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**U.S. DEPARTMENT OF ENERGY/NNSA**

**SAFETY GUIDE**

**OFFICE OF WEAPONS SURETY**

**PACKAGING AND TRANSPORTATION PROGRAM**

**Design Guide for**

**Testing Type B Packaging**

September 2002

**Revision 1**

**SG 600**

**US DOE SAFETY GUIDES**

Safety Guides are issued to describe and make available to DOE
contractors and the public methods acceptable to the DOE of implementing
specific parts of the Department\'s regulations, to delineate techniques
used by DOE in evaluating specific problems or postulating accidents, or
to provide guidance.

Safety Guides are not substitutes for regulations, and compliance with
them is not required. Methods and solutions different from those set out
in the guides will be acceptable if they provide a basis for finding
that the regulation has been met.

Number range CHAPTER**Design Guide for Testing**

**Type B Packaging**

CONTENTS

FOREWORD v

EXECUTIVE SUMMARY vii

ACRONYMS AND INITIALISMS ix

1.0 INTRODUCTION 1

1.1 Scope and Applicability 1

1.2 Purpose and Objective 1

1.3 Definitions 3

2.0 TESTING REQUIREMENTS 7

2.1 DOE Requirements 7

2.2 CFR Requirements 7

> 2.3 Other Reference Documents 9

3.0 PACKAGING TEST PLAN DEVELOPMENT 11

3.1 Requirements for the Packaging Test Plan 11

3.2 Planning 12

3.3 Acceptance Criteria 13

3.4 Test Prerequisites 14

3.5 Provisions for Data Acquisition and Recording (including

Photography/Video) 15

3.6 Test Controls 15

3.7 Test Procedures and Instructions 15

3.8 Use of Other Testing Documents 15

3.9 Test Results 16

3.10 Equipment Calibration 16

3.11 Personnel Qualifications, Experience and Training 16

3.12 Safety 17

3.13 Changes to the Test Plan Procedure 17

4.0 TESTING ACTIVITY METHODS 19

> 4.1 Assembly 20

4.2 Tests for Normal Conditions of Transport 21

4.2.1 Evaluation 21

CONTENTS (Cont'd)

4.2.2 Initial Conditions 21

4.2.3 Conditions and Tests 21

\(A\) Heat 22

\(B\) Cold 22

\(C\) Reduced External Pressure 22

\(D\) Increased External Pressure 22

\(E\) Vibration 22

\(F\) Water Spray Test 24

\(G\) Free Fall Drop Test 27

\(H\) Corner Drop Test 0.3 m (1 ft) 28

\(I\) Compression Test (Normal Stacking Test) 28

\(J\) Penetration Test 29

\(K\) Disassembly and Inspection 30

4.3 Tests for Hypothetical Accident Conditions 30

4.3.1 Evaluation 30

4.3.2 Initial Conditions 31

4.3.3 Conditions and Tests 31

\(A\) 9 m (30 ft) Free Fall Drop Test 31

\(B\) Crush Test 32

\(C\) 1 m (40 in) Puncture Drop Test 33

\(D\) Thermal Testing 33

a\. Thermal exposure - pool fire 34

> b\. Thermal exposure - furnace testing 36
>
> c\. Thermal exposure - radiant heat lamp 39
>
> d\. Post-burn activities 41
>
> \(E\) Test Package Disassembly 41

\(F\) SCV Leak Test (If Applicable) 41

\(G\) SCV Immersion Test, 0.9 m (3 ft) Fissile Material 41

\(H\) SCV Disassembly and Inspection (If Applicable) 42

\(I\) PCV Leak Test 42

\(J\) PCV Immersion Test, 0.9 m (3 ft) Fissile Material 42

> \(K\) Immersion Test, 15 m (5 0ft) for 8 Hours, All Packages 43

4.4 Disassembly and Post-test Inspections 43

5.0 TESTING REPORTING 45

5.1 SARP Requirements 45

5.2 Evaluation and Reporting of Test Results 45

6.0 TEST RECORDS 47

6.1 Test Record Attributes 47

CONTENTS (Cont'd)

6.2 Verification Plan and Actions 47

6.3 SARP Requirements for Testing Documentation 47

7.0 REFERENCES 49

FIGURES

1-1 Test configuration for a representative Type B package 1

1-2 Typical test preparation and performance activities with optional
test

> sequencing 2

4-1 10 CFR Part 71 structural review process 19

4-2 Test unit center of gravity marking 20

4-3 Positioning for water spray test 25

4-4 Drop test from an oblique position with the seam and top down 27

4-5 Corner 0.3m (1ft) drop test for a cylindrical package 28

4-6 Compression test 29

4-7 Penetration test 30

4-8 9m free fall drop test 31

4-9 Crush test 32

4-10 1m puncture drop test 33

4-11 Example of thermocouple (TC) locations in a furnace 37

4-12 Example of thermocouple (TC) locations on package test stands 37

4-13 Location of thermocouple lead wires 38

6-1 Testing requirements matrix 48

TABLES

1\. Insolation Data 22

2\. Criteria for Free Drop Test (Weight/Distance) 26

APPENDICES

A. Test Record Forms A-1

B. A Combination Test/Analysis Method Used to Demonstrate Compliance to
DOE

> Type B Container Thermal Test Requirements (30 minute fire test),
> DOE/AL
>
> Defense Programs Guideline for Packaging, Jan. 30, 1992 (SG 140.1) B-1

C. Vibration Environments for the AT-400R (Klenke to Glass, Sandia Lab
Memo),

August 20, 1993 C-1

CONTENTS (Cont'd)

D. Calculations for Normal Vibrations During Safe-Secure Trailer
Shipment of the

> DC-1 Package with HEU Oxide Contents, April 29, 1994 D-1

E. Recommended Random Vibration and Shock Test Specifications for Cargo
Transported on SST and SGT Trailers, April 19, 2002 E-1

> Number range CHAPTER**FOREWORD**

In a joint effort between U. S. Department of Energy (DOE)/National
Nuclear Security Administration (NNSA) Albuquerque (AL) Office of
Weapons Surety (OWS) Packaging and Transportation Program (PTP) and BWXT
Y-12 L.L.C. of Oak Ridge, Tennessee, this guide has been developed for
testing Type B Packaging for transport of Defense Programs materials.
This guide is a follow-on document to the *Design Guide for Shipping
Package Design* (November 1994). This Design Guide is the responsibility
of OWS PTP. The primary goal of the Design Guide series is to
standardize and document the design and test process that leads to a
certifiable Type B container that can be used to package and transport
of nuclear components that contain a Type B quantity of radioactive
material (RAM) and other RAM of national security interest. The
standardization of a packaging design and test process has the ultimate
goal of promoting the application of standard codes, evaluations,
computational techniques, and testing to increase the likelihood of
regulatory acceptance.

The Design Guides are a comprehensive set of documents which apply a
systems engineering approach to the design and testing of Type B fissile
packages for radioactive material handling and shipping. The specific
design aspects addressed in the guide are geared toward special nuclear
materials. However, the design guides can be used to design and test any
radioactive material package (fissile or nonfissile) for unirradiated
material. This Design Guide covers all elements of a successful test
plan development and its subsequent testing activities for normal
conditions and hypothetical accident conditions.

The Design Guide series are living documents that will continue to be
updated as new processes and/or technologies are developed and
implemented, and as management systems change.

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Number range CHAPTERU.S. Department of Energy

***SAFETY GUIDE***

**DESIGN GUIDE FOR**

**TESTING OF TYPE B PACKAGING**

EXECUTIVE SUMMARY

The U.S. Department of Energy/NNSA, AL OWS PTP is responsible for
evaluating and certifying Type B radioactive material packaging of
nuclear components in support of the National Defense Programs (DPs).
Evaluation and certification are conducted according to the Code of
Federal Regulations - Transportation, Title 49, Part 173, Section 416,
(49 CFR Part 173.416). This section of the CFR states that each Type B
packaging must be designed and constructed to meet the requirements in
10 CFR Part 71.

OWS PTP maintains a series of safety guides to describe methods to
implement specific parts of the Department's regulations, to delineate
DOE's techniques for evaluating specific problems or postulating
accidents, and to provide guidance. DOE Order O 251.1, *Directive
System*, states in section 4g that "Orders, Notices, and Manuals may be
accompanied by Guides when appropriate." This *Design Guide for Testing
of Type B Packaging* is required to complete the series for packaging
design. The design guide includes methods and techniques that provide a
basis for determining whether regulations have been met.

Packaging used for transporting nuclear components of radioactive
materials off DOE sites in U.S. Government owned conveyance must meet
criteria specified by the U.S. Government to ensure that the risk to the
public is minimized. These requirements are specified in 49 CFR and 10
CFR. The three specific functions that packaging is required to perform
are (1) containment of the radioactive material, (2) minimization of
risk to the public from transportation, and (3) the preservation of the
material in a subcritical configuration.

OWS PTP implements DOE policies and has established practices and
guidance for obtaining certification of packaging used by DOE and its
contractors for the transport of radioactive materials. These
certification review policies and guidelines have been established to
ensure (1) that DOE packaging designs and operations protect the public
health and safety, and (2) that they meet or exceed safety criteria
equivalent to the standards prescribed by the Nuclear Regulatory
Commission (NRC) certification process for packaging (10 CFR Part 71).
This guide is current with the April 2002 Federal Register Notice which
revised the 10 CFR Part 71, which now conforms with the *International
Atomic Energy Agency* (IAEA) *Safety Standard Series TS-R-1 (ST-1,
Revised)*, as amended in 1996.

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Number range CHAPTERNumber range CHAPTER**ACRONYMS** **AND INITIALISMS**

AL Albuquerque Operations Office

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

CFR Code of Federal Regulations

C of C Certificate of Compliance (DOE EM-5)

C of CA Certificate of Competent Authority (NRC, IAEA/DOT)

DOE Department of Energy

DOE/AL Department of Energy, Albuquerque Operations Office

DOT Department of Transportation

DP Defense Programs

HAC Hypothetical Accident Conditions

IAEA International Atomic Energy Agency

NCT Normal Conditions of Transport

NIST National Institute of Science and Technology

NNSA National Nuclear Security Administration

NRC Nuclear Regulatory Commission

P&TP Packaging and Transportation Program

OTC Offsite Transportation Certificate

OWS Office of Weapons Surety

PCV Primary Containment Vessel

SARP Safety Analysis Report for Packaging

SCV Secondary Containment Vessel

SNM Special Nuclear Material

USC United States Code

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Number range CHAPTER**1.0 INTRODUCTION**

**1.1 Scope and Applicability**

![](media/image2.jpeg){width="2.91875in"
height="2.558333333333333in"}OWS PTP has established practices and
guides for obtaining certification of packaging used by DOE and its
contractors for the transport of radioactive weapons materials. These
certification review guides have been established to ensure that DOE
packaging designs and operations protect the public health and safety
and that they meet safety criteria at least equivalent to the standards
prescribed by the NRC certification process for packaging (10 CFR Part
71, \"Packaging and Transportation of Radioactive Material\"). This CFR
addresses the testing requirements for Type B packaging (Figure 1-1)
which DOE requires for the certification of a new Type B packaging
design. The CFR also includes the requirements to evaluate the effects
of normal conditions of transport (NCT) and hypothetical accident
conditions (HAC) which are to be applied by testing or other methods to
determine their effects on a package. The results of these tests are
analyzed and reported in the Type B Packaging Safety Analysis Report for
Packaging (SARP). The flowchart in Figure 1-2 shows the sequence of
testing for the normal conditions of transport and for hypothetical
accident conditions.

> **Fig. 1-1. Test configuration for a representative Type B package.**

This design guide addresses these requirements as they apply to testing
and, specifically, the test methods applicable to the Type B packaging
designs. The scope of this design guide does not include the air
transport of plutonium.

**1.2 Purpose and Objective**

The purpose of this design guide is to provide a comprehensive document
that presents acceptable methods for planning and conducting the
required tests to supplement and verify the structural, thermal, and
shielding aspects of the package design. The objective of this document
is to cover all elements of a successful testing program, as discussed
below.

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**Fig. 1-2. Typical test preparation and performance activities with
optional test sequencing.**

Number range CHAPTER**1.3 Definitions**

The following terms are relevant to the overall subject of testing.

[Certificate of Compliance]{.underline} - An DOE EM-5 document which
certifies that a specific packaging design for specified quantities and
types of radioactive materials meets the applicable regulation
standards.

[Certificate of Competent Authority]{.underline} -- An NRC or IAEA/DOT
document which certifies that a specific packaging design for specified
quantities and types of radioactive materials meets the applicable
regulation standards.

[Containment System]{.underline} - The assembly of components for the
packaging intended to retain the radioactive material during transport.

[Containment Vessel]{.underline} - The receptacle in which principal
reliance is placed to retain the radioactive material during transport.

[Fissile Materials]{.underline} - Uranium-233, uranium-235,
plutonium-239, plutonium-241, or any combination of these radionuclides.
The following are not included in this definition: (1) unirradiated
natural uranium, (2) unirradiated depleted uranium, (3) natural uranium
that has been irradiated in a thermal reactor, and (4) depleted uranium
that has been irradiated in a thermal reactor.

[Hazardous Materials]{.underline} - A substance or a material including
a hazardous substance which has been determined by the Secretary of
Transportation to be capable of posing unreasonable risk to health,
safety, and property when transported in commerce and which has been so
designated in 49 CFR 172.101.

[Maximum Normal Operating Pressure]{.underline} - The maximum gauge
pressure that is expected to develop in the containment system in a
period of one year under the heat condition specified in
10 CFR 71.71(c)(1) in the absence of venting, external cooling by an
ancillary system, or operational controls during transport.

[Moderator]{.underline} - A material used to reduce the kinetic energy
of neutrons by scattering collisions without appreciable neutron
capture.

[Nuclear Components]{.underline} - Those parts of a nuclear explosive,
special assembly, test part, or subassembly that contain fissile
material and/or radioactive materials and other materials.

[Nuclear Criticality Safety]{.underline} - The implementation of
procedures and the application of limits to ensure that fissile material
remains in a subcritical state. Also, protection against the
consequences of an inadvertent nuclear chain reaction, preferably by
prevention of the reaction (Ref. ANS/ANSI 8.1). 10 CFR Part 71 and
associated regulatory guidance require maintaining a significant margin
from criticality.

[Offsite Transportation Certificate (OTC)]{.underline} - A DOE document,
approved and issued by the DOE/NNSA Certifying Official authorizing a
specific packaging for weapons-related transportation activities
involving quantities of radioactive and other hazardous materials, for
use on a one-time basis or for multiple uses for up to five years.

[Package]{.underline} - The packaging, along with its contents, as
presented for transport.

[Packaging]{.underline} - The assembly of components necessary to comply
with the packaging requirements of 10 CFR Part 71. It may consist of one
or more receptacles, absorbent materials, spacing structures, thermal
insulation, radiation shielding, and devices for cooling or absorbing
mechanical shocks. The conveyance, tie down system, and auxiliary
equipment may sometimes be designated as part of the packaging.

[Radioactive Material]{.underline} - Any material having a specific
activity greater than 70 becquerals per gram (0.002 micro curies per
gram).

[Radioactive Materials Associated with the Nuclear Weapons
Program]{.underline} - Type B quantities of weapons-grade special
nuclear material, Category I or II quantities of special nuclear
material, tritium, and other materials specifically designated by the
DOE/NNSA Deputy Administrator for Defense Programs and pertaining to the
certification of packaging for weapons, weapon components, and weapon
subassemblies only.

[Risk]{.underline} - The combination of the probability of an incident
releasing radioactive and/or hazardous materials and the consequences of
the release to the public and the environment which, taken over all
events relating to system operation, provides a meaningful picture of
the adverse impact of the operation. (Risk is built into the 10 CFR Part
71 regulations. A packaging that meets the requirements of
10 CFR Part 71 needs no additional assessment of risk.)

[Safety Analysis Report for Packaging (SARP)]{.underline} - A document
that provides a comprehensive technical evaluation of packaging. The
report identifies design, testing, operational procedures, maintenance
procedures, and a quality assurance program to demonstrate compliance
with NRC safety standards or equivalent standards established by DOE for
approving packaging and issuing Offsite Transportation Certificates.

[Special Assembly]{.underline} - Major assemblies of nuclear weapon
components that do not comprise a complete nuclear explosive and,
therefore, are incapable of producing a nuclear detonation.

[Special Nuclear Material (SNM)]{.underline} - Plutonium, uranium
enriched in the isotope 233 or in the isotope 235, and any other
material which the NRC (pursuant to the provisions of Section 51 of the
*Atomic Energy Act*) determines to be SNM but does not include source
material; any materials artificially enriched by any of the foregoing,
but does not include source materials (Ref. *Atomic Energy Act*, 42
U.S.C. 2014).

[Type A~1~/A~2~ Quantity]{.underline} - The maximum activity of a
radioactive isotope which can be transported in a Type A package. These
levels are listed by isotope in 10 CFR Part 71, Appendix A. A~1~
quantities apply to special form radioactive material (material that is
either a single solid piece or contained in a sealed capsule). A~2~
quantities apply to normal form radioactive material (material which
does not qualify as special form radioactive material).

[Type B Package]{.underline} - A Type B packaging along with its
radioactive contents.

[Type B Quantity]{.underline} - A quantity of radioactive material
greater than A~1~ or A~2~ quantities.

[Weapons-Grade Radioactive Material]{.underline} - Uranium that contains
greater than 20 percent of the isotope U-235, or plutonium that contains
less than 7 percent of the isotope

Pu-240.

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Number range CHAPTER**2.0 TEST REQUIREMENTS**

**2.1 DOE Requirements**

DOE/AL Supplemental Directive, 5610.12, *Packaging and Off-site
Transportation of Nuclear Components, and Special Assemblies Associated
with the Nuclear Explosive and Weapon Safety Program,* establishes the
DOE/AL Operations Office requirements, establishes standards of
performance, and assigns authorities and responsibilities for the
design, production, test, evaluation, procurement, documentation,
independent review, certification, maintenance, quality assurance, and
use of packages.

DOE O 460.1A, *Packaging and Transportation Safety* (replaces both DOE O
1540.2 and DOE O 5480.3), establishes safety requirements for the proper
packaging and transportation of DOE off-site shipments and on-site
transfers of hazardous materials, as well as requirements for modal
transport. It specifies that the, "Safety Analysis Report for Packaging
must demonstrate that the package will satisfy the standards of 10 CFR
71 Subparts E and F, the quality assurance program of Subpart H. . . ."

DOE O 460.2, *Departmental Materials Transportation and Packaging
Management* (replaces DOE O 1540.1A, DOE O 1540.2, and DOE O 1540.3),
specifies that "It is the DOE policy that, notwithstanding the
exemptions available through the National Security Provision, shipments
under this provision will comply with the 49 CFR 106-180 requirements."

DOE O 461.1, *Packaging and Transfer or Transportation of Materials of
National Security Interest*, establishes requirements for ensuring
compliance with Reg Guide 7.9, 10 CFR 71, and 49 CFR 100-199. Also
includes requirements for obtaining an Offsite Transportation
Certificate (OTC) or an Offsite Transportation Authorization (OTA), and
supporting documentation such as a Safety Analysis Report for Packaging
(SARP) or Transportation System Risk Assessment (TSRA).

DOE Implementation Guide, *Packaging and Transportation Safety*, DOE
G/460-1.1, dated June 5, 1997, supplements DOE O 460.1 and provides the
Department's expectations of its requirements as contained in rules,
orders, notices, and regulatory standards.

DOE/AL Safety Guide SG100, Rev. 1, *Design Guide for Packaging and
Transfer or Transportation of Materials of National Security Interest*.

**2.2 CFR Requirements**

10 CFR Part 71, Subpart H, *Quality Assurance,* §71.107, "Package design
control," (b), states that "Where a test program is used to verify the
adequacy of a specific design feature in lieu of other verifying or
checking processes, the licensee should include suitable qualification
testing of a prototype or sample unit under the most adverse design
conditions" and should include design control measures to items such as
to the "delineation of acceptance criteria for inspections and tests."

10 CFR Part 71, Subpart H, §71.101(f), allows the use of an existing
NRC-approved

10 CFR Part 50, Appendix B quality assurance program that satisfies each
of the applicable criteria of paragraphs 71.101 through 71.137. 10 CFR
50, Appendix B, "Quality Assurance Criteria for Nuclear Power Plants and
Fuel Reprocessing Plants," states that a test program should be
established to assure that all testing required to demonstrate that
structures, systems, and components will perform satisfactorily in
service is identified and performed in accordance with written test
procedures which incorporate the requirements and acceptance limits
contained in applicable design documents.

10 CFR Part 71, Subpart H, §71.123, "Test control," states that, \"The
licensee shall establish a test program to assure that all testing
required to demonstrate that the packaging components will perform
satisfactorily in service is identified and performed in accordance with
written test procedures that incorporate the requirements of this part
and the requirements and acceptance limits contained in the package
approval. The test procedures must include provisions for assuring that
all prerequisites for the given test are met, that adequate test
instrumentation is available and used, and that the test is performed
under suitable environmental conditions. The licensee shall document and
evaluate the test results to assure that test requirements have been
satisfied."

10 CFR Part 71, Subpart E, *Package Approval Standards*, states in
§71.41(a), "The effects on a package of the tests specified in §71.71
('Normal conditions of transport'), and the tests specified in §71.73
('Hypothetical accident conditions'), and §71.61 ('Special requirement
for irradiated nuclear fuel shipments'), must be evaluated by subjecting
a specimen or scale model to a specific test, or by another method of
demonstration acceptable to the Commission, as appropriate for the
particular feature being considered."

10 CFR Part 830.121, *Quality Assurance Program*, states in Section (b),
(1) that a DOE contractor must submit a quality assurance program to DOE
for approval and conduct work in accordance with the QAP. The quality
assurance program should include a discussion of how the criteria of
Section 830.122 will be satisfied and should be applied using a graded
approach. The contractor should use appropriate standards where
applicable (i.e., 10 CFR Part 71, Subpart H) to develop and implement
its quality assurance program.

49 CFR 173, Subpart I, *Class 7 (Radioactive) Materials*, §173.413,
"Requirements for Type B Packages," states that "Except as provided in
§173.416, each Type B(U) or Type B(M) package must be designed and
constructed to meet the applicable requirements of 10 CFR Part 71."

49 CFR §173.467 states that "Each Type B packaging or packaging for
fissile material must meet the test requirements prescribed in 10 CFR
Part 71 for ability to withstand accident conditions in transportation."

**2.3 Other Reference Documents**

IAEA Safety Standard Series No. TS-R-1 (ST-1, Revised), *Regulations for
the Safe Transport of Radioactive Material* (1996 edition), (paragraph
101) states that the purpose of these regulations is to establish
standards of safety which provide an acceptable level of control of the
radiation, criticality, and thermal hazards to persons, property, and
the environment that are associated with the transport of radioactive
material. Section VI states the requirements for Type B packaging, and
Section VII provides acceptable test procedures.

IAEA Safety Standards Series No. ST-2, *Advisory Material for the
Regulations for the Safe Transport of Radioactive Material (1996
Edition),* combines the former IAEA Safety Series No. 37 and Safety
Series No. 7 into a single text. This document gives information on
individual provisions of TS-R-1 as to their purpose, scientific
background, and how to apply them in practice. Its main purpose is to
provide advice to users on proven and acceptable ways of achieving and
demonstrating compliance with the Regulations. It must be used as a
companion to TS-R-1.

ASME NQA-1-2000, *Quality Assurance Requirements for Nuclear Facility*,
Applications Requirement 11, "Test Control," states that required
testing (including prototype qualification tests, production tests,
proof tests prior to installation, construction tests, preoperational
tests, operational tests, etc., as appropriate) should also be
controlled. Test requirements and acceptance tests should be controlled.
Test requirements and acceptance criteria should be based on specified
requirements contained in applicable designs or other pertinent
technical documents. 10 CFR Part 830.121, *Quality Assurance,* states
that a DOE-approved QAP is required which: describes how quality
assurance criteria in 830.122 are met; integrates the quality assurance
criteria with safety management system; and use voluntary consensus
standards for development and implementation, where practical and
consistent with regulatory requirements.

ANSI N14.5-1997, *American National Standard for Radioactive Materials -
Leakage Tests on Packages for Shipment of Radioactive Materials*,
specifies methods for demonstrating that Type B packages comply with the
package containment requirements of Title 10 CFR, Part 71, as amended,
and/or requirements of the IAEA Safety Standard Series No. TS-R-1,
(ST-1, Revised), *Regulations for the Safe Transport of Radioactive
Material*. These requirements are necessary for the following:

\(1\) Design verification

\(2\) Fabrication verification

\(3\) Assembly verification

\(4\) Periodic verification

ANSI N14.10.3, *Administrative Guide for Verifying Compliance with
Packaging Requirements for Shipments of Radioactive Materials.* This
standard presents (1) a method by which compliance with packaging
requirements may be obtained and documented, (2) guidance to be followed
if incidents occur that threaten package integrity, and (3) a plan for
receivers to verify the integrity of delivered packages.

Nuclear Regulatory Commission Regulatory Guides, Division 7 -
Transportation, are listed below.

7.1, *Administrative Guide for Packaging and Transporting Radioactive
Material*

7.2, *Packaging and Transportation of Radioactively Contaminated
Biological Materials*

7.3, *Procedures for Picking Up and Receiving Packages of Radioactive
Material*

7.4, *Leakage Tests on Packages for Shipment of Radioactive Materials*

7.5, *Administrative Guide for Obtaining Exemptions From Certain NRC
Requirements Over Radioactive Material Shipments*

7.6, *Design Criteria for the Structural Analysis of Shipping Cask
Containment Vessels*

7.7, *Administrative Guide for Verifying Compliance with Packaging
Requirements for Shipments of Radioactive Materials*

7.8, *Load Combinations for the Structural Analysis of Shipping Casks
for Radioactive Material*

7.9, *Standard Format and Content of Part 71 Applications for Approval
of Packaging of Type B, Large Quantity, and Fissile Radioactive
Material*

7.10, *Establishing Quality Assurance Programs for Packaging Used in the
Transport of Radioactive Material*

7.11, *Fracture Toughness Criteria of Base Material for Ferritic Steel
Shipping Cask Containment Vessels with a Maximum Wall Thickness of 4
Inches (0.1m)*

NUREG/CR-6007, *Stress Analysis of Closure Bolts for Shipping Casks*

**3.0 PACKAGING TEST PLAN DEVELOPMENT**

This section addresses the requirements for planning and developing
packaging test plans that are used to verify conformance of a package to
specified requirements or to demonstrate satisfactory performance for
its intended service. Each packaging owner/designer is responsible for
establishing a practice for controlling the testing of packaging and the
associated components identical to the packaging being modeled. Before
each test series, the prototype models are to be validated using the
same process specified for production packaging. Any differences between
the prototype model and the production model should be evaluated for
impact on test performance. The results of this evaluation should be
included in the test reports. The pedigree verification of each test
package must be completed prior to assembly. Pedigree verification is a
quality assurance process which documents that the test specimen meets
all safety and performance critical requirements of the package design
(e.g., materials, dimensions, surface finish, and leak tightness).

The DOT, NRC and international regulations are developed on the premise
that multiple hazards involving Type B quantities are not very frequent.
When there are multiple hazards, the material is classified as
radioactive and the regulations address predominantly the containment
requirements for Class 7 materials. Some DOE shipments of nuclear
components contain multiple hazards. Therefore, the item to be
transported should be completely identified and classified based upon
these distinct hazards. Based upon this proper identification, test
planning activities should include concerns related to these additional
hazards. For example, if an item contains a DOT explosive device, the
test should include the effects that fire, vibration, and dropping would
have on this device, including any increase of inside containment
pressure, release rates, etc.

**3.1 Requirements for the Packaging Test Plan**

10 CFR Part 71, Subpart H, §71.123, states that the licensee (packaging
owner), "shall establish a test program to assure that all testing
required to demonstrate that the packaging components will perform
satisfactorily in service is identified and performed in accordance with
written test procedures that incorporate the requirements of this part
and the requirements and acceptance limits contained in the package
approval. The test procedures must include provisions for assuring that
all prerequisites for a given test are met, that adequate test
instrumentation is available and used, and that the test is performed
under suitable environmental conditions. The test plan shall require the
documentation and evaluation of the test results to assure that test
requirements have been satisfied."

ASME NQA-1-2000, Requirement 11, "Test Control," states that required
tests (including prototype qualification tests, production tests, proof
tests prior to installation, construction tests, preoperational tests,
operational tests, etc., as appropriate) should be controlled. Test
requirements and acceptance tests should also be controlled. Test
requirements and acceptance criteria should be based on specified
requirements contained in applicable design or other pertinent technical
documents.

**3.2 Planning**

The planning for and the development of a packaging test plan involves
the evaluation of each package design for normal conditions of transport
and for hypothetical accident conditions. Package testing should be
performed, if possible, under the most adverse design conditions to the
specific features being verified. If the test program is intended to
confirm the adequacy of the overall design, all pertinent operating
modes should be considered in determining these design conditions. A
decision must be made as to whether simulated content(s) or mockup(s)
will be used in testing. If a mockup is used, the impact on test results
should be considered. No radioactive or hazardous materials should be
used for test contents. Every attempt should be made to utilize test
content that simulates (as close as practical) the weight, size, and
other characteristics of the actual contents. Test content should be
specified in the test plan. Hypothetical accident conditions are to be
based on sequential application of the tests as specified in 10 CFR Part
71 in the order indicated to determine their cumulative effect on a
package.

As applicable a test plan should:

-   Identify which test requirements will be satisfied by analysis,
    similarity testing, or a combination thereof.

-   Determine whether a specific test is required, and describe how the
    test is to be performed.

-   Identify the implementing documents to be developed to control and
    perform tests.

-   Identify items to be tested and the test requirements and acceptance
    limits, including required levels of precision and accuracy.

-   Identify test methods to be employed and instructions for performing
    the test.

-   Identify test prerequisites that address instrument calibration,
    appropriate and adequate test equipment and instrumentation, trained
    personnel, the condition of test equipment and the item to be
    tested, suitably controlled environmental conditions, and provisions
    for data acquisition.

-   Identify mandatory hold points.

-   Identify methods to record data and results.

-   Identify or develop safety plans.

-   Specify records retention.

-   Identify provisions for ensuring that prerequisites for the given
    test have been met.

-   Select and identify the measuring and test equipment to be used to
    perform the test to ensure that the equipment is of the proper type,
    range, accuracy, and tolerance to accomplish the intended function.

ASME NQA-1-2000 provides an acceptable outline for a packaging test
plan, including the provisions for implementing procedures. The test
plan is usually prepared by the packaging design organization and
approved by the appropriate packaging function and the quality assurance
organization or its representative.

During the planning process, the following items must be addressed and
the resultant information placed in the packaging test plan:

-   Description of packaging preparation/configuration prior to testing

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-   Test equipment to be used

-   Monitoring to be performed

-   Environmental conditions to be maintained

**3.3 Acceptance Criteria**

10 CFR 71, §71.41 (a) states that the effects of the tests specified in
§71.71 (NCT) and §71.73 (HAC) "must be evaluated by subjecting a
specimen or scale model to a specific test, or by another method of
demonstration acceptable to the Commission, as appropriate for the
particular feature being considered."

§71.51 states that for Type B packages, in addition to satisfying the
requirements of §71.41 through 71.47, the packaging must be designed,
constructed, and prepared for shipment with the criteria listed below.

\(1\) For the tests for all Type B packages specified in §71.71 (NCT),
there would be:

-   No loss or disposal of radioactive contents (as demonstrated to a
    sensitivity of 10^-6^ A~2~ per hour)

-   No significant increase in external surface radiation levels

-   No substantial reduction in the effectiveness of the packaging

\(2\) For the tests specified in §71.73 (HAC), there would be:

-   No escape of krypton-85 exceeding 10 A~2~ in one week

-   No escape of other radioactive material exceeding a total amount of
    A~2~ in one week

-   No external radiation dose rate exceeding 10 mSv/h (1 rem/h) at 1 m
    (40 in) from the external surface of the package

For fissile material packages, §71.55 provides additional acceptance
criteria following the NCT and HAC testing.

\(1\) For the tests specified in §71.71 (NCT) for fissile material
packages:

-   The contents would be subcritical.

-   The geometric form of the package contents would not be
    substantially altered.

-   There would be no leakage of water into the containment system
    unless, in the evaluation of undamaged packages under §71.59(a)(1),
    it has been assumed that moderation is present to such an extent as
    to cause maximum reactivity consistent with the chemical and
    physical form of the material.

-   There would be no substantial reduction in the effectiveness of the
    packaging, including:

    -   No more than 5 percent reduction in the total effective volume
        of the packaging on which nuclear safety is assessed

    -   No more than 5 percent reduction in the effective spacing
        between the fissile contents and the outer surface of the
        packaging

    -   No occurrence of an aperture in the outer surface of the
        packaging large enough to permit entry of a 10 cm (4 in) cube

\(2\) For the tests specified in §71.73 (HAC) for fissile material
packages, the package would be subcritical. For this determination, the
following must be assumed:

-   The fissile material is in the most reactive credible configuration
    consistent with the damaged condition of the package and the
    chemical and physical form of the contents.

-   Water moderation occurs to the most reactive credible extent
    consistent with the damaged condition of the package and the
    chemical and physical form of the contents.

-   There is full reflection by water on all sides, as close as is
    consistent with the damaged condition of the package.

**3.4 Test Prerequisites**

The following prerequisites should be included and addressed in the
packaging test plan:

-   Calibrated instruments

-   Appropriate equipment

-   Documentation of test prototype condition

-   Suitable site-specified environmental conditions

**3.5 Provisions for Data Acquisition and Recording (Including
Photography/Video**)

The packaging test plan, which may include associated test procedures,
should discuss provisions for acquisition of testing data. This
equipment should be selected and determined to be capable of properly
functioning during the period of the test. If required, backups of
selected equipment should be made available during the test.

Sufficient evidence, such as evidence to demonstrate regulatory
compliance, should be provided to document all tests as appropriate. For
example, video cameras may be used to document live action of drops,
burn tests, etc. The requirement for collecting such evidence should be
identified in the test plan.

Strip chart recordings, computer printouts, charts, and graphs of the
tests may be identified specifically in the test plan and included in
the test report.

**3.6 Test Controls**

During the planning process, all test controls (including environmental,
health and safety controls) should be identified and included in either
the packaging test plan and/or the testing procedures or instructions.

**3.7 Test Procedures and Instructions**

Tests should be performed in accordance with approved implementing
procedures or instructions that, as applicable:

-   Include or reference test objectives and provisions for ensuring
    that prerequisites for the given test have been met, that adequate
    calibrated instrumentation is available and used, that necessary
    monitoring is performed, and that suitable environmental conditions
    are maintained.

-   Include test requirements and acceptance criteria provided or
    approved by the organization responsible for the design of the
    package to be tested unless otherwise designated.

-   Identify potential sources of uncertainty and error. Test parameters
    affected by potential sources of uncertainly and error should be
    identified and controlled.

**3.8 Use of Other Testing Documents**

When testing packaging components, other testing specifications (such as
from American Society for Testing and Materials \[ASTM\], American
National Standards Institute \[ANSI\], or other testing specifications
containing acceptance criteria) may be used instead of preparing special
test implementing documents. If these sources are used, then the
information should be incorporated directly into the approved test
implementing document, or it should be incorporated by reference in the
approved test implementing document. Implementing documents should
include supplemental instructions as required to ensure the required
quality of the testing work.

**3.9 Test Results**

Test results are to be documented, and their conformance with acceptance
criteria will be evaluated by a qualified individual(s) within the
responsible organization to ensure that test requirements have been
satisfied. The test configuration should be clearly defined and
documented. If testing indicates that modifications to the packaging are
needed to obtain acceptable performance, the packaging should be
modified and retested, or otherwise verified to assure satisfactory
performance. If any test data from the premodified design is used in the
SARP, the original configuration tested should be identified, as well as
a description of all of the modifications incorporated in the final
packaging. When tests are being performed on models or mockups, scaling
laws should be established and verified. The results of model test work
should be subject to error analysis as applicable prior to use in final
design work.

**3.10 Equipment Calibration**

Equipment (e.g., gauges, fixtures, reference standards, and devices used
to measure product characteristics) used during test-related activities
should be calibrated, adjusted, and maintained at prescribed intervals
or prior to use. The measuring and test equipment should be labeled or
tagged to indicate the planned date of its next calibration, and the
calibration date and identification number should be identified and
recorded on the test records and be traceable.

All test equipment should be selected in accordance with the range,
accuracy, and type needed to conform to the established test
requirements. All equipment requiring calibration will be calibrated
with standards traceable to the National Institute of Science and
Technology (NIST) or an equivalent nationally recognized source. If no
nationally recognized standards exist, the basis for calibration should
be documented.

**3.11 Personnel Qualifications, Experience and Training**

All personnel performing packaging testing activities will have the
necessary training and qualifications before they perform those
activities. Training includes an orientation and indoctrination session
with packaging participants to ensure that personnel understand the
overall goals and methods of the packaging test program\'s quality
assurance program. This training is in addition to the specific
provision of the implementing procedures and instructions which each
individual has read and understood. Emphasis will be placed on the
following points:

-   Individual responsibility for quality and quality assurance

-   Importance of teamwork among all packaging test program participants

-   Importance of identifying and resolving problems

-   Importance of being alert for trends that indicate systemic problems

-   Prime importance of the customer\'s need for confidence in the work

**3.12 Safety**

Many of the tests described in this document involve potentially
dangerous activities. The safety, health, and well-being of personnel,
property, the environment, and neighboring communities are of utmost
importance, and every testing activity must be performed with this fully
in mind. No job is so urgent or so important that it cannot be done
safely. Safety is the responsibility of every employee, including
management. Each employee is responsible for his or her own safety and
must work to protect others. Management is responsible for providing
proper training in health and safety matters, equipment, controls, and
the environment to ensure the safety of all personnel involved. The safe
use of equipment includes equipment design and maintenance. Equipment
should be removed from use immediately if it is found to be in an unsafe
condition. Personnel should be trained in the safe use of all testing
equipment and related hoisting, rigging, and handling gear.

**3.13 Changes to the Test Plan Procedure**

Changes to the test plan or implementing procedures will be documented
and initialed by the responsible engineering designer and the cognizant
packaging function. Onsite redlining, deletions or changes to an
approved test plan should be acknowledged by the Test Engineer and
Package Design Engineer prior to proceeding with a test. The test report
should reflect what was actually done, and the SARP will show how the
testing satisfies the requirements of 10 CFR Part 71. If any test
requirements are changed, the packaging owner must be notified for final
approval.

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Number range CHAPTER**4.0 TESTING ACTIVITY METHODS**

During the design and structural validation activities, structural
validation can be accomplished by using analysis techniques or through
physical testing. As stated in the DOE/AL Safety Guide (SG 100, Rev. 1,
dated 11/7/94), in most cases it is advantageous to combine testing and
analysis to validate the packaging design. Various analysis techniques
can be used to identify the conditions for the test (e.g., worst case
orientation for free drop tests) and for obtaining test data (e.g.,
identifying the locations for thermocouples to be installed for thermal
testing). Figure 4-1 depicts the 10 CFR Part 71 overall structural
review process which includes the analysis and testing activities
described in this guide.

![](media/image4.wmf){width="6.3381944444444445in" height="4.375in"}

**Fig. 4-1. 10 CFR 71 structural review process.**

Number range CHAPTERThis section provides guidance for conducting and
reporting the structural and thermal tests used to demonstrate the
safety performance of shipping packages. Federal regulations in 10 CFR
Part 71 specify tests to be used to demonstrate the safety performance
of Type B packages. This section is not intended to discuss the theory
of each test determination or for use as a detailed test procedure.
Rather, techniques that have been successfully used and proven in
practice are described as illustrations of acceptable methods that are
currently being used by DOE contractors and laboratories for testing
Type B packaging. Some organizations may require a readiness review to
be conducted before commencement of a testing activity. Examples of
acceptable test forms are provided in Appendix A. They show the type of
information which should be recorded.

Number range CHAPTER**4.1 Assembly**

Prior to assembly of the test package, the primary containment unit
should undergo a dimensional inspection to ensure compliance of the
tested units with the design specifications. Explanations should be
provided for any nonconforming items, and the pretest condition pedigree
verification should be recorded. The test unit inspection results should
be documented on appropriate forms. The temperature of the simulated
content, the inner container, and the outer container of the test units
should be measured during thermal testing in accordance with the
approved instructions or assembly procedures. (Temperature indicator
labels have been used successfully.)

During the assembly process, the various components are to be identified
and weights are to be recorded, if required, on the test record form.
Identifying markings can be made with spray paint or other means so that
markings are clearly legible and durable on the surface to which they
are applied and will remain legible after testing. Photographs should be
taken as required in order to show the pretest condition of the test
packaging components, particularly those views which will also be
photographed after testing. As needed to orient the package for drop
tests, each test unit's center of gravity should be established and
marked or painted on the outside of each test unit (see Figure 4-2).

![](media/image5.jpeg){width="3.8201388888888888in"
height="2.9868055555555557in"}

**Fig 4.2. Test unit center of gravity marking.**

Proper closure of the inner container (e.g., torquing fasteners to the
value designated by the package design) shall be documented on the test
record form. The assembly process should ensure that temperature
monitors are installed as specified by the package designer or in the
test procedure for packages that will undergo thermal testing. If seams
exist in the inner and outer containers, the seams shall be aligned as
specified by the package designer or in the test procedure (e.g., the
inner and outer

containers shall be assembled so that their weld seams are radially
aligned). The inner container(s) must be leak tested in accordance with
an approved leak test procedure that conforms to ANSI N14.5 before being
assembled into the outer drum.

The assembly should be done in accordance with production processes and
documented on the test record forms. The instructions for assembly of
the test units should contain any special directions for assembly of
each unit, along with appropriate directions on the installation of
thermocouples, accelerometers, heat sources, etc. For example, testing
requirements may indicate the need for installing a self-contained
three-axis accelerometer to be mounted inside the inner container. The
instructions for using any accelerometer should be included in the test
plan or procedures. Following assembly, the test package should be
prepared in a manner to preclude damage during shipment to another
location for testing.

**4.2 Tests for Normal Conditions of Transport**

4.2.1 [Evaluation]{.underline}

10 CFR 71.71, "Normal conditions of transport," paragraph a, states that
"Evaluation of each package design under normal conditions of transport
must include a determination of the effect on that design of the
conditions and tests specified in this section." This subsection
describes in general terms methods for coordinating the physical tests
required to evaluate the results necessary to satisfy the requirements
of 10 CFR Part 71.

4.2.2 [Initial Conditions]{.underline}

§71.71. "Normal conditions of transport," states that with respect to
the initial conditions for the tests in this section, the demonstration
of compliance with the requirements of this part must be based on the
ambient temperature preceding and following the tests remaining constant
at the value between -29°C (-20°F) and 38°C (100°F) which is most
unfavorable for the feature under considerations. The initial internal
pressure within the containment system must be considered to be the
maximum normal operating pressure, unless a lower internal pressure
consistent with the ambient temperature considered to precede and follow
the tests is more unfavorable.

4.2.3 [Conditions and Tests]{.underline}

Following are test methods used by DOE contractors and laboratories for
performing the listed tests. Additional information regarding satisfying
steps 1-5 below can be found in the DOE/AL Safety Guide, SG-100, Rev. 1,
*Design Guide for Packaging and Transfer or Transportation of Materials
of National Security Interest.*

\(A\) *Heat:* Per 10 CFR 71.71(c)(1), the test package must be evaluated
for: heated conditions with an ambient temperature of 38°C (100°F) in
still air, decay heat and solar insolation. This requirement may be met
through the use of analysis using the solar heat flux in the following
table. (NOTE: Additional information regarding this subject can be found
in the ASME Paper, "Thermal Modeling of Packages for Normal Conditions
of Transport with Insolation." J. C. Anderson and M. R. Feldman, 11/95).

+-----------------------------------------------+-----------------------+
| **Table 1. Insolation Data.**                 |                       |
+-----------------------------------------------+-----------------------+
| Form and location of surface                  | Total insolation for  |
|                                               | a 12-hour period      |
|                                               |                       |
|                                               | (g cal/cm^2)^         |
+-----------------------------------------------+-----------------------+
| Flat surfaces transported horizontally:       | None                  |
|                                               |                       |
| \- Base                                       | 800                   |
|                                               |                       |
| \- Other surfaces                             | 200                   |
|                                               |                       |
| Flat surfaces not transported horizontally    | 400                   |
|                                               |                       |
| \- Curved surfaces                            |                       |
+-----------------------------------------------+-----------------------+

\(B\) *Cold*: Per 10 CFR 71.71(c)(2), the test package must be evaluated
for cold conditions with an ambient temperature of -40°C (-40°F) in
still air and in the shade. Typically, this requirement is met through
the selection of metal components which have a nil ductility transition
temperature of less than -40°F. Seals are also selected for acceptable
performance characteristics at this temperature. The package designer
also needs to consider the effects of expansion and contraction of
dissimilar materials.

\(C\) *Reduced External Pressure:* Per 10 CFR 71.71(c)(3), the test
package must be evaluated for an external pressure of 25 kPa (3.5
lbf/in^2^) absolute. This requirement may be met through the structural
analysis of the package and is included in the load combinations.

\(D\) *Increased External Pressure:* Per 10 CFR 71.71(c)(4), the test
package must be evaluated for an external pressure of 140 kPa (20
lbf/in^2^) absolute. The requirement may be met through the structural
analysis of the package and is included in the load combinations.

\(E\) *Vibration:* Per 10 CFR 71.71(c)(5), the test package must be
evaluated for vibration normally incident to transport. The vibration
test is not performed in conjunction with any other tests. This
requirement can be verified using either analysis by calculation or by
performing actual vibration testing.

> a\. Fatigue analysis
>
> Fatigue analysis per NRC Reg. Guide 7.6 may be performed if determined
> applicable or appropriate by the packaging designer. (The worst
> condition for vibration should be determined by the design agency, or
> it may be incorporated in the design requirements document.) Vibration
> testing should approximate, as closely as possible, the actual
> shipping arrangement, including tie-down method.
>
> For example, for one package, the worst condition from a vibration
> standpoint may be a single package mounted on and secured to the floor
> of the transporter since it is excited directly during transport;
> thus, the vibration mode acts as a linear system. It is stated in
> Schaum's *Outline of Theory and Problems of Mechanical Vibrations*
> that in the case of a transport system with a nonlinear restoring
> force, resonance does not occur in the same manner as in the case of a
> linear restoring force (a single package shipment). In a nonlinear
> shipment (not mounted directly to the floor of the transporter), the
> amplitude of vibration can never become very large for a driving force
> of any given frequency. This is due to the fact that the natural
> frequency of the system for small amplitudes of vibration is different
> from the natural frequency for large amplitudes of vibration.
>
> The radioactive vessel contents are usually shipped within a
> containment vessel with monothane inserts placed around the content
> can as cushioning against the primary vessel wall and heads during
> transport. Once the configuration of the test package is defined, this
> is then used as the basis of the model assumption. With the use of a
> single package shipment, an analysis similar to the calculations in
> Appendix D determines whether the test packaging is acceptable for
> vibration normally incident to transport. The example calculation in
> Appendix D is for the use of the DC-1 Packaging shipped in a Safe
> Secure Trailer (SST). Consideration must also be given to shipments
> made in a SafeGuards Transporter (SGT) which may have a different
> vibration profile.

b\. Vibration testing

-   Pretest conditions

1.  During transportation to the vibration test facility, proper
    handling should be performed to preclude damage to the test units
    during transport and handling.

2.  The test engineer should select the proper vibration equipment
    necessary to create the required vibration.

3.  The test engineer ensures that the test package temperature is
    within the specified limits. The temperature and time should be
    recorded prior to the vibration test. Environmental conditions
    should be monitored as required.

4.  If the closure is bolted, the test package bolt torque should be
    recorded on the test record form.

5.  Prior to initiation, the vibration input should be determined by the
    design engineer, including the upper limit on the frequency to be
    recorded.

6.  A calibrated accelerometer may be installed on the outside of the
    test package as determined by the test design engineer.

7.  The test package should be secured to the vibration table with the
    vibration test tie-down fixture.

8.  Documentary photographs of the test setup may be taken, or line
    drawings may be made to document the test setup. Photos or drawings
    should be included as a part of the test record.

9.  The test package should be thermally conditioned by placing it in a
    climatic chamber set at a specified temperature for the duration
    determined by the designer or test engineer. This information should
    be properly documented.

-   Conduct of vibration test

> All recording and monitoring equipment must be verified to be
> functioning.

-   Post vibration test activities

> Based on the acceptance criteria noted in the applicable test plan,
> the following may apply:

1.  If the closure is bolted, the test package fasteners should be
    checked for looseness by determining if they are finger-tight.
    Results of this check should be documented on test record form.

2.  The test package may be disassembled and inspected to verify that
    the vibration test has not resulted in dimensional changes to the
    package configuration to ensure that there is no substantial
    reduction in the effectiveness of the packaging.

3.  The results of the inspection should be documented on the test
    record form.

\(F\) *Water Spray Test:* Per 10 CFR 71.71(c)(6), the test package must
be evaluated for a water spray that simulates exposure to rainfall of
approximately 5 cm (2 in) per hour for at least one hour. The following
steps should be included in the water spray test:

1.  Transport the test package to the water spray test area.

2.  Position the test package as specified in the test plan (see Figure
    4-3). (Note that the orientation indicated is not appropriate for
    all package designs.)

3.  Ensure that the spray pattern is from above and from at least four
    sides.

4.  Ensure that the water spray test simulates exposure to rainfall of
    approximately 5 cm (2 in) per hour for at least 1 hour.

5.  After the water spray test, observe the test package for any
    apparent water leakage or damage.

6.  Record all observations on the test record form.

7.  Document the water spray test setup using photography and/or video.

![](media/image6.jpeg){width="3.173611111111111in"
height="3.1131944444444444in"}

**Fig. 4-3. Positioning for water spray test.**

\(G\) *Free Fall Drop Test:* Between 1.5 and 2.5 hours after the
conclusion of the water spray test, a free drop should be performed
through the distance specified in the table below onto a flat,
essentially unyielding horizontal surface. The test package should
strike the surface in a position for which the maximum damage is
expected. (As stated in IAEA ST-2, the mass of the target should be at
least 10 times that of the specimen for the tests.") The package
orientation for the free fall drop should be in the most damaging
packaging orientation as determined by the designer and test engineer.

+-----------------------+-----------------------+----------+----------+
| **Table 2. Criteria   |                       |          |          |
| for Free Drop Test    |                       |          |          |
| (Weight/Distance).**  |                       |          |          |
+-----------------------+-----------------------+----------+----------+
| **Package weight**    |                       | **Free   |          |
|                       |                       | drop     |          |
|                       |                       | di       |          |
|                       |                       | stance** |          |
+-----------------------+-----------------------+----------+----------+
| **Kilograms**         | **(Pounds**)          | **       | (*       |
|                       |                       | Meters** | *Feet**) |
+-----------------------+-----------------------+----------+----------+
| Less than 5,000       | Less than (11,000)    | 1.2      | \(4\)    |
|                       |                       |          |          |
| 5,000 to 10,000       | (11,000 to 22,000)    | 0.9      | \(3\)    |
|                       |                       |          |          |
| 10,000 to 15,000      | (22,000 to 33,100)    | 0.6      | \(2\)    |
|                       |                       |          |          |
| More than 15,000      | (More than 33,100)    | 0.3      | \(1\)    |
+-----------------------+-----------------------+----------+----------+

> For weapons program Type B packages, the weight is normally less than
> 11,000 pounds. Therefore, the following discussion addresses a 1.2 m
> (4 ft) free fall drop. Below are the typical steps for a free fall
> drop test.

-   The test package should be attached to a lifting mechanism and
    raised to a height at which the lowest point of the test package is
    1.2 m (4 ft) from the impact surface, with the center of gravity
    over the lowest point of impact.

-   The test package should be dropped from an oblique position with the
    top down. For example, the test package should make a free fall with
    the initial contact being between the top corner and the impact
    surface.

-   This activity should be recorded on the test record form.

The steps for a typical free fall lid and seam drop test are as follows:

1.  Attach the test package to a lifting mechanism and raise it to a
    height at which the lowest point of the test package is 1.2 m (4 ft)
    from the impact surface, with the center of gravity over the lowest
    point of impact.

2.  Drop the test package from an oblique position with the seam and top
    down. The test package should make a free fall with the initial
    contact being between the top corner and the impact surface (see
    Figure 4-4).

3.  Record this activity on the test record form.

![](media/image7.jpeg){width="3.2465277777777777in"
height="3.620138888888889in"}

**Fig. 4-4. Drop test from an oblique position with the seam and top
down.**

\(H\) *Corner Drop Test 0.3 m (1 ft):* A free drop should be performed
onto each corner of the test package in succession (or in the case of a
cylindrical package, onto each quarter of each rim) from a height of 0.3
m (1 ft) onto a flat, essentially unyielding horizontal surface. This
test should use the same test package as used in the free drop test. The
steps listed below should be included in the corner drop test:

> NOTE: These corner drop tests are not required for all containers.
> Specifically, the tests are not required for fissile material
> rectangular packages weighing more than 110 lbs and cylindrical
> packages weighing more than 220 lbs in accordance with §71.72(c)(8).

1.  Attach the test package to the lifting mechanism and raise it to a
    height at which the lowest point of the corner being tested will be
    0.3 m (1 ft) from the impact surface.

2.  Drop the test package successively on each corner (or each quarter
    of each rim) with the center of gravity over the lowest point of
    impact onto an essentially unyielding horizontal surface (see Figure
    4-5).

> ![](media/image8.jpeg){width="3.779861111111111in"
> height="3.873611111111111in"}
>
> **Fig. 4-5. Corner 0.3m (1ft) drop test for a cylindrical package.**

3.  For cylindrical packages, drop the test package from an oblique
    position with the rim down. The test package should make a free
    fall, with initial contact being between the rim corners and the
    impact surface through the center of gravity.

4.  After each corner drop, visually examine the test package for
    damage, and take measurements of any damage.

5.  Record observations and measurements on the test record form.

\(I\) *Compression Test (Normal Stacking Test):* This test is only
required for packages weighing up to 5,000 kg (10,000 lbs). Compressive
load is applied uniformly to the top and bottom of the package in the
position in which the package would normally be transported. The steps
below should be included in the compression test.

NOTE: Any test package which has undergone the water spray test may be
used for this test.

1.  Place the test package on a horizontal surface in the selected
    position.

2.  Measure the initial condition (top to bottom) of the test package
    and record it on the test record form.

3.  ![](media/image9.jpeg){width="2.558333333333333in"
    height="1.9416666666666667in"}Uniformly apply a vertical load of at
    least five times the maximum package weight, or the equivalent of 13
    kPa (2 lbf/in^2^) multiplied by the vertically projected area of the
    package (whichever is greater), to the top of the test package for a
    period not less that 24 hours (see Figure 4-6). (Constraints may be
    used to obtain a stable loading condition so long as the constraint
    does not result in a load less than five times the package weight.)

> **Fig. 4-6. Compression test.**

4.  After the load is removed, visually inspect the test package for
    damage, and its dimensions, including overall height, remeasured.

5.  Record any damage or other observations and the overall height on
    the test record form.

\(J\) *Penetration Test:* The steps listed below should be included in
the penetration test.

> NOTE: Any test package which has undergone the water spray test may be
> used for this test.

1.  Place the test package on a horizontal surface in a position
    specified by the designer (see Figure 4-7).

2.  Hoist the steel bar (cylinder) to a height of 1 m (40 in) over the
    "surface of the package that is most vulnerable to puncture"
    (§71.71(c)\[10\]). The steel cylinder should have a hemispherical
    end of 3.2 cm (1.25 in) diameter and 6 kg (13 lbs) mass. The long
    axis of the cylinder must be perpendicular to the test package
    surface. The cylinder should be dropped onto the exposed surface of
    the package that is expected to be most vulnerable to puncture, so
    that if it penetrates sufficiently, it will hit the containment
    system.

3.  Release the steel bar (cylinder) to impact, and allow it to free
    fall, with its long axis vertical.

> ![](media/image10.jpeg){width="3.7534722222222223in"
> height="3.126388888888889in"}
>
> **Fig. 4-7. Penetration test.**

4.  After the drop, visually examine the test package for damage.

5.  Record this activity on the test record form.

\(K\) *Disassembly and Inspection:* The steps shown below should be
included in the disassembly and inspection actions. (See acceptance
criteria in Section 3.3 of this guide.)

-   Move the inner assembly (i.e., containment vessel or boundary) to
    the leak test station and leak test it in accordance with an
    approved procedure based on the requirements of ANSI N14.5, *Leakage
    Test on Packages for Shipment* (1997).

-   Disassemble the inner assembly, and inspect the sealing surfaces
    should be inspected for damage.

-   Document the results of the leak test and the visual inspection on
    the test record form.

**4.3 Tests for Hypothetical Accident Conditions**

4.3.1 [Evaluation]{.underline}

Evaluation for the hypothetical accident conditions is to be based on
sequential application of the following tests in the order indicated to
determine their cumulative effect on a test package or array of
packages. An undamaged test package may be used for the 15 m (50 ft)
water immersion test noted below.

4.3.2 [Initial Conditions]{.underline}

Except for the water immersion tests, in order to demonstrate compliance
with the requirements of §71.73 during testing, the ambient air
temperature before and after the tests must remain constant at that
value between -29°C (-20°F) and +38°C (+100°F). The temperature should
be the most unfavorable for the feature under consideration. The initial
internal pressure within the containment system must be the maximum
normal operating pressure, unless a lower internal pressure consistent
with the ambient temperature assumed to precede and follow the tests is
more unfavorable.

4.3.3 [Conditions and Tests]{.underline}

Tests for the hypothetical accident conditions must be conducted as
follows:

\(A\) *9 m (30 ft) Free Fall Drop Test*

The following steps may be included in the free fall drop test:

1.  ![](media/image11.jpeg){width="1.9284722222222221in"
    height="3.5229166666666667in"}Transport the test packages to the
    drop test facility. The striking surface should be a flat,
    essentially unyielding horizontal surface. (\"Unyielding\" is
    defined by IAEA Safety Standard Series No. ST-2 as a steel plate or
    plates or other convenient materials with a mass at least ten times
    that of the package.)

2.  Locate two high-speed cameras at a 90 degree angle to each other to
    record the free fall drop from separate views.

3.  Orient the test package so that maximum damage is expected. Pretest
    evaluations should consider the following orientations and may
    result in multiple tests:

> \(a\) Horizontal with seam side down
>
> \(b\) Top up
>
> \(c\) Bottom up
>
> \(d\) Center of gravity over contact

\(e\) Orientation to provide maximum slap down force

> **Fig 4-8. 9 m free fall drop test.**

4.  Raise the test package to a height at which the lowest point of the
    test package is 9 m (30 ft) from the impact surface (see Figure
    4-8).

5.  Drop the test package and allow it to free fall.

> NOTE: To ensure that impact is at the desired location, the center of
> gravity must be determined and must be directly above the impact
> surface to preclude rotation of the package during free fall. If a
> guided drop is allowed, documentation should be provided to
> demonstrate that the guided drop and the analysis meet free drop
> requirement (i.e., §71.41\[a\]).

6.  Record the drop and observations of the damage to the test package
    on the test record form.

7.  Document the damaged areas of the package (for example, photographs
    and/or videotape).

\(B\) *Crush Test*

This test is required only when the test package has a mass not greater
than 500 kg (1100 lbs), an overall density not greater than 1000kg/m^3^
(62.4 lbs/ft 3) based on external dimensions, and radioactive contents
greater than 1000 A~2~ not as special form radioactive material. The
following steps should be included in the crush test.

1.  ![](media/image12.jpeg){width="2.3493055555555555in"
    height="3.33125in"}Position the test package on the target so that
    it will suffer maximum damage by the drop of the 500 kg mass from 9
    m onto the test package.

2.  Raise the 500 kg (1100 lbs) mild steel plate (1 m × 1 m) (40 in × 40
    in) to a height at which the lowest point of the steel plate will be
    9 m (30 ft) from the uppermost surface of the test package
    (see Figure 4-9).

3.  Measure the height of the drop from the underside of the steel plate
    to the highest point of the test package.

4.  Drop the steel plate in a horizontal position, with the center of
    the plate over the center of the desired impact area.

> **Fig. 4-9. Crust test.**

5.  Record observations of the damage sustained by the test package on
    the appropriate test record data form.

\(C\) *1 m (40 in) Puncture Drop Test*

The following steps should be included in the puncture drop test:

1.  Orient the test package in a position which has been determined to
    be the worst case.

2.  ![](media/image13.jpeg){width="2.384027777777778in"
    height="3.4652777777777777in"}Raise the package to a height at which
    its lowest point is 1 m (30 in) above the steel punch bar (see
    Figure 4-10). The bar must be 15 cm (6 in) in diameter, with the top
    horizontal and the edges rounded to a radius of not more than 6 mm
    (0.25 in), and a length which should cause the maximum damage to the
    package, but not less than 20 cm (8 in) long. The long axis of the
    bar must be vertical. The test bar should be rigidly mounted on an
    essentially unyielding surface.

3.  Drop the test package and allow it to free fall, with initial
    contact on the top of the punch bar.

4.  Record the observations of the puncture drop and damage sustained by
    the test package on the test record form.

5.  Photograph and/or videotape, if required, the damaged areas of the
    containers to document their conditions following the test.

\(D\) *Thermal Testing*

This subsection does not contain detailed and exhaustive methods for
thermal testing. The thermal testing of a package represents a challenge
to the packaging designer and test engineer. Along with this testing
challenge may come some details that cannot be foreseen. This testing
guide cannot address all possible circumstances and, therefore, it is
the responsibility of the packaging designer to apply good engineering
judgment.

In general, there are three methods of thermal physical packaging
techniques that are commonly employed: pool-fire testing, furnace
testing (gas fired or electric), and radiant heat lamp testing. Any of
these methods can be used satisfactorily, but caution and good sense
must be exercised.

The thermal test consists of the exposure of a test package fully
engulfed, except for a simple support system, in a hydrocarbon fuel/air
fire of sufficient extent and in sufficiently quiescent ambient
conditions to provide an average emissivity coefficient of at least 0.9,
with an average flame temperature of at least 800°C (1475°F). The test
package is engulfed for a period of 30 minutes. Any other thermal test
may be conducted if it provides the equivalent total heat input to the
package and if it provides a time averaged environmental temperature of
800°C.

a\. Thermal exposure - pool fire

For purposes of calculation, the surface absorptivity coefficient must
be either that value which the package may be expected to possess if
exposed to the fire specified, or 0.8, whichever is greater. The
convective coefficient must be that value which may be demonstrated to
exist if the package were exposed to the fire specified. Artificial
cooling may not be applied after cessation of external heat input, and
any combustion of materials of construction must be allowed to proceed
until it terminates naturally.

The steps listed below should be included in the pool fire test.

-   Pretest conditions:

1.  Position test packages and connect temperature indicators and/or
    thermocouples.

2.  Preheat the test packages to a stable temperature condition to
    simulate transport conditions, and hold for a minimum soaking period
    determined by the designer.

3.  If drum heaters are used to preheat the package, conduct the pool
    fire test within a pre-selected time period following removal of the
    drum heaters.

4.  If test package thermocouples are used, read and record information
    immediately prior to the time the pool fire test is performed.

5.  When testing multiple packages, position the test packages a minimum
    of 1 m from each other and the nearest pool boundary. The fuel
    source boundary must extend at least 1 m (40 in) from the package,
    but may not extend more than 3 m (120 in) from the package. The
    package must be positioned 1 m (40 in) above the surface of the fuel
    source.

6.  Orient the test package so that it will incur the greatest damage.
    If a different orientation is used, the test or design engineer
    should document both the orientation and the justification on the
    test record form.

7.  Check the wind speed at the pool fire test facility to verify that
    it is less than 2 m/s (4.5 MPH).

8.  Record the setup activities in order to sufficiently document the
    conditions prior to the pool fire test.

9.  If required by the test plan, install predetermined thermocouples in
    the pool fire pit and on the test package support stand.

10. If used, attach thermocouples from the test packages and the pool
    fire pit to the data acquisition system, and conduct a systems test
    prior to the pool fire test.

-   Conduct of burn test:

1.  Advise all personnel in the pool fire test area of the
    environmental, safety and health requirements pertaining to the test
    packages.

2.  When wind conditions are favorable, ignite a hydrocarbon (i.e.,
    JP4/JP8) fuel it should continue to burn for a period of 30 minutes
    (+5 min. -0 min.).

3.  Monitor the burn and by video cameras to determine if fire and smoke
    plumb rise vertically and to verify that the test packages are fully
    engulfed in flame. Document observations on the test record form.

4.  Monitor the wind conditions and any note variations to wind speed.

-   Post-burn activities:

1.  Allow the fire pit flames to die out naturally after the 30-minute
    fire test.

2.  Allow the burning test packages (combustion of materials) to
    continue burning naturally until the flames stop. The test packages
    should cool naturally.

3.  The data acquisition system should continue to record the
    thermocouples on the test packages and the fire pit for two hours,
    or until peak temperatures have been met.

4.  If required by the test plan, take documentary photographs and
    videos after the fire test is completed.

5.  Document post-test inspection and observations on the test record
    form.

6.  Collect and include strip chart recordings, videos, and other data
    recording device printouts as part of the test record.

b\. Thermal exposure - furnace testing

The steps shown below should be included in the thermal exposure test
using a gas-fired or an electric induction type furnace.

NOTE: Appendix B contains further detail regarding the combination
test/analysis method used to demonstrate compliance to DOE/AL Type B
container thermal test requirements.

-   Furnace preparation:

1.  Prior to the beginning of the thermal test, characterize the furnace
    for temperature, emissivity, heat recovery times, and radiant
    viewing factors.

2.  Install thermocouples in the furnace as shown in each applicable
    test plan. (An example of thermocouple locations in a furnace is
    shown in Figure 4-11.) Test package support stand(s) should be
    placed into the furnace on the floor prior to preheating. The stands
    typically have thermocouples attached as shown in Figure 4-12. It is
    noted that each test stand must be test package specific. One
    thermocouple should record the ambient temperature in the furnace
    area. These figures are for visual information only, and do not
    suggest thermocouple placement as shown.

3.  The furnace temperature controller may have several zone
    thermocouples and an overall temperature thermocouple. Preheat the
    furnace and allow it to soak at a temperature and time period
    determined by the furnace characterization study. If used, the
    thermocouple recorder should record data continuously on a strip
    chart or data recorder. The test engineer may adjust the furnace set
    point during testing to ensure that minimum temperatures are
    maintained.

![](media/image14.wmf){width="6.5in" height="3.8375in"}**Fig. 4-11.
Example of thermocouple (TC) locations in a furnace.**

> ![](media/image15.wmf){width="6.232638888888889in"
> height="3.4652777777777777in"}
>
> **Fig. 4-12. Example of thermocouple (TC) locations on package test
> stands.**

-   Number range CHAPTERPreparation of the testing packages:

1.  If required, Attach a predetermined number of thermocouples to the
    exterior of each test package (example shown in Figure 4-13) after
    completion of the drop tests. The operability of thermocouples
    installed on test record form should be recorded and verified.
    Figure 4-13 shows an acceptable method for thermocouple lead wires
    to be held in place by the use of metal retainer clips welded in
    place. The clips are to be made of 304 stainless steel approximately
    1.27 cm (0.5 in) wide, 5 cm (2 in) long and .15 cm (0.06 in) thick.
    Lead wires should be inserted underneath the metal clips.

> ![](media/image16.jpeg){width="2.473611111111111in"
> height="2.3333333333333335in"}
>
> **Fig 4-13. Location of thermocouple lead wires.**

2.  The thermocouple direction on the drum\'s surface should not be
    exposed to heat transfer by radiation from the furnace walls,
    ceiling, or floor plate. In order to eliminate any radiant viewing
    factors, fill the clips with refractory cement. Examples include #36
    refractory cement from A. P. Green Industries, Inc. (or an
    equivalent), which is a sodium silicate base cement. The refractory
    cement should completely enclose the tip of each thermocouple lead
    wire.

3.  If required by the test plan, install drum heaters with insulation
    around each test package for preheating. The packages should be
    preheated to a temperature predetermined by the designer until the
    inner container thermocouples have reached this temperature. The
    thermocouple temperatures of the inner container should be recorded
    on the test record form every 15 minutes for one hour prior to the
    burn test to assure that the package has reached a steady
    temperature.

-   Conduct of test:

1.  Load the first test package in the furnace on the preheated support
    stand in a position with an orientation that is most damaging.
    During testing of individual packages, the temperature recorder
    should be set to record data every minute. The test engineer may
    adjust the furnace set point during testing to ensure that the
    proper temperature is maintained.

2.  Expose the package to this radiation environment for a minimum of 30
    minutes after the minimum number of furnace thermocouples have
    recovered to a temperature of 800°C (1475°F), and four of the six
    thermocouples on the package drum have also attained that
    temperature also. Record the thermal test data on the test record
    form.

> NOTE: There is no regulatory requirement that the package skin be
> maintained at 800°C. In fact, for thick-walled outer containers it
> would result in significant over-test.

3.  Upon completing the 30 minute soak time, remove the test package
    from the furnace and place it in an area in which it will not be
    exposed to artificial cooling. Caution should be exercised during
    movement to limit artificial cooling. Combustion of packaging
    materials must be allowed to extinguish naturally and the package
    allowed to cool to room temperature unless the test package has an
    outer heat source. The thermocouple readings on the drum and inner
    container may be recorded every minute for three hours after
    removal. Then the readings from thermocouples on the inner container
    of at least one test package may be recorded according to the test
    plan for the next 48 hours of the cool down.

4.  If multiple test packages are to be fired, allow the furnace to
    reheat for a minimum of one hour (or according to the test plan
    thermal characteristics of the furnace used) between each individual
    test. Between packages, the furnace control temperature data should
    be recorded continuously on the strip chart recorder.

c\. Thermal exposure - radiant heat lamp

The following steps should be included in the radiant heat lamp test:

-   Facility preparation:

1.  Characterize the radiant heat test facility for temperature,
    emissivity, and radiant viewing factors.

2.  Determine the thermal effect of the test stand for the test package
    and prepare the test stand be prepared for the test (e.g., the test
    stand should be preheated to a temperature determined by the design
    and test engineer).

3.  Determine the required temperature for the radiant heat test
    facility elements (e.g., the shroud which will surround the test
    package), and test the necessary controls and data acquisition
    system for the heating system.

-   Preparation of the test package:

1.  If required, attach a predetermined number of thermocouples to the
    exterior of each test package after the completion of the drop
    tests. The number and operability of the thermocouples installed
    should be recorded and verified, along with the operability of any
    internal thermocouples. Document the results on the test record
    form.

2.  If required by the test plan, install drum heaters with insulation
    around each test package for preheating. The packages should be
    preheated to a temperature determined by the designer. Completion of
    this preheating may be determined by either all installed
    thermocouples reaching the temperature specified by the design
    engineer, or may be determined by the duration of the preheating
    period specified by the designer.

-   Conduct of test:

1.  Position the test package in the center of the radiant heat assembly
    in the orientation specified in the test plan.

2.  Reposition the shroud in the heating configuration.

3.  Energize the radiant heat assembly and bring the shroud to the
    specified temperature. The shroud temperature should be monitored to
    increase to the specified temperature within the time identified in
    the characterization study.

4.  Use if possible infrared thermography with the test configuration to
    monitor surface temperatures to confirm that the testing process
    matches the predicted heat transfer characteristics.

5.  Allow the test package and shroud to cool naturally upon completion
    of the 30-minute exposure period. The shroud should not be removed
    from the test package until it has returned to near ambient
    temperatures and there are no longer any flames visible from the
    test package.

6.  Monitor any installed thermocouples on the test package following
    the test for a duration specified by the designer.

d\. Post-burn activities:

1.  Disassemble and inspect the test packages. Each test package should
    be weighed, and weights should be recorded on test record form.
    Damage should be photographed. The inner container should be weighed
    and the weight recorded. The insulation should be visually inspected
    for damage, distortion, warping, burn depth, etc., in accordance
    with the test plan requirements.

2.  Document the condition of the package.

3.  Move the test package to the leak test station to ensure adequate
    containment. The leak test activity is noted below in Section
    4.3.3(6) and 4.3.3(9).

\(E\) *Test Package Disassembly*

The following steps should be included in the test package disassembly:

1.  Move the test package to the disassembly area. Open the drum
    assembly and remove the inner container assembly.

2.  If the inner container includes a secondary containment vessel
    (SCV), record the condition of components outside of the SCV and any
    support structure. If necessary, conduct a dimensional inspection of
    the SCV and record for comparison to original hardware requirements.

3.  If the inner container does not have an SCV, then record the
    condition of components outside of the PCV and any support
    structure. If necessary, conduct a dimensional inspection of the PCV
    and record for comparison to original hardware requirements.

\(F\) *SCV Leak Test (If Applicable*)

The SCV should be leak tested according to an approved leak test
procedure, and the results reported on the test record form. The maximum
acceptable leak rate should satisfy the acceptance criteria specified in
Section 3.3 of this guide.

NOTE: The leak test should either demonstrate leak tightness or should
be backed up by an analysis showing that the leak rate is acceptable.

\(G\) *SCV Immersion Test, 0.9 m (3 ft) Fissile Material (If
Applicable)*

NOTE: This test is applicable for fissile material subject to §71.55 in
those cases where water inleakage has not been assumed for criticality
analysis.

The steps below should be included in the immersion test.

1.  Transport the SCV to the immersion test area. (This test is not
    required when criticality analysis has assumed water in-leakage.)

2.  Fully immerse the SCV under a 0.9 m (3 ft) head of water in an
    upright attitude (or other attitudes for which maximum leakage is
    expected).

\(H\) *SCV Disassembly and Inspection (If Applicable)*

The following steps should be included in the inner package disassembly.

1.  Move the SCV package to the disassembly area and dry the exterior of
    the SCV.

2.  Open the top half of the SCV and examine it for inleakage of water.

3.  Remove the PCV from the SCV.

4.  Record the condition of components outside of the PCV and any
    support structure. If necessary, conduct a dimensional inspection of
    the PCV and record for comparison to original hardware requirements.

\(I\) *PCV Leak Test*

The PCV should be leak tested according to an approved leak test
procedure, and the results should be reported on the test record form.
The maximum acceptable leak rate should satisfy the acceptance criteria
specified in Section 3.3 of this guide.

NOTE: The leak test should either demonstrate leak tightness or should
be backed up by an analysis showing that the leak rate is acceptable.

\(J\) *PCV Immersion Test, 0.9 m (3 ft) Fissile Material*

This test is applicable for fissile material subject to §71.55 in those
cases where water in-leakage has not been assumed for criticality
analysis.

The steps below should be included in the immersion test.

1.  Transport the PCV to the immersion test area. (This test is not
    required for cases in which criticality analysis has assumed water
    inleakage.)

2.  Fully immerse the PCV under a 0.9 m (3 ft) head of water in an
    upright attitude (or other attitudes for which maximum leakage is
    expected).

> NOTE: With the proposed loading and a conceptual design of the
> containment system (i.e., inner container dimensions and volume), the
> criticality safety analyst must first determine if the contents would
> remain adequately subcritical if water inleakage were to occur (to the
> most reactive and most credible extent).

\(K\) *Immersion Test, 15 m (50 ft) for 8 Hours, All Packages*

An undamaged test package may be used for the water immersion tests
specified below. The following steps should be included in the immersion
test:

1.  Transport a separate, undamaged test package to the disassembly area
    and remove the inner container.

2.  Place the PCV into the immersion test fixture in the attitude for
    which maximum leakage is expected.

3.  Immerse the PCV so that water pressure equivalent to immersion under
    a head of water of at least 15 m (50 ft).

> NOTE: For test purposes, an external pressure of water of 150
> kilopascal (21.7 lbf/in^2^) gauge is considered to meet these
> conditions.

4.  Remove and inspect the package and record the results on the test
    record form.

**4.4 Disassembly and Post-test Inspections**

After physical testing activities are complete, the test packages should
be disassembled and inspected. Any damage or leakage of water should be
recorded on the appropriate test record form. The temperature indicator
readings will be recorded on the test record form. If applicable, once
the lid has been removed, the O-ring, O-ring groove and the seal surface
should be inspected for damage. Observations are to be recorded on the
test record form. If necessary, a dimensional inspection of the inner
container (i.e., containment vessel or boundary) may be conducted and
recorded for comparison to original hardware requirements. Conditions of
the mockup components and foam support structure should also be recorded
on the test record forms.

The following steps should be included in the disassembly and inspection
activity:

-   Transport the PCV to the disassembly area, and dry the exterior of
    the PCV.

-   If the locking mechanism is used, examine it for damage. Bolts
    should be removed and the loosening torque of each inner container
    bolt should be recorded on the test record form. The top half of the
    PCV should be removed.

-   Once the top half has been removed, inspect the PCV for in-leakage
    of water. The sealing area should be inspected for damage and the
    observations recorded on the test record forms.

-   Record the readings from any temperature indicators or
    accelerometers on the inner container and mockup on the test record
    form.

-   Document the disassembly activities and resultant components ,
    particularly the areas of resulting test package damage.

-   Record actual dimensions of the package components.

Number range CHAPTER**5.0 TESTING REPORTING**

**5.1 SARP Requirements**

DOE O 461.1, Section 4.b.(1)(a), states all packages to be transported
by TSS must be authorized by an Offsite Transportation Certificate (OTC)
or an Offsite Transportation Authorization (OTA), approved and issued by
the Manager, DOE/AL, certifying a specific packaging for nuclear
weapons-related cargo. It is issued if a DOE package meets applicable
requirements of 10 CFR 71, 49 CFR 100-178, and Reg Guide 7.9. Section
4.b.(1)(b) states that the request for an Offsite Transportation
Certificate shall be supported by the Safety Analysis Report for
Packaging (SARP), or a Transportation System Risk Assessment (TSRA) for
an Offsite Transportation Authorization. The recommendation for
approval/disapproval of the OTC or OTA will be documented in a Safety
Evaluation Report.

Section 5.e(1) states the applicants ensure that the SARP or TSRA or
other required supporting documents, are submitted to the Albuquerque
Operations Office at least 9 months prior to the first required shipment
date.

DOE/AL Supplemental Directive AL 5610.12, Section 10.c.(16), states that
the DOE/AL Procurement Engineer ensures that all DOE contractors
requiring packaging to ship nuclear components, special assemblies, and
other associated material have developed and submitted a SARP to OWS PTP
at least 40 weeks in advance of the projected date for use of the
packaging.

**5.2 Evaluation and Reporting of Test Results**

Each test package design will be considered as acceptable for normal
conditions of transport as specified in 10 CFR 71.71, and hypothetical
accident conditions as specified in 10 CFR Part 71 §71.73 if the
acceptance criteria in Section 3.0 of this document are met at the end
of the respective tests.

THIS PAGE INTENTIONALLY LEFT BLANK

Number range CHAPTER**6.0 TEST RECORDS**

The test record forms developed and used during all the physical and
thermal testing should be completed during or immediately following each
test. Each test form should be witnessed and signed off by the test
technician or engineer and a witness at the time of the test.

Color photographs should be taken of the test arrangements before and
after all tests and of any resulting damage to the test package. The
photographs should be printed at 8 in × 10 in format for ease of
examination and use in reports. Also, two high-speed video/movie cameras
could be employed to record the drop tests. The cameras should be
located at 90 degrees to each other. A video camera should be used to
record test results, along with a verbal narrative of the visible damage
to each test package. Other means can be used as defined in the
respective test plan.

**6.1 Test Record Attributes**

The following should be considered when developing test record forms:

-   Item tested

-   Date of test

-   Tester or data recorder

-   Type of observation

-   Results in connection with any deviations noted

-   Action taken in connection with any deviations noted

-   Persons evaluating test results

Figure 6-1 depicts the testing requirements and the applicable test
forms. Examples of test record forms are attached in Appendix A.

**6.2 Verification Plan and Actions**

The contractor or laboratory quality assurance function responsible for
monitoring the packaging testing activities should plan and conduct
assessments of the testing program to ensure that the requirements
specified are being satisfied.

**6.3 SARP Requirements for Testing Documentation**

DOE/AL Supplemental Directive 5610.12 states that the package SARP must
demonstrate that the proposed packaging design meets the compliance
tests specified by 10 CFR 71.71 and 71.73 regulations for normal and
hypothetical conditions for transport. The objective of the SARP
structural design evaluation section and the thermal evaluation section
is to ensure that the design uses acceptable analytical and/or test
methods and that it complies with 10 CFR Part 71 regulations.

![](media/image17.wmf){width="6.488194444444445in"
height="3.8722222222222222in"}

\*For tests outside the scope of this procedure, refer to the
appropriate SARP for explanation of how test requirements are satisfied
or why they do not apply.

**Fig. 6-1. Testing requirements matrix.**

Number range CHAPTER**7.0 REFERENCES**

1\. Anderson, J.C. and M.R. Feldman. *Characterization of Furnaces for
Hypothetical Thermal Accident Testing in Accordance with 10 CFR 71*.
Presentation to the Transportation of Hazardous Materials Thermal
Specialists Meeting, Albuquerque: 1992. Also presented at ASME Heat
Transfer Division Conference, 1995.

2\. Anderson, J.C. and M.R. Feldman. *Thermal Modeling of Packages for
Normal Conditions of Transport with Insolation*. ASME Paper, 1995

3\. Bronowski, D. R. *Performance Testing of Elastomeric Seal Materials
Under Low- and High-Temperature Conditions: Final Report*, SAND94-2207,
June 2000.

3\. Byington, G.A. *A Comparison of Radioactive Material Package Leakage
Tests, Between ANSI N14.5-1987 and the Proposed ANSI N14.5-1995*.
Packaging Conference, 1995.

4\. Feldman, M.R. *Furnace Characterization for Horizontal Shipping
Container Thermal Testing*. ORNL/ENG-12, 1994.

5\. Feldman, M.R. *Hypothetical Accident Condition Thermal Testing
Methods*. Packaging Conference, 1995.

6\. *Guide for Conducting Impact Tests*. UCRL ID-121673

7\. *A Guide to Thermal Testing Transport Packages for Radioactive
Material -- Hypothetical Accident Conditions*. UCRL ID-110445, Rev. 5

8\. Schaum. *Outline of Theory and Problems of Mechanical Vibrations*.

THIS PAGE INTENTIONALLY LEFT BLANK

**APPENDICES**

Appendix A: Examples of Test Record Forms

Form 1 Assembly of the PCV and SCV

> Form 2 Assembly of Test Package
>
> Form 3 Component Weights
>
> Form 4 Accelerometer
>
> Form 5 Vibration Test
>
> Form 6 1.2 m (4 ft) Free Fall Drop
>
> Form 7 0.3 m (1 ft) Corner Drop
>
> Form 8 Compression Test

Form 9 Penetration Test

Form 10 9 m (30 ft) Free Fall Drop

Form 11 9 m (30 ft) Dynamic Crush Test

Form 12 1 m (40 in) Puncture Drop

Form 13 Pool Fire Test Checklist

Form 14 Pool Fire Test Data Sheet

> Form 15 Thermocouple Verification

Form 16 Thermal Preheat Test

> Form 17 Thermal Testing

Form 18 Temperature Indicator Readings

Form 19 Post-Thermal Testing Inspection

> Form 20 0.9 m (3 ft) Immersion Test
>
> Form 21 15 m (50 ft) Immersion Test
>
> Form 22 Disassembly and Inspection

Appendix B: A Combination Test/Analysis Method Used to Demonstrate
Compliance to DOE Type B Container Thermal Test Requirements (30 Minute
Fire Test), DOE/AL Defense Programs Guideline for Packaging, Jan. 30,
1992.

Appendix C: Vibration Environments for the AT-400R (Klenke to Glass,
Sandia Lab Memo)

Appendix D: Calculations for Normal Vibrations During Safe-Secure
Trailer Shipment of the DC-1 Package with HEU Oxide Contents

**Appendix A**

**Test Forms**

**(Examples)**

Number range CHAPTER**APPENDIX A**

TEST FORM 1 Test Plan

ASSEMBLY OF THE PCV (AND SCV\*) Test Unit

Test Location:

VERIFIED TASK

PCV test unit serial number:

SCV test unit serial number: (if not applicable, write "N/A.")

All primary containment vessel (PCV/SCV) components have been
dimensionally verified to comply with drawing specifications.

Temperature indicators have been affixed to the interior surface of the
PCV/SCV. (No temperature indicators are required on prototype for normal
conditions testing.)

None of the temperature indicators indicate exposure to a temperature in
the measured range.

The containers, lids, mock-up, and inserts have been clearly marked as "
, Unit ."

The PCV/SCV O-rings, O-ring glands, and sealing surfaces have been
inspected for defects and found acceptable.

Foam inserts and mock-up have been weighed and weights have been
recorded on Form 3.

![](media/image18.wmf){width="1.2645833333333334in"
height="1.3694444444444445in"} The foam inserts and mock-up have been
inserted into the PCV/SCV, the lid installed with the leak port aligned
as close to the PCV/SCV seam as possible, and the bolts torqued to ±
in-lb ( ± ft-lb) in the sequence shown at right. Ambient temperature at
closure was [°]{.underline}C ( [°]{.underline}F).

> Torque wrench \# Expiration Date

Actual torque 1- 6- 11- 15-

for each bolt in 2- 7- 12- 16-

**in-lb** or **ft-lb** 3- 8- 13- 17-

(circle one) 4- 9- 14- 18-

5- 10-

The PCV/SCV assembly has been leak tested and found leak-free in
accordance with leak-test procedure .

Leak Rate Test Stand \# Expiration Date

The PCV/SCV assembly has been leak tested and found leak-free in
accordance with leak-test procedure .

Leak Rate Test Stand \# Expiration Date

The PCV/SCV assembly has been weighed and the weight has been recorded
on form 3.

Thermocouples have been attached to the exterior surface of the PCV/SCV
if this unit is to obtain time-temperature data. These thermocouples
have been surveyed to ensure they are working, which has been noted on
form 15.

\*\*Photographs of the assembly have been taken.

Comments: I certify that the above tasks have been performed and that
the observations and comments are correct.

Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

\*\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 2 Test Plan

ASSEMBLY OF TEST PACKAGE Test Unit

Location:

VERIFIED TASK

+-----------------------------------------+----------------------------+
| The test unit has been clearly marked   | CENTER OF GRAVITY MARKING  |
| "\_\_\_\_\_\_\_, Unit \_\_\_."          |                            |
|                                         |                            |
| Record the test unit serial             |                            |
| number:\_\_\_\_\_\_\_\_\_               |                            |
|                                         |                            |
| The center of gravity targets have been |                            |
| applied to the test unit as shown       |                            |
|                                         |                            |
| Each insulation insert has been clearly |                            |
| marked "\_\_\_\_\_\_\_, Unit \_\_\_."   |                            |
|                                         |                            |
| The insulation inserts were weighed     |                            |
| together and the weight has been        |                            |
| recorded on form 3.                     |                            |
|                                         |                            |
| The lower and middle insulation inserts |                            |
| have been loaded into the test unit.    |                            |
|                                         |                            |
| The SCV assembly has been loaded into   |                            |
| the test unit with the seams aligned.   |                            |
|                                         |                            |
| The top insulation inserts have been    |                            |
| loaded into the test unit.              |                            |
|                                         |                            |
| The gap between the top insulation      |                            |
| inserts and the top of the test unit is |                            |
| \_\_\_\_\_\_.                           |                            |
+-----------------------------------------+----------------------------+

![](media/image19.wmf){width="1.41875in" height="1.5798611111111112in"}

The test unit lid has been installed and the bolts torqued to
\_\_\_\_±\_\_ ft-lb

> (\_\_\_±\_\_ in-lb) in a crossing sequence like that shown at right.
>
> Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
> \_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_ 13-\_\_\_\_\_
17-\_\_\_\_\_ 21-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_14-\_\_\_\_
18-\_\_\_\_\_ 22-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_
11-\_\_\_\_\_15-\_\_\_\_ 19-\_\_\_\_\_ 23-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_16-\_\_\_\_
20-\_\_\_\_\_ 24-\_\_\_\_\_

A security seal has been attached to the test unit.

The test package assembly has been weighed and the weight recorded on
form 3.

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

> TEST FORM 3 Test Plan

COMPONENT WEIGHTS Test Unit

Test Location:

PRE-TEST WEIGHTS POST THERMAL TEST WEIGHTS

  --------------- ---------------- ---------------- ---------------- ------------ ---------------- ---------------- ----------------
  PART NAME       WEIGHT           BY               DATE             PART NAME    WEIGHT           BY               DATE

  Mock-up         \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_                                                  

  PCV inserts     \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_                                                  

  PCV assembly    \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_   PCV assembly \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_

  SCV inserts\*   \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_   SCV inserts  \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_

  SCV assembly\*  \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_   SCV assembly \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_

  Test unit       \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_                                                  
  insulation                                                                                                        
  inserts                                                                                                           

  Test package    \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_   Test package \_\_\_\_\_\_lb   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_
  assembly                                                           assembly                                       
  --------------- ---------------- ---------------- ---------------- ------------ ---------------- ---------------- ----------------

**EQUIPMENT**

Pre-Test: Post-thermal test:

  ------- ---------------------------- ---------------- ---------------- ------- ---------------------------- ---------------- ----------------
  Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_   Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_
  \#                                                                     \#                                                    

          Accuracy ±                   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_           Accuracy ±                   \_\_\_\_\_\_\_   \_\_\_\_\_\_\_

                                                                                                                               

  Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_   Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_
  \#                                                                     \#                                                    

          Accuracy ±                   \_\_\_\_\_\_     \_\_\_\_\_\_\_           Accuracy ±                   \_\_\_\_\_\_\_   \_\_\_\_\_\_

                                                                                                                               

  Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_   Scale   \_\_\_\_\_\_\_\_\_\_\_\_\_   Expiration date  \_\_\_\_\_\_\_
  \#                                                                     \#                                                    

          Accuracy ±                   \_\_\_\_\_\_     \_\_\_\_\_\_\_           Accuracy ±                   \_\_\_\_\_\_     \_\_\_\_\_\_\_
  ------- ---------------------------- ---------------- ---------------- ------- ---------------------------- ---------------- ----------------

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

TEST FORM 4 Test Plan

ACCELEROMETER Test Unit

Test Location:

VERIFIED TASK

Identification of accelerometer

> Model \_\_\_\_\_\_\_\_\_\_\_ Serial No. \_\_\_\_\_\_\_\_\_\_

The battery was functioning properly and the chart was installed
correctly.

The accelerometer chart drive was started at

> Date: \_\_\_\_\_\_\_\_\_\_\_\_\_\_ Time: \_\_\_\_\_\_\_\_\_\_\_

The accelerometer chart drive was read at

> Date: \_\_\_\_\_\_\_\_\_\_\_\_\_\_ Time: \_\_\_\_\_\_\_\_\_\_\_

The maximum spike values and their times are listed below.

> [Vertical]{.underline} [Lateral]{.underline}
> [Longitudinal]{.underline} [Time]{.underline} [Date]{.underline}

\_\_\_\_\_\_\_\_ The strip chart used in the test is attached to the
form.

\_\_\_\_\_\_\_\_ The certification of the commercial accelerometer is
attached to the form.

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 5 Test Plan

VIBRATION TEST Test Unit

Test Location:

Test Date/Time: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Test
Name/Test

Test Location & Organization:

Test Conducted by:

**Hardware**

Test Unit Number
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Test
Unit Weight: ­­­­­­\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Vessel Initial Temp.:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Ambient
Temp.: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Position of Mock-up: Pre-test:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Test Unit Fastener (Finger-tight Test)

Screw #1
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#7 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Screw #2
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#8 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Screw #3
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#9 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Screw #4
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#10 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Screw #5
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#11 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Screw #6
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Screw
#12 \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Vibration Input:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

**Instrumentation and Data Acquisition**

Accelerometer Manufactured by:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Model Number:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
Calibration Expiration Date: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Data Acquisition System Manufactured by:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Model Number:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Calibration
Expiration Date: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

The activities listed in this procedure have been completed
by:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Date: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

> TEST FORM 6 Test Plan

1.2 m (4 ft) FREE FALL DROP Test Unit

Test Location:

+---------------------------------------+------------------------------+
| VERIFIED TASK                         | PRE-DROP TEST UNIT           |
|                                       | ORIENTATION                  |
| The test unit shall be subjected to a |                              |
| water spray that simulates exposure   | ![](media/image20.wmf){      |
| to a rainfall of approximately 5 cm/h | width="2.7618055555555556in" |
| (2 in/h) for at least 1h.             | he                           |
|                                       | ight="3.2465277777777777in"} |
| > Start Date: Start Time:             |                              |
| >                                     | (Indicate tolerance on       |
| > End Date: End Time:                 | orientation)                 |
|                                       |                              |
| Still, video, and high-speed          |                              |
| video/movie cameras are set up to     |                              |
| take photographs/movies\* of the drop |                              |
| testing.                              |                              |
|                                       |                              |
| Photographs\* of the arrangements for |                              |
| the drop have been taken.             |                              |
|                                       |                              |
| The test unit has been raised so that |                              |
| the lowest point is 1.2 m (4 ft)      |                              |
| above an essentially unyielding,      |                              |
| horizontal impact surface.            |                              |
|                                       |                              |
| > Measuring device \# \_\_\_\_\_\_\_  |                              |
| > Exp. Date \_\_\_\_\_\_              |                              |
|                                       |                              |
| Ambient temperature at the time of    |                              |
| the test:                             |                              |
|                                       |                              |
| > °C ( °F)                            |                              |
|                                       |                              |
| The test unit was dropped from a      |                              |
| minimum of 1.2 m (4 ft), oriented as  |                              |
| shown at the right, onto an           |                              |
| essentially unyielding, horizontal    |                              |
| impact surface.                       |                              |
|                                       |                              |
| Video/high speed movies\* of the drop |                              |
| were made.                            |                              |
|                                       |                              |
| Photographs\* of the damage resulting |                              |
| from the drop have been taken.        |                              |
+---------------------------------------+------------------------------+
| Testing Damage Observations:          | POST-DROP SKETCH OF TEST     |
|                                       | UNIT                         |
+---------------------------------------+------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 7 Test Plan

0.3 m (1 ft) CORNER DROP Test Unit

Test Location:

+----------------------------------+-----------------+-----------------+
| VERIFIED TASK                    | PRE-DROP SKETCH |                 |
|                                  |                 |                 |
| The test unit has been dropped   |                 |                 |
| on the top and bottom corners.   |                 |                 |
| (Test Form 6 has been            |                 |                 |
| completed.)                      |                 |                 |
|                                  |                 |                 |
| The test unit has been raised to |                 |                 |
| a height of 0.3 m (1 ft) at an   |                 |                 |
| oblique angle with the corner    |                 |                 |
| (a) of the package at the lowest |                 |                 |
| point and the center of gravity  |                 |                 |
| directly over the corner.        |                 |                 |
|                                  |                 |                 |
| The test unit was dropped from a |                 |                 |
| minimum of 0.3 m (1 ft) on each  |                 |                 |
| of the four corners of the       |                 |                 |
| top/bottom (cross out one) of    |                 |                 |
| the test unit between 1½ and 2½  |                 |                 |
| h after the water spray test.    |                 |                 |
|                                  |                 |                 |
| Following the water spray, the   |                 |                 |
| test unit has been raised to a   |                 |                 |
| height of 0.3m (1ft) at an       |                 |                 |
| oblique angle with the corner    |                 |                 |
| (b) of the package at the lowest |                 |                 |
| point and the center of gravity  |                 |                 |
| directly over the corner.        |                 |                 |
|                                  |                 |                 |
| Following the water spray, the   |                 |                 |
| test unit has been raised to a   |                 |                 |
| height of 0.3m (1ft) at an       |                 |                 |
| oblique angle with the corner    |                 |                 |
| ([c]{.underline}) of the package |                 |                 |
| at the lowest point and the      |                 |                 |
| center of gravity directly over  |                 |                 |
| the corner.                      |                 |                 |
|                                  |                 |                 |
| Following the water spray, the   |                 |                 |
| test unit has been raised to a   |                 |                 |
| height of 0.3m (1ft) at an       |                 |                 |
| oblique angle with the corner    |                 |                 |
| (d) of the package at the lowest |                 |                 |
| point and the center of gravity  |                 |                 |
| directly over the corner.        |                 |                 |
|                                  |                 |                 |
| Photographs\* of the             |                 |                 |
| arrangements for the test have   |                 |                 |
| been taken                       |                 |                 |
|                                  |                 |                 |
| Ambient temperature at the time  |                 |                 |
| of the test:                     |                 |                 |
|                                  |                 |                 |
| > Date: Time:                    |                 |                 |
| >                                |                 |                 |
| > °C ( °F)                       |                 |                 |
|                                  |                 |                 |
| Test Damage Observations:        |                 |                 |
+==================================+=================+=================+
|                                  | Orientation (a) | Orientation (b) |
+----------------------------------+-----------------+-----------------+
|                                  | Orientation (c) | Orientation (d) |
+----------------------------------+-----------------+-----------------+
|                                  | POST TEST       |                 |
|                                  | SKETCH          |                 |
+----------------------------------+-----------------+-----------------+
|                                  | Orientation (a) | Orientation (b) |
+----------------------------------+-----------------+-----------------+
|                                  | Orientation (c) | Orientation (d) |
+----------------------------------+-----------------+-----------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

> Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 8 Test Plan

COMPRESSION TEST Test Unit

Test Location:

+------------------------------------+---------------------------------+
| VERIFIED TASK                      | TEST UNIT CONFIGURATION         |
|                                    |                                 |
| The drop tests have been performed |                                 |
| and test form 6 is complete.       |                                 |
|                                    |                                 |
| The test unit has been placed      |                                 |
| vertically on a horizontal surface |                                 |
| as shown at right.                 |                                 |
|                                    |                                 |
| Photographs\* of the arrangements  |                                 |
| for the test have been taken.      |                                 |
|                                    |                                 |
| Initial test unit overall height   |                                 |
| is \_\_\_\_\_\_in.                 |                                 |
|                                    |                                 |
| An unconstrained load of at least  |                                 |
| five times the weight of the       |                                 |
| package or the equivalent of 12.75 |                                 |
| kPa (1.85 lb/in^2^) multiplied by  |                                 |
| the vertically projected area of   |                                 |
| the package (whichever is greater) |                                 |
| was applied to the top of the test |                                 |
| unit for a minimum of 24 hours.    |                                 |
|                                    |                                 |
| > Vertically projected area of     |                                 |
| > test unit:                       |                                 |
| > \_\_\_\_                         |                                 |
| \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ |                                 |
| >                                  |                                 |
| > Based on weight of test unit     |                                 |
| > from test form 3, actual load    |                                 |
| > applied: \_\_\_\_\_\_\_\_\_\_    |                                 |
| >                                  |                                 |
| > Start Date \_\_\_\_\_\_\_\_      |                                 |
| > Start Time \_\_\_\_\_\_\_\_      |                                 |
| >                                  |                                 |
| > End Date \_\_\_\_\_\_\_\_ End    |                                 |
| > Time \_\_\_\_\_\_\_\_            |                                 |
+------------------------------------+---------------------------------+
| After the load was removed the     | POST-TEST SKETCH                |
| final height of the test unit was  |                                 |
| measured, and the unit was         |                                 |
| inspected for damage.              |                                 |
|                                    |                                 |
| Final test unit overall height is  |                                 |
| \_\_\_\_\_\_in.                    |                                 |
|                                    |                                 |
| Photographs\* of the damage        |                                 |
| resulting from the test have been  |                                 |
| taken.                             |                                 |
|                                    |                                 |
| Testing Damage Observations:       |                                 |
+------------------------------------+---------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

> Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 9 Test Plan

PENETRATION TEST Test Unit

Test Location:

VERIFIED TASK

+-----------------------------------+----------------------------------+
| The test unit has been placed     | TEST UNIT CONFIGURATION          |
| vertically on a horizontal        |                                  |
| surface as shown at right.        |                                  |
|                                   |                                  |
| Still, video, and high-speed      |                                  |
| video/movie cameras are set up to |                                  |
| take photographs/movies\* of the  |                                  |
| penetration testing.              |                                  |
|                                   |                                  |
| Photographs\* of the arrangements |                                  |
| for the drop have been taken.     |                                  |
|                                   |                                  |
| The test rod is a steel cylinder, |                                  |
| 3.2 cm (1.25 in) in diameter,     |                                  |
| with a hemispherical end and      |                                  |
| weighing 6 kg (13 lb), M&TE \#    |                                  |
| \_\_\_\_\_\_\_\_.                 |                                  |
|                                   |                                  |
| The hemispherical end of the rod  |                                  |
| was dropped with its long axis    |                                  |
| perpendicular (±5̊) to the test    |                                  |
| unit surface from a height of at  |                                  |
| least 1 m (40 in) onto the center |                                  |
| (± 2 inches) of the test unit     |                                  |
| lid.                              |                                  |
|                                   |                                  |
| Photographs\* of the damage       |                                  |
| resulting from the drops have     |                                  |
| been taken.                       |                                  |
|                                   |                                  |
| Following the drop, the unit was  |                                  |
| examined for damage.              |                                  |
|                                   |                                  |
| Depth of penetration:             |                                  |
| \_\_\_\_\_\_\_\_                  |                                  |
+-----------------------------------+----------------------------------+
| Observations:                     | POST-TEST SKETCH OF TEST UNIT    |
|                                   |                                  |
| The test unit has been placed on  |                                  |
| its side on a horizontal surface  |                                  |
| as shown to the right.            |                                  |
|                                   |                                  |
| Photographs\* of the arrangements |                                  |
| for the drop have been taken.     |                                  |
|                                   |                                  |
| The hemispherical end of the test |                                  |
| rod was dropped with its long     |                                  |
| axis perpendicular (±5°) to the   |                                  |
| test unit surface from a height   |                                  |
| of at least 1 m (40 in) onto the  |                                  |
| side of the test unit.            |                                  |
|                                   |                                  |
| Following the drop, the unit was  |                                  |
| examined for damage.              |                                  |
|                                   |                                  |
| Depth of penetration              |                                  |
| \_\_\_\_\_\_\_\_                  |                                  |
|                                   |                                  |
| Observations:                     |                                  |
|                                   |                                  |
| Photographs\* of the damage       |                                  |
| resulting from both drops have    |                                  |
| been taken.                       |                                  |
+-----------------------------------+----------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

TEST FORM 10 Test Plan

9 m (30 ft) FREE FALL DROP Test Unit

Test Location:

+-------------------------------------+--------------------------------+
| VERIFIED TASK                       | PRE-DROP TEST UNIT ORIENTATION |
|                                     |                                |
| The test unit has been prepared in  | ![](med                        |
| accordance with the test plan.      | ia/image21.wmf){width="2.95in" |
| Forms 1, 2, 3, and 4 are complete   | height="3.0in"}                |
| and the pre-test weights are        |                                |
| recorded on form 3.                 | (Indicate tolerance on         |
|                                     | orientation)                   |
| Still, video, and high-speed        |                                |
| video/movie cameras are set up to   |                                |
| take photographs/movies\* of the    |                                |
| drop testing.                       |                                |
|                                     |                                |
| Photographs\* of the arrangements   |                                |
| for the drop have been taken.       |                                |
|                                     |                                |
| The test unit has been raised so    |                                |
| that the lowest point is 9 m (30    |                                |
| ft) above an essentially            |                                |
| unyielding, horizontal impact       |                                |
| surface.                            |                                |
|                                     |                                |
| > Measuring device \#               |                                |
| > \_\_\_\_\_\_\_ Exp. Date          |                                |
| > \_\_\_\_\_\_                      |                                |
|                                     |                                |
| Ambient temperature at the time of  |                                |
| the test:                           |                                |
|                                     |                                |
| > °C ( °F)                          |                                |
|                                     |                                |
| The test unit was dropped from a    |                                |
| minimum of 9 m (30 ft), oriented as |                                |
| shown at right, onto an essentially |                                |
| unyielding, horizontal impact       |                                |
| surface.                            |                                |
|                                     |                                |
| Video/high speed video/movies\* of  |                                |
| the drop were made.                 |                                |
|                                     |                                |
| Photographs\* of the damage         |                                |
| resulting from the drop have been   |                                |
| taken.                              |                                |
+-------------------------------------+--------------------------------+
| Testing Damage Observations:        | POST-DROP SKETCH OF TEST UNIT  |
+-------------------------------------+--------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 11 Test Plan

9 m (30 ft) DYNAMIC CRUSH TEST Test Unit

Test Location:

+----------------------------------+-----------------------------------+
| VERIFIED TASK                    | TEST UNIT CONFIGURATION           |
|                                  |                                   |
| The test unit has been prepared  | ![](                              |
| in accordance with the test      | media/image12.jpeg){width="2.7in" |
| plan. Forms 1 and 2 are          | height="3.826388888888889in"}     |
| complete, and the pre-test       |                                   |
| weights have been recorded on    |                                   |
| form 3.                          |                                   |
|                                  |                                   |
| Ambient temperature at the time  |                                   |
| of the test:                     |                                   |
|                                  |                                   |
| > °C ( °F)                       |                                   |
|                                  |                                   |
| The test unit has been placed on |                                   |
| an essentially unyielding        |                                   |
| surface, configured as shown at  |                                   |
| right.                           |                                   |
|                                  |                                   |
| The 500 kg (1100 lb), 1m (3.28   |                                   |
| ft) square, mild steel test      |                                   |
| weight, M&TE \# \_\_\_\_\_\_\_,  |                                   |
| has been raised to a height of 9 |                                   |
| m (30 ft), with the center of    |                                   |
| the plate directly over the      |                                   |
| intended impact point.           |                                   |
|                                  |                                   |
| Measuring device \#              |                                   |
| \_\_\_\_\_\_\_ Exp. Date         |                                   |
| \_\_\_\_\_\_                     |                                   |
|                                  |                                   |
| The test weight is dropped in a  |                                   |
| free fall from 9 m (30 ft) onto  |                                   |
| the test unit.                   |                                   |
|                                  |                                   |
| Photographs\* showing the damage |                                   |
| resulting from the test have     |                                   |
| been taken.                      |                                   |
+----------------------------------+-----------------------------------+
| Testing Damage Observations:     | POST-DROP SKETCH OF TEST UNIT     |
+----------------------------------+-----------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 12 Test Plan

1 m (40 in) PUNCTURE DROP Test Unit

Test Location:

+-------------------------------------+--------------------------------+
| VERIFIED TASK                       | PRE-DROP TEST UNIT ORIENTATION |
|                                     |                                |
| The test unit has been prepared in  | ![](media/image22.wmf          |
| accordance with the test plan.      | ){width="2.9479166666666665in" |
| Forms 1 and 2 are complete and the  | height="2.9659722222222222in"} |
| pre-test weights are recorded on    |                                |
| form 3. The free fall drop has been | (Show tolerance on             |
| completed as recorded on Form 10.   | orientation)                   |
|                                     |                                |
| Still, video, and high-speed        |                                |
| video/movie cameras are set up to   |                                |
| take photographs/movies\* of the    |                                |
| drop testing.                       |                                |
|                                     |                                |
| Photographs\* of the arrangements   |                                |
| for the drop have been taken.       |                                |
|                                     |                                |
| The steel puncture bar is no        |                                |
| greater than 15 cm (6 in) in        |                                |
| diameter and no less than 20 cm (8  |                                |
| in) long, with the corners having a |                                |
| radius of no more than 6 mm (0.25   |                                |
| in) and rigidly attached to on an   |                                |
| essentially unyielding, horizontal  |                                |
| impact surface.                     |                                |
|                                     |                                |
| Ambient temperature at the time of  |                                |
| the test: °C                        |                                |
|                                     |                                |
| > ( °F)                             |                                |
|                                     |                                |
| The test unit was raised to 1m (40  |                                |
| in), oriented as shown at right.    |                                |
|                                     |                                |
| > Measuring device \#               |                                |
| > \_\_\_\_\_\_\_ Exp. Date          |                                |
| > \_\_\_\_\_\_                      |                                |
|                                     |                                |
| The test unit was dropped from a    |                                |
| minimum of 1 m (40 in) onto the     |                                |
| steel bar.                          |                                |
|                                     |                                |
| Video/high speed video/movies\* of  |                                |
| the drop were made.                 |                                |
|                                     |                                |
| Photographs\* of the damage         |                                |
| resulting from the drop have been   |                                |
| taken.                              |                                |
+-------------------------------------+--------------------------------+
| Testing Damage Observations:        | POST-DROP SKETCH OF TEST UNIT  |
+-------------------------------------+--------------------------------+

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 13 Test Plan

POOL FIRE TEST CHECKLIST Test Unit

Test Location:

Test Description:

Test Unit No.

VERIFIED TASK

The assemble of the test unit was recorded on form 1

Comments:

The pretest weight of the test unit was recorded on form 1

Comments:

The test unit was thermally conditioned to a minimum of 70°C.

> Comments:

All personnel in the test area were advised of the Environment, Safety,
and Health requirements pertaining to the testing of the test unit.

> Comments:

The test unit was positioned as specified in the Pool Fire Test Facility
requirements.

> Comments:

The temperature of the test unit was required prior to the Pool Fire
test.

> Comments:

The wind speed was checked and was than less than 2 m/s (4.5 MPH)

> Comments:

Thermocouples were attached to the data acquisition system and a systems
test was conducted prior to the test unit Pool Fire Test.

> Comments:

Documentary photographs were taken or a line drawing made of the test
setup.

> Comments:

Post-test observations were documented.

> Comments:

Observations were documented by taking photographs.

> Comments:

The post-test weight of the test unit was recorded.

> Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

> TEST FORM 14 Test Plan

POOL FIRE TEST DATA SHEET Test Unit

Test Location:

Test Unit No.

Test Unit Pretest Weight:

Test Unit Orientation:

Personnel shall monitor the temperature of the test unit and record the
time , temperature, and thermocouple number. The test unit temperature
shall be recorded prior to the time the pool fire test is performed.

Test Unit

Time: Temperature: Thermocouple Number:

Time: Temperature: Thermocouple Number:

Thermocouple Type:

Temperature Indicator:

Calibrated using:

Model No: Calibration Expiration Date:

Time that the pool of JP4/JP8 fuel was ignited:

Time that the Pool Fire Test ended:

Test Unit Post-test Weight:

Test Unit weight change:

Observations:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

> TEST FORM 15 Test Plan

THERMOCOUPLE VERIFICATION Test Unit

Test Location:

THERMOCOUPLE VERIFIED

1 \_\_\_\_\_\_\_\_

2 \_\_\_\_\_\_\_\_

3 \_\_\_\_\_\_\_\_

4 \_\_\_\_\_\_\_\_

5 \_\_\_\_\_\_\_\_

6 \_\_\_\_\_\_\_\_

7 \_\_\_\_\_\_\_\_

7 \_\_\_\_\_\_\_\_

9 \_\_\_\_\_\_\_\_

10 \_\_\_\_\_\_\_\_

11 \_\_\_\_\_\_\_\_

12 \_\_\_\_\_\_\_\_

13 \_\_\_\_\_\_\_\_

14 \_\_\_\_\_\_\_\_

15 \_\_\_\_\_\_\_\_

16 \_\_\_\_\_\_\_\_

17 \_\_\_\_\_\_\_\_

18 \_\_\_\_\_\_\_\_

19 \_\_\_\_\_\_\_\_

20 \_\_\_\_\_\_\_\_

21 \_\_\_\_\_\_\_\_

22 \_\_\_\_\_\_\_\_

23 \_\_\_\_\_\_\_\_

24 \_\_\_\_\_\_\_\_

25 \_\_\_\_\_\_\_\_

26 \_\_\_\_\_\_\_\_

27 \_\_\_\_\_\_\_\_

28 \_\_\_\_\_\_\_\_

29 \_\_\_\_\_\_\_\_

30 \_\_\_\_\_\_\_\_

31 \_\_\_\_\_\_\_\_

32 \_\_\_\_\_\_\_\_

33 \_\_\_\_\_\_\_\_

34 \_\_\_\_\_\_\_\_

35 \_\_\_\_\_\_\_\_

36 \_\_\_\_\_\_\_\_

37 \_\_\_\_\_\_\_\_

I certify that the thermocouples have been verified to be working as
indicated above.

Testing Technician Date Witness Date

> TEST FORM 16 Test Plan

THERMAL PREHEAT TEST Test Unit

Test Location:

Record test unit serial number

Thermocouple Time Time Time Time

Description S/N# Temp Temp Temp Temp

Arrange Thermocouples Per Figure .

1\. Preheat the test package until the inner container thermocouples
have indicated at least 38°C (100°F) for at least 2 hours. Record the
drum and inner container thermocouples at 15 minutes for 1 hour.

2\. All thermocouples shall be surveyed to ensure that they are working.
(Any erratic or malfunctioning thermocouples shall be recorded in the
comments section of this form.)

3\. Photographs\* have been taken to show test set-up.

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 17 Test Plan

THERMAL TESTING Test Unit

(Furnace) Test Location:

VERIFIED TASK

The test plan calls for thermocouples attached to the test unit primary
containment vessel (or inner container if only one), thermocouples
attached to the test unit secondary containment vessel, \_\_\_\_
thermocouples attached to the test unit drum, thermocouples in the
furnace, and \_\_\_\_ thermocouples on the test stand.

The test package weight has been recorded on test form 3 and
thermocouples have been attached to the test unit as shown in the test
plan.

Thermocouples and test stand have been installed in the furnace as shown
in the test plan.

Photographs\* of the arrangements for the test have been taken.

All thermocouples have been surveyed to ensure that they are working,
and this has been recorded on form 14. (Any malfunctions or erratic
performance will be addressed in the comments section below.)

The furnace reached set point temperature of [°]{.underline}C (
[°]{.underline}F) at , and has soaked at this temperature for a minimum
of 24 hours. The unit has reheated at least one hour between tests.

Date Time

The thermocouple recorder(s) is (are) set to read at least once a
minute.

The unit has been placed in the furnace on the support stand with the
damaged area up at:

> Date Time Open furnace door time: sec.

The 30-minute timed test began when a minimum of test unit thermocouples
reached the test temperature of 800°C (1475°F) as specified in the test
plan.

> Date Time

Immediately following the timed test (a minimum of 30 minutes at 800°C),
the test unit was taken out to cool naturally.

> Date Time Ambient Temperature [°]{.underline}C ( [°]{.underline}F)

The unit stopped outgassing (flames) at ; outgassing/burnout lapsed time
was .

The thermocouple recorder has been reset to record at 5-minute
intervals.

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

\*\* Figure identifiers to be filled in.

> TEST FORM 18 Test Plan

TEMPERATURE INDICATOR READINGS Test Unit

Test Location:

A visual inspection of each temperature indicator on the SCV\*, PCV, and
mock-up shall be made to determine the values of the blackouts which
occurred. Those values recorded below:

RECORDED BLACKOUT TEMPERATURES:

[SCV SURFACE:]{.underline}

  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------
          #1               #2               #3               #4               #5               #6               #7               #8

  ROW A   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW B   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW C   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW D   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW E   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F
  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------

[PCV SURFACE:]{.underline}

  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------
          #1               #2               #3               #4               #5               #6               #7               #8

  ROW A   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW B   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW C   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW D   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW E   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F
  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------

[MOCK-UP SURFACE:]{.underline}

  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------
          #1               #2               #3               #4               #5               #6               #7               #8

  ROW F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW G   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F

  ROW I   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F   \_\_\_\_\_\_°F
  ------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ---------------- ----------------

Comments:

I certify that the above temperature readings and comments are correct.

Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

TEST FORM 19 Test Plan

POST-THERMAL TESTING INSPECTION Test Unit

Test Location:

VERIFIED TASK

Following the thermal test and after cooling, the test package was
weighed and the weight recorded on Form 3.

The drum, lid, and bolts have been visually examined to determine the
extent of damage.

Observations:

The camera(s) is (are) set up to take photographs\* of the damage due to
thermal testing.

The upper inserts have been removed and visually inspected to determine
the extent of damage and char depth.

Observations:

The SCV assembly has been removed and visually examined for damage.

Observations:

The SCV assembly has been weighed and the weight recorded on Form 3.

The lower inserts have been removed and visually inspected to determine
the extent of damage and char depth.

Observations:

All inserts have been placed in separate polyethylene bags, marked
"\_\_\_\_\_\_\_, Unit \_\_\_," taped closed, and prepared for storage
with the test package.

Photographs\* of the damage resulting from the testing have been taken.

Comments:

I certify that the above tasks have been performed and that the
observations and comments are correct.

Testing Technician Date Witness Date

\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 20 Test Plan

0.9 m (3 ft) IMMERSION TEST Test Unit

Test Location:

VERIFIED TASK

A leak test in accordance with procedure was performed on the SCV\*
assembly following the termal inspection and Test Form 19 is complete.

The SCV\* assembly was immersed under a head of water of at least 15 m
(50 ft or 21.6 psig) to highest point of SCV\* assembly for a period not
less than 8 hours.

Facility Gauge \# \_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Date In \_\_\_\_\_\_\_\_\_\_ Time In \_\_\_\_\_\_\_\_\_\_ Date Out
\_\_\_\_\_\_\_\_\_\_ Time Out \_\_\_\_\_\_\_\_\_\_

![](media/image23.wmf){width="1.2013888888888888in"
height="1.3916666666666666in"} Following the immersion test, the SCV
assembly was opened and examined to determine if any in-leakage of water
had occurred. The SCV lid was removed with the bolts untorqued in the
sequence shown at right. Note: Leak Port as reference point for bolt
numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\* have been taken of the opened SCV to show the amount of
water inleakage.

> Observations:

A leak test in accordance with procedure was performed on the PCV
assembly.

The PCV assembly was taken to the Equipment Testing and Inspection
Department in Building 9201-1, where it was immersed under a head of
water of at least 15 m (50 ft or 21.6 psig) to highest point of PCV
assembly for a period not less than 8 hours.

Facility Gauge \# \_\_\_\_\_\_\_\_\_\_ Expiration Date

Date In \_\_\_\_\_\_\_\_\_\_ Time In \_\_\_\_\_\_\_\_\_\_ Date Out
\_\_\_\_\_\_\_\_\_\_ Time Out

![](media/image23.wmf){width="1.3180555555555555in"
height="1.4597222222222221in"} Following the immersion test, the PCV
assembly was opened and examined to determine if any in-leakage of water
had occurred. The PCV lid was removed with the bolts untorqued in the
sequence shown at right. Note Leak Port as reference point for bolt
numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\*\* have been taken of the opened SCV to show the amount of
water inleakage.

> Observations:

I certify that the above tasks have been performed and that the
observations and comments are correct.

> Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

\*\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 21 Test Plan

15 m (50 ft) IMMERSION TEST Test Unit

Test Location:

VERIFIED TASK

The SCV\* assembly was immersed under a head of water of at least 15m
(50ft or 21.6psig) to the highest point of SCV\* assembly for a period
not less than 8 hours.

Facility Gauge \# \_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Date In \_\_\_\_\_\_\_\_\_\_ Time In \_\_\_\_\_\_\_\_\_\_ Date Out
\_\_\_\_\_\_\_\_\_\_ Time Out \_\_\_\_\_\_\_\_\_\_

![](media/image23.wmf){width="1.2013888888888888in"
height="1.3916666666666666in"} Following the immersion test, the SCV\*
assembly was opened and examined to determine if any in-leakage of water
had occurred. The SCV\* lid was removed with the bolts untorqued in the
sequence shown at right. Note: Leak Port as reference point for bolt
numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\*\* have been taken of the opened SCV to show the amount of
water inleakage.

> Observations:

The PCV assembly was taken to the Equipment Testing and Inspection
Department in Building 9201-1, where it was immersed under a head of
water of at least 15 m (50ft or 21.6psig) to the highest point of PCV
assembly for a period not less than 8 hours.

Facility Gauge \# \_\_\_\_\_\_\_\_\_\_ Expiration Date

Date In \_\_\_\_\_\_\_\_\_\_ Time In \_\_\_\_\_\_\_\_\_\_ Date Out
\_\_\_\_\_\_\_\_\_\_ Time Out

![](media/image23.wmf){width="1.2458333333333333in"
height="1.4333333333333333in"} Following the immersion test, the PCV
assembly was opened and examined to determine if any in-leakage of water
had occurred. The PCV lid was removed with the bolts untorqued in the
sequence shown at right. Note Leak Port as reference point for bolt
numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\*\* have been taken of the opened SCV to show the amount of
water inleakage.

Observations:

I certify that the above tasks have been performed and that the
observations and comments are correct.

> Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

\*\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

> TEST FORM 22 Test Plan

DISASSEMBLY AND INSPECTION Test Unit

Test Location:

This form shall be used to record the disassembly of the test package,
PCV, and SCV\*.

VERIFIED TASK

![](media/image23.wmf){width="1.2013888888888888in"
height="1.3916666666666666in"} The SCV\* lid was removed with the bolts
untorqued in the sequence shown at right. Note Leak Port as reference
point for bolt numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\*\* have been taken of the opened SCV.

> Observations:

![](media/image23.wmf){width="1.2458333333333333in"
height="1.4333333333333333in"} The PCV lid was removed with the bolts
untorqued in the sequence shown at right. Note Leak Port as reference
point for bolt numbering.

Torque wrench \# \_\_\_\_\_\_\_\_\_\_\_ Expiration Date
\_\_\_\_\_\_\_\_\_\_

Actual torque 1-\_\_\_\_\_ 5-\_\_\_\_\_ 9-\_\_\_\_\_

for each bolt in 2-\_\_\_\_\_ 6-\_\_\_\_\_ 10-\_\_\_\_\_

**in-lb** or **ft-lb** 3-\_\_\_\_\_ 7-\_\_\_\_\_ 11-\_\_\_\_\_

(circle one) 4-\_\_\_\_\_ 8-\_\_\_\_\_ 12-\_\_\_\_\_

Photographs\*\* have been taken of the opened SCV\*.

> Observations:

Tests/Tasks: Following the drop tests, the inner container was removed
from the outer drum, and the unit was inspected to determine the extent
of damage to the insulation. The results of this visual inspection were:

The exterior of the inner container was visually inspected to determine
the extent of any damage. The results of this inspection were:

I certify that the above tasks have been performed and that the
observations and comments are correct.

> Testing Technician Date Witness Date

\* Applicable only if SCV is being tested. If not applicable, write
"N/A."

\*\* All photographs/movies shall be uniquely identified with test unit,
date and time of test unit, roll and frame to ensure that the proper
sequence can be reconstructed.

**Appendix B**

**Combination Test/Analysis Method Used to**

**Demonstrate Compliance to DOE Type B Container**

**Thermal Testing Requirements (30 minute fire test),**

**DOE/AL Defense Programs Guideline for Packaging,**

**February 10, 1992**

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**Appendix C**

**Vibration Environments for the AT-400R**

**(Klenke to Glass, Sandia Lab Memo)**

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**Appendix D**

**Calculations for Normal Vibrations During**

**Safe-Secure Trailer Shipment of the DC-1 Package**

**with HEU Oxide Contents**

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**Appendix E**

**Recommended Random Vibration and**

**Shock Test Specifications for Cargo**

**Transported on SST and SGT Trailers**

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