floor.

Among the equipment is the fuel manipulator and its associated cooling ducting. Also seen

are portion of the wide angle viewer; and a small instrument package.

i

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HNF-SD-NEL-ER-007, Rev. 0

TABLE OF CONTENTS

EXECUTIVE SUMMARY . . . . . . . . . . . . , , , . . . . . . . . . . . . . . . . . . . . . . . i

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Characterization Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.1. General Approach and Philosophy . . . 2.2. Work Description

3. CELL AND EQUIPMENT BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . 3 3.1. Facility History . . 3.2. Fuel Examination F

3.2.1. Physical Description . . . . . . . . . . . . 5 3.2.2. Principal Equipment . . . . . . . . . . . . 11

4. FEF CELL RADIOLOGICAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . 13 4.1. Radiation Dose Rates , . . . . . . 13 4.2. Smearable Contamin 4.3. Neutron Monitoring

5. CHEMICAL CHARACTERIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.1. Oxygen Monitoring . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2. Regulated Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.3. Glyptal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.4. Anti-Seize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6. FEF CELL VISUAL OBSERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6.1. General Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6.2. Fuel Manipulation Machine 6.3. FEF Samples or Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.5. FEF Cell Floor . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . 22 6.6. External Observation . . . . . . . . . 6.4. FEF Lighting and Cooling . . . . . . . . . . . . . . 22

7. CELLSTATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

iii

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HNF-SD-NEL-ER-007, Rev. 0

TABLES

Table 1. Table 2. Table 3. Table 4.

Figure 1 Figure 2

FEF Cell Dose Rate Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Radiological Sampling Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Oxygen Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FEF Lead Inventory Estimate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FIGURES

PRTR Containment Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel Exam Facility Cover Block Arrangement . . . . . . . . . . . . . . . . . . . 6

Figure 3. General Construction of Fuel Examination Facility . . . . . . . . . . . . . . . . . 7 Figure 4. Fuel Examination Facility Access and Penetrations . . . . . . . . . . . . . . . . . 8 Figure 5 . Fuel Examination Facility Utilities and Lighting . . . . . . . . . . . . . . . . . . 9 Figure 6. Fuel Examination Facility Viewing and Manipulation Equipment . . . . . . . . 10 Figure 7. Dose Rate Profile in FEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

APPENDICES

APPENDIX A: Fuel Examination Cell Photographs and Images APPENDIX B: Radiological Measurement ReportdSurveyslAnalyses APPENDIX C: Smearable Radiological Contamination Estimate APPENDIX D: MSDS Sheets APPENDIX E: 309 FEF Fuel Manipulation Machine CVI Excerpts

ABBREVIATIONS

CP CVI GM FEF HEW MSDS PRTR RCT RSR

Cutie Pie (radiation instrument) Certified Vendor Information Geiger-Mueller (detector tube) Fuel Examination Facility Hanford Engineer Works Material Safety Data Sheet Plutonium Recycle Test Reactor Radiation Control Technician Radiation Survey Report

iv

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HNF-SD-NEL-ER-OW, Rev. 0

CHARACTERISTICS O F THE 309 FUEL EXAMINATION FACILITY

1. INTRODUCTION

The 309 Building has been declared surplus and is in the transition process to surveillance and maintenance, pending ultimate decontamination and decommissioning. transition process requires that existing conditions be identified and stabilization performed. Transition requirements are identified by the facility Transition requirements checksheets (WHC-SD-NEL-RD-001). The Fuel Examination Facility (FEF) characterization and stabilization needs are addressed by this document.

The

This report constitutes the final report on the status and condition of the FEF Cell. This report describes the results of the physical, radiological, and chemical characterization of the 309 FEF Cell. The purpose of the report is to document the present status of the FEF cell and its contained equipment. The characterization work is done to provide information to best protect workers, the environment, and provide information for use in future restoration, and cleanup work activities. The characterization work is primarily directed toward determining the Cell content and radiological and chemical conditions.

2. Characterization Process

The FEF characterization process includes: (1) background information search, (2) radiological characterization, (3) chemical characterization, (4) cell equipment identification and condition review, and (5 ) generate FEF Cell status report.

2.1. General Approach and Philosophy

The FEF background information search included a review of 309 drawings, published reports, manuals, construction specifications, radiological survey reports, and certified vendor information.

The radiological conditions in the FEF are determined by monitoring radiation dose rates, gaseous and particulate contamination, smearable contamination levels, and neutron radiation. Dose rate measurements provide an indication of potential exposure and equipment radiological activation. Smearable contamination levels provide release potential information and radiological contamination stability. Neutron radiation measurement provide evidence of transuranics. Air samples quantify the particulate Contamination directly available for release and for controlling personnel exposure.

The chemical characterization identifies hazardous materials and conditions for planning maned entries. For this reason, the cell atmosphere is monitored for oxygen, and visually examined for evidence of chemicals or oils.

1

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HNF-SD-NEL-ER-007, Rev. 0

A video search of the cell is made to identify equipment, assess structural conditions and look for chemical indications. Remote video equipment is used to record and monitor conditions. Video provides easy access for observation and isolation from radiation. A video survey establishes what equipment is installed and an indication of the physical conditiodstatus of the cell and equipment. Pictures are easily obtained from video tape and can readily be include in reports.

2.2. Work Description I The FEF field work characterization procedures are given in Work Package

3B-96-00144. Process highlights and difficulties are presented below.

Access into the FEF may be achieved from the containment floor by removing plugs or cover blocks, and from the shield door in B-Cell at the -32 ft. level. Entry through a plug in the cover blocks was selected for the initial entry. This provided easy access and minimized radiological exposures potential.

The first step was to expose access plugs and attach rigging equipment. A layer of sheet metal was removed. The sheet metal provided protection to the painted floor when the containment was used as a shop. Next paint and a material resembling an epoxy grout were removed from around several access plugs. The plug drop anchors were exposed and cleaned. A radiological control area was then set up around the work area.

Cell entry was attempted through five separate plugs. The Fuel Access Plug (center plug) was pulled first, since it was the plug normal entry during operations. Full cell access was blocked by the fuel examination manipulator and a peace of equipment identified as a part of a PRTR Shim Rod Assembly. Attempts to lift plugs on either side of the fuel Access Plug were not successful. The Viewing Plug was them removed, providing a triangular access area which was open to the FEF floor. The accessible FEF area was bounded by the lighting fixture in each of the northern comers and the fuel handling machine mounted on the cell south wall. Sufficient access was provided, eliminating the need for entry at the -32 ft level.

measurements were made at the opening and at 30.5 cm (one Ft.) increments. An air sample was obtained to determine airborne contamination. Air quality measurements were made for explosive gases and oxygen level. A remote operated video camera was used to observe and record conditions and equipment inside the cell. Smear samples were taken from representative surfaces and equipment in the cell. A six meter telescoping pole was used to reach down into the cell and take smears from equipment and walls. Floor samples were obtained from material on the protective sleeving placed around radiological instrumentation, which was scraped across the cell floor. A standard sue smear was taken, read by the RCTs, and the results recorded. Smear samples were analyzed by the PNNL Analytical Chemistry Laboratory, located in the 325 building. Sampling and analysis result are located

Sampling was performed through the view plug opening. Radiological dose rate

2

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HNF-SD-MEL-ER-007, Rev. 0

Following a review of the data the FEF was reentered and the radiological dose rate measurements at 30.5 cm increments repeated. The instrument used was not responding correctly to conditions above 800 mR/hr. While the FEF was open a neutron counter was also inserted and measurements taken a three levels. Neutron data were analyzed by PNNL NDA System personnel.

After all data was gathered the viewing plug was replaced. The temporary radiation area was surveyed and dismantled. The FEF was left in a state to easily access the view plug in the future.

3. CELL AND EQUIPMENT BACKGROUND

3.1. Facility History

The original 309 building mission was to provide an operating test reactor in the Hanford Engineer Works (HEW) Plutonium Fuels Utilization Program whose purpose was to research and develop nuclear fuel technology. This test reactor was known as the Plutonium Recycle Test Reactor (PRTR). A General Layout of the facility and it's various features are shown in Figure 1.

In 1963, Fuel Element Rupture Test Facility, (hereafter called the Rupture Loop) operations began in one channel of the PRTR. The Rupture Loop itself was a pressurized, light-water-cooled loop within the main, heavy-water-cooled PRTR. The Rupture Loop was used as a pilot irradiation facility to test new fuel element designs and new operating regimes. Many of its tests involved pre-defecting fuel elements with pinhole breaks to study the stability of various pre-defected materials under irradiation. The FEF was used to examine fuel from the rupture loop as well as the PRTR.

Such Rupture Loop tests continued until a serious (Type A) operating accident occurred on September 29, 1965 (fuel rod failure). After the subsequent cleanup, the PRTR resumed critical experiments, known as the Batch Core Experiment. This experiment ran for only about half of its planned duration before a flaw was discovered in the P-4 valve (the main valve in the primary coolant inlet system). The PRTR was shut down in order to replace the valve in early 1969. The U.S. Atomic Energy Commission (AEC) decided not to refuel the PRTR. The PRTR was laid away in 1969 and subsequently decommissioned. By 1975 the PRTR had been deactivated, all fuel removed and the fuel storage basin decontaminated.

In the late 1970's, the ground floor level inside the PRTR containment dome was emptied and converted into a "clean shop" (i.e., one using no radioactive materials and no sodium) to fabricate sodium test loops used in the 324, 335 and 337 buildings. This conversion removed the fuel handling machine and FEF control equipment at the 0 Ft. level.

3

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HNF-SD-NEL-ER-007, Rev. 0

Figure 1. Fuel Examination Facility Location and Configuration

4

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HNF-SD-NEL-ER-007, Rev. 0

In 1986-87 a space technology development program known as SP-100 was assigned to the 309 Building. This program immediately undertook an extensive clean-out of the PRTR facilities in the building. The clean-out included removal of all PRTR process equipment from the containment floor, A, B, and C cells. Among the equipment removed were the FEF ventilation and cooling equipment and the B Cell sump pump equipment.

In 1991, the SP-100 program was placed on a 5-yr "hold," thus ceasing any further clean-out. The SP-100 program was terminated by DOE in November 1993, which has brought about the transition of the facility.

3.2. Fuel Examination Facility Description

The FEF cell was an experimental hot cell used to exam PRTR fuel and process tubes. The FEF functioned as a hot cell where personnel conducted remote manipulation of fuel elements or process tubes. The FEF was used for making observations, preliminary gamma scans, and other tests on irradiated and sometimes breached fuel. (Gerber, 1992) The type of fuel characteristics studied included: warpage, swelling, cladding anomalies, and other defects.

The FEF physical description and equipment are described below. The general layout and configuration is depicted in Figure 2 through 6. A more detailed FEF description, operation and maintenance requirements are found in the FEF Operating Manual (Kelly, 1961). The construction specification is HWS-6340.

3.2.1. Physical Description

The FEF Cell is located inside containment in the radial wall between B-Cell and A- Cell. A control console for the facility was located on the ground floor level of the containment dome (north side). Ventilation supply and exhaust equipment, process water connection, drain equipment and cell access were in B-Cell.

Air was normally for cooling sample, provided by the FEF heating and ventilation system. But, the cell also contained a vertical set of water spray riser units that served two purposes, back up cooling or cell decontamination and cell wash down. The cell contains a 10 cm (4 in.) floor drain, discharging into the B-Cell sump. In the B-Cell sump were a solenoid valve and pump, operated from the control console. This equipment removed waste water to the 309 Tank Farm hold-up tanks. The valve, pump and waste lines in B-Cell have been removed, waste lines capped, and the tank farm shut down.

The FEF Cell viewing and fuel handling equipment were operated from a Control Console. It sat between the containment north wall and FEF shielding blocks. The control console, periscope, fuel handling vehicle, and equipment protruding above the containment floor were removed during facility conversion to the sodium test loop fabrication shop. Portions of the periscopes may still be in the FEF. The control console and wiring into the FEF are removed. The connecting trench is empty, and portions filled with concrete.

5

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HNF-SD-NEL-ER-007, Rev. 0

=cb-N-

0 0 . West / IJguhgt Bank

El

\East Ll Light Bank

OPlug 0

AG97020185.1

Figure 2. Fuel Exam Facility Cover Block Arrangement

6

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HNF-SD-MEL-ER-007, Rev. 0

Figure 3. General Construction of Fuel Examination Facility

7

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Yentilation Inlet -

Shield Wall - 6 Thick. Steel

< Mainpulators (Secondary)

Sealed Step Plug -- Typical

Locking Lugs\

Sealed Access Port- Typical

Access Door -.- 24" x 45"

Viewing Windows (2

Outlet

I RG97020i85.5

Figure 4. Fuel Examination Facility Access and Penetrations

8

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.', I' ' Elect. Cable Trench Lighting Fixture Access Plug

@ 0 0 0

E-

!

1

il. - 32' - 0" - .............. RG97020185.6

Figure 5. Fuel Examination Facility Utilities and Lighting

9

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1 Loading Plug Entrance Plug L 1

Figure 6. Fuel Examination Facility Viewing and Manipulation Equipment

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The cell is a 1.8 m by 1.2 m by 8.5 m (6 ft by 4 ft by 30 ft) structure with a stainless steel liner. The A-Cell side wall is constructed of 1.1 m (3.5 ft) heavy aggregate (high density) concrete (bulk density 4,325 kg/m3 (270 lbs/fP.) The north and south walls are structural concrete. The B-Cell side wall is constructed of 0.56 m (22 in.) thick, tightly fitting, cast iron blocks (Meehanite). The overall cell is lined with 16 gauge stainless steel. The Cell is covered with three 0.6 m (24-inch) deep shielding plugs, which form portions of the containment floor. A 15 cm (6 in.) vertical steel plate is mounted in the top half of the FEF near the north wall, providing shielding for the periscope and optical viewing equipment.

Access into the cell is through ports, plugs and a door. In the shield plugs are eight 32 cm (12.75 in.) diameter access and equipment plugs. These plugs provided for sample insertion, cell viewing, and cell lighting. A manned entry into the bottom of the cell is provided through a heavy metallic bank vault type door located in B-Cell at the -32 ft level. Observation ports and access plugs are also available at various levels into the side of the cell. Characterization work performed was accomplished through the Sample Access Plug (fuel entry) and the Viewing Plug located in the containment floor (0 foot level).

3.2.2. Principal Equipment

Equipment used for the FEF included sample handling and viewing, and cell support equipment. Sample handling and observation was provided by two remote controlled periscopes, the fueling vehicle, and in cell manipulators. Support equipment included the ventilation and cooling system, two light fixtures, water cooling and decontamination, and liquid drain equipment.

Fuel Manioulator

The manipulator is essentially a 9.1 m (30 foot) long vertical lathe bed with two translatable carriages on each is a mounted a rotatable universal chuck. The manipulator is designed to handle 8.9 cm (3.5 in) cylindrical specimens weighing up to 137 Kg (300 lbs.) The only engineering drawings located for the fuel handling machine were: manipulator assembly, SK-3-1161;, Upper manipulator head SK-3-11509; lower manipulator head SK-3-11511 and SK-3-11508.

The manipulator heads were translated either up or down by electrically driven screws. A PRTR fuel assembly was 4.4 m (14 ft. 5 in.) long, the active core was 2.2 m (7-113 ft.) long, and a shim rod assembly is 7.7 m (15-112 ft) long. Shorter fuel rod lengths were also tested at PRTR, but longer lengths were undoubtedly rare and nothing in the 30 foot range would be expected. The vertical drive motor for the manipulator is listed as a 5 h.p., 3500 rpm, 240 volt D.C., General Electric totally enclosed, non-ventilated piece of equipment. (Additional information is in CVI file No. 15449, portions are in Appendix E.) The chuck motor is a variable 0.5 to 2.0 h.p. 1750 rpm, 72 volt D.C. motor. The equipment was connected to controls outside the cell and is not operational.

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Ventilation and Cooling EauiDment

There were two ventilation systems, a 0.12 m3/s (250 CFM) and a 0.68 m3/s (1500 CFM) System. The two supply fans and one exhaust fan were located in B-Cell. The smaller system used 4 inch Schedule 40 pipe, and the larger 25.4 cm (10 in.) inside diameter tubing. Ducting into the cell is at the -5.8 ft level. Inside the cell the ventilation systems supplied air through specially designed ducts attached to the fuel manipulator. The 250 CFM system provided axial cooling through the chuck. The 1500 CFM system provided cooling along the length of the sample. The 38 cm (15 in.) inside diameter exhaust duct intake was located in the north cell wall. After passing through a HEPA filter the exhaust entered the containment exhaust system. The B-Cell ventilation equipment has been removed.

In the event of a power failure, reduction of cooling airflow or specimen overheating during FEF operation, water spray cooling was available. The cooling air system was shut off and an automatic water spray rinse system was energized. Water jets were located inside the cell directing coolant onto the sample. The spray cooling was shut off if the water level in the cell reached the -8 ft. level.

Optical EauiDment

Optical equipment used in the FEF included periscopes and a boroscope. Two optical periscopes, operated from the control console, were used for observation, measurement and photographing irradiated specimens. One periscope had a two headed wide angle viewer providing a 70" field view at the -2 ft 6 in level and the -19 ft level. The other periscope was dual purpose providing a 5X magnifier and a profilometer. The prodlometer functioned at the -19 ft level. A boroscope was also used for viewing the inside of process tubes and disassembled elements. The boroscope operated through the fuel element loading plug. The optical equipment outside the cell is no longer present.

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4. FEF CELL RADIOLOGICAL CONDITIONS

4.1. Radiation Dose Rates

Measured dose as a function of depth for the FEF Cell is given in Table 1. These values have been plotted and are shown in Figure 7. Note that the graph shows a sharp maximum dose rate value that corresponds to the location of the lower fuel handling chuck mechanism.

The FEF shield plug was effective in eliminating any appreciable dose rate with the FEF closed. A dose rate of 2 mR/hr was measured after the fuel Access Plug was removed in the first characterization attempt. However, hardware that prevented the access port from being useful, probably also kept the dose rate down to 2 mR/hr. Dose rates in the FEF were measured via the fuel Access Plug port. The dose rate values measured from the Access Plug port were later found to be inaccurate above 0.800 mR/hr. The instrument calibration was rechecked and measurements repeated through the view port.

A dose rate of 7 mWhr was measured later when the Viewing Plug was removed. Dose rate values varied with depth up to a maximum of 6700 mFUhr. The depth of the maximum dose rate was about 12 feet. This is in the vicinity of the manipulator lower chuck and the shim rod assembly Inconel shims. Dose rate dropped sharply as the lower in the cell, to roughly 5 mR/hr at the bottom. The Cell has very little equipment in the lower half which probably explains the low dose. The Radiological Survey Reports are provided in Appendix B.

A PRTR shim rod assembly is the primary radiation source. Based upon the shim rod geometry, materials and radiation dose rate profile; the shim rod Corn source is estimated at 0.9 Ci. The shim rod assembly is the principal contributor to the FEF dose.

4.2. Smearable Contamination

Radioactive dose rate and contamination smear results show the FEF cell contamination to be fixed (almost non-smearable). Smearable contamination summaries are presented in Table 2. Samples were taken from the readily accessible surfaces in the FEF, and are representative of the vault conditions. The smears taken were standard 100 cm2 samples. Radiation survey report and assay reports are located in Appendix B.

Radiological contamination smear results listed in Table 2 indicate the highest smear level to be 90,000 dpm. Typical Geiger Muller (GM) beta/gamma instruments used at Hanford exhibit about a 350,000 dpm reading for a 1 mR/hr Cutie Pie (CP) or RO-7 instrument reading. This means the highest smearable contamination reading is less than 0.3 mR/hr compared with the highest dose rate reading of 6,700 Whr. The radioactively contaminated material at the (-)12 foot level of the FEF cell is therefore primarily fixed, it is in an encapsulated form, or not readily accessible.

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Table 1. FEF Cell Dose Rate Readings

0030 low range (LR) probe (0 - 2R) and a DTEB7-0047 medium range (MR) probe (0 - ZOOR)]

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0 -

4

a

12

h iz g v

f l 16.-

20

24

28

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Dose rnR/hr 10 100 1,000 10,000 1

--

--

--

--

--

--

-

f . ... . .,

; .. _. .:;

Figure 7. Dose Rate Profile in FEF

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The greatest source of contamination is the fuel manipulator lower chuck and the surrounding area. Analysis of the smears show high beta and Cow which account in part for the sharp dose rate. Total alpha is comparatively low indicating little or no nuclear fuel residues.

The smearable contamination inventory is estimated at 23.3 pCi total for the FEF. The smearable content is 99.9% beta/gamma. Details for this estimate are presented in Appendix C. The inventory is based upon a surface area estimated and isotopic smear averages for horizontal and vertical surfaces. The surface areas are estimated because detailed component drawings were unavailable, from which exact dimensions could be obtained. Smear samples are expected to be representative of the FEF conditions.

The shim rod assembly, mounted in the manipulator, is the only item with AmB1. AmB1 is a decay product of PuZ4l which indicates a PRTR fuel presents. During PRTR operation the shim assembly was cooled with heavy water. Smearable contamination on the shim rod are comparable to those found in the reactor moderator system (Ref. HNF-SD-ER- 008). Shim Rod estimates surface area is 11,400 cm2 (1,771.40 in’) which will yield the following isotopic estimates: Total Alpha, 7.65 nCi; Total Beta, 18.4 nCi; Corn, 5.28 nCi; Csl”, 13.8 nCi; Am241, 3.15 nCi (For PRTR this is equivalent to 0.297 pg TRU;) Total Ci, 48.2 pCi.

4.3. Neutron Monitoring

Neutron probe measurements were taken to determine if appreciable PRTR reactor fuel is located in the FEF. A neutron probe was lowered into the FEF Cell and measurements were made just above the Cell, the top of the Cell -0.91 m (- 3 ft.), -3.7 m (- 12 ft.), and -5.5 m (-18 ft.). The measurements indicate the neutron count is consistent with background levels. The uncertainty of the measurement supports the claim that less than 0.5 of TRU can be present in the FEF. This number is conservative because of the potential multiple counting of neutrons due to a neutron cavity effect in the FEF. The sample report is located in Appendix B. No fuel was detected in the FEF.

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Sample Information Field Radiation

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Depthlhcation

Outside Cell (Reference)

5. CHEMICAL CHARACTERIZATION

Oxygen Monitoring Results (% Oxygen)

20.9 to 21.0

5.1. Oxygen Monitoring

The FEF Cell has not been opened for approximately 25 years. Before entry there was concern that the oxygen level might have decreased, constituting a potential confined space issue. An oxygen monitor no. 9308101-049 using sampling pump no. 9309069-106, calibrated Feb. 4, 1997 was used to monitor the oxygen levels at 5 foot depth intervals on the 2/4/97. Table 3 shows the results, oxygen levels are normal or very nearly normal being 20.9% oxygen versus 20.9 to 21.0% for the reference level measurement.

1.5 m (5 ft)

3.0 m (10 ft)

4.6 m (15 ft)

6.1 m (20 ft)

20.9

20.9

20.9

20.9

7.6 m (25 ft)

9.1 m (30 ft)

20.9

20.9

5.2. Regulated Materials

Materials in the cell which may be potentially regulated include the following.

The FEF structure and components FEF contain an estimated 2,680 kg (5,910 lbs) of lead. See Table 4 for location details and quantities.

During sampling there were indications of oily film on lower manipulator. A repiew of the operations manual and procurement specification provides information on two oils and a grease. A review of the available documentation did not indicate equipment listed nor observed as being hydraulic driven, therefore, no hydraulic oil is expected in the FEF.

There is an oil in upper gear box on the upper drive head and lower drive head fuel handling machine manipulator, the oil used is not stated in the operating manual.

A lubricant was routinely applied to manipulator guide rods. The lubricant is Nuclear Grade Radiation Resistant Grease #335 (NLGI #O Grade) produced by Standard Oil of California 225 Bush Street San Francisco, CA.

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Each air motor (Gardner-Denver,) spline connected to the chuck jaws, holds approximately 4 lbs of grease. The reference materials did not state what type of grease was used

A small amount of penetrating type oil (Aerokroil) was added with a dropper to the seal plug seams to make it easier to remove the cell plug. The MSDS no. is 10231, residual material is not regulated. There might remain some residual oil on the Access Plug and the Viewing Plug. Oily rags and waste are regulated, but we did not generate any and would not expect there would be sufficient residual oil to generate any regulated waste in the future.

0 Glyptal (MSDS no. 14680) paint on the nuts and bolts that one can see looking back up the cell towards the bottom of the upper chuck in Figure 16.

There is also the Anti-Seize lubricant (MSDS no. 12828) residue on the seal plugs, but none of these (Aerokroil, Glyptal, or Anti-seize) should present any appreciable cleanup problems.

In cell FEF equipment is designed for decontamination with water, solvents (xylene or acetone) or acids (dilute nitric.) However, these materials are not expected to be present. If Water rinse was inadequate the solvents and acids in limited quantities could be used. (Ref. HW-70880 page 26)

5.3. Glyptal

A chemical condition was noticed when the cell was video taped. It was noted that the bolts and nuts were painted with a reddish colored material. Based upon prior experience with similar material the material is Glyptal insulating paint. Glypital was used extensively in the 1960 and 1970’s. The nuts, bolts, fittings, and similar items were painted with Glyptal to inhibit rust and prevent bolted joints from freezing, but, could be easily removed. The MSDS for Glyptal is 14680 (see Appendix D). Glyptal residues are not regulated. Glyptal product and coated rags are regulated due to volatile constituents. The removal of Glyptal treated bolts, nuts, or fittings should not result in the generation of a hazardous or mixed waste.

5.4. Anti-Seize

The Viewing Plug was very difficult to remove initially, requiring approximately 2 tons of force to remove a 660 lb plug. Rust, sand, and other foreign materials were found to be on the outside of the plug. Anti-Seize lubricant (MSDS No 12828) was applied to the outside of the plug to make it easier to remove in the future. The Anti-Seize lubricant residues are not regulated, but the product and rags are regulated similarly. No hazardous or mixed waste was generated in coating the View Plug with Anti-Seize lubricant.

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Location Component 1 Estimate Source Drawing/Zone I MateriaUquantity

D \-.--- --”, Containment, 0 ft Level I Floor Plugs IH-3-119851G9 -”_ _- Fuel Examination Facility (FEF), I 1500 CFM Air Duct Adapter lH-3-13372, sheet 31G10 /Asbestos Gasketll31 cm’ (8 in’) 11 FEF, Cell

FEF, Cell

lo 0

Comer Shields H-3-119871DlO Lead Wool/l,704 cm’ (104 in’)

Air Supply and Exhaust System Asbestos Cloth/574 cm’ (35 in’) (REMOVED)

H-3-11975/F3,G4; H-3-119901H2

FEF, Cell

FEF, Cell

FEF,

FEF, Cover Block El 0’-0” FEF, Cover Block El 0’-0”

FEF, Cover Blocks

FEF, Light Fixture

Wide Angle Viewer

250 CFM Air Duct Adapter

Service Entry Plug H-3-119851D3 Lead/304 Kg (672 lbs)

Viewing Plug H-3-11981/B6; H-3-11979 Lead Glass/27,550 cm’ (1,681 in’)

Viewing Plug H-3-119811B6; H-3-11979 Lead Woo11737 cm’ (45 in’)

Cover Block Plugs

Light Fixture Plugs

H-3-9100, sheet l1B3; H-3-9100, sheet 4/c7

H-3-133841E7

Lead1108 Kg (239 lbs)

Asbestos Gasket166 cm’ (4 in’) (REMOVED)

H-3-11978, sheet l1D4; H-3-11978, sheet 2 Lead11,215 Kg (2,681 lbs)

H-3-11982, sheet l1B2; H-3-11982, sheet Lead1550 Kg (1,214 Ibs) oi

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6. FEF CELL VISUAL OBSERVATION

6.1. General Observations

The FEF is stable and in good condition. Equipment in the cell appears to be intact with little or no signs of deterioration. There is a PRTR shim rod assembly mounted in the fuel manipulation machine. A thin layer of dried material is on the FEF floor. A light coating of oil was observed on the fuel manipulator lower chuck. There is very little loose equipment found in the cell. There appears to be some equipment inside the shielded periscope area that was not identified. video tape and a reference listing of archived photographs.

I Appendix A contains pictures captured from the

The port hardware shows indications of rust spots, because of this the viewing plug was lightly coated with an Anti-Seize lubricant (MSDS 12828) before replacing the plug. The bottom section of the plug port was clean as shown in Appendix A Figure 1. As far as working space, the south end of the sample port has limited access due to the Fuel Manipulation Machine and Shim Rod Assembly, but otherwise is clear. Access through the viewing plug provides ready access to the FEF.

6.2. Fuel Manipulation Machine

The first piece of equipment visible in the cell from the view port is the fuel manipulation machine upper chuck. (See Appendix A Figures 2 through 10.) At present the upper chuck is just below the cell block at about the -5 foot level, with the lower chuck at the -16 foot level. A PRTR fuel core was 2.2 m (7-113) ft long, and a shim rod assembly is 7.7 m (15-112 ft) long. Shorter fuel rod lengths were also tested at PRTR, but longer lengths were undoubtedly rare and nothing in the 30 foot range would be expected.

The carriages are translated either up or down by electrically driven screws. The screw drive mechanism for the lower chuck of the fuel handling machine can be observed in Appendix A Figure 10. Hidden behind the center drive is another screw drive which is readily observed. The chuck jaws are spline-coupled to air motor drives shown in Appendix A Figure 10. (SK-3-11512 is an isometric drawing of the air motor.)

6.3. FEF Samples or Specimens

The FEF examination revealed that there was a piece of equipment mounted in the manipulator. Appendix A Figures 13 through Figure 18 show the specimen. People familiar with PRTR operations recognized it as a PRTR Shim Rod Assembly. Neutron monitor established that it was very unlikely there are any appreciable fuel material (fuel pieces) in the FEF Cell.

Shim Rod Assembly drawings are H-3-14913 for a Mark I11 design and H-3-13484 for an earlier design. The actual shim was three 0.9 M (36 in) long Inconel "half rods." (Wittenbrock, 1959) The shims were used to balance the reactor neutron flux by absorbing

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some of the neutrons, thus changing the neutron flux profile. The shim rods became radioactive (Co-60) in the process and are responsible for the bulk of the FEF cell dose rate. The shim rods are estimated to contain 0.89 Ci of Corn the activated nickel produces an X- Ray.

6.4. FEF Lighting and Cooling

FEF lighting is provided by two vertical fixtures, containing eight flood lights each. The fixtures are located on either sides of the view port. Protection is provided for the flood light bulbs by a ladder like structure. The light fixtures are shown in Appendix A Figures 8, 9 and 13. The light fixture drawing is H-3-11982.

Also, observable in the figures are the two water spray risers adjacent to each light fixture. Appendix A Figure 12 shows a typical spray nozzle. Water spray could be used for washing the FEF down or as back up fuel element cooling.

6.5. FEF Cell Floor

The FEF Cell floor is shown in Appendix A Figures 2 and 3. The FEF floor is easily visible below the lower chuck and light fixture. Magnification of the floor in Appendix A Figure 4 shows a dried solids material. The material appears to be a wash-down residue. These solids were sampled via a contamination smear and were submitted for analysis. Smear contamination levels were low compared with other smear samples. Since radiation dose rates were also low near the bottom, the cell access door in B-Cell could potentially be used for monitoring purposes, or manned entry. Near the floor is an instrument bundle with connecting cable, and two metal plates which appear to have gone around a pipe, such as the floor drain.

6.6. External Observation

Portions of the FEF and related equipment can be visually observed without cell entry. The operational configuration had equipment in the B-Cell and on the containment floor. Drawings for the various parts are as follows: air supply and exhaust, H-3-11975; water cooling and decontamination, H-3-11976; and electrical equipment, H-3-11999.

The process water cooling supply piping in B-Cell has been removed and the pipe entering the cell structure capped (See Appendix A Figure 21 .) exhaust fans, duct, dampers and instrumentation are no longer present. The ducting to and from the cell have been capped. The two duct inlets are visible in Appendix A Figure 20.

The Air Cooling supply and

The FEF control console, external periscope equipment were removed in the 1970’s. along with the control console, electrical power, control cable, and tubing. The south half of the cable trench was filled with concrete. The trench going back into the motor control center is empty.

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7. CELL STATUS

The FEF Cell remains essentially the same as when it was operational, except for some removed equipment. The main FEF control console outside the cell is completely removed. The periscope viewing equipment is gone, the ventilation equipment is no longer operable, the lighting equipment is intact, but no power is available, the cooling water sprays headers have no water supply, and the B-Cell sump pump has been removed. The FEF utilities have been removed. The fuel handling machine manipulator appears to be intact, as well as the water spray risers and the lighting banks.

Cell Structure - The stainless steel lined cell appears to be in sound condition. The cell walls are all present and all access plugs are in place. No cracks or leaks in the system were apparent. There is smearable low level contamination on the cell walls and cell floor. The cell floor is painted white. The bottom part of the cell is empty except for one peace of instrumentation and connecting cable and some residual dried solids on the floor. The cell door at the -32 ft level is locked and bolted closed. On the door is High Radiation Area posting.

Control ConsolelODtical EauiDment - The control console is no longer present. The FEF control console was located inside containment on the north center side at the 0 ft level. All ties to equipment inside the cell have been removed. The cable trench is empty it contains no pipe tubing or wiring. Portions of the trench have been filled with concrete. This concrete may be why some of access plugs in the containment floor could not be removed.

SamDle - Shim rod Assembly - Portions of a PRTR Shim Rod Assembly are mounted in the manipulator. The shim rod is held in position buy the manipulator chuck. Attached to the top of the shim rod assembly is a fuel handling chuck. This chuck may have been used to insert the shim rod into the cell with the fuel handling machine, (which is no longer present.) The shim rod dose is 6.7 Whr from activated Inconel contains an estimated 0.89 Ci of Corn, and activated nickel which emits X-Rays on decay. The shim rod assembly has smearable contamination similar to the PRTR Primary Cooling system.

.

ManiDulator - The FEF manipulator assembly is in place and undisturbed from the time the PRTR was shut down. There is an oily film on lower manipulator head top surfaces. The film is believed to be from the manipulator gear box and/or guide lubricants.

Oatical Viewing EauiDment - The optical viewing equipment outside the cell has been removed. Inside the FEF the optical equipment was located behind shielding. A video tape review showed one item resting on the lower shelf of the shielded space. The item was not identified but it may be a potion of the optical equipment, perhaps the wide angle viewer.

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Lighting EauiDment - The two lighting fixtures used in the FEF are present. Eight flood Power and electrical connections to the lights lights are mounted in each assembly.

have been removed.

Cooling EauiDment - The 250 cfm and 1500 cfm air cooling assemblies are present inside the FEF. Interfacing supply and exhaust fans, ducting, dampers and instrumentation which were in B-Cell have been removed (See H-3-11975 for a layout of the original installation.) The ducts have been covered at the cell structure surface (This work was accomplished in 1986 clean-out activates.)

Water SUDD~V and Drain - Cooling water supply to the FEF spray system has been removed (See H-3-11976 for a description of the original installation.) The spray headers inside the FEF are still present. The cooling water pipe in B-Cell have been cut and capped. The containment process water systems have been drained.

The FEF floor drain was connected to equipment in the B-Cell Sump. The pump, valves and pipe were removed during the 1986 clean-out. At present the cell drain pipe extends approximately 7 cm (3 in) into the B-Cell sump, and is not plugged.

8. RECOMMENDATIONS

The FEF is stabile and does not require significant work to meet transition requirements. The only stabilization work needed is to plug the floor drain in B-Cell. Any further equipment removal or deactivation should be delayed until the FEF dose will allow contact handling of the equipment. This is expected to be 10 to 20 years. At that time the fuel manipulator could be removed through the containment floor shield blocks, using methods described in the operating manual. With the manipulator removed the shim rod assembly could be removed. As the FEF is now configured the air motors on the upper and lower carriage can not be opened to remove the shim rod assembly.

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9. REFERENCES

Gerber, M. S . , 1992, Past Practices Technical Characterization Study-300 Area- Hanford Site, WHC-MR-0388, Westinghouse Hanford Company, Richland, Washington.

Kelley, W. S . , Straley, R. L., 1961, PRTR Fuel Element Examination Facility Operations Manual, HW-70880, General Electric, Richland, Washington.

Wittenbrock, N. G., Walkup, P. C., Anderson, J. K., 1959, Plutonium Recycle Test Reactor Final Safeguards Analysis, HW-61236, General Electric, Richland, Washington.

HWS-6340, Specification for Fuel Element Examination Facility Plutonium Recycle test Reactor 309 Building, Hanford Atomic Products Operation, General Electric Company February 5, 1959

CVI File No. 15449, Vendor Information File, 309 FEF Fuel Manipulation Machine

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REFERENCE DRAWING LIST Drawing No. H-3-09113 Sheet 1 H-3-11970 Sheet 1 H-3-11971 Sheet 1 H-3-11975 Sheet 1 H-3-11976 Sheet 1

H-3-11977 Sheet 1-6 H-3-11978 Sheet 1-3 H-3-11979 Sheet 1 H-3-11980 Sheet 1 H-3-11981 Sheet 1 H-3-11982 Sheet 1-2 H-3-11985 Sheet 1 H-3-11987 Sheet 1 H-3-11990 Sheet 1 H-3-13373 Sheet 1-3 H-3-13374 Sheet 1-3 H-3-13412 Sheet 1 H-3-13412 Sheet 1 H-3-11999 Sheet 1

SK-3-07909 Sheet 1 SK-3-09393 Sheet 1-3 SK-3-09394 Sheet 1-3 SK-3-11508 Sheet 1-2 SK-3-11509 Sheet 1-2 SK-3-11510 Sheet 1 SK-3-11511 Sheet 1 SK-3-11512 Sheet 1 SK-3-11513 Sheet 1 SK-3-11514 Sheet 1 SK-3-11516 Sheet 1 SK-3-11661 Sheet 1-3 SK-3-11662 Sheet 1 SK-3-11663 Sheet 1

Title PRTR FUEL EXAM CELL WIDE ANGLE VIEWER ASSY STRUCT CONCRETE FUEL EXAM PIT PLANS, SECTS SHIELDING WALLS FUEL EXAM PIT PLNS, SECT F.E. EXAM FACILITY MECH. COOLING AIR SUPPLY & EX FUEL EXAMINATION WATER COOLING & DECONTAMINATION SYSTEM FUEL EXAM FACILITY WALL BLOCK ASSY & DETS FUEL EXAM FACILITY COVER BLOCKS ASSEMBLY & DETAILS FUEL EXAM FACILITY VIEWING PLUG DETAIL FUEL EXAM FACILITY ACCESSPLUG DETAIL FUEL EXAM FACILITY BLOCKS ARRANGEMENT FUEL EXAM FACILITY LIGHT FIXTURE & PLUG ASSEMBLY FUEL EkXAMINATION FACILITY SERVICE & FLOOR PLUG DETAIL FUEL EXAM FACILITY CORNER SHIELDS F.E. EXAM FAC.COOLING AIR EXH. FILTER BOX ARRANG 250 CFM PRTR FUEL EXAM DUCT ASSY 250 CFM PRTR FUEL EXAM DUCT TROLLEY FUEL EXAM FAC EQPT ARRGT FUEL EXAM FAC EQPT ARRGT ELECTRICAL - FUEL ELEMENT EXAMINATION FACILITY CND.

F.E. EXAMINATION FACILITY 1500 CFM PRTR FUEL EXAMINATION DUCT ASSY 1500 CFM PRTR FUEL EXAMINATION DUCT TROLLEY ASSY LOWER GEAR HEAD PRIMARY MANIPULATOR UPPER GEAR BOX PRIMARY MANIPULATOR

LOWER DRIVE HEAD PRIMARY MANIPULATOR AIR MOTOR FEEF MANIPULATOR UPPER GEAR BOX LIMITS + CYLINDERS BALL NUT ASSEMBLY FEEF UPPER AND LOWER CHUCK FEEF MANIPULATOR PRIMARY MANIPULATOR ASSY ROLLER WAY CARTRIDGE ASSY TROLLEY WIRE DETAILS

PLAN ELEV -32"O"

SPLICE PLATE DETAILS-SHIPPING BEAM

26

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Appendix A

Fuel Examination Cell Photographs and Images

App. A-1

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Fuel Examination Cell Photographs and Images

Presented in this appendix are images of the Fuel Examination Facility. The figures shown in this appendix are from two sources. The first source is images captured from video surveillance performed in the Fuel Examination Facility. This document is the only place where these images are available. The other source is from still photograph. Not all photos are include, however the photographs may be obtained from Photograph Archieve. A listing of applicable photos is at the end ofthis appendix.

There are other pictures available that may be u s e h l in D&D planing, they were not included with this document, because they are found in other documents under configuration control (HW-70880, PRTR Fuel Element Examination Facility Operations Manual, and CVl #15449, FEF Fuel Manipulation Machine.)

Below is a listing of the figures and their page numbers.

Figure Number Subiect Figure 1. View into Fuel Examination Facility Through Access Plug Hole ........................................................ A-3

Figure 3. View of Cell Floor .............................................................................................................................. A-4

.............................. A-5

Figure 2. View From -5 A. Level Showing Manipulator and Light Fixture ........................................ A-3

Figure 4 Cell Floor and Drain, Enlarged View ................................................................................................. A-4 Figure 5. Upper Manipulator Top View ....................................

Figure 7. Upper Manipulator Head Guide Rods ................................................................................................. A-6 Figure 8. Light Fixture and Lower Manipulator Head ...............................

Figure 6. Manipulator Connections View,. .................................

Figure 9. Lower Manipulator and Light Fixture ........................................ Figure 10. Lower Manipulator Head Equipment Detail ............................. Figure 11. Light Fixture Plug - Bottom View ................................................................................................... A-8 Figure 12. Auxiliary Cooling and Decontamination Spray Nozzle ..................................................................... A-8 Figure 13. Upper Manipulator and Shim Rod Lifting Fi xture ...........................................

Figure 15. Shim Rod Assembly Passing Through Upper Manipulator ............................................................. A-10 Figure 16. Shim Rod Detail Showing Lead Screw ........................................................................................... A-10 Figure 17. Shim Rod Passing Trough Lower Manipulator ......................................... A-11

A-11 Figure 19 Replacing View Plug into FEF ........................................................................................................ A-12 Figure 20 Fuel Exam Cell Wall in B-Cell ....................................................................................................... A-13 Figure 21 Fuel Exam Cell Process Water Isolation Valve ............................................................................... A-14 Figure 22 Fuel Exam Cell Duct Interface to Containment Exhaust System ....................................... Ay15

Figure 14. Shim Rod Assembly Passing Through Upper Guide Cone ...............................

Figure 18. Shim rod Assembly Passing Through Lower Manipulator ........................

App. A-2

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Figure 1. View into Fuel Examination Facility Through Access Plug Hole

Figure 2. View From -5 ft. Level Showing Manipulator and Light Fixture

App. A-3

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Figure 3. View of Cell Floor

Figure 4 Cell Floor and Drain, Enlarged View

>

App. A-4

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Figure 5 . Upper Manipulator Top View

Figure 6. Manipulator Connections View

App. A-5

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Figure 7. Upper Manipulator Head Guide Rods

Figure 8. Light Fixture and Lower Manipulator Head

App. A-6

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Figure 9. Lower Manipulator and Light Fixture

Figure 10. Lower Manipulator Head Equipment Detail

App. A-7

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Figure 1 1. Light Fixture Plug - Bottom View

Figure 12. Auxiliary Cooling and Decontamination Spray Nozzle

App. A-8

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Figure 14. Shim Rod Assembly Passing Through Upper Guide Cone

App. A-9

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Figure 15. Shim Rod Assembly Passing Through Upper Manipulator

Figure 16. Shim Rod Detail Showing Lead Screw

App. A-10

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Figure 17. Shim Rod Passing Trough Lower Manipulator

Figure 18. Shim rod Assembly Passing Through Lower Manipulator

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App. A-I2

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t

-.

Figure 20 Fuel Exam Cell Wall in B-Cell (TEF Photo # 97040252 -3 1CN)

App. A-I3

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.Figure 21 Fuel Exam Cell Process Water Isolation Valve REF Photo # 97040252 -27CN)

(REF Photo # 97010252 -28CN)

App. A-14

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Subiect of Reference Photogra~hs ....................................................... Picture No . Upper FEF West Wall from B-Cell (Covered Cell Inlet Duct) ........................................... 97040252 31CN

Mid FEF West Wall from B-Cell ...................................................................................... 97040252 30CN

FEF Vault Door in B-Cell -32 Ft Level ............................................................................. 97040252 29CN

Note: Covered 4 and 10 inch pipe for Cooling Air Supply is shown

Note: Cell Door is bolted and Locked .

FEF Air Exhaust Ducting Inlet to Containment Exhaust ................................................... 97040252 28CN

FEF Process Cooling Water Shutoff Valve ....................................................................... 97040252 27CN

Preparation for Removing Paint Accessing ....................................................................... 97020291 45CN

Contamination Control Bull Pen Setup ............................................................................. 97040291 41CN

Rigging Crew For Plug Removal ...................................................................................... 97020291 39CN

Fuel Plug Rigged for Removal, With Tension on Rigging

Note: Pipe from valve to FEF is removed .

............................. 97020291 37CN

Fuel Plug Rigged for Pulling ............................................................................................ 97020291 36CN

Fuel Plug Being Raised (Note, Doubled Rigging) .............................................................. 97020291 35CN

Fuel Plug Being Raised, RCT Checking Smears ............................................................... 97020291 34CN

RCT Performing Direct Raxjiation Measurements on Plug ................................................. 97020291 33CN

Attempting to Shrink Stuck Plugs with Dry Ice ................................................................. 97020291 32CN

Fuel Access Plug .....................................

Fuel Access Plug - Showing Rust ....

Fuel Access Plug - Showing Identification Markings

RCT Performing Survey Through Fuel Access Plug

Lighting Plug Shown with Cover Removed

Cover Plate Tack Welded in Place over View Plug ............................................................ 97020291 26CN

View Plug Being Lifted .................................................................................................... 97020291 06CN

............................. 97020291 31CN

................................... 97020291 30CN

................................... 97020291 29CN

.................................... 97020291 28CN

................... 97020291 27CN

Containment Configuration while Pulling Air Sample ....................................................... 97020291 05CN

View Plug Being Inserted, Note Silver Anti-Sieve Coating ................................................ 97020291 04CN

App . A-15

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Blank Page

Appendix A-16

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APPENDIX B: Radiological Measurement Reports/Surveys/Analyses

Contents

Radiation Survey Report R00081. Fuel Exam Cell 02/04/1997 . . . . . . . . . . . . . . . . B-3

Smear Sample Analytical Chemistry Laboratory Report . . . . . . . . . . . . . . . . . . . . B-7

Radiation Survey Report R00094. Fuel Exam Cell 02/24/1997 . . . . . . . . . . . . . . . . B-8

Fuel Examination Cell Neutron Counting Report . . . . . . . . . . . . . . . . . . . . . . . B-11

Appendix B-1

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Blank Page

Appendix B-2

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-A i r Sarnpls Losstion

. Large Ares Smear c - Cont8cI Reading

Appendix B-3

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I

I

\, \

\ \

i ! I

I BD-6000.010R IO61961

Appendix B-4

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RESOLUTION/RETEST Page J -4A (Continuation) 9 of 10

PTS NUMBER 33-96-00144/W

Top port radiation levels:

1.1. Gefore plug removed: 0 7

1.2. After plug removed: 5 f ~ - f k # C

Radiation Monitor Readings (units WC(N):

ct +.-/..- eo- i ae i .44'

0- ./ 1 ft. - 17- 17 ft. - ?Po 2 ft. - 19 18 ft. - ILe, 3 ft. - 35 19 ft. - L 4 ft. - bb 20 ft. - 50

21 ft. - 1-8 5 ft. - 104 6 ft. - 1 5 ' 4 22 ft. - lb 7 ft. - 220 23 ft. - 8 8 ft. - -00 24 ft. - 1 9 ft. - w.5 25 ft. - 5

26 ft. - 3 10 ft. 11 ft. - (100 IlLOO 27 ft. - 3 12 ft. - to50 28 ft. - L 13 ft. - 4x0 29 ft. - 2-

14 f t . - -110 30 ft. - L 15 ft. - qq5 31 ft. - 16 ft. - 3ia 32 ft. - 4

- qgo - ,,'fIFL.

3 . Air Sampling and Oxygen Monitoring:

R O O O O % l

P*Lr 3 CF 3

Appendix B-5

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PRTR-FX-0 1 PRTR-FX-02 PRTR-FX-03 PRTR-FX-04 PRTR-FX-05 PRTR-FX-06 PRTR-FX-07

FUEL EXAM CELL TECH SMEARS &AIRSAMPLE

FOR ANALYSIS AT 325 LAB

Perform GROSS ALPHA, GROSS BETA, GEA on smears

FLOOR 81 4000 DPM py FLOOR82 2000 DPM py CHUCKLOWER WESTSIDE 20000 DPM py WALL @ 15" EAST 2000 DPM py LIGHT TREE BOTTOM EAST 30000 DPM py CHUCK LOWER EAST 90000 DPM py

._ CHUCK ROD 2000 DPM by PRTR-FX-08 CHUCK TOP- 15000 DPM py PRTR-FX-09 WALL @ 15' WEST 2000 DPM py PRTF-FX-IO WEST LIGHT BOTTOM 6000 DPiM py

<20 DPM a <20 DPM a c20 DPM a <20 DPM u 0 0 DPM a <20 DPM a <20 DPM u 120 DPM a <20 DPM a <20 DPM a

PRTR-FX-I 1 AIRSAMPLE PRTR-FX-12 CHARCOAL CARTRIDGE

READINGS AFTERREMOVAL 7000 DPM py 1000 DPM py

Several ofthe smears are on whatman 5 filter papers. While others were taken on stickly backed smear papers and stuck to a whatman 5 filter paper.

AIR SAMPLE RUN FOR 4 HOURS AT 2 CFM

Readings were taken with a EGM and a PAM for reference only.

Contact RCT Chuck Wildman at 376-51 15 for any questions about the smears.

aoooo8~ ?bLF y o p ~

cIzzm-- Z l Y I ~ - l

Appendix B-6

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9%8> ¶ 9 G >

9-3'L> 9-3'2>

¶-?E> 9-3'2>

9-31,> 9-3'9>

%8Z

%¶Z %L

9-a'tr> 9-39VE

9-39L'Z C.312'1

t 3 ' E > Va'Z>

9-32> 9-33>

9-3'1> 9-33>

%81 9-33> V3C9.1

9-3.2, 9-3'L>

9.3'82

%Z L 9.1192'9

Yo 9 E-312'2

%9 V3P9.Z

% 9 E-IIOWE

% L 83Wtr

%9 Z3Gt'E

%9 Z3ZV L

%¶ V3G9.Z

%9 Z-PLO'E

%¶ V3GVt

%OZ 'L-3GL'9 %/.EO L

%6 9-3LL'G

%f C4L9'1

Xtr V398.1

%tr E-3LG.L

%t t-3LO'L

%t z-3op'z

%t Z-392'1

%tr t 3 Z L ' Z

%tr Z-3LL'l

%t tr-PZ11'E

%tr

8'3 'G> %GG

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%LL 9.380'1

%Otr LJ9V9

% L ¶-3zc'8

9-3LL.9

%9Z 9-3611'9

%9Z 93L8'Z

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%OZ 9'3L0'9

L 9 G >

%9Z

%9 '

W * ! O 1 , pASp"~1s

z I -XPUlUd 1 LL L-L6

1 1-Xd-UlUd OLLL-LG

0 1-XdUlUd BOLL-LG

GO-Xd-UlUd 89LL-LG

8o-XJ.UlUd L9LL-LG

LO-XJ'tUUd 99Ll-LG

80-XPUlUd 99LL-LG

IlO-Xd-UlUd t9LL'LG

i.O-Xd-UlUd COLl'L6

/.EO-XJ.Ulyd Z9LL-LG

ZO-XPUlUd 19LL-LG

lo-Xd'UlUd O9LL'LG

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'

Survay No.

R 000094 Westinghouse Hanford Company - Radiological Control

RADIOLOGICAL SURVEY REPORT

RWP No.1~1 Pago 1 Of -4

Date Time

e - I.(% RCO 0 0 1

F.C. o A \ 7 . ( \ \ 4 4 1 O I O Y . 1 1 0 0

Ar~alBldp.lRoomnoca(ion (Cede)

x O O ~ e C * [ acs &,br. I c.rri.&-c-.r I F--7 e%*.- CCLL R purposa of survsy Ichsck appropriate borlsrll:

Alarm Rcrponm: 0 CAM. 0 ARMIRAMI. P5D

?.&CY=- C . I U T T T C R l l ' ? l * - 2 *: Conlaminailon Incident: 0 Skin. 0 Clothing, Spill Job Dsrcripdon

c ruFL -a-

-\A -.---- HRANHRA Work Job Covoraga Othot

0 EXPOIUI~ Incident 0 Mstorisl Rslassa

1 0 RM Tmnrfcrlshipmam 0 Requirad. Task No.

Msplsketch

~

BD.8000-010 1061961

Appendix B-8

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Commrnrr

rc7AL < D = inches / sec L r r o r L B ~ C e D = A inches I see

0.25 inches from item

No audihla counts above background

O.LS inches from item A %of item surveyed

No audib!e counts above background %of item surveyed

8D.6000-DlDR l061961

Appendix B-9

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Pacific Northwest Laboratories Baiielle Boulevard P.O. BOX 999 Richland. Warhing:on 99352 Telephone 15091 376-0105

June 18, 1997

Bruce C. Cornwell BWHC Mail Stop L5-70 Richland, WA 99352

Dear Mr. Cornwell:

PNNL DOWN-HOLE ASSAYER RESULTS: FUEL ELEMENT EXAMINATION FACILITY

Enclosed is a s e t of data for work performed on February 24, 1997, using the PNNL Down-Hole Assayer System inside the sample chamber o f the Fuel Element Examination Facil i ty. The assay was performed a t the request of Mr. Wilbur Greenhalgh (decd.) t o provide posit ive confirmation that no fuel elements or fragments were stuck inside the chamber.

The PNNL Down-Hole Assayer System is a nonzdestructive assay (NOA) system that employs high-resolution (HPGe) gama-ray spectrometry and/or passive neutron counting t o characterize a local radiological environment with confined space o r where physical access is restricted. Only the passive neutron counter was deemed necessary f o r achieving the requested radiological characterization.

Aloha-Particle Activitv Measured via Passive Neutron Countinq

The neutron count f o r the PNNL Down-Hole Assay System is performed with a single %F, neutron counting tube with 5-cm diameter and 1.83 m length. The neutron count was taken with a bare tube ( i . e . , no polyethylene wrap t o provide moderation f o r higher energy neutrons i n the source term.)

The neutron tube counts ambient neutrons tha t a re low enough i n energy t o be captured by the %. The counting model assumes two sources of neutrons: one from natural background and one from transuranic (TRU) isotopes. The natural background source of neutrons consists mostly of spallation products caused by cosmic-ray bombardment o f surrounding structures, which i n this case was depressed because of the shielding e f fec ts of the massive concrete overburden. The other source of neutrons is transuranic materials, which has two components associated with i t : 1) alpha-particle ac t iv i ty resu l t s in neutron emissions via (a,n) reactions, predominantly w i t h oxygen and other l igh t elements of the matrix and 2) spontaneous fission of various transuranic isotopes (typically even- numbered isotopes) releases several neutrons.

Appendix B-1 1

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6. C . Cornwell Page 2 June 18, 1997

In cases where no process knowledge i s provided o r available, the TRU value determined from the neutron count i s based on the spec i f ic alpha-particle ac t iv i ty of weapons-grade PuO,, a conservative estimate since weapons-grade plutonium yie lds the lowest alpha-particle ac t iv i ty (hence,- the lowest neutron emission ra te ) o f any TRU material t h a t can reasonable be expected i n Hanford waste. T h i s assumption i s appropriate i n t h i s instance because of available process knowledge.

Data were collected a t 3 depths inside the sample chamber t o prof i le the e n t i r e length. Counting intervals were a t 1.8 m, which i s the length of the neutron counting tube used. The tab le sumarizing the upper-limit levels of weapons- grade PuO, a t the 3 depths is presented i n Exhibit 1. Computer printouts from the code NANAL, used t o document the neutron-count data, a re provided i n Appendix A.

Passive Neutron Counter Efficiencv Calibration

Direct efficiency calibrations were previously performed on several the passive neutron counter using the same configuration tha t was used f o r acquiring counts i n the sample chamber o f the Fuel Element Examination Facil i ty. The neutron source used i s the M-710 Z’9Pu6e, whose neutron emission r a t e corresponds t o a 953-9 weapons-grade 2’9Pu0, source. This neutron emission r a t e i s relative t o the PNNL NIST-traceable 100-9 weapons-grade PuO, standard, 196148. Calibration consists of a se r ies of counts with the standard centered on the length of the neutron counting tube, as specified i n the PNNL Technical Procedure SGS-001. A count i s taken w i t h the standard moved back in 1 f t increments. Five such counts were performed as part of the calibration. The resu l t s of the calibration a re provided i n Appendix 6.

The observed passive neutron data and the corresponding efficiency are used i n the PNNL NANAL Neutron Analysis Code t o determine TRU levels or gram-quantity values. The result ing hardcopy outputs a r e enclosed f o r each of the corresponding depths. An a rb i t ra ry net sample weight o f 1 g was used; consequently, the TRU ac t iv i ty ra t ios , expressed as nCi-alg a re a r t i f i c i a l l y high and should be ignored -- the “Total grams of TRU“ portion of the printout provides the appropriate upper-limit values.

Please note tha t the stated upper-limit values a r e conservative since the concrete walls of the sample chamber provide an adequate neutron cavity tha t allows a given neutron multiple chances of detection before being absorbed by materials i n the walls; t h i s e f fec t has not been taken in to account i n this

Appendix B-12

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6 . C. Cornwell Page 3 June 18, 1997

study, but would, in practice, lower the amount o f plutonium that could be present and still escape detection.

Field Calibration Source Check

The passive neutron counting tube was checked before use by counting the background (ambient) level inside the facility. The counts were compared to previous background counts taken both inside the same room and taken when the tube was calibrated against a known source o f neutrons.

No accuracy or precision noncompliance issues exist for this report

,

Recommendations and Conclusions

The data show that the observed neutron count inside' the sample chamber of the Fuel Element Examination Facility is consistent with background levels. The data supports the claim that less than 0.5 g TRU can be present inside the sample chamber and still avoid detection. As mentioned previously, the 0.5 g value i s conservative, since the concrete of the sample chamber would allow an emitted neutron multiple chances for detection so that detection would actually occur with a smaller amount of TRU.

Hard copies of the data are enclosed for you to maintain as record copies. The hard copies are a documented summary o f data contained in the paginated PNNL Assay Systems Log Book. Any questions may be directed to me at Mail Stop P8-08, by cc:Mail, by FAX at 376-2329, or by phone at 376-0405.

Attachments

cc w/attachments: MD Winterrose, P8-01 File /LB

Appendix B-13

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B . C. Cornwell Page 4 June 18, 1997

HNF-SD-NEL-ER-007, Rev. 0

Exhibit 1

Results o f PNNL Down-Hole Assayer System (Passive Neutron Count) on the Sample Chamber o f

the Fuel Element Examination Facility

Depth TRU Upper Limit

6 f 0.498 g

(ft.) (1 u)

12

18

i 0.405 g

f 0.366 g

Appendix B-14

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Appendix A

'Computer Printout o f NANAL Code Used t o

Process and Document Neutron-Count Results

Appendix B-15

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t t * * t * t * * * * * * * m * * t * * * t f 97022408.~~~ t * * NANAL: Neutron Analysis Code (Version 2.00) Date Analyzed - - (12:59:0 Neutron ANALYSIS fi Le: \OATA\97022408.NAN Segment CountTim Neutroncount Discard Sigma from Median

1 200.00 36. . 00 2 200.00 36. .oo 3 200.00 37. .17 4 200.00 32. -.67 & 800.00 141. 4-Sample Median 36.00

BARREL: Sample chamber a 18' SITE: Fuel Element Exam Facil.

OPERATOR: ndu statistics on 4 counts (Differences in Sigma units) CenMoment CaLc Value Poisson Value Diff/CalcSO Oiff/PoiSsonSD 2 3.687500E+00 3.525000E*01 -15.40 -1.26 3 -7.0312SOE*00 3.525000Et01 -15.13 -.16 4 3.039453ElOl 3.7629381+03 -458.23 - .58 Mean 35.25 35.25 SOofMEAN 1.11 2.97 Std Dev 2.22 5.94 -6.97 -1.76 SO of SD .53 2.11 Skeuness -.992966 .168430 -1.01 - .94 Kurtosis - .764723 .028369 -.30 -.29 Median 36.00 35.00 .72 .27 SOof KED 1.39 3.72 .......................... - _ - _ - UARNING! - - - - - ** NO NET NEUTRON COUNT ** NEGATIVE NET NEUTRON COUNT *tt*t*********t********f**~** INCONSlSTENT WITH ZERO1

******tt**t*******tt*****t*********t***********~*******~***************

** Measurement error dominates detection efficiency error ** Can profitably increase measurement time by factor of 2.840+00 ** **********Xt******t**********.****************

EFFNEU= 5.25D-04 2.6203-05 5.00% Y1- 28.287330 Y2= 16.794670

**

Only the 4 GOO9 neutron counts used in TRU calculations Measured Neutron Count Rate = 1.762508-01 CIS +/- 1.48429E-02 t 8.42%

3 1771 Net Est Neutron Count Rate = 1.00000E-20 CIS + I - 2.46776E-02 :*****'**%I Measured N Source Strength = 1.90578E-17 n/s +/- 4.70301E+01 [********%I

PRELIMINARY TRU activity 1.3122E-11 nCi

TRU activity Density 1.31208-14 ncilgram * I - 3.2376€+04 nCilgram C'******%l LESS THAN 5.32591+04 nCi/gram based on GROSS UT= 1000. gram

TRU activity Density 1.31228-11 nCi/gram +I- 3.2382E+07 ncilgram [******'%I LESS THAN 5.3268E+07 nCi/gram based on NET UT= 1. grams

Total grams of TRU in barrel 1.48188-19 gram +/- 3.6568E-01 gram [*******%I LESS THAN 6.01558-01 gram

Estimated Bkgd N Count Rate = 6.218758-01 c/s +/- 1.97148842

E*******%, +I- 3.2382E107 nCi LESS THAN 5.3268E+07 nCi ( 1.64-sigma threshold)

CALCULATIONS BASED ON: 1.000 kg Net barrel weight 1 N-tubes Neutron Efficiency = 5.24728-04 ( 2.6236E-05) tcts/sl/Cn/sl C 5.0Wl Calibration Factor = 6.8854E+05 ( 3.4427Et04) nCi/tn/sl t 5.00%1 Specific Activity = 8.8552E107 ( 4.000OE+06) nCi/gram I 4.52%1 Meas Bkg Count Rate= 6.2187E-01 < 1.97151-02) cps t 3.17M Btg Gross Barrel Ut= 3.202 # BkgAdjFactOr' 1.0000000 CFERR= 0.0000E+00 TRU material assumed to be: Ueapons grade Pu oxide

Appendix B-16

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t t t t t t * * * * * t * * * * * * * * * * 97022403.nan * t t NANAL: Neutron Analysis Code (Version 2.00) Date Analyzed - - (12:58:52

Neutron ANALYSIS f i le: \OATA\97022403.NAN Segment CountTime Neutroncount Discard Sigma frm Median

1 200.00 93. .42 2 200.00 84, -.53 3 200.00 89. . 00 ?. 600.00 266. 3-Sample Median 89.00

BARREL: Sample Chamber a 6' S ITE : Fuel Element Exam Fac i l .

OPERATOR: mlu S t a t i s t i c s on 3 counts (Differences i n Sigma un i ts ) CenMOment Calc Value Poisson Value - OifflCalcSD Diff/PoissonSD 2 1.355556E+01 8.866666E*01 -13.57 -1.03 3 -6.740637Et00 8.866666E+Q1 -2.21 -.08 4 2.7562961*02 2.367400E+04 -207.94 -.51

Mean 88.67 88.67 SOofMEAN 2.60 5.44 Std Dev 4.51 9.42 -6.53 -1.27 SO o f SD .75 3.86 Skewness -.I35059 .lo6199 -.27 -. I7 Kurtosis -1.500000 .011278 -2.17 -.51 Median 89.00 88.00 .31 .15 SDof MED 3.26 6.81

WARNING1 - - - - - .......................... _ _ _ _ _ ** NO NET NEUTRON COUNT ** NEGATIVE NET NEUTRON CWNT .......................... lNCQNSlSTENT

** Measurement e r r o r dominates de tec t ion e f f i c i e n c y er ro r

EFFNEU- 5.25D-04 2.620-05 5.00%

ZERO,

**********t*****t***t**t*t*tt**tt****************************************~"*

** ** Can p r o f i t a b l y increase measurement time by factor of 1.5ODCOO ** **t*****t*********t.tt**t**t**************************************~~~~***

Y1- 51.803840 Y2= 42.244750

Only the Measured Neutron Count Rate = 4.43333E-01 c l s +I- 2.71825E-02 Estimated Bkgd N Count Rate = 6.21875E-01 c l s +I- 1.97148E-02 Net Est Neutron Count Rate = 1.00000E-20 CIS +I- 3.35792E-02 Measured N Source Strength = 1.90578E-17 n l s +/- 6.39945EiOl

PRELIMINARY TRU a c t i v i t y 1.31221-11 nCi +/- 4.4063E+07 nCi LESS THAN 7.2483E107 nci ( 1.64-sigma threshold

TRU a c t i v i t y Density 1.31208-14 nci lgram +I- 4.4055Et04 nCilgram LESS THAN 7.24701+04 ncilgrarn based on GROSS UT=

TRU a c t i v i t y Density 1.31228-11 nc i l s ram +I- 4.4063Ec07 nci lgram LESS THAN 7.2483E+07 nci lgram based on NET UT=

Total grams of TRU i n b a r r e l 1.4818E-19 gram +I- 4.9759E-01 gram

3 GOOD neutron counts used i n TRU ca lcu la t ions

LESS THAN 8.18538-01 gram

CALCULATIONS BASED ON: 1.000 kg Net bar re l weight Neutron Ef f i c iency = 5.2472E-04 ( 2.62368-051 t c t s l s l l t n / s l Ca l ib ra t ion Factor = 6.88548+05 ( 3.4427E+04) nCi/ t n l s l Specif ic A c t i v i t y = 8.8552E107 ( 4.0000E+06) nCi/gram Meas Bkg Count Rate= 6.2187E-01 ( 1.9715E-02) cps Bkg Gross Bar re l Ut= 3.202 # BkgAdjFactor= 1.0000000 CFERR= TRU mater ia l assuned t o be: Weapons grade Pu oxide

I 6.13%1 3.17%1

[********XI

[*******%,

1000. grams [*******%I

1. grams [*******%I

1 N-tubes 1 5.00%1 t 5.00kI t 4.52%3 L 3.17/,1

O.OOOOE+OD

Appendix B-17

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* * * t * * * t * * * * t t * * * * * * t t * t 97022406.nan t * * NANAL: Neutron Analysis Code (Version 2.00) Date Analyzed - - (12:59:00 Neutron ANALYSIS file: \DATA\97022406.NAN Segment Countlime Neutroncount Discard Sigma frcm Median

1 200.00 45. .15 2 200.00 44. .oo 3 200.00 40. ~ .60 & 600.00 129. 3-Sample Median 44.00

BARREL: Sample Chamber zl 12' SITE: Fuel Element Exam Facil.

OPERATOR: mdu Statistics on 3 counts (Differences in Sigma units) CenMoment Calc Value Poisson Value DifflCalcSD Diff/PoissonSO 2 4.666667E*00 4.300000E+01 -20.12 -1.09 3 -6.000000E+00 4.300000E+01 -5.61 -.I2 4 3.266667E+01 5.590000E+03 -416.71 -.51 Mean 43.00 43.00 SDofMEAN 1.53 3.79 Std Dev 2.65 6.56 -8.87 -1.45 SD o f SD .44 2.69 Skeuness -.595170 .152499 - .63 -.52 Kurtosis -1.500000 .023256 - .96 -.49 Median 44.00 43.00 .52 .21 SDof MED 1.91 4.75 **************ttt*t******* _ _ - - _ WARNING! - - - - - ** NO NET NEUTRON COUNT ** NEGATIVE NET NEUTRON COUNT **tt.**.**t************t***** [NCONSlSTENT WITH ZERO!

***********************tt*t*********tttt*****************************

** Measurement error dominates detection efficiency error ** Can profitably increase measurement time by factor of 3.100+00 ** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EFFNEUz 5.2%-04 2.62D-05 5.00% Y1= 36.075800 Y2= 20.487120

Only the Measured Neutron Count Rate = 2.15000E-01 cls +I- 1.892978-02 1 8.80%1 Estimated Bkgd N Count Rate = 6.21875E-01 c/s +/- 1.97148E-02 3.17% Net Est Neutron Count Rate = 1.00000E-20 CIS *I- 2.73314E-02 :********%I Measured N Source Strength = 1.90578E-17 n/s +I- 5.208768+01 [********%I

**

3 G O W neutron counts used in TRU calculations

[*******%I PRELIMINARY TRU activity 1.3122E-11 nci

TRU activity Density 1.31208-14 nCi/gram +/- 3.5858E104 nCi/gram [*******%I LESS THAN 5.8986Et04 nCi/gram based on GROSS UT= 1000. grams

TRU activity Density 1.31221-11 nCi/gram +/- 3.58641+07 ncilgram [*******%I LESS THAN 5.8997E+07 nCilgram based on NET UT= 1. grams

Total grams of TRU in barrel 1.4818E-19 gram [*******%I LESS THAN 6.66248-01 gram

c / - 3.5864E+07 nCi LESS THAN 5.89971+07 nCi ( 1.64-sigma threshold)

+/- 4.0501E-01 gram

CALCULATIONS BASED ON: 1.000 kg Net barrel ueight 1 N-tubes Neutron Efficiency = 5.2472E-04 ( 2.6236E-05) [cts/sl/[n/sl [ 5:00%1 rnlihration Factor = 6.8854E105 ( 3.4427E+04) nCiltnls1 t 5.00%1 &Tfic-A&i;iiy- = 818552E107 i 4.0000E106j nCijgram 4.52363 Meas Bkg Count Rate= 6.2187E-01 ( 1.9715E-02) CpS t 3.17'1 Bkg Cross Barrel Ut= 3.202 # BkgAdjFactor= 1.0000000 CFERR- 0.0000E+00 TRU material assumed to be: Weapons grade Pu oxide

Appendix B-18

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HNF-SD-NEL-ER-007, Rev. 0

Appendix B

Spreadsheet Printout Showing Values and Data Used

to Establish the Efficiency Calibration for

the PNNL Passive Neutron Counter

Appendix B-19

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2.00-H x 2 . 0 0 ' ~ x 6.oo'W Waste Container 97022503 counted: 02/25/97

calibration Factor (c/n):

Calibration Factor (c/n):

File: 97022103.XLs

2.4866E-04 1.2433E-051

2.6622E-04 f 1.3311E-OS[

Container ID: M-710 PuBe w/ s i n g l e BF-3 Tube

Cross: 1 l b 0.5 kg Tare: 0 l b 0.0 kg

Net: 1 l b 0.5 kg

Detector Placement: D f t away

Side A Side 6 Side C Side D

Count of Container a t Specified Detector Placement

114 126 114 126 138 1 2 1 138 121

H 24 " W 72 *' D 2 4 "

Type of Count: 4-sided

9.4

02/25/97 C a l i b r a t i o n i n f o r m a t i o n

Distance Distance Net Rate et Rate Inc f t . ) l n ( r a t 4 <F i t> (c/s)

Count Time Cross Count (ft) (CIS) (ft) (SI (C)

0 ft away 1 ft 600 s 2 ft 600 s 3 ft 400 s 4 ft 5 ft

400 s 400 s

30196 c 22094 c 11508 c 9658 c 8206 c

1 49.70 CIS 50.66 2 36i20 c i s 3 28.15 c/s 4 23.52 c/S 5 19.89 c/s

34.89 28.05 24.03 21.31

6 19.31 Expected count r a t e using neutron standard

I 1.00 51.321

I 3.74 24.321

I 3.32 26.041

I 2 . 0 0 34.671

I 1.41 42.181

0.000 3.906 0.693 3.589 1.099 3.337 1.386 3.158 1.609 2.990

Type Homogenous

1-Sided

2-Sided

)-Sided

4-Sided

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0

( s p ) esuodsa

Appendix B-21

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Blank Page

Appendix B-22

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Rev. 0

APPENDIX C: Smerable Radiological Contamination Estimate

Appendix C-1

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Blank Page

Appendix C-2

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HNF-SD-NEL-ER-007, Rev. 0

Smearable Contamination Estimate.

The smerable contamination is estimated for use in release calculations. The releasable quantity of material is obtain from surface area estimates in the FEF. Vertical and horizontal surfaces are considered separately. Smear survey results are averaged for horizontal and vertical surfaces samples. The results should only be considered as an estimate because the cell surface areas are approximated and quantified smerable contamination from all surfaces were not available.

Surface area calculations are shown inC-1 Detailed drawing of several of the cell components were unavailable. Internal surface area is considered for duct assemblies and components. Smerable contamination estimates from horizontal and vertical surfaces are show inC-3. Contamination levels on all surfaces were not available, however the samples taken are expected to represent the conditions inside the FEF.,

Appendix C-3

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HNF-SD-NEL-ER-007, Rev. 0

5.46E-01 1.86E+02 2.54E+02 -- 8.22E-01 2.12E+02 2.698+02 --

PRTR-FX-09 Wall Q -15' (west side) PRTR-FX-04 Wall Q -15' (east side)

Vertical Surface Average 6.843-01 1.993+02 2.623+02

Unless otherwise noted units = pCill00 cm2 Table C-3. Average Smear Sample Results

___ _ _ _

1. Samples are grouped into horizontal, vertical and misc. categories. 2. Calculated surface average is calculated on the number of sample represented by the surface (7 for horizontal, 2 for vertical) 3. Below detection limits are include as 0.0 in the average, because the average will be applied to the bulk area for isotope estimation purposes

--- Below detection limit P 5

Appendix C-4

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APPENDIX D: MSDS Sheets

MSDS #010231, Aerokroil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

MSDS #11219, Glyptal, Air Drying Enamel . . . . . . . . . . . . . . . . , . . . . . . . . . D-5

Appendix D-1

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Blank Page

Appendix D-2

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. L . - . &-23 S i 03:43 FROFI:KG% LRBORRTORIES 161583357% T0:5053438557 l=az:01

'- ..i...!.___rr_ :... . . .. . . ._... ........_., . . , . .. .-, , , -. .- ....: ...-. .-. ._. /..: ..., ,.,..._,.... .,.. .._,. . . .

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HNF-SD-NEL-ER-007, Rev. 0

. . * . . +-23-% Em49 FROF1:KPNO LF.ZOTITORIES 16158335790 T0:5095438557 PffiE:W

. . ... .. . .... :... . . . ..... # :..

Appendix D-4

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385 ERSTERN RUE C H E L S E R , FIR 02150

T E L E P H O N E : 617-884-€318 P R O D U C T CLRSS. : R I R DRY ENRPIEL C O D E I D E N T I F I C A T I O N : 1201 T R R D E NRME: G L Y Y T R L

I R O N O X I D E a. 2 C R S NUIIHER 130'3-382 H M I S H E f l L T H = E F L R i ' I N R H I L I T Y = l R E R C T I U I T Y = l F E R R I C O X I D E '

H Y D R R T E D M R G N E S I U M S I L I C R T E 17.0 20 C R S NUllHER 14807-36-6 H M I S H E R L T H = 2 F L R M M R H I L I T Y = 0 R E R C T I U I T Y = 0

R O I L I N G RRNGE: 250.0 TO 345.0 F URPOR D E N S I T Y : . H E R U I E R THRN R I R E U R P O R R T I O N R A T E : SLOWER THRN E T H E R F'EKCEN'T U O L R T I L E BY VOLUME: 56.3 VOC ( less w a t e r ) : 3.35 L H S / G A L U E I G H T PER GALLON:. 1 3 . 3 2 P O U N D S U.O.C. I s d e t i m l i n e d p e r E P R R e f e r e n c e m e t h o d 24 u s i n q R S T M p ' r o c e d u ' r e s D 2 3 6 3 , D 1 4 7 5 a n d D 3 ' 3 6 0 . U R P O R P R E S S U R E : 5.73 mm/hg - N E L T I N G F ' O I N T : NOT RF'F 'LICRHLE

Appendix D-5

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mas: i201 PRGE: 2

SOLUBILITY IN WRTER: NEGLIGBLE RPPERRRNCE AND ODoq: RED LOUID WITH PAINT ODOR r&DS ## /la19 ___--__-___-_------_____________________---------------------------~--------==

SECTION IV - FIRE RND,EXF'LOSION HRZRRD DqTR OSHA CRTEGORY: FLRPINRHLE LIOUID

FLRSH POINT : 72 F PENSKY PIRRTIN LEL: 1.0 UEL: N/R EXTINGUISHING NEDIR:

UNUSURL FIRE RND EXPLOSION HRZRRDS: C a r b o n d i o x i d e , d r y c h e m i c a l OT foinl

P r e s s u r e may b u i l d up i n c l o s e d c o n t a i n e r s t h a t a r e e x p o s e d t o h e a t . S o l v e n t v a p o r s a r e h e a v i e - r t h a n a i r and may t ' r a v e l a c o n s i d e r a b l e

d i s t a n c e a l o n g t h e g'round t o a n i y n l t i o n s o w r c e a n d " f l a s h back". SF'ECIRL FIRE FIGHTING PROCEDURES:

Wate'r nlay b e i n e f f e c t i v e , howeve-r , w a t e r may b e u s e d t o c o o l c l o s e d c o n t a i n e . r s t h a t a're e x p o s e d t o h e a t . F i ' r e f i g h t i n g p e ' r s o n n e l s h o u l d wea'r s e l f - c o n t a i n e d b r e a t h i - n g a p p a ' r a t u s .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION V - HERLTH HRZRRD DRTR

THRESHOLD LIPIIT VFLUE: SEE SECTION I1

I n h a l a t i o n and s k i n c o n t a c t

Headache , n a u s e a , d i z z i n e s s , c o n f u s i o n , f r r i t a b i l i t y .

R e s p i r a t o r y d i f f i c u l t i e s O P p r e e x i s t i n g s k i n s e n s i t i z a t i o n .

PnImcmY ROUTE(S) OF ENTRY:

EFFECTS OF OVEREXPOSURE:

PIEDICRL CONDITIONS RGGRRVRTED BY EXF'OSURE:

CflRCINOGENICITY: None o f t h e c o m p o n e n t s o f t h i s p r o d u c t a're . r e p o r t e d c a r c i n o g e n s i n R/C w i t h

EPlERGENCY FIRST RID PROCEDURES: OSHR,NTP, IRRC a n d NIOSH.

INHRLRTION: Remove t o f . r e sh a i r . R d m i n i s t e r a r t i f i c i a l r e s p i r a t i o n

SKIN: Wash a f f e c t e d a'rea w i t h s o a p and w a t e r . Remove and l a u n d e r o'r o x y g e n i f b ' r e a t h i n g i s d i f f i c u l t .

c o n t a m i n a t e d c1oth:np. Consult a p h y s i c i a n i f irritation pe.r 5 i s t 5 .

EYES: F l u s h i m m e d i a t e l y w i t h l a ' r g e a m o u n t s o f w a t e r f0 . r it l e a s t 15 m i n u t e s . Take t o a p h y s i c i a n f o r m e d i c a l t r e a t m e n t .

INGESTION: Call a p h y s i c i a n i m m e d i a t e l y .

RCUTE: S k i n and e y e con tac t :Fv in ia ' ry i r r i t a t i o n . CHRON1C:Xylene c o n t a i n e d i n t h i s m a t e r i a l h a s b e e n f o u n d t o c a u s e t h e f o l l o wing e f f e c t s i n l a b o r a t o r y a n i m a l s : a m e n l a , l i v e r a b n o r n i a l i t i e s , l i v e r and e y e damage. P r e - E x i t i n g l i v e r a n d / o r k i d n e y d i s o . r d e r s may. b e a g g r e v a t e d by e x p o s u r e t o x y l e n e . R e p o r t s h a v e a s s o c i a t e d ' r e p e a t e d and p . ro longed o c c u p a t i o n a l o v e r e x p o s u r e t o x y l e n e w i t h pe rmanen t b ' r a i n a n d ne ' rvous s y s t e m damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION VI - REACTIVITY DRTR STRBILITY: NORPIRLLY STRBLE CONDITIONS TO RVOID:

None known

Appendix D-6

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HNF-SD-NEL-ER-007, Rev. 0

,.. . . .

NSDS: 1261 PAGE: 3

INCONPRTIBILITY ( N a t e r i a l s t o a v o i d ) S t r o n g a c i d s a n d bases

HRZFlRDOUS DECONPOSITION PRODUCTS: BY FIRE: No.rmal p r o d u c t s o f i n c o n i p ' l e t e c o m b u s t i o n .

HRZRRDOUS F'OLYNERIZATION: DOES NOT OCCUR CONDITIONS TO R V O I D :

None known

= = = P = = = = = I = P P = I I = = = E = P = = = = = = P = = I P = ~ = = = = = = = = = = = ~ = = = = = = = = = = = = = = = = = = = = = = = =

SECTION V I 1 - S P I L L OR LEAK PROCEDURES

STEPS TO BE TRKEN I N CASE NRTERIRL-IS RELERSED OR SPILLED: P r o v i d e a d e q u a t e v e n t i l a t i o n . Remove a l l p o s s i b l e i g n i t i o n s o u r c e s . R b a o r b a n d d i s p o s e u s i n g n o n - s p a r k i n g t oo l s . , .

E l i m i n a t e a l l s o u r c e s o f i g n i t i o n . E v a c u a t e u n p r o t e c t e d p e r s o n n e l . Water s p r a y may b e . u s e d . T o c o n t a i n ' r u n - o f f , c o v e r w i t h a n a b s o r b e n t m a t e r i a l a n d p l a c e i n c o n t a i n e r s f o ? p r o p e r d i s p o s a l . F l u s h a r e a wi . th water t o r e m o v e r e s i d u e . WRSTE DISF'OSRL NETHOD:

D i s p o s e o f u s i n g a n a p p r o v e d i n c i n e r a t i o n p r o c e s s o r i n a c c o r d a n c e w i t h l o c a l , s t a t e , a n d f e d e r a l r e g u l a t i o n s r e g a r d i n g h e a l t h a n d p o l l u t i o n .

.............................................................................. .

D i s p o s e i n a c c o r d a n c e w i t h l o c a l a p p l i c a b l e r e g u l a t i o n s .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION V I 1 1 - SPECIRL F'ROTECTION INFORNRTION ..............................................................................

RESF'IRRTORY F'ROTECTION: I n o u t d o o r OT o p e n areas 1158 B u r e a u o f N i n e s a p p r o v e d m e c h a n i c a l f i l t e r r e s p i r a t o r t o remove s o l i d a i r b o r n e p a r t i c u l a t e s o f o v e r s p r a y . I n d o o r s , w h e r e v e n t i l a t i o n is i n a d e q u a t e . u s e Bureau o f N i n e s a p p r o v e d c h e m i c a l - m e c h a n i c a l r e s p i r a t o r s d e s i g n e d t o ' remove b o t h p a r t i c u l a t e a n d v a p o r .

VENTILRTION: PROTECTIVE GLOVES: ~~~~ ~~~

Recommended i f s k i n c o n t a c t i s l i k e l y .

C h e m i c a l s p l a s h g o g g l e s ' recommended i f p o t e n t i a l for s p l a s h o r e y e c o n t a c t is l i k e l y .

OTHEK'PROTECTIVE ERUIPIIENT: Reconiniended as n e e d e d t o a v o i d c o n t a c t .

EYE F'ROTECTION:

--____--__--______====___________ --__-__--______-__ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION I X - SF'ECIRL PRECRUTIONS

PHECRUTIONS TO BE TRKEN I N HRNDLING OR STORING: S t o r e i n a cool d r y p l a c e a w a y f'roni h e a t , s p a r k s a n d o p e n f l a r e . K e e p c o n t a i n e r s c l o s e d a n d u p r i g h t t o p r e v e n t l e a k a g e . O u t s i d e o r d e t a c h e d s t o r a g e is p r e f e r r e d . I n s i d e s t o r a g e s h o u l d b e i n a s t a n d a ' r d f l a m m a b l e l i q u i d s t o r e r o o m or c a b i n e t . Netal c o n t a i n e r s s h o u l d b e n r o u n d e d w h e n t r a n s f e r r i n 0 mater ia l f r o m o n e c o n t a i n e r t o a n o t h e r . Do not r e u s e p r o d u c t c o n t a i n & f o r a n y p u r p o s e .

OTHER PRECRUTIONS:

Appendix D-7

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HNF-SD-NEL-ER-007, Rev. 0

PREPRRED BY: TECHNICRL STAFF

REFERENCE DRTE: 81/26/83

PEDS: 1261 F'QGE: 4

MSDS # uaiq RCCORDING TO STRTE OF CRLIFORNIQ'S LIST OF CHENICRLS KNOWN TO CRUSE CRNCER OR REPRODUCTIVE TOXICITY,THERE RRE NONE PRESENT IN THIS F'RODUCT.

. , . . . . * . . . .

MSDS# //A19

TO WHOM IT MRY CONCERN: EFFECTIVE JQN 1 1989, WE RRE RE(IU1RED HY SRRFl TIT

PERCENTAGE OF QNY INGREDIENT IN R PRODUCT WHICH IS IN THE 313 LIST OR RS A N LISTING RS R COMPONENT OF Q IIRTERLRL WHICH IS IN Q CRrEGORY OF CIiEIIICRL LIST.

LE 111 SECTION 313 OF THE RIGHT TO KNOW'LEGISLQTION, TO INFORPI YOU OF THE

PRODUCT: l2El GLYPTRL

34.3% XYLENE (CQS NUFlIlER 1538-26-7)

IF YOU WILL MULTIPLY YOUR TOTRL F'URCHRSES F R O N US RS WELL RS FRON OTHER SU PPLIERS BY THE F'ERCENTRGE OF ERCH INGREDIENT FOUND IN ERCH F'RODUCT RND IF THE TOTRL OURNTITY EXCEEDS THE REPORTABLE (IURNTITY FOR THRT INGREDIENT YOU ORE REOUIRED TO FILE FORM R REPORTS.

Appendix D-8

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APPENDIX E: 309 FEF Fuel Manipulation Machine CVI Excerpts

(CVI File No. 15449)

Appendix E-1

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HNF-SD-NELER-007, Rev. 0

Blank Page

Appendix E-2

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HNF-SD-NELER-007, Rev. 0

SECTION I

PURPOSE AND GEKERAL DESCRIPTION

The Pr imary Manipula tor is d e s i g n e d and b u i l t for remote c o n t r o l l e d m a n i p u l a t i o n of f u e l e lements , or p r o c e s s t u b e s , d u r i n g e x a m i n a t i o n by remote o p t i c a l means. I n t h i s manual , un le s s o t h e r w i s e noted , t h e e x p r e 3 s i o n " f u e l e lements" , or "elements" w i l l i n c l u d e f u e l e l e m e n t s w i t h h a n g e r s and p r o c e s s t u b e s .

The Manipula tor w i l l be i n s t a l l e d i n a v e r t i c a l p o s i t i o n i n a s h i e l d e d cel l . F u e l e lements , suspended from one end, w i l l be lowered i n t o t h e m a n i p u l a t o r by a n overhead d e v i c e ( Jugger - n a u t ) , w h i l e t h e m a n i p u l a t o r is e i t h e r o p e r a t e d at a n a d j u s t - a b l e ver t ica l t r a v e l rate, or h e l d s t a t i o n a r y .

A f t e r an e lement is lowered i n t o t h e ce l l it w i l l be chucked by t h e m a n i p u l a t o r for thO scanning o p e r a t i o n .

The s c a n n i n g mot ions of t h e manipula tor w i l l p e r m i t se lec t ive 2 d i r e c t i o n , 2 speed , r o t a t i o n of t h e element on its own a x i s , and for 2 d i r e c t i o n , 2 speed v e r t i c a l t r a v e l a l o n g t h e axis.

Other f u n c t i o n s of t h e m a n i p u l a t o r w i l l inc lude :

(a) S e l e c t i v e o p e r a t i o n of 2 d r i v e heads

(b) Chucking and r e l e a s i n g , d u r i n g r o t a t i o n .

(c) A d j u s t a b l e v e r t i c a l r a p i d t r a v e r s e r a t e for

(d) T a i l s u p p o r t a d j u s t i n g and p i v o t o p e r a t i o n .

(e) C o o l i n g a i r b a f f l e opening and c l o s i n g .

( f ) A numer ica l r e a d o u t , a t t h e o p e r a t o r ' s

l o a d i n g and unloading .

c o n s o l e , of t h e v e r t i c a l p o s i t i o n of t h e upper d r i v e head.

- 1 -

I

' Appendix E-3

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SECTION I V

INSTALLATION

1 - PREPARATION FOR INSTALLATION

(a) Remove c o v e r i n g and a t t a c h m e n t s l e t t i n g t h e beam c o n t i n u e t o rest on t h e s k i d .

(b) Examine m a n i p u l a t o r for any p o s s i b l e damage i n sh ipment , c h e c k i n g i n p a r t i c u l a r a i r l i n e t u b e s , t r o l l e y rods, and e l e c t r i c a l and a i r f i t t i n g s . I f d e s i r e d , a f t e r removing any i n t e r f e r i n g b locks , or s t r a p s , t h e m a n i p u l a t o r may be o p e r a t e d over a s h o r t t rave l (1" or 2") , a t s c a n speed o n l y , by temporary c o n n e c t i o n s . O t h e r i u n c t i o n s may a l s o be t e s t e d t h r u s h o r t mot ions .

(c) Remove any beam a t t a c h m e n t c lamps which w i l l i n t e r f e r e w i t h t h e i n s t a l l a t i o n of t h e a i r d u c t s ( f u r n i s h e d by c u s t o m e r ) . Also, remove any beam a t tachment c lamps which would be i n a c c e s s i b l e a f t e r i n s t a l l a t i o n of t h e a i r d u c t s .

t o t imber s k i d ,

Do n o t d i s t u r b t h e (B) wedge t y p e j a c k s on t h e s h i p p i n g beam, -

(d) I n s t a l l a t i o n of a i r d u c t s :

1 - Upon e x a m i n a t i o n of t h e c o o l i n g a i r t r a n s i t i o n s i t w i l l be found t h e y are des igned t o f i t i n s i d e of t h e t r a v e l i n g a i r d u c t c a r r i a g e members.

The a i r d u c t s are t o be a t t a c h e d t o t h e v e r t i c a l t r a c k frame by a series of t h r e e d o v e t a i l e d s u p p o r t b l o c k s and s t r i p s . The s t r i p s w i l l b e found mounted i n l i n e , numbered and a t t a c h e d t o t h e . s i d e s of t h e v e r t i c a l t r a c k frame.

Taking f u l l a d v a n t a g e of t h e edge of t h e " i n l i n e " s u r f a c e of t h e l e v e l i n g j a c k s , as found a t t a c h e d t o t h e " s h i p p i n g beam", by p l a c i n g t h e p r o p e r a i r d u c t s i n p l a c e on t h e edge o f t h e l e v e l i n g j a c k s and t h e end of t h e d u c t a g a i n s t t h e bottom s u p p o r t b r a c k e t s , t h e d o v e t a i l e d s u p p o r t b l o c k s (H-37750) c a n be s p o t t e d f o r a t tachment t o t h e d u c t p r o p e r , a f t e r b e i n g f i r s t p l a c e d in p o s i t i o n between t h e i r s u p p o r t s t r i p s for l e n g t h w i s e l o c a t i o n .

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Appendix E-4

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SECTION I V

INSTALLATION (Continued)

1 - PREPARATION FOR INSTALLATION

(d) I n s t a l l a t i o n of a i r d u c t s ( c o n t i n u e d ) :

When t h i s is b e i n g done t h e t r a v e l i n g duc t c a r r i a g e and f l e x i n g s e a l i n g s t r i p should not be i n p l a c e on t h e d u c t s i n c e it w i l l be re- q u i r e d t o d r i l l four c l e a r a n c e h o l e s from t h e i n s i d e of t h e d u c t i n t o t h e s u r f a c e of t h e s u p p o r t b l o c k s ( f o u r 3/8 N.C. -16 x 5 / 8 long head s t a i n l e s s s teel s c r e w s p e r b lock should s u f f i c e ) .

A f t e r t h e h o l e s are s p o t t e d through t h e duc t w a l l i n t o t h e s u p p o r t b l o c k s , t h e b locks should be numbered, s l i d o u t o f t h e i r s u p p o r t s t r i p s , d r i l l e d and t a p p e d f o r t h e 3/8 N.C. suppor t sc rews , t h e n a t t a c h e d t o t h e d u c t wal l with t h e 3/8 round head machine screws , t a k i n g c a r e so t h e screws will n o t p r o j e c t t h r u t h e blocks.

A f t e r t h e b l o c k s a r e a t t a c h e d t o t h o duc t w a l l t h e f l e x i n g s e a l i n g s t r i p or band and t r a v e l i n g d u c t c a r r i a g e s h o u l d be assembled w i t h t h e d u c t .

The n e x t s t e p w i l l be t o p l a c e t h i s assembly a d j a c e n t t o t h e v e r t i c a l t r a c k frame with t h e bot tom of t h e d u c t a g a i n r e s t i n g on t h e edge of t h e l e v e l i n g j a c k s . However, t h e d u c t must be p l a c e d w i t h t h e bot tom end f a r enough away from its end s u p p o r t b r a c k e t s t o allow t h e suppor t dove t a i l blocks t o be s l i d t o g e t h e r a f t e r f i r s t b r i n g i n g t h e t r a v e l i n g d u c t c a r r i a g e t o t h e p o s i t i o n where t h e a i r t r a n s i t i o n e x t e n s i o n s c a n be i n s e r t e d i n t o same. I t w i l l be found t h e d u c t c a n t h e n be s l i d i n t o p o s i t i o n (Provid ing t h e d u c t is s t r a i g h t ; o t h e r w i s e a s h e e t metal shim may be r e q u i r e d ) (Also it may be wise t o provide f o r some i n t e r n a l s t r e n g h t e n l n g s t r i p s t o t h e duc t w a l l , depending on its i n h e r e n t s t r e n g t h )

A f t e r t h e d u c t assembly is i n p l a c e t h e only t h i n g remain ing is t h e a t tachment of t b e c a r r i a g e c l e v i s p l a t e s (A-37715) t o t h e t r a v e l i n g duc t c a r r i a g e s and c o n n e c t i n g t h e R. and L . hand s i d e d r a g r o d s .

- 6 -

Appendix E-5

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SECTION I V

INSTALLATION (Continued)

1 - PREPARATION FOR INSTALLATION

(d) I n s t a l l a t i o n of a i r d u c t s (cont inued)

Once t h e above assembly s t e p s have been fol lowed t h e d u c t s can be q u i c k l y removed, or r e i n s t a l l e d with t h e a i d o f t h e s h i p p i n g beam as a guide , a f t e r removing t h e c l e v i s p i n (H-37712). The duct can be s l i d forward t o d i s e n g a g e t h e d o v e t a i l s u p p o r t b l o c k s t h e r e b y f r e e i n g t h e d u c t assembly.

2 - INSTALLATION -- ( 8 ) Check t o make s u r e t h a t t h e manipula tor is a t t a c h e d

t o t h e " s h i p p i n g beam" a t e a c h end and a t l e a s t one p o i n t near t h e middle . The hooks provide a t t a c h - ment a t each end. A f t e r d u c t i n s t a l l a t i o n , i t may be n e c e s s a r y t o add a t i m b e r c lamping arrangement near t h e middle . T h i s should b e a r on t h e main v e r t i c a l t r a c k , n o t on any s h a f t or l e a d screw, o r t e l e s c o p i n g a i r l i n e s .

P r e v i o u s t o t h e s e p r e c a u t i o n s t h e s u p p o r t b r a c k e t s should be checked f o r h a v i n g been p r o p e r l y a t t a c h e d t o t h e ce l l w a l l , a s t o s q u a r e n e s s of t h e i r mount- i n g r e l a t i v e t o t h e plumbness of t h e cell w a l l s .

L ikewise , a l l a i r l i n e s a t t a c h a b l e w i t h t h e i r r e s p e c t i v e m a n i f o l d s , as w e l l as e l e c t r i c a l p l u g j a c k s , s h o u l d be s e p a r a t e d a t t h e i r r e s p e c t i v e mat ing s e c t i o n s and a l l l i n e s should be f r e e o f t h e manipula- t o r p r o p e r so as n o t t o become f o u l e d on t h e beam when lower ing or removing t h e manipula tor .

(b) E r e c t i n g

Move t h e manipula tor and s h i p p i n g beam assembly i n t o t h e p o s i t i o n d e s i r e d f o r e r e c t i n g , depending on which of two methods is used f o r e r e c t i n g .

For t h e f i r s t method, the l o c a t i o n of t h e beam and manipula tor assembly a t t h e t ime of l i f t i n g t o v e r t i c a l is n o t i m p o r t a n t .

For t h e second method, t h e assembly i s l o c a t e d f a i r l y a c c u r a t e l y w i t h respect to t h e c e l l chambers.

_ .

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Appendix E-6

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HNF-SD-NELER-007, Rev. 0

SECTION IV

INSTALLATION (Cont inued)

2 - INSTALLATION (Continued)

(b) E r e c t i n g (Continued)

For e i t h e r method a s e p a r a t e p r o v i s i o n must be made t o hold t h e beam a f t e r t i l t i n g t o t h e v e r t i c a l p o s i t i o n , so t h a t t h e c r a n e can be r e l e a s e d from t h e beam, and a t t a c h e d t o t h e manipula tor l i f t i n g e y e s . Guy w i r e s or r o p e s a r e s u g g e s t e d , wi th b l o c k s t o r e s t r a i n t h e lower end.

FIRST METHOD: Block t h e lower end of t h e s h i p p i n g beam t o prevent i t s s h i f t i n g w h i l e t i l t i n g . For t h i s purpose, a b a r c a n be i n s e r t e d t h r u t h e lower l i f t i n g c r o s s member, and s u p p o r t e d i n b l o c k s h igh enough so t h a t t h e l o w e r end o f t h e beam w i l l c l e a r t h e f l o o r a s it p i v o t s .

A t t a c h t h e s l i n g t o one or t w o b a r s t h r u t h e upper l i f t i n g c r o s s member. Use b a r s l o n g enough so t h a t t h e s l i n g w i l l n o t b e a r a g a i n s t t h e manipula tor . L i f t t h e beam and m a n i p u l a t o r assembly t o a v e r t i c a l p o s t i o n In such a manner t h a t t h e manipula tor is r e s t i n g on t h e beam on t h e way up.

Avoid t i l t i n g p a s t t h e v e r t i c a l .

A t t a c h guy w i r e s t o t h e beam, or l o c k it i n t o p o s i t i o n i f f a c i l i t i e s permi t .

Unhook t h e c r a n e from t h e beam and a t t a c h t o t h e manipula tor l i f t i n g e y e b o l t s , u s i n g a s u i t a b l e s l i n g . One l i f t i n g eye b o l t w i l l have t o be t e m p o r a r i l y screwed i n t o t h e p r o v i d e d hexagonal e x t e n s i o n and re- moved a f t e r t h e m a n i p u l a t o r is i n p o s i t i o n i n t h e ce l l , due t o crowded c o n d i t i o n s .

Remove beam a t t a c h m e n t c lamps from t h e manipula tor and remove t h e r e t a i n i n g s t r a p s (H-38129) from t h e lower hooks on t h e s h i p p i n g beam.

A d j u s t t h e s l i n g so t h a t t h e m a n i p u l a t o r w i l l hang c l o s e t o a v e r t i c a l p o s i t i o p . T h i s c a n be done by l i f t i n g t h e manipula tor s l i g h t l y o f f t h e beam s u p p o r t hooks t o check t h e s l i n g a d j u s t m e n t , and hanging It back on t h e h o o k s ' w h l l e a d j u s t i n g t h e s l i n g .

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HNF-SD-NELER-007, Rev. 0

SECTION I V

INSTALLAT ION (Continued)

2 - INSTALLATI03 (Cont inued)

(b) E r e c t i n g (Continued)

I FIRST METHOD (Cont inued)

A f t e r a d j u s t i n g and s e t t i n g t h e s l i n g , t h e manipu- l a tor c a n be l i f t e d o u t of t h e hooks, and lowered i n t o t h e c e l l chamber t o r e s t i n t h e upper s u p p o r t b r a c k e t s and be r e t a i n e d by t h e lower s u p p o r t b r a c k e t s .

The t r a v e l i n g c r a n e , a f t e r having r a i s e d t h e manipu- l a t o r from t h e c r a d l i n g of t h e s h i p p i n g beam, should be inched away from t h e hook s u p p o r t i n g wal l i n such a d i r e c t i o n so a s t o a l l o w t h e manipula tor assembly t o be lowere'd, c l e a r i n g t h e a i r d u c t c o n n e c t i o n s i n t h e ce l l w a l l , a f t e r which t h e c rann should r e t u r n t h e m a n i p u l a t o r towards t h e c e l l w a l l t h e r e b y a l low-

' i n g t h e m a n i p u l a t o r t o come t o i ts p o s i t i o n w i t h t h e cross p i n s i n t h e i r r e s p e c t i v e s u p p o r t hook b r a c k e t s . I t w i l l be noted t h e hooks c a u s e a caming a c t i o n of 1/8 i n c h towards t h e s u p p o r t b r a c k e t s from t h e i r p o i n t of e n t r y , t h i s a c t i o n a c t i n g t o s e a l t h e a i r d u c t s r e l a t i v e t o t h e i r j o i n t f a c e s wi th t h e d u c t o u t l e t s i n t h e ce l l w a l l . For t h i s reason some form of s t a i n - less s t ee l b e l l o w s should be provided by t h e cus tomer between t h e i n c e l l w a l l d u c t o u t l e t s and d u c t i n l e t s , so a s t o p r o p e r l y s e a l t h e c o n n e c t i o n s a i r t i g h t .

NOTE: B e f o r e removing t h e s l i n g from t h e m a n i p u l a t o r , r e c o r d i n f o r m a t i o n on t h e s l i n g ad jus tment , so t h a t it c a n be a r r a n g e d t h e same way f o r any subsequent s e r v i c e removal from t h e ce l l , or l o c k t h e s l i n g ad- j u s t m e n t s w i t h c a b l e c lamps.

SECOND =HOD: T h i s method p e r m i t s u s i n g t h e s h i p p i n g beam a s a g u i d e when l o w e r i n g t h e manipula tor i n t o t h e c e l l . The m a n i p u l a t o r and beam assembly is p o s i t i o n e d v e r t i c a l l y so t h a t t h e c e n t e r l i n e of t h e hooks on t h e beam is s l i g h t l y back of t h e c e n t e r l i n e of t h e hooks i n t h e ce l l chamber. For t h i s purpose, e i t h e r

(a) P r o v i d e a j i g p l a t e , w i t h dowels t o match t h e b o l e s i n t h e bot tom end of t h e s h i p p i n g beam, and mount t h e j i g p l a t e i n p r o p e r l o c a t i o n on t h e floor. A f t e r e r e c t i n g t o v e r t i c a l as i n t h e F i r s t Method, and b e f o r e p r o c e e d i n g f u r t h e r , move t h e beam and m a n i p u l a t o r assembly, s t e a d y i n g t h e lower end, t o l o c a t i o n on t h e dowels .

I

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Appendix E-8

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HNF-SD-NEL-ER-007, Rev. 0

SECTIOY I V

INSTALLATIOS (Cont inued)

1 - INSTALLATION (Continued)

SECOM) METHOD (Cont inued)

(b) A f t e r e r e c t i n g t o v e r t i c a l as i n t h e F i r s t Method and b e f o r e proceeding f u r t h e r , move t h e beam and manipula tor assembly, s t e a d y i n g t h e lower end t o a measured l o c a t i o n above t h e ce l l chamber and back t h e lower end i n p o s i t i o n .

A f t e r proceeding a s i n ( a ) or ( b ) , a d j u s t t h e beam and manipula tor assembly so t h a t it 1s t r u e v e r t i c a l i n a f r o n t view, and s l i g h t l y t i l t e d back (1.' o r 2" i n t h e h e i g h t of t h e beam) so t h e manipula tor l e a n s a g a i n s t t h e beam.

A t t a c h guy w i r e s t o t h e beam, l a s h it i n t o p o s i t f o n i f f a c i l i t i e s permi t or i f t h e c r a n e is equipped wi th a n a u x i l i a r y hook u s e i t f o r s u p p o r t i n g t h e beam.

Unhook t h e c r a n e from t h e beam and a t t a c h t o t h e manipula tor l i f t i n g e y e s , a f t e r i n s t a l l i n g t h e one temporary eye b o l t i n its e x t e n s i o n , u s i n g a s u i t a b l e s l i n g .

Remove beam a t t a c h m e n t c lamps from t h e manipula tor , and remove t h e r e t a i n i n g s t r a p s (H-38129) from t h e lower hooks on t h e s h i p p i n g beam.

Adjus t t h e s l i n g so t h a t t h e manipula tor w i l l hang c l o s e t o a v e r t i c a l p o s i t i o n . T h i s c a n be done by l i f t i n g t h e m a n i p u l a t o r s l i g h t l y off t h e bottom of t h e hooks on t h e beam, t o check t h e s l i n g ad jus tment t a k e up, and hanging it back on t h e hooks while a d j u s t - i n g t h e beam.

A f t e r a d j u s t i n g t h e beam, r a i s e t h e c r a n e j u s t enough t o t a k e u p t h e weight of t h e manipula tor . Then re- move t h e hooks from t h e s i d e s of t h e beam.

The manipula tor can now be lowered i n t o t h e ce l l chamber o n t o t h e hooks i n t h e c e l l , u s i n g t h e beam as a rough s t a r t i n g guide .

CAUTION: While l o w e r i n g t h e manipula tor keep j o g g i n g t h e c r a n e forward t o m a i n t a i n t h e manipula tor i n a v e r t i c a l p o s i t i o n , so a s t o a v o i d an undue bending movement due t o t h e p o r t i o n of t h e manipula tor l e n g t h which e x t e n d s below t h e end of t h e beam; l i k e w i s e so t h e d u c t s w i l l n o t be f o u l e d on t h e upper hooks.

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Appendix E-9

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HNF-SD-NEL-ER-007, Rev. 0

SECTION I V

INSTALLATION (Continued!

DISPOSITION OF TKG SHIPPING BEAM

For t h e r e a s o n s g i v e n e l s e w h e r e , t h e manufac turer u r g e n t l y recommends t h a t t h e m a n i p u l a t o r never be t i l t e d from v e r t r c a l to h o r i z o n t a l , or v i z e v e r s a , WithO>Jt t h e u s e of t h 6 s h i p p i n g beam. Anv attempt t o d o so s h a l l a u t o m a t i c a l l y absolve t h e =fact;rer frbm any r e s p o n s i b i l i t y due t o t w i s t of any components. T h i s i n c l u d e s s e r v i c e removal from t h e p i t , a l t h o u g h t h e beam need n o t be used if t h e manipula tor is removed f o r i n s p e c t i o n b u t n o t l a i d i n a h o r i z o n t a l plane.

For machine assembly, t e s t i n g , and s h i p p i n g purposes , t h e s h i p p i n g beam h a s been f a b r i c a t e d a s one p i b s e . I n t h e e v e n t

' it is i m p o s s i b l e , because of s p a c e l i m i a t i o n a , t o s t o r e and re- u s e t h e beam i n one p i e c e , it c a n be c u t i n t o s e c t i o n s i n t h e following manner:

(a) Machine off s e c t i o n of s u i t a b l e l e n g t h f u r s t o r a g e p u r p o s e s (3 o r 4 s e c t i o n s are p r e f e r r e d ) , i n such a manner t h a t t h e j o i n t s w i l l n o t occur a t t h e c r o s s b r a c e s , or a t t h e wedge j a c k s . D o n o t c u t y e t .

(b) For e a c h j o i n t , p r o v i d e (2) s p l i c e p l a t e s n o t l e s s t h a n 14" wide by 54" l o n g for t h e s i d e s of t h e channels , and (4) s p l i c e p l a t e s 2-1/2" wide by 24" l o n g f o r t h e channel f l a n g e s . A l l t h e s p l i c e p l a t e s are t o be not less t h a n 1/2" t h i c k (one 14" and (2) 2-1/2" p l a t e s a r e used on e a c h c h a n n e l a t e a c h j o i n t ) .

(c) D r i l l s p l i c e p l a t e s i n p o s i t i o n f o r a generous d i s t r i b u - t i o n of b o l t s . P r o v i d e a t l e a s t (4) dowels i n each p l a t e , one n e a r t h e j o i n t on e a c h s i d e of t h e jm, and one n e a r e a c h end of t h e p l a t e . Stamp s p l i c e p l a t e s as t o j o i n t and l o c a t i o n .

(d) Remove a l l s p l i c e p l a t e s , and c u t beam i n t o t h e s e c t i o n s as marked.

A f t e r c u t t 1 n g " s h i p p i n g beam" a p a r t and reassembl ing , t h e wedge j a c k s should be checked f o r b e i n g f l a t and i n t h e same p l a n e as p r e v i o u s l y u s i n g i t f o r h a n d l i n g t h e m a n i p u l a t o r .

One way t h e j a c k s c a n be s e t l e v e l is t o e n p l o y a music wire s t r e t c h e d t a u t between t h e t o p and lower hook c e n t e r l i n e , and measur ing 2.625 from t h i s c e n t e r l i r , e t o t h e t o p of t h e wedge j a c k shims.

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_. Appendix E-10

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HNF-SD-NEGER-007, Rev. 0

SECTION V -- MECHANICAL DESCRIPTIOH

EMERGENCY UAWAL ACTUATIONS

CAUTION:

To p r e v e n t damage t o t h e manipula tor c o n s i d e r t h e f o l l o w i n g fac ts b e f o r e u s i n g t h e emergency v e r t i c a l t r a v e l a c t u a t i o n :

1 - T h e p o s i t i o n s of t h e t h r e e a i r s h i f t e d jaw c l u t c h s s in t h e v e r t i c a l t r a v e l d r i v e d e t e r m i n e t h e r e s u l t s of t u r n - i n g t h e motor s h a f t .

The p o s i t i o n of t h e t h r e e c l u t c h e s are as i n d i c a t e d by t h e i r r e s p e c t i v e s e l e c t o r s , as d e s c r i b e d below, when t h e g r e e n lamp is lit . (When i n the"disassemb1y" c o n d i t i o n - ElT-suppor t open and b a f f l e s open - t h e amber "d is - assembly" lamp t a k e s t h e p l a c e o f t h e g r e e n lamp). If t h e g r e e n ( o r amber) lamp is n o t l i t , t u r n t h e s e l e c t o r t o a p o s i t i o n t h a t l i g h t s t h e g r e e n !or amber) lamp, i f p o s s i b l e . I f t h i s is not p o s s i b l e , (and t h e i n d i c a t i n g power i s on, and p r o p e r l y f u n c t i o n i n g ) i t i n d i c a t e s t h a t t h e c l u t c h is i n an i n t e r m e d i a t e , and p o s s i b l y , a p a r t i a l l y engaged p o s i t i o n . Under t h i s c o n d i t i o n , i t might be pOSSibie t o s t r i p o r damage t h e c l u t c h .

To c o r r e c t t h e c l u t c h ambigui ty , a l t e r n a t e l y t u r n t h e motor s h a f t and s h i f t t h e s e l e c t o r u n t i l t h e green lamp l i g h t s . U n l e s s t h e c a r r i a g e ( o r c a r r i a g e s ) is a t t h e lower l i m i t , t u r n t h e motor c o u n t e r c l o c k w i s e , t h u s p u t t i n g less l o a d on t h e c l u t c h . The amount o f r o t a t i o n r e q u i r e d w i l l va ry widely, a c c o r d i n g t o t h e p i t c h of t h e c l u t c h t e e t h and t h e mechanical advantage involved .

2 - T h e two speed c l u t c h p r o v i d e s two d i f f e r e n t mechanical ad- v a n t a g e s from t h e motor s h a f t t o t h e l e a d screws.

(a) When i n t h e " load" p o s i t i o n of t h e speed s e l e c t o r s w i t c h (wi th g r e e n lamp l i t ) , one r e v o l u t i o n of t h e motor s h a f t p r o v i d e s .OS" of v e r e i c a l t r a v e l - 12.5: 1 (approximate) mechanical a d v a n t a g e t o t h e l e a d screws.

(b) When i n t h e 15" or 7.5" p o s i t i o n s , one r e v o l u t i o n of t h e motor s h a f t p r o v i d e s .0045" of v e r t i c a l t r a v e l - 220 : 1 (approximate) mechanica l advantages t o l e a d screws .

The p a r t i c u l a r mechanicnl a d v a n t a g e in use should be c o n s i d e r e d t o avoid e x e r t i n g undue f o r c e .

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HNF-SD-NEGER-007, Rev. 0

SECTION J -- MECHANICAL DESCRIPTION

EXERCENCY MANUAL ACTUATIONS <Cont inued)

CALkION (Continued)

3 - The"ver t ica1 motion" s e l e c t o r s h i f t s t h e o t h e r two c l u t c h e s t o d r i v e e i t h e r "upper c a r r i a g e " , "lover c a r r i a g e " , or b o t h . I f t h e g r e e n i n d i c a t i n g lamp is l i t , it v e r i f i e s t h e c l u t c h e s are i n t h e p o s i t i o n i n d i c a t - ed on t h e " v e r t i c a l uo t ion" s e l e c t o r .

4 - Under normal (power) o p e r a t i n g c o n d i t i o n s , t h e v e r t i c a l t r a v e l motions of t h e two c a r r i a g e s are l i m i t e d wi th r e s p e c t t o t h e e n d s of t h e m a n i p u l a t o r , and t o each o t h e r , by proximi ty l i m i t s w i t c h e s .

When manual ly a c t u a t i n g t h e v e r t i c a l t r a v e l i t is p o s s i b l e t o o v e r t r a v e l t h e s w i t c h e s , and j a m t h e s a d d l e s a g a i n s t mechanical end l i m i t s , or to e a c h o t h e r . Unless e x c e s s i v e f o r c e is a p p l i e d , t h e a n t i - f r i c t i o n c h a r a c t e r i s t i c s of t h e b a l l screws should make i t p o s s i b l e t o e a s i l y r e l e a s e t h e jammed c o n d i t i o n . B e f o r e t h a t p o i n t is reached , however, i t may be p o s s i b l e t o set u p undue s t r a i n s .

For t h i s r e a s o n , manual v e r t i c a l t r a v e l should be backed o f f i f a s u b s t a n t i a l r i s e i n t o r q u e l o a d is not iced .

The f o l l o w i n g t a b l e g i v e s c r u d e estimates of t h e t o r q u e r e q u i r e d a t t h e motor s h a f t for v a r i o u s c o n d i t i o n s of v e r t i c a l t r a v e l upwards:

Torque (Pound Inches)

Speed S e l e c t o r : "Load" 15" o r 7?$*

Both C a r r i a g e s 52 3

(High Speed) (Low Speed)

Upper Carr i a g e 17

Lower C a r r i a g e 35

(only)

(only)

1

2

Torque r e q u i r e d f o r downward t r a v e l is t o o l i g h t f o r a r e a l i s t i c e s t i m a t e .

NOTE: These estimates were made a t t h e e n g i n e e r i n g s t a g e , and may vary wide ly from e x p e r i m e n t a l v a l u e s , due t o v a r y i n g f r i c t i o n a l f a c t o r s .

- 14 -

Appendix E-12

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HNF-SD-NEGER-007, Rev. 0

Blank Page

Appendix E-13

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DISTRIBUTION SHEET To D i s t r i b u t i o n

From Page 1 of 1 Advanced Fuel F a c i l i t i e s Date 07/09/97 Trans i t i on/19110

R. J. A r t h u r (PNNL) E. J. B i t t e n F. J. Carvo B. C. Cornwell (10 copies) T. N. Draper (ERC) J. E. Ham G. 0. Hayner L. A. Johnson D. E. Rasmussen J. M. S t e f f e n S. D. S t i t e s (RL) E . E. Utz C. W. Wildmann

Project TitleNVork Order C h a r a c t e r i z a t i o n o f t h e 309 Fuel Examination F a c i l i t y / B 7 0 0 6

P8-08 N1-41 N1-41 L5-70 x5-53 L5-70 L5-65 N1-41 N1-47 N1-47 R3-79 L5-70 L6-52

OEDT No. 605787

ECN No. N/A

X X X X X X X X X X X X X

Name

F a c i l i t y F i l e L5-70 X

Central F i l e s (2 copies) A3-88 X

Text Text Only Attach./ EDT/ECN MSlN Wi th All Appendix Only

Attach. Onlv

A-6000-135 (01/93) WEF067