ORNL-2464.txt

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ORNL-2464
UC-80 Reactors-General
TID-4500 (15th ed.)

 

 

ART REMOVAL AND DISASSEMBLY

A. A. Abbatiello
F. R. McQuilkin

   
  
 
 
 
  
 

 

 

 

OAK RIDGE NATIONAL LABORATORY

operated by
UNION CARBIDE CORPORATION
for the
U.S5. ATOMIC ENERGY COMMISSION

 

 

  
 

Printed in USA, Price & Availeble from the

Dffice of Technical Services
Department of Commarce
Washington 25, D.C.

 

 

 

LEGAL NOTICE

This roport was prepared as on occount of Government sponsored work. Neither the United States,
not the Commiszion, nor any persen ccting on behalf of the Commission:
A. Mekes wmny werronty or representation, expressed or implied, with respect to the sccuracy,

 

 

cemplatensss, or usefulness of the informotion contained in this report, or that the use of
any Information, epparatus, method, or process disclosed in this report moy not infringe
privately ewned rightz; ar
B. Assumes any liabilities with respect to the use of, or for damages resulting from the use of
any informotion, appaoratus, methad, or process disclosed in this 'rnpefl.
As used in the obova, ""person ccting on behalf of the Commission' includes aony employee or
confractor of the Commission, or employse of such contracter, to the extent that such employee
or contractor of the Commission, or employee of such contractor prepares, disseminates, or
provides access 1s, any information pursudnt-to his employment or controct with the Commission,

or his employment with such contractar. i

 

 

 

 

 
Contract No, W-7405-eng-26

REACTOR PROJECTS DIVISION

ART REMOVAL AND DISASSEMBLY
A. A. Abbatiello and F. R. McQuilkin

DATE ISSUED

MAR 4 1960

 

OAK RIDGE NATIONAL LABORATORY
Oak Ridge, Tennessee
operated by
UNION CARBIDE CORPORATION
for the
U.S. ATOMIC ENERGY COMMISSION

ORNL-2464

 

R
mm o 0N W

CONTENTS

e INTRODUCGTION .ottt st cas s et st st e sb s s st s s e b a s s on e s basa s basbensessssatsasases

OBJECTIVES AND CRITERIA oottt crtseiste s ceststssava st et ssessas et e sonssresessessssassssssesessnsssssessss
FRfOrmation REQUITEd.. ..o ettt r et et e s e e e e b e s sbesenas etentessnasasseesesseensarons
Problems Considered ...ttt et e ettt et aete s bt s eaearer et e bt tereeret e enen b bees
Off2Gas LeaKage . coocuiiieeiiiiieiitie ettt st sttt e sttt ats s eas se e teasasbesaasaens sesesaasternsntesnssesseestssnseseress
ReEMOVAI MEthods ..ocueeiieee ettt et s et et e s m e e e s s essese e tessersens satesensasesasnnas
Disassembly Facility .o et st ns e e st saa b s bans s et eaans

REMOV AL oottt ettt eere et vee e teae s e e s tat e e seesas s e e e e sanaee sesssnea e sesassaseasasnssss seantsnsssassassnsasassorsnssssrnnnsns

Philosophy and General Plan for Removal ......ccooveiiiinininceiiececnnin et csresses s esnssssssssssssnens
RAIOGCHIVITY ittt et ettt b sate s bs e e e bt esbeeseesabeeaeaesssessaeabasabesabessaesneeensennsaenesantenstesnsaensas
Access into the 7503 Cell .. e ettt e e et a st s e s e s e et a e s e e e ennennas

Severing the Reactor for REMoval ..ottt sttt et ere s b eaaateeae
W NArawal OF the Re GO Or woooveiieeecciie i e eeeeteeseeeeteteeesases e asesaassasesaeeaeasansasesssssasnsesssssssusssssansnnnsussaseeesssnsas

DISASSEMBLY ..ottt ittt et et e et et be bbb a e s ee bt ebabesttats b ebe st emeab b et abebesbeseas shesenbere e eteasebebeseaseabarane
Disassembly in the Hot Cell ..ottt sr e et s et bs s beas b b erebas s et s bessans
Hot Cell EQUIpMent Criteria oot ettt es s etsaei bt et ass s st s e s bseseben b esemeaeensebsetersessssa s
CUtING MEhod S oottt ettt e et e e e b se e e besbesaeeaesabetesssbaansen
Methods of MeasSUIEMENT .. ...cieeeieerteieeee ettt tete et et et et ere e he et e ae e e et s esns serseemteaantesaas e eaes seeseebeeas

SPECIAL STUDIES oiioteiiiietetetteeteissee e seesetes s ete st ssasseses bbb ssansanessesasesbusssssessestasnsesessesentsasesesssessensesnsns
ShiElding StUIES eeveei ittt e et e st e seas e e s et s nt e sn e en e et g st e s e s s e neeenes
Decontamination of Pressure Vessel, Hot Cell, and Tools ...coovooeieiniinieien e
Size Distribution of Waste Particles from Severance Techniques .....ccoooeiverivimiiniicnncni i
Disposal of Radioactive Materials ....c.coevieirnenriceiini ettt ne s sae s
Facility Mockup for Cold Testing... oo iriconieceioniite ettt s e
Underwater Disassembly STUAY .o et s s seares et ses seeseaseseseaens crasaesensseses

F A G L T Y et et ees et st e b e s e s e en e e sa e s et £ e anae e e aeneeeeare e s renae st sae e b
Consideration of 7503 Facility vttt e s s
Consideration of Other Arrangements.........ccvevirriieneeiiien ittt bbb
Proposed Facility oo e e e
St INVESH GATIONS 1ouieiiiiiiieriseeesse sttt ettt e sene seme et sae bt s st b ae st s aes e sr e a bbb bbb ea bbb nes

Scale Model of Large Hot Cell .ottt e e

. SCHEDULE AND COST ESTIMATE .....ccccvves et eeeeee e et e et et eeehae e e e e ah e e e tee et eaas e e b as et s b sne e s resenneaan

SR AULE e et e e e e e e eae e e aaeeetan——————meennaesee b eetoetnneetesutestatnesstutentrasreraatsaastrntasaeraarnras
OSt E S imM@t® ovovvveeieirerererssuseeessenereaessesanaeseseaneaeenressbesaassesaesssssssusssssssatasnssessanssnsssasssssssnensnssssrassntssnsessrararsnsons

ACKNOWLEDGMENTS -ttt sttt sttt st e sh bbb e st sh e ber e s e snsans e e snes

APPENDICES

COMPILATION OF REQUIRED ART SAMPLES, MEASUREMENTS, AND
EXAMINATIONS .ottt sttt s ae s b s be e va s b e bR b sh e ek s s b ek e e s be st e s e banaeba e sara s

. OUTLINE OF ART DISASSEMBLY PROBLEMS ..ot

RDHC HOT CELL EQUIPMENT oottt ittt sa e s sas e s e sas s be s sasi e s

. ABRASIVE GRINDING INVESTIGATIONS .coiiiciiiericititinins ettt b s sre s s

HELIARC TORCH CUTTING oottt sns s s as s eas sasens s e sab s et
ULTRASONIC CUTTING (ALSO CALLED MAGNETOSTRICTION)....coomiiiiitiniit e

 
G, ELOX CUTTING . ettt sttt st sr e bbb bbb ettt e b e s b e s bbb bt s b assaesbeaneb b see s 76
H. A COMPARATIVE CONTOUR MEASURING SYSTEM...cciiviiiiimirice ettt s 78
. FLAME SPRAYED REPLICAS. ..ottt sttt ssebe sttt st st s s s s b b 80
J. SPRAYING OF GYPSUM CEMENT .ottt s eriinssss et snes e s s 81
K. CAST GYPSUM CEMENT REPLICAS ..ot s 82
L. OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS (ZINC BROMIDE)...ccoccvevemeueieierine. 84
M. OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS

(EARLY DESIGN LEAD GLASS) ittt sttt svsn et s e sassarrbsn s sb et a e 86
N. OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS

(CURRENT DESIGN LEAD GLASS) oottt st sresaeas sasissnsnsssansnsestevsess s s se s 88
0. ART DISASSEMBLY CELL (ADC) FACILITY CRITERIA .o s, 91
P. SITE INVESTIGATIONS — REACTOR ENGINEERING HOT CELL

A L T IES ettt e s et ee e e et e s et sae e s e st e nebecnebesat sete sarateenen 116
ABSTRACT

 

A study of a high-level-activity hot cell for the major dissection of the ART was made. Such
dissection was necessary to obtain metallurgical and design data on which future high-performance
reactors might be based, The study included severing ond removing the reactor from the test cell
after operation, o procedure for a component removeal sequence, and a proposed disessembly build-
ing facility.

Evaluations of handling, measuring, and cutting techniques for remote work are presented. Al-
though these are based on limited experimenta!l work, progress is edequate to indicate their poten-
tial value for any high-level reactors which must be hondled ofter irradiation. In many cases details
of the work in the form of the original report have been included in the Appendix.

With the termination of the ART project in September 1957, the draft for what was to have been
a status report was revised to become this termination report. Thus, the plans ond experimental

work are recorded for those who may find the information useful on similar problems.

 
 

ART REMOVAL AND DISASSEMBLY

1. INTRODUCTION

The major effort of the ANP program at ORNL was
directed toward the construction and operation of a
reactor known as the Aircraft Reactor Test (ART).
It was expected that much information would be de-
rived during the scheduled 1000-hr test period.
However, there were many items which could not be
learned except by disassembly and careful analysis
of the reactor itself after the completion of the oper-
ating period. With the recent decision not to com-
plete and operate the reactor, actual performance
and test data will not be available, but the detailed
planning carried out for the disassembly of this re-
actor should provide a sound basis for any com-
parable reactor.

Because of the unusual performance requirements,
the ART was to operate with power densities many
times higher than had heretofore been obtained.
Weight limitations for aircraft reactors require a
highly refined design in which many of the parts
may undergo plastic deformation during operation.
While predictions of the conditions of the ART re-
actor parts have been made, based upon careful
analysis of a long series of experiments on a
smaller scale, it is not possible to duplicate all of
the operating conditions simultaneously prior to
running the reactor. Thus it was extremely im-
portant that a fairly complete disassembly and post-
mortem examination be conducted on the reactor to
determine how well it withstood the test conditions.
Therefore, the disassembly, inspection, and precise
measurement of the parts, coupled with complete
metallographic examinations, were to be a vital
phase of the over-all experiment.

It was recognized from the inception of the ART
project that disassembly of the reactor would be re-
quired. However, it had been believed that the ART
reactor pit and the hot fuel dump tank pit, plus the
surrounding area in Building 7503, would be ade-
quate and available for the ART reactor as it was
for the ARE disassembly.] Accordingly, this phase
of the project work was not pursued immediately, as
an all-out effort was needed to get the ART reactor
components into the production stage and to modify
and prepare the 7503 building so that it would be

 

1. E. Crabtree, Disassembly of the Aircraft Reactor
Experiment, ORNL CF-57-3-56 (Apr. 5, 1957).

suitable for the ART test. Sufficient progress was
made in both of these phases to show clearly that
disassembly of the ART reactor would have been a
very difficult operation and that the existing ARE
pits in Building 7503 were grossly inadequate.

In extrapolating experience gained in the disas-
sembly of the ARE, the differences in proposed
power level and operating time for the ART were
taken into account. The ARE was operated for a
total of 100 Mwhr, whereas the ART was scheduled
to operate for a total of 30,000 Mwhr. This increase
by a factor of 300 in the total irradiation of the re-
actor components meant vastly increased difficulty
in disassembly. Since the bulk of the radioactivity
100 days or more after shutdown would be from long-
fived isotopes, the radioactivity would be directly
proportional to the number of megawatt-hours that
the reactor was operated. Whereas disassembly of
the ARE was possible in the Building 7503 pits by
using improvised methods and ‘‘long-handled tools"”’
from above with roof plugs removed (see Fig. 1), the
operation was marginal and certainly could not have
been repeated for disassembly of a reactor having a
radiation level 300 times greater. Both the shield-
ing and dusting problems would have made it pro-
hibitive.

The ARE reactor was a relatively simple piece of
equipment, consisting of six sets of parallel-flow
pipe runs, each formed into a serpentine shape with
a series of U-bends arranged with headers at either
end, surrounded by the solid moderator and all con-
tained within a welded tank. Disassembly of this
unit was accomplished by removing the end plates
and pipe header manifolds, cutting the U-bends from
one end, and pulling all remaining pipe from the re-
actor container. However, the ART reactor (Fig. 2)
is a complex piece of machinery which is best de-
scribed as a multilayer pressure vessel because of
its multiplicity of precision-made shells, or casings,
which either direct the flow of the fuel or encase
such components as the reflector-moderator, the
boron carbide shield, and the several sodium pas-
sages required for internal cooling. Atop the reactor
is the north head, consisting of a series of pre-
cision-built labyrinth-type channels. Heat ex-
changers built to close-tolerance specifications
were to be located within the fuel-channel layers of
the vessel and within the north head. Because of
the numerous precision-built parts in this reactor, it
 

UNCLASSIFIED
PHOTO 14205

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Fig. 1. Disassembly of the ARE. Main fuel pump being lifted from cell.

 
 

   
  
 
  
  
  
 
 
   
     
         
    
   
  
  

UNCLASSIFIED
ORNL-LR-DWG 16041

FUEL PUMP
CONTROL ROD .

.

.
Na EXPANSION TANK .

NoK
FUEL EXPANSION TANK.._

Na-TO-NoK
HEAT EXCHANGER - _

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: z
3 HEAT EXCHANGER
2 ASSEMBLY
- —~PRESSURE
SO SHELL
REFLECTOR 7> N
ASSEMBLY . _ J|FUEL TURN

 

T VANES
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DN
THERMOCOUPLE
JINSTALLATION -
v NN \‘\\\k
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SRR

 
  

   

TILE LAYER -~ |}

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~ BERYLLIUM ™/
- REFLECTOR— /"~
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~FUEL-TO-NoK
HEAT EXCHANGER

SPHERICAL B,C
TILE LAYER

. THERMOCOUPLE SLEEVE -~

FILLER PLATES

FUEL DRAIN-—

Fig. 2. Cross Section of the ART Reactor.

 
was known that both the assembly process and the
disassembly operation would be difficult and te-
dious.

Since the ARE reactor was essentially a plumbing
system, the principal types of information sought by
disassembly were those obtainable from chemical
and metallurgical studies. Since the unit was rela-
tively simple and operated at very low stress levels,
there was no need for accurate physical measure-
ments to determine dimensional changes resulting
from its operation. However, the ART reactor is de-
signed very closely; in fact many parts were ex-
pected to deform no more than 0.2% during the start-
up and off-design-point operations. Many non-
nuclear tests, such as the ETU, were planned to
prove the design insofar as possible, but without
nuclear heat the actual temperature distribution can-
not be exactly duplicated. Therefore precise
physical measurements were to be taken after oper-
ation to confirm many of the decisions made during
the design, assembly, and operation of the machine.
For these reasons, the requirements for postoper-
ation measurements and samples for chemical and
metallurgical studies were numerous.

Accordingly, approximately a year ago a concerted
effort by the ANP Project was started to examine
the problems of ART reactor removal and disas-
sembly. Although the experience gained from the
ARE disassembly was available, the fact remains
that neither the Oak Ridge National Laboratory nor
any other USAEC installation has performed a
thorough dissection of a radioactive reactor to
obtain information such as that required for the
ART.

Therefore the objective of developing a program
for safe removal and disassembly of the ART con-
stituted something of a pioneering effort in a new
field. Significant progress was made; however,
much of the work is preliminary. Even so, it was
deemed advisable to bring together in one report the
results of work accomplished. This is a termination
report designed to present the plans, methods, and
information as tentatively developed.

Not only has preparation of the report provided the
authors another opportunity to evaluate the numerous

facets of the program, but its study by reviewers
should stimulate development of program improve-
ments and application of this information to other

reactor studies. The authors, therefore, solicit com-
ments and suggestions from readers. -

In general, the investigations have been divided
into the following categories:

1. Removal: disengagement, withdrawal, and
transportation of the radioactive reactor and com-
ponents from the Building 7503 operations cell to
the disassembly hot cell

2. Disassembly: dismantling of the radioactive
reactor and components in a hot cell plus obtaining
the required postoperation specimens and infor-
mation

3. Special studies: shielding studies, particle
size distribution, cutting methods evaluations,
sealing systems, replication and measuring tech-
niques, and scale models

4. Hot cell facility: the physical plant, including
dismantling hot cell, service and maintenance hot
cell, hot storage, and basic equipment as required
for the disassembly operations -

Before the detailed discussions under the above
headings, a discussion of criteria has been included
to make the program objectives more definitive. For
completeness, a brief review of tentative schedules
and budget considerations is presented at the end of
the report. A considerable portion of the material
has been included in the Appendix in order to permit
presentation of the information in detail without dis-
turbing the continuity of the report.

While the development of handling methods, meas-
urement techniques, and cutting processes has been
directed toward a specific reactor, namely, the ART,
it is believed that many of the features are appli-
cable to the dismantling of other large reactors.
Certainly the basic schemes may be adapted to
other disassembly situations. Experience has in-
dicated that each new advance in technology re-
quires a corresponding advance in its associated
facilities. Thus, the highly radioactive reactor
equipment requires specialized methods capable of
safely handling the physical units. The necessity .
for working through remote devices increases the
difficulties by a large factor. |t is realized that
practically all new reactors will be faced with
similar problems, and any solutions which are de-
veloped during this work should find application in
reactors which follow.

 

 
2. OBJECTIYES AND CRITERIA
Information Required

The major types of information required from dis-
assembly of the ART were:

1. information and dimensional data on the effects
that power operation of the reactor has upon the
structural stability, distortion, warping, crack-
ing, and local behavior in the vicinity of welds,
brazed joints, ete., of all major reactor compo-
nents;

2. chemical analyses of samples of the reactor
parts to determine whether significant reactions
occurred during operation;

3. metallurgical study of specimens from each
region and each major part of the reactor to as-
certain the extent of plating-out of fission
products, if any occurred, and to determine what
changes were brought about by the unique oper-
ation of radiation, temperature, fuel circulating
velocities, pressure, and corrosion;

4. material studies to ascertain the compatibility
of beryllium and Inconel, the integrity of a boron
carbide shield layer and its cladding, and the
effects of radiation damage on various metals,
particularly those associated with the boron
carbide layer;

3. in the event of a failure of any part during oper-
ation, study of the exact conditions at the point
of failure.

The first step after the formation of the ART Dis-
assembly Group was to establish in precise termi-
nology exactly what was required from the disas-
sembly that would satisfy the above general require-
ments.? A compilation of the resulting details can
be seen in Appendix A. A study of the ‘‘before’’
and “‘after’’ measurements required for creep defor-
mation revealed that simpler methods of getting this
data could be devised, as will be explained later.

Problems Considered

Accordingly, steps were taken to identify all
problems and circumstances which would exist or
might arise that would have a definite bearing on
the disassembly operations. Therefore, in an effort
to establish an early set of design criteria, a report
entitled Outline of ART Disassembly Problems was
prepared and discussed with all parties who were to

 

2L. W. Love, Meeting on Measurements Related to ART
Disassembly, ORNL CF-57-4-31 (Apr. 12, 1957).

 

be concerned with this project. This report is pre-
sented herein as Appendix B.

At this stage it was recognized that the ART Dis-
assembly Group could progress faster if the group
could review its work and problems frequently with
Project management as well as others concerned.
Accordingly, a “‘Disassembly Planning Meeting'’
was organized on a semiformal basis. In the weekly
meetings during late 1956, considerable assistance
was obtained through the establishment of several
important criteria, particularly those dealing with
the conditions for which shielding, ventilation, and
accessibility are vital. Minutes of these meetings
are available in the Project records; however, all
technical data have been included in this report in
the appropriate places.

Another major step in the establishment of criteria
was a series of studies of the postpower operations
and shutdown procedures for the ART. From these,
determinations were made of likely starting con-
ditions for removal and disassembly of each com-
ponent. A. P. Fraas® prepared the first report on a
general basis at the outset of the disassembly pro-
gram; W. B. Cottrell4 reviewed the problems in

detail late in 1956.
Off.Gas Leakage

In connection with shielding requirements, a de-
cision was made to establish an arbitrary, though
realistic, radiation source of a certain intensity that
could be used for calculations. Accordingly, an as-
sumption was made that during the operation of the
ART there would occur from the reactor inside the
pressure vessel an ‘‘off-gas’’ leakage of 1%. This
value is considered to be an abnormal one with ref-
erence to a successful and normal operation by the
ART, but it is believed that the use of this figure is
conservative and also provides a safety factor ex-
cept in the case of a major reactor failure. Activity
levels have been calculated for normal reactor oper-
ations and have been reported.®

Removal Methods

The exact method of removing the ART from the
pressure vessel was not determined; however, five

 

3A. P. Fraas, Disassembly of the ART, ART Design
%V\emc)) No. 2-A-1, ORNL CF-DM-55-1-104, vol 1 (Aug. 8,
956 .

4w. B. Cottrell, ART Disassembly Operating Proce-
dures, ORNL CF-56-12-131 (Dec. 27, 1956).

SA. P. Fraas and A. W, Savolainen, Design Report on
the Aircraft Reactor Test, ORNL-2095 (Dec. 7, 1956).
methods or basic types of equipment were analyzed.
The final selection of one of these methods would
have established most of the design criteria asso-
ciated with the ART removal phase of this program.
The five principal methods considered were:

1. radisphere,

flat top or floating floor,

remote C-crane,

rigid polar,

. swinging polar.

S SEANN

Studies indicated that either the floating floor or
the remote C-crane was likely to be the most
practical method, with the final selection to be made
on the basis of existing activity level, accessi-
bility, and cost.

Disassembly Facility

With regard to the large hot cell facility, design
criteria were established in rough draft form as pro-
posed for submittal to an architect-engineer. The
architect-engineer, in turn, was to prepare the de-
tailed engineering and construction drawings for the
facility. In addition to the problems associated with
space, equipment, maintenance, and basic design of
the large hot cell, two problems that were of par-
ticular concern were contamination and personne!
shielding. The air-borne radicactivity would require
adequate filtering systems and a negative air pres-
sure within the cell in order to keep the operating
area low in activity. Complete circulating, filtering,
and disposal systems were required for all working
solutions, such as cutting fluids, decontaminants,
and wash solutions. Personnel shielding was to be
provided by 4'/2-ft-fhick barytes concrete walls and
shielded viewing windows.

3. REMOVAL

Upon completion of operation of the ART it was
planned? that, while the pressure vessel of the 7503
cell was still closed, all the process fluids would
be transferred to their respective removal containers.
The fuel system was to be rinsed, the NaK was to
be removed, and the sodium was to be drained from
all parts of the reactor except the contro! rod. All
these operations were to be performed by remote
control. After sufficient time for decay of activity
in the fuel, the cell (Fig. 3) was to be unsealed and
cautiously opened. At this stage the program for
disassembly of the ART was to begin.

Philosophy and General Plan for Removal

While successful removal, transport, and disas-
sembly of the ART were to be dependent upon the
radioactivity level of the fuel and equipment, it
must be recognized that the possible activity level
could have been anywhere from very low to very
high. The former represented the case wherein
operational difficulties occurred shortly after nu-
clear operations began, while the latter represented
the extreme case of a near catastrophe, in which
efforts to recover the equipment could yet have been
justified, The normal case was to be that in which
the reactor was successfully operated for 500 hr at
60 Mw without leaks from the off-gas, fuel, NaK, or
sodium systems, and consequently all activity in
the cell would have been successfully contained.
However, for the design case, criteria were assumed
that would represent a situation somewhere between
the normal and subcatastrophe cases. The two
basic situations recognized as causes for trouble- -
some activity were leaks from the off-gas system
and accidents where fuel would get outside the con-
tainers and shields. Either case would require both -
means for controlling or reducing contamination, and
shielding protection for man entry into the cell.

Arbitrarily, it was established that removal design
criteria would not go beyond the case of off-gas
system leaks. Improvised measures would be em-
ployed for worse situations.

To avoid the possibility of contaminated lines at
the manhole and to ensure an early transfer of fuel
to the recovery tank, it was planned to relocate the
control panel for the fuel transfer from the temporary
location on the main floor to the auxiliary equipment
room panel. Also, to eliminate the need for vacuum
distillation of sodium from the reactor, plans were to
permit the sodium in the control rod to freeze. It
was to be removed subsequently from the reactor in
the disassembly hot cell.

To reduce the quantity of sodium within the com-
ponents, the reactor shell sodium and moderator
sodium were to be drained through separate lines to -
a common line having a bismuth valve and then
through the 7503 cell wall to a drain tank in the
radiator pit, It was recognized that residual sodium
would remain in pockets within the reactor.

Because of the possible contamination on all sur-
faces within the cell, it was proposed to wash these
many surfaces down with a portable deluge shower
head. To remove the waste water and to simplify
drainage of the water from shield systems, it was

 

 
UNCL ASSIFIED
r S PHOTO 28275

 

Fig. 3. Model of the ART. The reactor is shown in the operating cell prior to removal.

 

 
planned to install a sump pump that could transfer
water to a safe drainage system.

To facilitate removal of components with remote
equipment, it was proposed that every line that had
to be cut should have an accessible horizontal sec-
tion of pipe. The only exception to this was the
fuel drain line. For this, it was first proposed to
preinstall a severance device; however, later it was
planned to use a portable one. Wherever gas leak-
age from severed pipes appeared likely, a sealing
device such as the ‘'sealant injector’’ was to be
used,

In order to reduce spread of contamination in the
building, it was planned to provide a containment
can into which the fuel recovery tank could be
drawn for the transfer. The can was to be equipped
with a blower and filters to promote convection
cooling of the tank.

For removal and transportation of the hot reactor,
it was proposed to drain the reactor water shield,
lift and carry it through the 7503 building with the
remotely controlled 30-ton building crane, and mount
it on a heavy-duty low-boy trailer. If deemed neces-
sary, the reactor water shield would be refilled for
the trip to the disassembly hot cell.

Radioactivity
A compilation of postoperation dose rates as pre-
dicted for the ART is presented in Table 1,
Pursuant to the decision that shielding design
criteria would be based on the off-gas system leak

Table 1. Predicted Dose Rates for ART Reactor*

100 days aofter shutdown
Based on operation for 500 hr at 60 Mw

 

Dose Rate at

 

No. Case Shield Surface
(r/ hr)
1  Undrained reactor, 100% of fuel, 6500
no water, and no lead shield
2 2% of fuel, no water shield, and 750
no lead shield
3 2% of fuel, no water shield, but 0.4
with lead shield
4 2% of fuel, water in shield, and 3.5 x 10~3

lead shield

 

*D. E. Guss, ANP Quar. Prog. Rep. Dec, 31, 1956,
ORNL-2221, p 85; A, A, Abbatiello, Dose Rates for ART
Reactor, ORNL CF-57-7-91 (July 25, 1957).

case, calculations for gamma dose rates and amounts

of beta activity were performed by D, E. Guss of

the Solid State Division, It was assumed that:

1. during the entire operation period 1% of the off-
gas somehow leaked from the off-gas plumbing
system into the 7503 cell,

2, the gaseous fission products which escaped
plated out on the simple geometrical surface of
a 12-ft-radius sphere,

3. the computed dose rate would be based on the
gamma activity of the daughters of these fission
products at 10 days after shutdown following
500 hr of continuous operation at 60 Mw.

For this case the gamma dose rate through a 1-in.
lead shield would be 6 r/hr. The most serious of-
fender in dose would be La'4? with l]/z-Mev gamma-
ray energy. Since it is the decay product of 12.8-
day Ba'40 and has a 40-hr half life itself, the dose
rate should fall fairly fast to the next dose-rate
level as the La'4% decays. This new level is a -
dose rate of 600 mr/hr through a 1-in. lead shield
approximately 40 days following the shutdown.

The amount of beta activity in the cell 10 days -
after shutdown was calculated to be as follows:
Half Life Curies
13 days 710
20 days 1387
28 years 13
Total 2110

Most of these betas are of 1',-Mev energy and have
a maximum range of 18 ft in air. This amount of
activity would require appropriate protection for
personnel in the vicinity of the open manhole. Since
approximately ¥ cm of Lucite should be sufficient
to stop betas at the manhole location, it was recog-
nized that the gamma dose through the cell top fol-
lowing such an off-gas leak might well be the more
serious problem, It would exist immediately upon
lowering of the annulus water level.

Access into the 7503 Cell )
Five methods were considered for providing ac-
cess and for performing the removal from the pres- .

sure cell, These methods are described below and
are compared in detail in Table 2,

1. Radisphere. — This device is a shielded per-
sonnel container with windows and with articulated
cutting tools mounted externally. The operator and
all controls are inside the container, which is at-
tached to the pressure cell crane hook. Precautions

 
Table 2. Comparison of Pressure Cell Guillotine Handling Systems*

 

 

Factor

 

Relative . o Contamination Failure )
Device Cost Safety Maneuverability Viewing Spread Consequence Advantage Disadvantage
Radisphere 1(10) Bad (0) Fair to bad Good direct; Some (5) Large (0) QOperater can Failure of motors
(55) (10) good TV approach work or controls locks
(30) operator in radia-
tion field
Floating floor 1.25 (8) Good (20) Good (20) Fair direct; Little (8) Small (10) Good air control, Requires maximum
91) good TV visibility, cell opening at an
(25) shielding, and early date
control
Remote C- 0.5 (20) Fair to good Fair to bad Poor direct; Some (5) Small (10) Goed air control Large inertial forces
crane (80) (15) (10) good TV and shielding will make exact
(20) placement difficult
Rigid polar 1 (10) Good (20) Fair to good Poor direct; Some (5) Large (5) Good air control, Long stroke of
(75) (15) good TV shielding, and cylinder (7 ft)
(20) control would complicate
design
Swinging polar  0.75 (13) Good (20) Goed (20) Poor direct; Little (8) Large (5) Good air control, lInertia of tool would

(86)

good TV
(20)

shielding, con-
trol, and sim-
plicity

require care in
operation

 

*Numbers in parentheses ore arbitrary rating factors.
taken in the design of this tool should include dual
controls for the crane (internal and external), radi-
ation monitoring equipment, communication equip-
ment, and an external source of breathing air.

2, Floating Floor. = This device consists of a
ring-shaped float on which a circular floor is placed,
The circular floor contains a rotating disk which has
a slot across the diameter. A vertical tube, which
carries the shear, operates through the slot in the
floor. The shear can be manipulated to any point in
the cell by a combination of rotary and linear travels.
Shielding is provided on the floor and is limited
only by the buoyancy of the float. The device is
locked at any point by flooding the float tank and
letting the floor rest on the pressure cell edge.

3. Remote C-Crane. — The tool used in this tech-
nique is a large horseshoe made of large-diameter
pipe. One end of the horseshoe is suspended from
the 30-ton crane, and the other end is snaked through
the manhole. The in-cell end of the tool has a shear
attached to it which is moved by a combination of
the crane movements and fulcrum location.

4. Rigid Polar. — This method makes use of the
pressure cell crane bridge, to which is attached a
trolley containing a vertical telescoping member
that carries the shear. The telescoping member
would have to have a long travel, 8 to 10 ft, which
may not be practical.

5. Swinging Polar. = In this system the hydraulic
shear is suspended from the hook of the pressure
cell crane and is placed in position by crane move-
ments. A rotation at the hook would have to be
added to the existing equipment; in addition, it
would be necessary to motorize the trolley and to
provide external crane controls.

Of the systems described, the floating floor and
the remote C-crane appear the most attractive.
Final selection was deferred for completion of de-
sign studies. The floating floor method offered
direct visual observation through shield-type win-
dows placed in the floor, while the remote C-crane
would depend upon properly located television
cameras for directing and observing the work. Since
televiewing for removal was considered promising
by some, in a preliminary test with one camerq, it
is believed that a satisfactory job could be done in
the cell with three cameras of types that are com-
mercially available. One would be suspended from
the outside edge of the manhole, pointing in the
general direction of the reactor. It would have re-
mote plane, tilt, focus, and lens change, and would

10

watch the over-all operation, Two fixed-lens cam-
eras would travel with the remotely operated tool
carrier and follow the progress of the operation.
One would be mounted on the carrier so as to look
down on the tool; the other would be mounted on the
tool itself so as to look horizontally at the work.

Severing the Reactor for Removal

Choice of methods for severing the reactor free of
its numerous connections was based on the follow-
ing factors:

1. It must sever the connections effectively.

2. It must cause a minimum of contamination.

3. It must require a minimum of time to do the
work.

4, It must lend itself to remote operation.

5. It must require a minimum of maintenance.

6. It must be priced within economic justification.

An evaluation study was made to determine which
cutting method most nearly approached the ideal, as
well as to determine which facets of the ideal must
be relaxed to achieve the desired end result. For
removal from the cell, shearing of pipes, wires, and
instrument lines appeared most desirable because of
the minimal activity spread and the partial closure
effected when the cut was made. Accordingly, it
was decided that severing of large diameter pipe
(3]/2-in.-|D sched-40 Inconel) in the pressure cell
should be done with a hydraulic guillotine-type
cutter (Fig. 4). The shear has been designed and
built, and tests have demonstrated that it will cut
4-in. pipe satisfactorily.® It is hydraulically oper-
ated and is manipulated by the crane. The hydrau-
lic controls provide rotational motion, so that the
tool can be adjusted to the proper cutting angle for
the pipe. Small pipes (3/8-in.-|D sched-40 Inconel)
would be cut with a "*hook-shear."”” This device,
which would be smaller for use in close quarters,
has yet to be designed and tested. A logging-type
saw which could be fitted with a band filer has also
been considered for this service. Test work would
be required for an evaluation of this tool.

A special problem was encountered where the fuel
drain line connects the reactor and the dump tank.
It was planned to use the large hydraulic shear,
mounted in the horizontal position, for this cut. A
cartridge-actuated sealant injector (Fig. 5) was

 

SA. A. Abbatiello, Remote Shearing, ORNL CF-58-11-7
(Nov. 5, 1958),
UNCLASSIFIED
PHOTO 31563

 

Fig. 4. Hydraulic Shear for 4-in. Pipe.

11

 

 
UNCLASSIFIED
ORNL-LR-DWG 35467

  
  

 

 

 

 

 

 

 

 

 

 

 

 

 

TWO CONCENTRIC PIPES '\

 

 

 

 

 

 

 

 

 

 

 

GUARD

 

 
 
 

ADAPTER RING

 
 
 
 
  
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

"DRIVE-IT 410" OR
EQUAL STUD GUN

 

NEW BARREL COLLAR
WITH BALL DETENT

"HYP0 NEEDLE

   

HOLLOW

TUBE TO SEALANT SUPPLY

 

TO CPERATE
1., PLACE ADAPTER RING OVER GUN MUZZLE .
2. SET "HYPONEEDLE" IN BARREL TO GAGE DEPTH. .
3. PLACE CHARGE iN BREECH AND LOCK.

4. HOLD STUD GUN FIRMLY AGAINST SURFACE TO BE
PIERCED AND RELEASE TRIGGER.

 

 

 

Fig. 5. Cartridge-Actuated Sealant Injector for Pipes Containing Radioactive Materials.

12

 

 
designed’ for sealing the activity within this pipe
before it was severed. Figure 6 shows a cross
section of two concentric pipes into which injection-
type pins were driven with a stud gun in a prelimi-
nary test for the purpose of determining the proper
propelling force for adequate penetration. As indi-
cated in Fig. 5, the concentric pipes would be
crimped prior to injection of the sealant, After the
inner pipe was sealed, the two pipes would then be
severed by means of the guillotine cutter. The
same general scheme, except for different pipe
sizes, would be used for the snow-trap vent lines.
Although development work on this device is incom-
plete, it is believed that this method of sealing
would have prevented the spread of activity from
the severed ends of pipes.

 

?A. A. Abbatiello, Cartridge Actuated Sealant Injector
for Radioactive Pipes, ORNL CF-57-5-59 (May 21, 1957).

 

l!]fllll Ilr'fTIl l'l'!'lll

0 1 2
INCHES

 

 

 

The tool maintenance problems for the severance
devices were expected to vary with the extractability
of the tool system. Dropping of cut lines was con-
sidered as probably acceptable but somewhat un-
desirable, Schemes for eliminating this exist, so it
was not considered a serious problem.

Withdrawal of the Reactor

The possibility of the reactor wedging on the sup-
port columns was considered. |t was recognized
that for this possible problem, as well as other un-
scheduled difficulties, a foolproof removal tool
such as an extended cutting torch would have to be
available as a contingency tool. Whatever the re-
moval scheme is, special attention would be re-
quired for releasing the reactor stop device.

When all severing of reactor connections was com-
plete, it was planned to lift the reactor by means of

UNCLASSIFIED
FHOTO 28724

 

Fig. 6. Two Concentric Pipes Pierced with Hollow Sealant Injector Needles by Using Stud Gun.

13

 
a bail carried by the building crane. This bail was
designed to engage the lifting pins on the support
structure with only visual observation from above.
If activity levels permitted, the crane operator
would work from the crane cab; otherwise, a remote
control cable would be necessary, The crane was
to lift the reactor and carry it to the front of the
building, where it would be placed on the low-boy
carrier. Since the capacity of the building crane is
fimited, it was intended to drain the water jacket
for this phase, and then replace the water in the
jacket for the additional shielding it would provide
during transit. Adequate dust covers to prevent the
spread of activity would be applied, and the unit
would then be towed to the hot cell. Suitable
shielding was to be placed between the reactor and
the operator during transit.

4, DISASSEMBLY

Upon arrival of the reactor at the Reactor Dis-
assembly Hot Cell (RDHC), it was to be positioned
in the unloading area under the extended rails for
the hot cell bridge crane. After the water shield
was drained to reduce weight, the reactor was then
to be transferred into the cell. At this stage dis-
section operations were to begin,

The program was to make visual observations,
take physical measurements, make replications,
take photographs, and remove original specimens
as the reactor was dismantled in a carefully planned
sequence. Pieces removed were to be decontami-
nated and conveyed to hot storage for subsequent
dissection and examination or for disposal. It was
planned that operations performed in the large hot
cell would be limited to large units, while work
on the smaller items would be done in specially
equipped small cells.®

A component disassembly method (the approxi-
mate reverse of the assembly order) was planned to
provide the best accessibility, as well as to yield
the required specimens with minimum distortion.

Disassembly in the Hot Cell

A detailed set of operation planning sheets forms
the nucleus of the disassembly procedure. These

 

8Hz’gb-.Raa’iatz'on-Leve.e' Examination Laboratory. Part [
grel]imsim)zry Proposal No. 243, ORNL CF-57-5-105 (May
3, 1957).

14

sheets cover a step-by-step analysis of each oper-

ation required to disassemble the ART and are ar- "
ranged in a sequence that specifies the cutting
operations, the samples to be obtained, the measure-
ments or observations to be taken, and the tools re-
quired. They also include views of the reactor at
various stages of disassembly, so that the reader
can visualize the operations more easily. |t starts
with the arrival of the ART aboard a low-boy at the
main entrance doors of the large hot cell.

For the convenience of the reader in understanding
the procedures which follow, a series of sketches
has been included, Figure 2 shows the reactor in
cross section. Figures 7—9 show the reactor at
various stages of disassembly, and Fig. 10 is a
typical page from the eighty-odd operation sheets
that were developed for the sequential disassembly
work.

By means of the 30-ton hot cell overhead crane,
the support structure with the reactor attached is -
picked up from the low-boy and transported into the
disassembly section of the hot cell, where it is
suspended from wall brackets. The water shield -
sections are removed, and the lower NaK manifolds
and the fuel dump lines are severed with a hydraulic
shear. The purpose of this operation is to permit
removal of the south lead shield and to permit at-
tachment of machining fixtures. The south lead and
equatorial lead shield sections are then removed.

The reactor is then moved into the turntable area of
the hot cell, where final machining and trimming of
the south NaK manifolds, the fuel dump lines,
thermocouple stubs, and any other projections on the
bottom of the reactor are performed. Next to be re-
moved is the snow trap, which is suspended from
the support structure. It is followed by the fuel
pumps and sodium pumps, which are removed from
the reactor as individual units, By raising the
turntable, the reactor load is transferred from the
support structure to the turntable, and the support
structure is then removed from the reactor. At this
point the reactor is securely attached to the turn- .
table on a special mounting fixture which readily
permits positioning and alignment of the reactor,

In order to remove the north lead, the north NaK
manifolds are then severed and trimmed. Next, the
four pump barrels are cut off as close as possible
to Shell VIl by using a tool similar to an internal
boring bar. The control rod is severed near Shell
VI, and all other projecting elements from the
north head are machined away to give maximum

 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

UNCLASSIFIED
ORNL-LR-DWG 20286A

V“@N

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

i 2 (o)
() T [ ]

 

:

 

. -~
g
-
s
v

Fig. 7. Preparatory Steps for Disassembly of the ART in the Hot Cell. (a) Remove water jacket, (4) Remove

lead shield. (c) Trim off NoK headers. (4) Remove snow trap.

structure.

(e) Place reactor on turntable and remove support

15
 

 

 

 

 

Step 1
a, Trim NaK lines
b. Remove pump barrels

|
+

   

Step 4
a. Cut Shell VI just below girth

weld
b. Remove Shell VI, north head,

heat exchanger, and reflector-

moderator subassembly

 

Step 7

a. Remove north islond beryllium

b. Cut lower holf of Shell 1 verti-

cally and at bottom
c. Remove lower half of Shell

 

Step 2

a, Trim off thermocouple stubs

b, Remove sodium expansion tank
dome

¢. Remove control rod thimble

d. Free Shell Vi from fuel pump
barrel adapter

e, Drill thermocouples and tubes to
free Shell V1I

f. Drill three holes through to Shell
IV to establish reference points

g. Cut Shell VI below girth weld

h. Remove upper halt of Shell VIl

 

 

Step 5

a. Cut Shell VI around circumfer-
ence at blowout patch leval

b. Remove upper portion of lower
half of Shell VI

c. Remove thermocouple frombottom
of island

 

Step 8

a. Invert subassembly

b. Drill out sodium drain tube

c. Remove section of Shell VII
with sleeve intact

d. Counterbore thread on island
tis-down rod

e. Remove Shell Vii, filler plates,
Shell V1, and Cu-B4C disk under

island

UNCLASSIFIED
ORNL-LR-DWG. 44400

 

Step 3
a, Remove upper portion of lower

half of Shell Vi1

b. Remove fuel chamber top

 

Step 6

 

Step 9

a. Clear turntable

b, Return Shell VI, north head,
heat exchanger, and reflector-
moderator subassembly to turn-
table

Fig. 8. Major Steps for Disassembly of the ART. Steps 1-9.

16

 
 

 

Step 9A

a,

b.

Ste,
ad.

b.

St
a.

b.

Drill out pins which join heat
exchanger channels to Shell Vi
Affix retention band about girth
of hect exchangers

Cut weld joining lower deck to
Shell V|

Remove Shell VI north {with
Shell V and tiles)

 

p 12

Invert remeaining assembly

Cut Shell 1V north at north end
and at equator, then make two
vertical cuts digmetrically oppo-
site each other on north portion
Remove all segments of Shell |V

 

ep 15
Invert to upright position
Sever Shell |1 4 in. south of
north end
Drill access holes through load
ring aond drill out locks and

screws attaching beryllium to
load ring

Remove strut ring and Shell (11
upper

 

 

UNCL ASSIFIED
ORNL-LR-DWG. 35469

HEE]

 

 

Step 10
a, Cut beryllium suspension tube
{sodium return outer wall)

b. Lift off north head Step 11

a. Remove heat exchangers

 

 

 

 

 

Step 13 Step 14
a, Remove equatorial tiles a, Make equatorial cut in Shell 11§
and one specific tile b. Sever Shell Il south from Shell
Il
c. Remove Shell I1l south

 

  

    

a®®

ael

 
 

MTEagar
o S gy
<o

Ioe

 

.
| ™ ey
T~

Step 16
a. Remove berylliu,‘rn C-clamps
b. Lift off beryllium north half

 

Step 17
a. Remove Shell 1]
b. Clear turntable

Fig. 9. Major Steps for Disassembly of the ART. Steps 9A-17.

17
18

OPERATION No.

OPERATION

contact with ring support

UNCL ASSIFIED
ORNL-L R-DWG, 35470

Sheet No. 80

HOT CELL DISASSEMBLY

Remove copper cermet at pressure ring; also B,C tile ring support and care specimens of beryllium in

 

TOOLS

1. Remote milling machine
2. Hollow mill or end mill {to cut plug)

 

SPECIMEN

I Ft 2Vis 2DBA
VD 1DBA

I D4 3 Mp

11 D5 3 Mp

 

DISPOSITION

All specimens tc small cells

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 10. Sheet No.

o o @a d g
¢ 2 2 d i
L Q0 0 g

. — :
¢t 3 8 0 a

g 8 8 3 P

¢t ¢ a g z
S ¢ 8 87

% 4 8 g
S & 4 8 )
\-? QQQQ Q 0“ Q & .

 

80 from the Operation Maonual for ART Disassembly.

 
access. The sodium expansion tank dome top is
then cut away by abrasive grinding, sawing, or
drilling a series of interlocking holes, followed by
the removal of the wall in a similar fashion. A
series of interlocking holes at a 45° angle from the
horizontal is made around the circumference of the
control rod thimble in the vicinity of Shell VII, the
fuel tank top, and the stack to the fuel tank. In
order to remove the control rod to complete freeing
the north head from Shell VII, both fuel pump barrels
must be disconnected at the weld to Shell VIl. There
are also a number of miscellaneous dip lines, ther-
mocouples, etc., which must be disconnected. A
cut with an abrasive grinder around the circumfer-
ence of Shell VI| at approximately 1 in. below the
equator completes partial freeing of Shell VIl from
the reactor, and the north hemisphere of this shell
may now be lifted off,

With the reactor in this condition, much of the ma-
chining in connection with obtaining specimens and
measurements of the north head assembly may now
be done. When this work is completed, an abrasive
cut may be made through Shell V| at the equator,
This frees the subassembly consisting of Shell VI,
the north head, heat exchangers, and reflector-
moderator, which may be lifted off at this time and
stored for further work. Shells VIl and VI are then
severed completely in the blowout patch area, thus
leaving Shell | exposed for examination, specimen
removal, and measurement, Shell | is then removed,
and this exposes the island beryllium and spacers.
The north half of the island beryllium is removed at
this time, and the remaining portion of the reactor
on the turntable is sent to storage.

The subassembly consisting of Shell VI, the north
head, the heat exchangers, and the reflector-moder-
ator assembly is placed in a saddle fixture on the
turntable and clamped down. Pins connecting Shell
V1 and the fuel-to-Nak heat exchangers are then ma-
chined away at 24 places, and a temporary band is
placed around the heat exchangers just below the
lower edge of Shell VI. In order to separate Shel!
VI from the subassembly, a cut is made around the
connection of Shell V| to the lower deck and also at
the connection of Shell VI to the heat exchanger
therimal sleeves. Shell VI may now be lifted off,
exposing the heat exchanger cluster for measure-
ment and examination. At this point the sodium flow
dividing elbow is severed in a vertical plane at the
pump outlet, as is also the outside wall of the
sodium annular return passage. This completes the

severing of the lower deck connections, and the
lower deck and attached parts may now be lifted

off. A sling is attached to the heat exchanger
bundles, the temporary restraining band is removed,
and the heat exchangers are lifted clear of the sub-
assembly. Shell IV is now exposed, and the required
specimens and measurements are taken.

The subassembly is now removed from the turn-
table and replaced in the inverted position, that is,
north end down. Shell IV is now severed around the
circumference at the south end, the equator, and the
north end. This permits the north hemisphere of
Shell IV to drop down, and the south hemisphere may
be lifted off. The tiles surrounding the reflector-
moderator are now available for examination and
sampling.

The necessary tiles and cermet are next removed
so that Shell Il may be severed around the circum-
ference at a point slightly north of the equator and
also at the south end, The Shell 11| segment is re-
moved so that the beryllium south hemisphere is ex-
posed. The spacers and sodium passages may be
examined now. The assembly is once again inverted
and secured to the turntable. The bolts through the
pressure ring into the beryllium are counterbored
away, and Shell || is severed at the north end. The
support ring and the attached portion of Shell |11
may then be lifted off, exposing the north beryllium
hemisphere for an examination of spacers and so-
dium passages. The band which locks the two be-
ryllium hemispheres is cut and removed, This
permits the removal of the north beryllium hemi-
sphere, which is sent to another cell location’so
that the sodium passages may be examined, This
completes the primary disassembly of the reactor;
however, many of the removed pieces and subas-
semblies must go to small hot cells for further and
final processing.

Other items that may require further work in the
large hot cell machining area are the pumps, dump
tank, snow trap, control rod, and valves. Support
fixtures will be required for carrying each specific
part, as well as special tools for the required
cutting.

Hot Cell Equipment Criteria

The needs for hot cell equipment were studied
intensively, and much still remained to be done to
select the practical equipment, methods, and tech-
niques that would accomplish the desired result.

19

 
Appendix C covers the design criteria which had
been developed for the hot cell equipment.

Cutting Methods

A development program for the required tools for
both the test cell and the hot cell was worked up,
with the most promising cutting devices specified
for procurement or further testing. In connection
with these studies, a hydraulic shear capable of
pinching through a full-sized 31zi-in. IPS NaK line
has been designed and built.” This tool is re-
motely operable and will shear pipes, producing
almost complete closure with minimum contamination
spread (see Fig. 4). A portable band saw intended

 

9A. A. Abbatiello, Remote Shearing, ORNL CF-58-11-7
(Nov. 5, 1958).

for remote operation with a manipulator has been
procured and tested in a hot cell'? (see Fig. 11).

Hot cell disassembly operations to this date have
included plans for milling heads to be used for
drilling and milling, A Z]Q-in.-dic: by 0.051-in.-
thick slitting saw cut satisfacterily and held up
reasonably well, but requires a rigid support. It
was planned to use a Bridgeport-type milling head
to drill a series of interlocking holes to part various
members, Tests to determine tool feeds, speeds,
expected life, changing method, production rate,
and control were to be run. Although all the data
were not obtained, sufficient tests were completed
to select the more practical cutting methods,

 

 

104, A. Abbatiello, A Portable Bandsaw for Hot Cell
Use, ORNL CF-58-2-110 (Feb, 19, 1958).

UNCLASSIFIED
PHOTO 42835

Fig. 11. Remotely Operated Band Saw. Shown supported from manipulator.

20
Preliminary tests showed that the interlocking
- drilled hole method was slow and tool life was short,
The drilling of alternate large and small holes was
most effective and cut a %-in. Inconel plate at a
rate of "5 ft/hr. It could be used if access to the
cut area could not be gained in any other way, but,
in general, other processes look more attractive from
the standpoint of cutting rate and tool life.

Sawing operations were planned for the inner
shells, which would be highly active, Band saws,
reciprocating saws, and circular saws were con-
sidered, with preference given to the heavy chip
producers to keep activity down. Methods of con-
trolling the direction of cut, saw speed, and rate of
feed have to be developed. Blade life and speed
of accomplishing a given task are to be determined.

Grinding wheels, due to their high cutting rate,
warrant more detailed study., Controlled tests must

 

   

WET GRIND CUT

be done to determine optimum operation conditions,
and methods of control and elimination of airborne
contamination must be sought, Two types of ab-
brasive grinding were evaluated on Inconel: (1) a
dry wheel mounted on a radial arm and (2) a wet
wheel mounted on a horizontal track. The results
indicate extremely high cutting rates for both of
them, with acceptable wheel wear. As is shown in
Figs. 12 and 13, a plate and three concentric
Incenel pipes (to mock up the NaK sleeve) were cut
through in about 1 min. However, these methods
would spread activity and require more elaborate
filtering and decontamination systems, The details
of this test are described in Appendix D.

Flame or arc cutting is the fastest known method
of separating Inconel. It has some major disadvan-
tages; for example, it leaves rough edges, it spreads
microscopic contamination, and the high temperature

UNCLASSIFIED
P‘HIJTQ 2_‘]]19

  
  

HELIARC TORCH CUT

Yy o —= y -
= = 7 - e

o — —— : e :
- . v 3 —iee |
vl
?W‘i’ AT
I [ =y 'y 5 ’ gl
L " "? o "'-1“‘,' - = 3 - -
B+ e } |

- ¥

-

k. A

 

Fig. 12. Wet Grind Cut. A 1-ft length of }z-in.--rhi:k Inconel plate, cut in approximately 1 min with a water-
flushed, 24-in.-dia abrasive wheel operating at about 10,000 surface feet per minute.

21

 
 

 

 

._‘ il R TY ‘ ITrrTIT \ YT \
INCHES

 

UNCLASSIFIED
PHOTOQ 29109

DRY GRIND CUT

Fig. 13. Dry Grind Cut.

abrasive wheel operating ot 10,000 surface feet per minute.

Three concentric Inconel pipes, cut through in about 1 min with a dry 16-in,-dia

may cause metallurgical changes. This process is
of limited usefulness for hot cell requirements but
should not be confused with the Heliarc cutting
process, which is described later,

The Heliarc cutting torch is relatively new and
was recently observed in action. It is believed
adaptable to cutting Inconel and stainless steels
from a remote mounting, and, since it does not re-
quire an oxidant, it has certain advantages for hot
cell work. However, the amount of activity released
will probably limit its use to those outer shells
which have the greatest bulk and are difficult to
reach, but where the activity level is relatively low.
The ability to cut through several layers of Inconel
in one pass has been demonstrated and will be
useful, especially when conventional cutting proc-
esses are unable to reach the area to be severed.

A more complete description of this torch appears
in Appendix E.

22

The ultrasonic (or magnetostriction) system of
cutting was tested on Inconel, but the cutting rate
was so slow that this method was not considered
satisfactory. It can be applied with better results
on materials which are too hard for normal cutting
processes, such as the boron carbide tiles. It is
not expected that these tiles will be cut unless
some special requirement makes it necessary, in
which case this process is available. Descriptions
of both these processes may be obtained from Ap-
pendix F.

The electric disintegration (Elox) process of ma-
chining appears to have some usefulness for special
applications in the hot cell, principally in the aux-
iliary cells rather than in the main cell. A brief
test of Elox cutting was made on cutting Inconel on
an available machine. Slow cutting action was ob-
served, which was somewhat erratic and unsatis-
factory on Inconel. However, the process has showr

 
 

 

 

its usefulness in cutting extremely hard materials
which are good electrical conductors. One excep-
tion is the boron carbide tiles. It was found that
boron carbide is not sufficiently conducting to
permit the electric arc to do its work. In case
boron carbide tiles are tobe sampled, the only proc-
esses for cutting them are ultrasonic cutting (previ-
ously described), grinding with boron carbide, and
splitting them by fracturing, as the material is quite
brittle,

Methods of Measurement

The determination of the dimensions of the reactor
after it has been operated, in order to obtain direct
comparisons with the physical size and shape before
operation, is one of the major problems. Since the
second phase of these measurements must be made
in the hot cell, several measuring systems have been
studied and test work has been done on those which
looked promising, within the available time and fa-
cilities. Measurements to determine the following
possible changes were planned:

1. alignment of parts,

. creep deformation,

. buckling,

. thermal distortion,

. discontinvity due to stress or thermal shock,
. wear (pump parts),

In order for measurements to be of value in de-

o WN

termining the above factors, a certain minimum ac-
curacy is required. For the purposes of this dis-
cussion it is assumed that changes in size due to
creep, to be significant, will be of the order of 0.1
to 1.0% of the original dimension and that measure-
ments should be accurate to within £20% of the
change. On this basis the pressure shell would
change in size in the range from 0.058 to 0.580 in.
on the diameter, and accuracy of £0.012 to £0.120
in. would be required, On Shell | at the smallest
diameter (6.75 in. approximately) the expected
changes will be in the range from 0.0067 to 0.067
in. and the accuracy required will be from +0.0013
to £0.013 in. It follows that the desired accuracy
on the smaller parts is 20,001 in., which would re-
quire careful work even outside a hot cell.

The measuring systems may be arranged into four
main classifications, as follows:
1. optical systems,
2. photographic systems,
3. replication,
4. direct measurement.

Each of these classifications has several vari-
ations which were investigated. These are briefly
described below, and the important differences are
outlined in Table 3.

A. Optical Systems, = A-1, Rectilinear Tele-
scope, - This device consists of a telescope with
cross hairs, so mounted on ways that it can be
moved to any point in an area, in this case an area
about 5 ft wide by 7 ft high. The line of sight of
the telescope remains normal to the plane in which
the telescope moves at all times. The telescope
and ways would be mounted on the inside wall of
the hot cell with provisions made to view the cross
hairs of the telescope and to measure the exact
position of the telescope from outside the walls of
the cell. In the case of the pressure shell, for in-
stance, measurements would be made by sighting
the telescope on the visible edge of the pressure
shell on one side, noting the position of the tele-
scope, then moving the telescope across a diameter
until it sights on the opposite visible edge. The
difference in measurement between the two sights
would be the diameter of the pressure shell at that
particular point in the vertical direction and at that
particular rotational position of the reactor. As
many measurements as desired around the sphere
could be made by rotating the reactor on its mount-
ing turntable, and measurements from top to bottom
of the reactor could be made by moving the tele-
scope up or down.

A-2, Theodolite Range Finder. — This system of
measuring is essentially a surveying technique. Two
theodolites are mounted gn an accurately measured
base line. |f a diameter is to be measured, targets
are placed against the reactor at the ends of the
diameter. The distance from the center of the target
to the edge is accurately known. Then, by angular
measurement with the theodolites, the coordinates
of the target center for each target are calculated,
From the distance between target centers, the di-
ameter is derived by subtracting twice the distance
from the center to the edge of the target.

A-3. Optical Measurement Through Hot Cell
Windows. — This system uses conventional optical
tooling instruments mounted outside the cell win-
dow.!! These instruments sweep the entire window
area and permit horizontal and vertical measurements

 

”A. A. Abbatiello, Optical Tooling for Hot Cell Ap-
plications, ORNL CF-57-8-87 (Aug. 26, 1957),

23
Table 3, Comparison of Measurement Systems

 

 

A, Optical B. Photographic C. Replication
-1 A-2 A-3 B-4 c-2, C-3
A B-1 B-2 B-3 ] C-1 !
Rectilinear Theodolite Measurement Through . i . Comparative Contour Plastics, Resins,
Lofting Contour Mapping Photogrammetric Metals

Telescope Range Finder

Hot Cell Windows

Measurement

Gypsum Plasters

D. Direct Measurement

 

D-1

Direct Measuremant

 

Brief de- S5cope on rectilinear Surveying technique
scription mounting carriage

inside cell

Estimated +0.003 10.005
accuracy,
in.

Advantages Difficult mainte- Difficult to align
and disad- nance because of remotely; does not
vantages contaminatian;eye-  see a flat plane

piece must be re-
motely viewed

Complexity High High

Estimated $10,000-15,000 $16,000
cost

Availobility Not standard; 6-9 9-10 months
months to can-

struct

Adaptability Good Good

to a variety
of parts

Too complex for use in
a radioactive area

Once considered at-
tractive, but now of
academic interest
becayse itis super-
seded by simpler
methods (see A-3)

Evaluation

References

A coardinate opticaltools

ing systeam set up out-
side cell windew and
reading dimensions of
part on a vernier scale
by optical means

10.003

Clean, as no instruments

are within the cell, but
depends on the accurocy
of the cell window; area
limited to glass area, or
the part must be lifted
and rotated for proper
orientation

Medium; uses standard,

available equipment

$8000

3-4 months

Good, within the limits

of the window area, or
the ability to position
the part

Appears as the most

useful system for wide
application, leaving un-
disturbed working
spoce within the cell;
a full-scale demonstra-
tion has been made

Appendixes L, M, and N

Measurement of accurate

full-scale photographs

10.005

Records much infor-
mation rapidly

Medium

$6400

6—9 months

Good

An attractive system for
medium accuracy
measurement, and as a
progress recard; could
be very useful but
needs further work for
adaptation

Project plane lines
on a surface and
photograph to

rroduce contour

ines

10.010 ()

Would quickly show
major contour
changes; delicate,
would have to be
mounted within
the cell

High

$14,400

Not standard, must
be designed and
custom built

Fair

Comments are about
the same as for
B-1,except for the
added complexity
of the light source
within the radio-
active area

Aerial mapping; like
lofting, except that o
4 x 5 in. photo is
measured with
cathetometer-type
instrument

+0.004

Gives a rapid phote-
graphic record; is
compact

Medium

$4700

6 months; some design
required

Good

A variation of and simi-
lar to photolofting, but
using smaller nega-
tives, requiring read-
ing them with magnify-
ing optical instru-
ments; should be in-
vestigated further

A grid is placed before
the surface to be
measured; the shadow
of the grid cast at a
45°ang?e and the grid
are photographed on
a common plate; the
distance between the
wire image and its
shadow represents
the distance from its
plane to the contour
surface

+0.010

Is convenient and
should give reproduc-
ible results because
all elements (camera,
light source, and grid)
are mounted on one
dolly; would require
adequate shielding for
camera to prevent film
fogging or would be
limited ta low-activity
areas

Medium; uses easily
available parts

$8000

Not a standard item,
but may be con-
structed from ovail-
able parts

Fair; best adapted to
gradual contour sur-
faces; not suitable
for extremely irregular
surfaces

Might be auseful device
to get ‘‘before®’ and
““after'’ records of the
outer shell contours

Appendix H

Metal is sprayed on a
surface and the
replica is lifted off

10.001

Extremely good sur-
face detail and
actual contours re-
corded, but limited
to items which can
hove parting lines
for casfin? with-
drawal; on "“before"’
replicasrequires ex-
treme cleanliness to
limit impurities left
in system

Requires remote oper-
ation of the metal
spray gun

$4000

2 months

Limited to parts
which can be with-
drawn

A useful tool for
making accurate
physical records of
contour and surface
finish before and
after operation;
large reductions in
activity will possi-
bly moke direct ex-
amination of casts
feosible, relisving
hot cells

Appendix |

Plastics or gypsum
plasters are poured
into a form placed
over the surface to
be copied and allowed
to harden, then re-
moved; the gun-em-
placed gypsum is ap-
plied with a Gunite-
type mixing gun

0,001

Not quite as good de-
tail as for C-1, but
quite satisfactory;
cleanliness require-
ments are not quite
as severe as for C-1

Requires remote oper-
ation of the emplace-
ment gun or setting
of molds

$1000 plus varied mold

construction cost

2 months

Limited to parts
which can be with-
drawn

Same comments as for
C-1 apply, exceptthe
casting and pouring
techniques replace
the metal spraying

Appendixes J and K

Arrangement of snap
or dial gages are
mounted on appropri-
ate supports and
meved by means of
manipulators within
the cell and placed
across the object to
be gaged

10.002

Simple in construction
but difficult to use
remote ly; probably
extremely slowand of
limited usefulness

Gages are simple but
handling them re-
motely presents
problems for accurate
placement

Gages are low in indi-
vidualcostbutalarge
number may be re-
quired

2 months

New or adjustable gage
required for each part

Direct measurement
sounds simple, but
would be difficult to
obtain full useful-
ness; would be most
appropriate for some
of the major over-all
dimensions

 

24

 

 
in this plane. Thus, any object within the direct the cell wall is used to align the instrument at
view normal to the cell window may be scanned, and various elevations, as shown in Fig. 14, This

the coordinate measurements may be read directly system places all instruments outside the cell,

on the vernier scales outside the cell. where they are not exposed to contamination, and
Tests have indicated modern lead glass windows  utilizes the cell interior for working area, The

to be of sufficient accuracy to make this system part to be measured must be capable of being lifted

practical (see Appendixes L, M, and N), An opti- and rotated, for which the lift-turntable is available

cally flat reference bar mounted on the exterior of within the hot cell.

UNCLASSIFIED
ORNL-LR-DWG 34275

 
 
   
   

STEEL OPTICAL

FLAT
ALIGNMENT .
TELESCOPE MOVABLE | |

. MIRROR ‘

 

  
 

TOOLING BAR
VERTICAL SCALE PRECISION
LEVEL

LEVELING
SCREW

   

Fig. 14. Optical Measurement for Hot Cell Application.

25

 
B. Photographic Systems, = B-1. Photographic
Lofting, — This system is essentially the photo-
graphic mapping of an object to produce a full-sized
image, which is then measured. The equipment re-
quired is a periscopic camera lens system of long
focal length capable of producing an image perhaps
18 in. in diameter. An enlarging system with a
movable image board, such as a vertical plate, is
suspended from tracks in the ceiling in such a
manner as to permit the board to be brought closer
to the lens or farther away to obtain the full-sized
image. Equipment for measuring the image, such
as trams, is also required, Two or more target
points are placed in the object space in a plane
normal to the optical axis and parallel to the axis
of the reactor. The plane is a known distance from
the axis of the reactor. The distance between the
target points is accurately determined. A negative
is made on a glass plate. An enlargement is made,
with the image adjusted in size until the distance
between target points on the image is the same as
the actual distance. Measurements are then made
of diameters, for instance, on the enlargement. From
these measurements the actual diameter is calcu-
lated,

B-2. Photograpbhic Contour Mapping (by projecting
a grid), — This system is basically the same as the
lofting reproduction measuring system described in
the preceding section, with the addition of a grid
projecting system normal to the optical projector
capable of producing a sharply defined spot of light
about ]4 in. or less in diameter on the reactor. The
projector would swing on a horizontal axis so that
the spot of light would sweep a plane perpendicular
to the optical axis of the camera. With the hot cell
dark, the camera shutter would be opened and the
projector would sweep the spot of light over the re-
actor, thus recording on the film the intersection of
a plane with the surface of the reactor, Next, the
projector would be moved a specified distance, say
1 in., along its horizontal axis and again swept
over the reactor, thus producing on the film the
intersection of a second plane with the surface of
the reactor. This process would be repeated until
the image of a quadrant of the reactor was mapped
on the film. The reactor would then be rotated 90°
on its mounting turntable, and a contour map of a
second quadrant made; and so on for the third and
fourth quadrants. It may be feasible to use a mul-
tiple projector so that a quadrant can be mapped
with one sweep of the projector. From the contour

26

map as produced above, by either mathematical or
graphic techniques, the rectilinear coordinates of
any point on the exposed surface of the reactor
could be determined.

B-3. Photogrammetric Technique, — This may be
described as an aerial mapping technique and differs
from the procedure described earlier under lofting in
that the photograph would be only 4 x 5 in. approxi-
matelv.

The equipment would consist of a camera with
periscopic lens system, for shielding the film, so
mounted in the wall of the hot cell that the optical
axis of the camera system would intersect the axis
of the reactor. The lens system would need to be
carefully calibrated, and the exact distance of the
lens system from the axis of the reactor would need
to be established. The photographic negative
would be measured with a coordinate measuring
microscope. For instance, from the diameter of the
reactor as measured on the negative, the actual di-
ameter of the reactor could be calculated.

C. Replication, — The purpose of replication on -
disassembly is to obtain a replica surface which is
accurate enough to be measured, |t is intended to
measure on the replica the distance between scribed
lines, between weld beads, and in some cases to
measure the curvature.

The intent of the development work on replicas is
to determine the feasibility of producing replicas of
sufficient accuracy to provide a measurement of the
reactor parts on disassembly. This accuracy should
be within 0,003 in. Also to be determined is the
amount of radioactive contamination that will adhere
to the replicas. It is expected that an activated
surface which has been decontaminated will not
transfer activity to the replicas.

There are two methods of applyingthe replicating
material -~ by spraying and by pouring into a mold.
Due tothe difficulty of design for and positioning of
molds on odd-shaped contours in the hot cell, the
spraying methods appear most promising. The
spraying technique will require development of a
parting method so that the replica will cover only
an area which can be withdrawn and thus canbe re-
moved, There are some cases, such as a replica of
the fuel passage at the bottom, where the pouring
technique will be preferred.

Three types of material can be used to produce
replicas: metals, plastics, and plaster, Each is
discussed separately later,

 

 
There are three questions regarding replication
for which answers are required:

1. How accurately can replicas be prepared, and
which method and material provide greatest accuracy ?
(Tests have indicated satisfactory accuracy with
both metal spraying and gypsum casting methods.)

2, How are molds to be built or parting lines
provided in the hot cell?

3. How much radioactive contamination will
adhere to the replica?

C-1. Metal Replicas. — Although metals are
readily cast in normal operations, the use of such
methods does not cppear feasible in a hot cell.
Flame-spraying of metals, however, is practical.
Metals are flame-sprayed by a special metallizing
oxyacetylene torch which automatically melts metal
wire and blows the molten metal on the surface to
be coated in the manner of a paint sprayer. The
temperature effects on the accuracy of the replica
are believed minor in that it is reported that metal
can be sprayed on paper without charring the paper,

Various metals can be used in this operation,
such as aluminum, brass, lead alloys, or steel. In
order to minimize the heating of the part being
coated, the lead alloys appear most desirable. From
the point of view of strength and rigidity of the
replica without unwieldy thickness, aluminum or
brass would be better. The proper metal to use can
be determined only by trial, with the principal con-
sideration being the accuracy of duplication with
sufficient strength to permit hot cell handling. Use
of reinforcing wire mesh or a stiff backup metal
may be found necessary. Lead alloy wire has been
used with a metallizing gun and trial replicas have
been successfully made, as shown in Fig. 15.

Several replicas have been produced of Shell |
sections, and a comparison of the dimensions, sur-
face finishes, and duplication of detail makes this
process look excellent. However, traces of lead
alloys left within the reactor could seriously weaken
Inconel, and for this reason it is not likely that
lead alloy metallizing will be permitted for the
“before’’ dimensions. Interested divisions have
been requested to comment on this problem and
make recommendations,

C-2. Plastic or Resin Replicas. — The thermoset-
ting resins that cure at room temperature after the
addition of an accelerator, such as the epoxies or
polyesters, are suitable for use in preparing replicas.
The usual method of handling is to pour into a mold
and allow to harden. It is reported that there is a
spraying method for handling them, but it is not
known whether this method could be used in a hot

 

MCLAMFIED
HETD T

  

Fig. 15. Lead Alloy Replica of o Reactor Component.

cell. It appears that developing a thick layer would
be particularly troublesome with a spraying tech-
nique because of the setting time required,

The epoxies are frequently used in preparing rep-
licas, but they have extreme adhesiveness when ap-
plied to metal. Applying a releasing material with
adequate thoroughness might cause difficulty in a
hot cell and would rule out the use of resins for the
replica of the fuel passage at the bottom of the re-
actor. For other replicas to which a pour technique
is adaptable, such as the replicas of Shells | and Il,
the casting resins may be suitable.

The process of making resin replicas consists in
preparing a mold, with the area to be duplicated as
one side of the bottom, and filling the mold with the

mixed resin and accelerator.
C-3. Plaster Replicas. — There are several types

of gypsum plasters available with varying amounts
of shrinkage or expansion on setting. The U. S.
Gypsum Co. markets several under various trade
names such as Hydrocal, Ultracal, and Hydrostone.
Some are reported to have an expansion on setting
of as little as 0.0002 in./in. These materials will
show extremely fine detail (such as scribe lines on
the test piece) which we will require.

Unfortunately the gypsum plasters are not readily
sprayable. Two test cases were produced by the
spraying technique by the Gunite method, but actu-
ally with the Bondact gun. Detail was fair with
adequate strength, but the poor performance of the
specific gun used indicates the need for better
equipment if this program is to be pursued. The
replicas produced are shown in Fig. 16.

 
 

UNCLASSIFIED
PHOTO 28720

 

 

UNCLASSIFIED
PHOTO 28721

 

 

 

(8)

Fig. 16. Replicas Made with Gun-Emplaced Gypsum:. (@) Replica made without use of a release agent.
(b) Replica maede with an oil release agent.

28

 
During the setting period the plasters pass through
a so-called plastic stage when they can be handled
as a mason handles mortar. Whether replicas could
be made in the hot cell by this means is not known.
It appears doubtful,

However, there are some replicas required on dis-
assembly to which a technique of pouring into a
mold is applicable. These are the replicas of the
fuel passage at the bottom of the reactor and the
replicas of the surfaces of Shells | and Il, and pos-
sibly the replica of the bottom of Shell Iil. The
process consists in preparing a mold for containing
the cement in the liquid state. The area to be du-
plicated is one side or the bottom of the mold. The
mold is filled with a plaster-water mixture, When

 

the mixture is hard, the mold and plaster replica
are removed (Figs., 17 and 18).

D. Direct Measurement. — The use of snap gages
for direct measurement of the item in the cell has
been proposed, because it has been used at other
AEC installations. The method has ruggedness and
simplicity to recommend it, but becomes awkward
for handling the large number of required gages by
remote manipulators. Schemes for using direct
reading dial indicators mounted in a suitable frame-
work to ride over the reactor have also been
sketched, Such methods can be used if no better
tools are available, but their use is to be avoided
because of the problems involved in their use and
the excessive time required.

UNCLASSIFIED
PHOTO 40715

 

Fig. 17. Mold for Mcking Replicas of Radioactive Components.

29

 
 

UNCLASSIFIED
PHOTO 40713

 

Fig. 18. Gypsum Plaster Replica of the Surface of o Reoctor Component. The tube contains o lubricant used

to release the replica from the mold.

30

 

 
5. SPECIAL STUDIES

Associated with the specific studies for removal,
disassembly, tools, and facilities were studies of
shielding, decontamination, size of air-borne parti-
cles, disposal of radicactive materials, and a mock-
up of the hot cell facility., This work is discussed
separately as much for emphasis on its importance
as for lack of a more suitable place for the material.

Shielding Studies!?2

The wall thickness required for the ART hot cell
is dependent upon reactor power level, operating
time, time elapse after shutdown, fraction of the
fission products contained by the reactor, and allow-
able dosage rate established for the outside of the
cell wall. The wall thickness was calculated for a
reactor power of 60 Mw and infinite operating time
(in order to approximate operation for 1000 hr), At
least 20% of the curies of activity would have plated
out on the reactor. The reactor would also have
contained activity in fuel which had not been rinsed
out. For the purposes of calculation, the fraction
of fission products contained in the reactor was
taken as 100%. A change from 20% to 100% only
represented an increase of 5 in. in the required wall
thickness.

The assumed maximum permissible dose for a
person outside the cell wall is 100 mr/week, or 2.2
mr/hr for an 8-hr day and 5-day week., To allow cell
operators to accumulate a margin of allowable dose
for necessary work in higher radiation fields, a
dosage rate of 0.5 mr/hr was selected. These wall
thickness calculations were based on a comparable
study!? for similar conditions. This study was a
multigroup calculation for gross fission products
and Co®? radiation using data from shielding design
manuals.'4:15 The results are shown in Fig. 19,
The required thickness is indicated as 4 ft of ba-
rytes concrete. |t was recommended that a con-
servative thickness of 4.5 ft be used to allow for
future application of the cell to higher power re-
actors,

Penetrations through the cell walls for manipu-
lators and other equipment would have produced

 

12¢ ntributed by W. E. Browning.
13p, K. Trubey, memo to D. B. Trauger, Aug. 21, 1956.

14J. Moteff, Miscellaneous Data for Shielding Calcula-
tions, APEX-176 (Dec. 1, 1954).

lST. Rockwell (ed.), Reactor Shielding Design Manual,
TID-7004 (March 1956).

UNCLASSIFIED
ORNL—LR—DWG 3547/

 

 

 

 

 

 

 

 

 

 

 

 

104 ‘ ; ‘
FISSION PRODUCTS
FISSION PRODUCTS, :
102 |- BARYTES CONCRETE ’/.ORD'(N’-\_R;( ;?NCRETE _—
(p=35) | Pr e
\g 1 \\ \
= \ \
[
<
o
B o2 N\ ™.
8 N \
k\__ __OSmi/h
e \
Co®0, BARYTES CONCRETE ——-\ \
s |
o 1 2 3 4 5 6
WALL THICKNESS (ft)
Fig. 19. Calculated Dose Rate Outside Hot Cell
Wali. Assumptions: (1) 100% of fuel in reactor; (2) op-

eration for infinite time (approximating operation for
1000 hr) ot 60 Mw; (3) reactor located 6 ft from inner
surface of shield; (4) 100 days ofter shutdown.

local radiation dose rates higher than 0.5 mr/hr,
Reasonable precautions would have been required
when intense sources were brought into line with a
hole; however, special shielding would not have
been required unless it proved necessary to keep
personnel in line with a hole at the same time that
major sources inside the cell were also in line.

Decontamination of Pressure Vessel,

Hot Cell, and Tools

Decontamination of the ART pressure vessel, the
hot cell, and other associated tooling has been con-
sidered, but no definite or final steps have been
specified because they are directly contingent upon
the results of the ART operations.

For the pressure vessel, the procedure may be to
wash down the reactor, support structure, and tank
walls with hydrauvlic jets that are lowered down
through the access hole. A dilute acid wash so-
lution appears to be the most suitable for this pur-
pose. A sump pump installed near the floor of the
pressure vessel would remove this contaminated
liquid through the access hole, or if the volume is
not too great, it could be left in the pressure vessel
for removal after the reactor has been removed.

In the hot cell the problem is somewhat different.
The walls may have tobe decontaminated at frequent

31

 
intervals to permit safe entrance of operating and
maintenance personnel. Each of the reactor pieces,
as it is removed, will have to be decontaminated
before it is sent to storage or to a small cell for
further work. All of the tools which will require
maintenance must also be decontaminated before
being withdrawn into the intermediate hot cell.
Visits to otherhot cells at ORNL, and discussions
with the operating personnel, have revealed differ-
ent philosophies on hot cell operations,

One group feels that the cell area should be capa-
ble of being cleaned up adequately for personnel
entry. Another group advocates the complete rinse-
down of the walls and equipment with a powerful
spray or rinse, washing all water and contaminants
into a hot drain. One installation, where water is
permitted, cuts up all critical assemblies under 10
to 15 ft of water. The underwater technique cannot
be seriously considered because of the presence of
sodium as well as the radioactivity dispersion from
fused salt systems, but when the major elements
have been severed and opened, cleaning the cel!
interior may proceed safely.

Work at the 4501 cell has been successfullycarried
on in disassembling “‘in-pile”’ loops by cutting
through the surface of the loop with a high speed
grinding wheel. The radiocactive dust which accumu-
lates on the cell walls and on the equipment has
been washed down by means of high velocity jets,
and all the contamination products have been washed
down a hot drain. This method might be satisfactory
in the large hot cell, but it introduces complica-
tions. For example, there could be a reaction with
sodium or NaK which might be left in lines or crev-
ices around the reactor. The possibility of washing
active materials into areas which cannot be easily
cleaned is highly undesirable. However, an effort
has been made to design the large hot cell with
straight clean walls and scuppers so that the wash
solution will easily drain,

Small tools may be cleaned in a dilute acid so-
lution. Large tools and machinery, however, may
not be dipped in cleaning baths and may have to be
sprayed. In many cases it should be possible to
cover the tools with plastic hoods in order to limit
the amount of contamination they collect.

Size Distribution of Waste Particles
from Severance Techniques

A study'® was made by an MIT Practice School
group on particle size distribution, that is, the size

32

of air-borne particles given off by the sawing, grind-
ing, Heliarc cutting, and hydraulic shear cutting
methods. It is apparent that the shear is the clean-
est of all the methods considered. All the others
gave rather large dust contamination values. [t was
found, for example, in grinding Inconel, either wet
or dry, that 104 to 107 particles per cubic centimeter
of air were drawn through a filter of the measuring
equipment. This amount of possible activity could
be tolerated only if the hot cell were equipped with
an adequate filtering system, For this reason the
hydraulic shear appeared to be the most desirable
method for cutting pipes in the pressure vesse! and
probably also for rough cutting and removal of mani-
folds in the hot cell. Torch cutting is the least de-
sirable of the methods considered, from the air
contamination standpoint. It resulted in the creation
of about 107 to 10? particles per cubic centimeter.
However, it might have been practical to use either
the torch or grinding for the outer shell girth cut be-
cause of the low level of activity in this shell (VII)
as compared with Shells | and 11,}7

Disposal of Radioactive Materials

Radiocactive materials were expected to consist of
reactor parts, air-borne particles, and contaminated
solutions.

The Health Physics Division recommends that
contaminated waste solutions be disposed of in
ORNL waste pit No, 3. Seolution transport to this
pit may be in the Operations Division's 4300-gal-
capacity tank truck, which has 1 in. of protective
fead shielding in front of the tank. Solutions must
be made slightly alkaline before or when they are
transferred into the truck tank.

The reactor parts were to be placed in storage
containers and placed in a vault or other storage
facility until required in the auxiliary cells.

The philosophy at ORNL on discharge-air quality
required that the released air should be normally
suitable for human breathing; therefore, the dis-
charge system should be designed either for con- -
tainment of the discharge air or for release at an
elevation in the ORNL plant area approximately
equal to that of the isotope area stack No. 3039. -
In the case of the RDHC this would have meant
not only that the air must be discharged through

 

wJ. C. Bolger, S. F. D'Urso, and M. H. Fontanna,
Particle Size Distribution Study for Disassembly of
ANP Reactor, KT-243 (Nov. 12, 1956).

"D. E. Guss, ANP Quar. Prog. Rep. Dec. 31, 1956,
ORNL-2221 (Parts 1-5), p 86.

 

 
an absolutely efficient and reliable filter system
but that the discharge air would have to be either
recirculated as clean air supply to a hermetically
sealed facility or discharged up a 250-ft stack. It
was planned to investigate this problem further,
particularly from the point of view of possibly dis-
charging the properly filtered air at the facility roof
elevation. Of course, the used filters after removal
were to be placed in dust-tight containers and dis-
posed of at the burial grounds.

Tools and equipment used in the hot cell were to
be thoroughly decontaminated before they were taken
out of the auxiliary cell. If the count could not be
brought to tolerance levels, it was planned to dis-
pose of the equipment at the burial ground rather
than risk the spread of contamination.

Facility Mockup for Cold Testing

In the event project schedules did not allow time
for preliminary testing, a full-scale cold mockup of
a portion of the hot cell was considered necessary
for checking and shakedown of tools and procedures
as well as for personnel training.

There was the possibility of using the ETU for
this work, although it was realized that the need
for rapidly gaining entry into this unit would not
result in a procedure identical with that planned
for the hot cell. Nevertheless, the direct operation
of tools and fixtures on a full-sized model was con-
sidered a practical approach to the problems under
hot conditions. This would have been especially
useful in the development of replication technique,
optical measurements, testing of cutting methods,
and development and checking of special tools and
fixtures,

Underwater Disassembly Study

Some consideration was given to underwater dis-
assembly for removal of the reactor from the pres-
sure cell. Since plans were to effect the fuel
transfer, sodium transfer, and the fuel flush opera-
tion remotely, the first step upon removing the man-
hole cover was to cut the recovery tank free, In
view of this it was proposed that, following the re-
moval of the recovery tank and the postoperation
sample tank, the cell be decontaminated, the top
hemisphere of the cell be cut off, and then the cell
be flooded with water. It was then planned that
the remaining removal operations would be handled
under water from a suitable platform. Accordingly
a study was initiated to investigate the contami-
nation aspects of such a system.

 

To obtain a rough idea as to what would happen
to the estimated 2000 curies of beta activity under
flood conditions, a simple experiment was per-
formed.'® Water slightly acidified with nitric acid
was agitated in a 10% x 14 x2Y in. pan as suc-
cessive quantities of radioactive Sr?0 were dis-
solved. Readings of beta activity were taken with
a ‘‘cutie pie’’ instrument at a point 81/2 in. above
the liquid level. The activity was primarily of
1-Mev energy. Samples of the solution were ana-
lyzed for activity content with the following results:

Beta Activity 81/2 in.

Above Surface Activity Content (uc/ml)

{mr/ hr)
18 0.35
85 1.50
110 2.00

Although it appears that the activity count meas-
ured above the surface was roughly proportional to
the activity content of the liquid, the study was not
pursued further because of the potential hazard of
working with sodium submerged in water.

6. FACILITY
Consideration of 7503 Facility

As was stated previously, the early project think-
ing was that the two pits in Building 7503 (ART
facility) used for ARE operation and disassembly
would provide suitable space for ART disassembly.
A single pit 28 ft by 21 ft by 22 ft deep would result
if the partition between them were removed. Inas-
much as the walls of these pits are constructed of
standard reinforced concrete 18 in. thick, an ad-
ditional 3]/2 ft of dense concrete shielding would
have to be added to each wall. The resulting 21 x
14 ft floor space is obviously too small when com-
pared with the 20 x 52 ft area needed for disas-
sembly in a hot cell or the 3000-ft? area required for
the assembly of the reactor.

The space available for an operating area for such
a hot cell is completely inadequate. Experience
with hot cells has shown that a shielded area for
the repair and decontamination of tools and equip-
ment adjacent to the working area is imperative.
Space limitations prohibit constructing such a cell

in Building 7503. While the 30-ton crane installed

 

185, R. P. Shields, Solid State Division.

33

 
in the building is adequate for transporting the re-
actor from the operating cell to the disassembly
cell, radiation levels would be too high to permit
removing the shield plugs of the disassembly cell
after the reactor shield has been removed, thus pro-
hibiting further use of the crane. The low head
room in such a cell would not permit the installation
of adequate handling equipment inside the cell.
Underwater disassembly of the ART in this or any
other area is not feasible because of the violent
chemical reactions between water and liquid metals
and because of the requirement for precise measure-
ment.

Consideration of Other Arrangements

The feasibility of constructing the RDHC adjacent
to Building 7503 was considered so as to minimize
the movement of the reactor and to take advantage
of the 30-ton overhead crane. To do this would re-
quire that the RDHC be located directly in front of
the building, replacing the main access ramp to the
building. The RDHC would then have to be built
essentially underground, with the cell roof serving
as the building access driveway. The cost of such
underground construction and the fact that movement
of the shielded radiocactive reactor within the Labo-
ratory area is not a critical problem offset any real
advantages for this arrangement. It has the further
disadvantage of requiring that construction proceed
simultaneously with the installation and operation

of the ART reactor.

Since ORNL has no hot cell facilities which are
capable of handling an assembly as large as the
ART, use of the GE-ANP hot shop was reviewed for
its svitability for the ART disassembly. However,
this was considered impractical on the basis of (1)
the potential shipping hazard to the ART, (2) the
necessary revision to the GE-ANP facility, and (3)
the probable scheduling difficulties.

As was pointed out above, a large portion of the
information to be gained from the ART is obtainable
only from examination during and after disassembly.
No estimate of any damage to the reactor resulting
from shipment would be possible. Therefore the
information obtained by disassembly would have to
be discounted an unknown amount. Basically, the
GE-ANP hot shop has adequate shielding, crane
facility, and remote handling equipment for ART
disassembly. However, the elevation and location
of the viewing windows as designed for the G-E re-
quirements might be somewhat awkward to work

34

through on the ART; also, use of the underwater
storage facility would be prohibitive for the ART,
because of the NaK and sodium explosion hazard.
To use the GE-ANP facility, then, would require
sufficient modifications to make certain that all
ART disassembling operations could be performed,
to provide a dry storage facility, and to install the
specialized tooling required for ART disassembly.
Since the GE-ANP facility would have to be avail-
able on a continuvous basis for the estimated amount
of time needed to disassemble the ART, scheduling
and operations would be exceedingly difficult and
costly for both the GE-ANP and ART programs.
Disassembly and inspection of the ART will re-
quire approximately 12 to 18 months. Because ex-
perience indicates that the need for handling large
pieces of highly radiocactive assemblies is increas-
ing rapidly both in number and scope, it is antici-
pated that the usefulness of the facility for other
applications will be extensive. Therefore it is be- .
lieved that, by the time the facilities would be
completed, reactor programs in progress would pro-
vide problems requiring the massive collection of -
data from numerous loops and irradiation experi-
ments. Hence, it is anticipated that the proposed
facility for the ART would be in constant use from
the time it is completed.

Proposed Facility

The proposal for a large hot cell provides for con-
struction of a large, single hot cell divided into two
rooms (Figs. 20 and 21). One of these rooms, the
disassembly and decontamination area, is approxi-
mately 52 ft long by 20 ft wide by 36 ft high, clear
inside dimensions. The other, for shielded mainte-
nance of cell tools and equipment, is approximately
20 #t long by 20 ft wide by 36 ft high, clear inside
dimensions. The area is served by an overhead
crane and by two overhead manipulators mounted
from a common bridge. Along the sides and one end
of this cell are operating areas equipped with re-
motely controlled handling equipment and high
density viewing windows. Wall plugs over each of
the windows provide access for master-slave manip-
ulators. A tool and equipment setup area is located
along a portion of one side of this cell. A change
room adjacent thereto provides for control of per-
sonnel access to and egress from the contaminated
setup area. A tunnel connects the cell to a shielded
storage area, so that radioactive materials can be

 
Gt

 

 

 

 

FACE OF GELL DOCRS

Fig. 20. Proposed Reactor Disassembly Hot Cell:

     

 

Floor Plan.

 

ACCESS

 

UNCLASSIFIED
ORNL-LR- DWG 19299

DOOR
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UNCLASSIFIED

ORNL-LR-DWG 19298

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

i

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fig. 21. Proposed Reactor Disassembly Hot Cell: Section of Disassembly Area. Section A-A of Fig. 20,

 
transferred from the cell and safely stored until
needed without requiring entry into the cell. Full-
width double shielding doors at the end of the cell
and between the two cell rooms are provided for in-
sertion of the equipment to be disassembled. Also,
an access door is provided for each room, to permit
man entry or small tool transfer into the cell while
contaminated. The cell is constructed of high-
density concrete, with the walls about 4]/2 ft thick
and the roof 2]/2 ft thick. A reinforced concrete floor
will be provided.

The operating areas will be steel frame, with the
exterior walls of masonry construction. A 30-ton
overhead crane will operate over the entire length
of the cell and will extend over a loading platform
at the end of the cell. A remotely operated mechan-
ical conveyor system will take radioactive parts
from the cell, through the tunnel, to the storage fa-
cility.

Special disassembly tools and equipment will be
required both for the disassembly work in the RDHC
and for the removal of a reactor from its operating
station, such as the ART cell in Building 7503.
The hot cell will contain a disassembly table (lift-
turntable) where a reactor can be held in position,
rotated, and raised or lowered for disassembly oper-
ations. When the lift-turntable with the reactor is
lowered into the shaft and a shielding cover is
placed over the opening, a ‘‘safe’’ is formed. The
working area of the cell may then be cleaned to
permit entrance of maintenance personnel.

Included in the RDHC building are the facility
requirements for space, equipment and furniture for
office, laboratory, and building services.

All air entering the building will be filtered. The
exhaust air will pass through a double set of filters
into a stack. With the exception of the cells and
building services areas, the building will be air

conditioned. Building services that will be provided
include clean compressed air, vacuum cleaning
system, intercommunication, telephone, power,
lighting, heating, demineralized water, sanitary
water, sanitary waste, and provisions for special
decontamination solutions. All radicactive waste
solutions will be transferred to the existing ORNL
tank farm. A fire detection system will be installed.
Also included will be instrumentation as required
for air flow control and radiation activity monitoring.

The RDHC building will occupy an area of approxi-
mately 11,000 ft2, and the combined facilities will
occupy approximately 30,000 ft2, including the
storage unit. A list of layout drawings prepared for
study of tool placement and space utilization is
given in Table 4.

Site Investigations

In conjunction with the establishment of design
criteria for the large hot cell facility, possible site
locations ot ORNL were investigated. This investi-
gation was conducted with the assistance of other
laboratory personnel and in particular with people
from the Solid State Division. The results are pre-
sented in Appendix P.

Shortly after this report was prepared, a group
called the Central High Level Laboratory Advisory
Committee reviewed the study and indicated a site
in the 3500 area at X-10 as the most favorable lo-
cation for the RDHC (see Fig. 22). It should be
noted that the Central High Level Laboratory
(CHLL) was a large proposed facility which in-
cluded the RDHC as a unit. A design subcommittee
for the CHLL advisory committee was established
to serve in an advisory and review capacity with the
objective of obtaining a facility that not only would
be useful for disassembly of the ART but would
have lasting usefulness as a general hot cell fa-
cility.

Table 4. Layout Drawings for Reactor Disassembly Hot Cell

 

 

X-10 Dwg. No. Y-12 Sketch No. Drawing Title Date
E-29279 SK-JEC-1303 Sect. A-A Thry Cell, Set 2 1-25-57
E-29280 SK-JEC-1306 Cell Plan Sh. No. 1, Set 2 1-28-57
E-2928] SK-JEC-1307 Cell Plan Sh. No. 2, Set 2 1-28-57

 E-29282 SK-JEC-1320 Sect. B-B Thru Cell, Set 2 1-28-57

 

37

 

 
|
|
|
l

  
 
 

 

 

 

  
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3022 M M
ISOTOPE CIRCLE
- L K
\/ w
w
@
l 3024 -
v
- - >

 

ENTRAL

  

 

 

 

 

 

   

HIGH - RADIATION ~ LEVEL
EXAMINATION LABORATORY
BUILDING 3525

PLOT PLAN

 

PLOT PLAN
00 %0 © 100 200 300 400 500
[ 4 ) ' ‘ y HIGH-RADIATION - LEVEL EXAMINATION LABORATORY

SCALE IN FEET BUILDING 3525
OAK RIDGE NATIONAL LABORATORY

C-28494 NOT CLASSIFIED DRAWING A

Fig. 22. Plot Plan for Proposed Reactor Disassembly Hot Cell.

Scale Model of Large Hot Cell niques envisioned. It is believed that it will aid
A model of the hot cell (Figs. 23—-25) has been in the further development of such items as hot cell
constructed to a scale of 1in. = 1 ft. In order to design criteria, operational sequences, handling
visualize more clearly in three dimensions the fixtures, tools, and equipment. It was expected that
handling and cutting problems associated with the the completed model, together with the operation -
ART disassembly, sufficient detail has been pro- manual, would aid in dissemination of information
vided to permit a realistic approach to the tech- and in hot cell operator instruction.

38

 
UNCLASSIFIED
PHOTO 29864

 

 

 

Fig. 23. Scale Model of Proposed Reactor Disassembly Hot Cell: Front View. The completely shielded re-
actor and support structure are shown being placed on the wall brackets. The location of the mounting stands for

optical tooling is shown in the foreground, as well as the lift-turntable and the mounted cutting head units.

39

 
 

 

UNCLASSIFIED
PHOTO 28279

 

Fig. 24.

Scale Model of the Proposed Reactor Disassembly Hot Cell:
shown mounted on the disassembly table
picture.

Top View.

The cutting and machining tools are mounted near the bottom of the

The unshielded reactor is

40

 

 
_ v : sEamen ; SEETIUNCL ASSIFIED
- . i E ! as e . A:;diafil""’*“. PHOTO 28277
o 7 o

 

 

 

Fig. 25. Scale Model of the Proposed Reactor Disassembly Hot Cell: Perspective View of Disassembly Area.

4]

 

 
7. SCHEDULE AND COST ESTIMATE
Schedule

Construction of the large hot cell and procurement
of disassembly tools and fixtures were scheduled so
that they would have been available for use in the
event that disassembly of the ART was required fol-
lowing commencement of nuclear operation,!' 720
Allowing the time necessary to remove and transfer
the ART to the RDHC, it was concluded that, to
avoid delaying the program, the completion date was
to be September 30, 1960, If the RDHC facility had

not been available for use at that time, there would

 

wOak Ridge National Laboratory Proposal for Reactor
gggi'ngeseg)ing Hot Cell Facilities, ORNL CF-56-8-96 (Aug.

20J. A, Swartout, Construction Project Data Sheet for
the Reactor Engineering Hot Cell Facility at ORNL,
ORNL CF-56-8-105 (Aug. 20, 1956).

have been a delay in inspecting and evaluating the
reactor machinery to obtain the valuable data on
what happened to the ART components during re-
actor operation,

It was estimated that disassembly of the ART
would take 12 to 18 months. When that operation
was finished, the cell was to be available for dis-
assembly and maintenance requirements of other
large radioactive equipment. It would also meet
one of the basic facility requirements for the de-
velopment of advanced aircraft reactors.

Cost Estimate

The cost of the basic RDHC structure is estimated
to be $528,000. This does not include the shielded
hot cell. The cost of services, estimated at
$705,000, includes air conditioning for building work
areas and a separate system for special filtration
and cleaning of contaminated air from the hot cell.

 

 

Table 5. Details of Cost Estimates for RDHC
Contractor ORNL Total )
Engineering, design, and inspection® $ 250,000 ¢ 447,000 $ 697,000
Construction costs**
Land and land rights
Improvement to land 50,000 50,000
Building
Structure 508,000 20,000 528,000
Services 700,000 5,000 705,000
Other structures
Structure 275,000 109,000 384,000
Services 25,000 1,000 26,000
Utilities 90,000 5,000 95,000
Equipment and installation 1,330,000 1,639,000 2,969,000
Removal costs less salvage
Contingency 323,000 223,000 546,000 "
Tatal $3,551,000 $2,449,000 $6,000,000

 

*Major Contractor and Intended Type of Contract:

ORNL ($447,000): title | engineering services for building, and titles li, 1ll, and 1V engineering services for

cells and cell equipment.
AEC ($250,000):

**Construction:

prime AEC contract — Titles Il and Ill engineering services for building.

ORNL ($2,002,000): utility extensions and connections and all specialized cell equipment.

AEC ($3,301,000):

42

lump-sum prime contract, construction of facility.

 

 
 

The estimated cost of $384,000 for other struc-
tures covers the shielded storage cell for radio-
active reactor components and parts. The cost of
the shielded transfer tunnel connecting the storage
cell with the main disassembly cell is also in-
cluded.

The large item of $2,969,000 for equipment and
installation covers the very expensive heavily
shielded hot cell with its crane and built-in equip-
ment plus the remote-control equipment needed in
reactor disassembly. The transparent shielding
windows to permit viewing of the operations are
included in the total equipment cost, along with the
manipulators, cutting and machining tools, and
special equipment items required to make the hot
cell fully usable for the purposes for which it is
designed. A tabulation of the estimated cost is
presented in Table 5.

8, ACKNOWLEDGMENTS

The authors wish to acknowledge the leadership
and guidance of S. J. Cromer, W. F. Boudreau, and
M. Bender. Valuable assistance was given by D.B.
Trauger and W. B. Cottrell in the activity levels
study and the removal and disassembly phases. The
cooperation of F. Ring, Jr., and his associates, par-
ticularly A. M. Tripp and M. G. Willey, was invalu-
able in developing the cell plans and the operating
procedures. A. P. Fraas and R. V. Meghreblian
provided able assistance from the Power Plant
Engineering Department. V. J. Kelleghan contri-
buted with the cell facility criteria.

The shielding studies were developed by W. E.
Browning, R. P. Shields, and D. E. Guss of the

Solid State Division. The early coordination of

this program with other ORNL hot cell studies was
provided by S, E. Dismuke and O. Sisman.

It would be difficult to recognize individually all
those who contributed to the test and development
work, but some who come to mind will be mentioned
for their specific part. The Chemical Technology
Division provided facilities and assistance for the
Elox test and also for the hot cell optical tooling
test, The dry grinding test was made with equipment
and help of the Engineering and Mechanical Division
in their Source and Fissionable Material Machine
Shop. Other work contributed by that division in-
cluded the cutting methods evaluations tests, ma-
chining of the sealant injection needles, and the
optical flat for the optical tooling test.

One of our consultants was Professor J. Litton of
Purdue University, who collaborated on the early re-
moval studies and later reviewed the over-all plan,
with which he generally concurred,

To associated contractors on this Project we are
indebted to Pratt & Whitney Aircraft for the help
provided by L. W. Love, especially on the studies
of replication by casting and metallizing, and to
Convair for the services of J. H, Dowdy, who made
many contributions to the planning studies.

Commercial equipment manufacturers cooperated
in providing equipment or tests at no cost on items
which were not otherwise available to us, We are
grateful to the Osborne Equipment Co. of Knoxville
for the gun-emplaced gypsum replicas, to the Ty-Sa-
Man Machine Co. of Knoxville for the wet grinding
test on Inconel, to the Lucey Boiler & Manufacturing
Corp. of Chattanooga for the Heliarc torch cutting
demonstration, and to the Brunson Instrument Co. of
Kansas City, Mo., for the optical tooling course and
the loan of the optical measuring instruments.

43

 
APPENDIX A. COMPILATION OF REQUIRED ART SAMPLES, MEASUREMENTS, AND EXAMINATIONS

45

 
 

9y

Table A-1. Sample Request Compilation. Part 14

 

Observations Requiredb

 

 

Number of 5 -
Sample or Observation I_\S,:mp.lesd Visual BT:‘::,:.::: Dye  Photomi-  chemical Other Notes Requester®
quire After Check crograph
|. Sheils

A. Inner core shell, Ne. |

1. At points of greatest temperature 2 * * * M,H,C
fluctvation

2. At inlet 2 * * * M H,C
3. At outlet 2 * * * M, H, C
4. At midplane 2 * * * Include weld samples M, H, C
5. At turning vane 3 * * H

B. Outer core shell, No. |l
1. At points of greatest temperature 2 * * H

fluctuation

2. At inlet 2 * * M,H,C
3. At outlet 2 * * M, H, C
4. At midplane 2 * * Include weld samples M, H, C
5. Weld ot south end 3 * H
6. Weld, Shell Il to Shell I1, at top 3 * H

C. Shell No. 1l
1. Weld at equator 2 * H
2. Lower region 2 * * * Observe buckling at bottom M
3. Joint between Shells 11l and 1V * Observe alignment M

D. Shell No. IV
1. At midplane 2 * * * Include weld samples M, H, C
2. Atinlet 2 * * * M, H, C
3, At outlet 2 * * * M, H,C

E. Shell No. V
1. At midplane 2 * * * Include weld samples M, H,C
2. At inlet 2 * * * M, H,C
3. At outlet 2 * * * M, H,C
4. Special samples, Shell ¥ 15, 1in.2 * * Radiochemical For evaluation of chemical proc- B

surface essing plant problem; should come
from top, center, and bottom of walli

5. Joint between Shells V and VI * Observe alignment M

F. Shell No. VI
1. Shell No. VI 2 * * H, M
2, Shell Vi blowout patch 1 * Section required H, M
Table A-1 (continued)

 

 

Sample or Observation

Observations Required®

 

Notes

Requester®

 

Ly

G. Shell No. VI
1. Island {girth?) weld

Weld, Shell Vi1 to Shell VI

Weld, Shell VIl to MF pump barrel
Weld, Shell VII to sedium pump barrel
Blowout patch, Shell VII

Pressure shell {No. VIi)

o e W

H. Shell ot bottom of island

1. Shell buckling

2. Expansion joint at isiand top
I. Shell ot core exit channel
J. Thermal sleeves

1. Thermal sleeves distortion

2. Thermal sleeve attached to lines and
Shell ViI
K. Support ring
1. Support ring welds at base
2. Support ring
3. Support ring feet

L. Weld of ByCcanto island at south end
M. Lead from shield

Beryllium reflector

A. Slices (pie cuts) at various latitudes

B. Coolant heles (inner surface)
C. Region under support ring pads

D. Inconel-beryllium competibility

. Spacer holes

. Staples

. Spacers from island

. Ring support

. Beryllium in contact with ring support
. Control rod thimble

o A WN e

—_— N N W

AN O BN

MW oy N A

Large weld sample required, commen-
surate to weld size

Weld actually part of north head
Creep deformation required
Creep deformation required
Section required

Creep deformation

Buckling of shells enclosing tiles

Thermal distortion

Buckling of shells enclosing tiles

Thermal distortion as seen in longi-
tudinal section preferred

Stress concentration in weld

Creep deformation

Observe vicinity of Na heles; include
one section at outlet

One from last row at south end

Take from south end

Contact points

I

O T T =T X

M,C.H

x
I

I =

-

LT T T T ITX

 

 
 

8y

Table A-1 (continued)

 

Observations Required®

 

 

Number of 5 -
Sample or Observation Samples tmensions . Not Requester®
P Required Visual Before ond Dye  Photomi- ¢ omical Other e °s
q After Check crograph
7. Centrol rod thimble section 1 * H
8. Beryllium around control rod thimble 2 * At contact points M
9. Seal grooves and support pads 3 * For stress concentration M
E. Dimensions of outer contour 30 * Photographs and general visual in- M
spection, particularly the region
under strut
F. Cu-B,C at pressure ring 2 * * H
l1l. Main heat exchanger
A. North header with &' of tube intact 12 or 3 min. * * > * * Chemical analysis Examine tube-to-heoder welds M,H,C,5
of deposits
B. South header with 6'' of tube intact 12 or 3 min, * * * * * Chemical onalysis Examine tube-to-header welds S, M,H,C
of deposits
C. One complete heat exchanger in channel 1 * * * * * For flow test If obtainable, might supplant lIID, F  §
D. Heat exchanger channals 2 * > For creep deformation information M
E. Channel wedge from heat exchanger 1 To be taken where channel is hottest H
F. & section with spacer comb at equator 12 or 3 min. * * * * Chemical anolysis S
of deposits
1V. Auxiliary heat exchangers
A. Inlet header with 8" of tube of heat ex- 1 * * * * * Analysis of deposits Flow tests may be required; include $,H,C
changer A or B and activation 4’ of inlet nozzle if from B
B. Outlet header as before for same heat 1 * * * * * Analysis of deposits Flow tests may be required; include S,H,C
exchanger and activation 4" of inlet nozzle if from B
C. Sample at midpoint of heat exchanger 2 Analysis of activation and mass C
transfer
V. Boron carbide tiles
A. BC tile from equator region 1 * Complete tile requested H, C
B. Cu=B,C tile from equator region 1 * Complete tile requested H
C. Cu-B,C disk intact from south end of 1 * Complete tile requested - H
island
D. Cu-B,C from pressure ring 1 * Complete tile requested H
V1. North head
A. Sleeves on pump barrels 2 * Follows cut No. 2 M
B. Sodium expansion tank dome top 2 * * * Follows cut No. 3; discontinuity M

stress or therma! shock

 
) 4

Table A-1 (continued)

 

Observations Requiredb

 

 

Number of 5 -
Sample or Observation Samples Imensions . Notes Requester®
P Re rired Visual Before and Dye  FPhotomi- o) Other 4
q After Check crograph
C. Sodium expansion tank dome floor 2 * * * Follows cut No. 5; discontinuity mé
stress or thermal shock
D. Intersection of upper deck to expansion 2 * Section weld M
tank
E. Sodium pipe expansion joints 2 * * Thermal distortion M
F. Sodium return tube from reflector
1. Return tube 1 * * Creep deformation of part attoched M
to torus
2. Weld ot sodium cutlet from reflector 2 * H
G. Structure exposed to surface radiation
1. Expansion tank lines 2 * * * Thermal distortion; examine for M, C
deposits
2. Contro!l rod thimble 2 * * * Thermal distortion; examine for M, C
deposits
H. Flat plates, disks, wolls under pressure
1. Bottom of expansion chamber * * Examine for deposits C
2. North head lower deck 2 * Creep deformation M
3. North head upper deck 2 * Creep deformation M
4., Wall below liquid level 2 * Creep deformation M4
5. Wall above liquid level 2 * Outside and inside castings after
l. Snow trap line 2 * * Mass and octivity Examine for deposits
of deposits
J. Sodium level device 1 * Observe for thermal distortion ond w
condition of MgO packing
K. Reactor thermocouples 6 Remove for cali- w
bration check
L. Pressure transmitters 2 Remove for cali- W
bration check
M. Heated section of rod 1 * * Radiochemical
N. Sodium sample from rod thimble 1 * Radiochemical Observe for leaching of rod
VIl. Both MF and MN reactor pumps
A. Rotary elements, MF 2 * * * * Inspect for erosion and damage; re- D, H
move one element intact
B. Rotary elements, MN 2 * * * * Inspect for erosion and damoge; re- D, H
move one element intact
C. Thermal barrier, MF Tor2 * * * * Observe for deposits in cooling D, H

passages, distortion; ramcve one
intact

 
 

o
o

Table A-1 (continued)

 

Observations Requiredb

 

 

Number of = -
. imensi ’
Somple or Observation ;p:mp'letj Viseal Bef:re ::: Dye  Photomi- Other Notes Requestar®
quire After Check crograph
D. Thermal barrier, MN 1or2 * * * As for MF, Jesser importance D
E. Volutes, MF Surfoce * * * H
F. Volutes, MN Surface * * * H
G. Shaft, MF 1 * Load-deflection test D
H, Shaft, MN 1 * Load-deflection test
f. Seal assembly, MF 1 * Bellows spring Observe for damage and deposits, D
characteristics condition of seal faces
J. Seal assembly, MN 1 * Bellows spring As for MF D
characteristics
K. Oil samples, MF ond MN 4 * Physical properties  Observe for carben D
L. Lubricating and cooling possoges All for one MF * Observe for carbon and resin D
and one MN
M. Beorings, MF 4 * * * Determine hardness  Check for wear D
N. Bearings, MN 4 * * * Determine hardness  Check for wear
0. Elastomer seals, MF ond MN All for one MF * * Determine hardness
and one MN and elosticity
P. Off-gas lines (supply and catch * Activity of deposits  Observe for snow, gunk, salt D
basin), MF
Q. Off-gas lines (supply and catch * Observe for gunk and NaK D
basin}, MN
VIII. NaK auxiliary pumps
A. Rotary elements 2 * * * * Inspect for erosion and damage; re- D
move one intact
B. Volutes 2 * * Determine hardness  Inspect for erosion D
C. Shaft 1 Load-deflection
D. Seol assembly 2 * Bellows spring Inspect seal faces for wear
charocteristics
E. Lubricating and cooling passages One pump * Observe for carbon
F. Bearings 2 * * * Determine hardness  Check for wear D
G. Elastomer seals All for one * * Observe general condition D
pump
H. Gas lines (supply and catch basin} All for one * Observe for NaK D
pump
LS

 

 

 

v 1 ' v 2
Table A-1 (continued)
Nomber of Cbservations Requiredb
umber o
Sample or Observation Samples Dimensions .
P Required Visuol Before and Dve  Photomi- oo pig| Other Notes Requester®
After Check crograph
IX. NaK special pumps
A. Rotary elements 2 * * * * Inspect for erosion and damage; re- o
move one intact
B. Volutes 2 * * Determine hordness Inspect for erosion D
C. Shaft 1 Load-deflection D
D. Seal assembly 2 * Bellows spring Inspect seal faces for wear D
characteristics
E. Lubricating ond cooling passages One pump * Observe for carben D
Bearings 2 * * * Determine hardness  Check for wear D
G. Elastomer seals All for one * * Observe general condition D
pump
H. Gas lines (supply and catch basin) All for one * * Observe for NoK - D
pump
X. Dump valves
A. Valve seat 2 * * * Remove intact
B. Valve stem and poppet 2 * * * Remove intact
C. Bellows 1 * *
X|. Dump tank
A. Heads 4 * * * Measure distortion and remove M
samples
B. Lower region of cylindrical shell 3 * Remove samples at liquid-gos inter- M, C
face and at bottom for examination
C. Tube sheet with &'’ of all tubes 1 * * * * * Flow test may be Chemical analysis of deposits only S
required
Xil. Reactor snow trap
A. Samples at inlet, center, outlet 3-6 * * Radiechemical Determine total amount of snow
B. Dump tank snow trap * Determine total amount of snow
X{lk. Off-gas line
A. Representative samples 4 * * Radiochemical Observe for deposits
B. Solencid valves in line 2 * Observe for deposits, particularly
around seat
C. Throttle valves 1 * Observe for deposits C

 

 
 

s

Table A-1 (continued)

 

Observations Requiredb

 

 

Number of B -
Sample or Observation Samples Imensions . Notes Requester®
P Re Sired Visval Before and Dye  Photomi-  cpemical  Other g
q After Check crograph
D. Disoster block valve * Observe for deposits
E. Representative samples in adsorber * * Radiochemical C
XIV. Miscellaneous items from cell
A. Fluid samples
1. Postpower sampling pots * Radiochemical and Deliver tanks to Chemicol Tech- C
physical nology Division
2. Sodium > Radiochemical Remove sample when draining C
system
3. Qil from rad drive gear box *
B. Rod drive gear box * Mechanice! con- Remove intoct W
dition
C. Hydraulic motor seal {MF pump) * Radiation damage C
XV, ltems outside reactor cell
A. Main radiator * * * > * Flow tests; chemi- Remove intact S, C
col analysis of
deposits
B. Special radiator * * * * * Flow tests; chemi- Remove intact 5, C
cal analysis of
deposits
C. Pipe joints in NaK manifolds * * Examine for thermal distortion M

1. Inside cell on reactor

2. Samples from weld at onchor point

D. Hydraulic drive oil
E. Lube oil (type K stands)

F. Auxiliary radiator

Radiochemical
Radiochemical

Radiochemical

Check for damage and contamination
Check for damage and contamination

Compare activities of deposits with

those for main radiators; other meas-
vrements for main radiator of interest
if main shows damage

 

9This sample list, deted September 18, 1956, wos compiled by D. B. Trauger from items submitted by the Power Plant Engineering, Chemistry, Metollurgy, and Solid State organizatians. It was the
basis af ecrly planning, although revisions were later made when better measurement and replication metheds were develaped. A summary of the changes made after discussions with the Stress Analysis
Group is shown in Table A-2.

Blndicoted by asterisks.

“Symbols: M Meghreblion, Power Plant Engineering, Stress Anclysis
C Cottrell, Reactor Operotions
H Hikido, Metallurgy
S Schultheiss, Power Plont Engineering, Heot Transfer

9Request canceled March 5, 1957.

D Dytko, Engineering Development
W  Walker, instrumentotion
B Bruce, Chemical Technology, Fuel Reprocessing
wn
w

 

Table A-2. Somple Request Compilation, Part nab

 

Observations Required®

 

 

 

{tem Reference Direct Measyrement Replication Standord Photos General Remarks
Before After Before Aiter Remarks Before After

Shell | 3 weld buttons on tap transition None None * * {Hydracal cast) * *

Shell 11 {Prick marks an top of collar) None None * * (Hydrocal cast) - *

Shell {1{ 3 prick punzhes an support ring; 2" scratch * None None * {None} * Decision on 2" or coarser grid (Meghreblion
grid on lower machine bregk edge or chisel says 2" OK); feasibility of reforence and
mark on spur {meridian mark with azimuth measurement during assembly (Abala says
determined) oK)

Shall IV None None Neone ™) {None} (None)} {Nane) {Contour photo before ond after of lower half}

Shell Vv None None None * (See generol remark s} None {None) (Salad bowl: Hydrocal; type V—-V| weld:

Hydrocal)

Shell V) 2 punch moark s outside near blowout patch - * None . Qur choice None None

Shel! Vil girth weld 2 sets af 7 punch marks for diameter * * None None None None
measurement

Weld, sheli VIl to MF pump borrel d d None Nene None None 6 weld specimens esach borval

Weld, shell VIl to MN pump barrel d d None None None None 2 wald spacimens saoch borrel

Shell VII 2 sets of 3 weld buttons * * None * {Local) {Cast 2' of None None

circumference)

Thermal sleaves {None) None Nane None None None 1 thermal sleeve sample

Support ring Nane * None None None None

Beryllium reflector None None None None {None) *

Main heat exchanger d d None * None None 1 haat exchangsr required intact

Auxiliory heat exchanger None None None None None None

Sodium exponsion tank dome top 2 weld beads on dome None None * > {L ead or Hydrocal OK) None None

Fluid exponsion tank top None None None * {Lead or Hydracal OK) None None

Intarsaction of upper deck to expansion tank None Neone None None Nona None 2 wald samples

Sodium pipe expansion joints None None Nons None None None Remove intact as sample

Sodium return tube from reflector None None None None None None Remove intact as sample

Expansion tank lines None None None None None None Remove sections os samples

Cantrol rad thimble None None Nane None None None Remove intact as somple

North head lower deck None *e None None None Nons

North head upper deck None * None None None None

Wall below liquid level None None - * {Abele to investigate) None None

Dump tank heads None None Nane * None None

Lower region of cylindrical shell None None None * None None

 

aSummury of revised measyrements after meeting on March 5, 1957, with Stress Analysis Group. Compiled by F, R, McQuilkin, doted June 13, 1957,

Comments from raview meeting an June 11, 1957, are in parentheses,

SIndicatad by ostarisks,
Plans in abeyance,

“Special gage required.

 

 
APPENDIX B. OUTLINE OF ART DISASSEMBLY PROBLEMS'I
|. Reactor removal.
A. Removal preparations.
1. Establishment of fluid removal sequence.

a) Need for NaK as heating medium during draining and flushing to keep fuel and Na
hot.

b) Accessibility of fluid removal connections.

c) Pressure and temperature restrictions on fluid circuits during draining and flushing.

d) Conditions which must be established for charging investment material, if used.
2. Safety requirements of cell during removal operations.

a) Conditions for water to be drained from around reactor cell.

b) Circumstances when manhole cover can be removed from cell.

¢) Conditions and methods under which upper part of cell can be cut off and removed.

d) Ventilation and purging requirements placed on cell when cover is removed.

¢} Decontamination requirement of the cell interior to permit personnel entrance.
Provisions necessary for fire protection during rinsing and disassembly operations.
Personnel access limitations during removal operations.

(1) When the fuel has been rinsed from the reactor, can personnel enter the cell
without being shielded if water bag is filled? If so, for how long?

(2) When water is drained from the water bag, will this impose additional access
restrictions on the cell?

b) Establish radiation dosage per hour for personnel in cell during removal operations
under conditions as follows:

(1) After the reactor fuel passages have been rinsed.
(2) When the Chem Tech tank and fuel samples have been removed.
(3) When the snow trap is removed.

i) How will spread of active chips, dust, and vent gases be controlled to reduce con-
tamination?
3. Rinsing operations.

a) What is the fuel holdup in the reactor after draining, and how much activity is it
contributing to the reactor?

b) What rinsing fluids can be used to reduce the residual fuel activity?

(1) Are the potential rinse fluids limited to barren carrier, fused salts, lead, and .
lead alloys?

(2) Of the rinse fluids considered, how are they evaluated for the following: di-
lution of residual activity, wall washing, residual fuel displacement, distortion
and corrosion effect on the reactor components, interference with subsequent in-
spection, potential shielding value?

 

1Report by M. Bender and F. R. McQuilkin dated September 14, 1956.

54

 

 
c) How will sodium be removed?
(1) Will permanent lines be needed from the moderator and island circuits?
(2) Will vacuum extraction equipment be needed for the moderator circuit?
(3) Can a displacement fluid be used?
d) After the NaK is drained, how will low spots be flushed?
(1) Can the NaK be displaced by another fluid?
(2) Whaf dangers will be introduced in line severing if all NaK is not removed?

e) Can fuel rinse fluids be stored and transferred to the reactor from points outside the
cell?

(1) If so, what are the locations and connections required?
(2) How are the spent fluids handled?
(3) How are fluids transported into and out of the reactor?
f) How will effectiveness of fuel rinse be determined?
(1) Can rinse fluid be monitored to determine the amount of activity being removed?

(2) What means can be used to determine the reduction in activity in the cell re-
sulting from rinsing? Will the spectrometer tubes be useful for this purpose?

(3) What facilities are required for this operation?
Investment materials.

a) Can lead, lead alloys, fused salt, plaster of paris, plastic, or other materials be
used to invest the reactor?

b) What value is gained from investment material?
(1) Dimensional relationship of parts may be fixed.
(2) Possible displacement of fuel may reduce activity.
(3) Possible self-shielding effect of investment material.
c) Disadvantages of investment.
(1) Difficulty in investing any parts except fuel passage.
(2) Possible distortion of parts by excessive mass and shrinkage stresses,

(3) Difficulty of insuring thorough investment because of gas entrapment and
shrinkage pockets.

(4) Possible concealment of evidence by investment material.
(5) Introduction of additional cutting problems during disassembly.

(6
7

Problem of radiation deterioration of organic investment materials.

———

)
) Additional handling load problems from investment materials.
) Dust problems introduced from plaster of paris.

)

(8
(9

Need for transfer device for investment material.

B. Cell disassembly.

1.

Components to be removed from cell.
a) Fuel containers ~ Chem Tech tank, sample tubes.
b) Snow traps — must these be removed in the cell?

c) Offgas lines.

55
d)
e)
/)
g)
h)
1)
7)

Instruments and lines including control rod.
NaK piping - main and auxiliary.

Auxiliary piping — lube, hydraulic, air, water.
Dump valve actuator.

Water bag — should this be removed in hot cell?
Reactor, including support platform.

Fuel dump tank.

2. Handling of high-activity parts requiring shielding and remote handling.

a)
b)
c)
d)

Shearing techniques for shielded lines, including preinstallation.
Shielding devices for active parts and severed lines.
Remote lifting devices and manipulators.

Observation tools.

3. Handling of moderate activity parts.

a)
b)
c)
d)

Application of quick mounting and extension tfools.
Contamination dust control by vacuum and liquid washing.
Handling fixtures for moderate activity parts.

Personnel shielding for *‘in cell’” operations.

4. Handling of low-activity parts.

a)
b)

c)
d)
e)

Physical access problems.

Protection against radiation exposure from adjacent equipment during “‘in cell”’
operations.

Hazard problems other than radiation.
Tools required for severing of low-activity lines.

Handling means for equipment during severing operations, particularly reactor
support.

(1) Shielding requirements or remote operating requirements for overhead crane and
transport truck.

(2) Attachment fixtures and appurtenances for parts.

(3) Remote observation devices such as periscopes, mirrors, closed circuit TV,
etc.

5. Personnel requirements for disassembly.

a)
b)

c)

Radiation dose limits of personnel.
Period of time personnel can be in cell:
(1) In shielded basket.

(2) Without shielding. ;

Manpower estimates for disassembly, including craft classification.

6. Self-shielding considerations of reactor parts.

a)

56

Will the water bag have sufficient shielding value to warrant leaving it on until the
reactor is removed to the hot cell?

(1) Can it be filled with a fluid more dense than water during disassembly for shield
purposes?

 
(2) Can the reactor assembly be handled when the water bag is full of fluid?
&) Will investment materials provide any self-shielding benefits?
C. Experimental program requirements.
1. Chemical.

a) Evaluate fuel rinse fluids for the following: corrosion effects, evidence of destruc-
tion, reduction of activity by fuel dilution and displacement, wall washing effect,
personnel hazard, potential distortion of parts.

b) If investment materials are used, evaluate their shielding benefits, chemical reac-
tivity with fuel, soundness of solidification, gas entrapment, potential distortion
effects, and compatibility with other fluids such as Na and NaK.

c) Evaluation flushing media for the NaK and Na systems for the following: displace-
ment effect, reactivity, conditions of charging, potential hazard, compatibility with
reactor structure and contents.

d) Review chemical sample requirements.
2. System testing.

a) Determine system holdup in ETU by spiking fuel or by preliminary check with other
fluids.

b) Determine heat exchanger holdup from measurement of holdup in heat exchanger test
rigs.

c) Try flushing operations for removal of Na and NaK on ETU.
d) Test flushing operations for fuel on ETU,

e) Attempt investment charging on ETU or other mockup, if evaluation shows that it
would be desirable.

3. Metallurgical.

a) Review and condense metallurgical specimen requirements for all parts of reactor,
including connecting equipmeni and instruments. '

b) Evaluate the pros and cons of investment materials for the following: metallurgical
information to be gained, techniques to be developed, evidence of destruction,
metallurgical compatibility with the structure.

c) Cutting materials for shears which must be preinstallied adjacent to hot lines.
d) Practicability of induction melting for line shearing techniques.

e) Electrical and gas-torch cutting equipment for disassembly operations where chips,
fumes, dust, and spatter must be completely controlled.

4. Mechanical development.
a) Design, procure, and test remote tools such as shears, induction melting coils.
b) Test manipulating devices for removing hot equipment from cell.
c) Metallurgical evaluation of severing devices.
D. Design program.

1. Establish personnel access, remote operation, and remote removal requirements of all
disassembly operations.

2. Review the practicability of introducing flushing media from outside the cell, the means
of transporting it to and from the reactor, the storage problems, the fuel rinse cycle, the
Na extraction techniques.

57

 
58

Establish the sequence of equipment removal and line severing from physical access
considerations.

Incorporate working space for disassembly operations and preinstalled tools in the cell
design.

Make provisions around lines for preinstalled severing tools, where needed.

Modify 7503 design to incorporate remote crane operation, cell ventilation requirements,
additional cell penetrations, and flushing facilities.

Il. Reactor disassembly.

A. Transport requirements for movement with 30-ton building crane in 7503.

1.
2.

~NOON O

What are the attachments and conditions of the reactor at the time of removal?

What are the limitations or specifications of each unit to be removed plus its environ-
ment for both the normal and abnormal situations?

What lifting lugs or rig will be on the reactor?

Will the lifting rig permit remotely controlled hook engagement?

Will shielding of the crane cab be necessary?

Will a remote control for the crane be necessary? .

What special precautions should be observed while lifting, moving, and placing reactor
with building crane?

B. Transport carrier.

1.

|s there certainty that the transport carrier will not be a limiting factor in the transfer
of the reactor under abnormal conditions?

Technique for mounting reactor on trailer — must this operation be done remotely?

What shielding, it any, is required for trailer cab — will sky shine and road reflection
amplify this problem? Would refilling the water bag provide useful shielding? Would
modification of the mounting be required?

Problem of shielding a K-25 trailer and/or cab to be borrowed for reactor movements —
will this trailer be available for this purpose?

What special precautions should be observed while transporting reactor to hot cell?

a) Will unusual traffic control be required?

-

Will incident control be required?

0

)
)
) Will personnel evacuation be necessary?
)

&,

Will road contamination control be necessary?

) Should a drip pan or drop cloth be used on trailer?

o

C. Hot cell facility requirements.

1. Establish physical location for facility using the following criteria:

a) Within the controlled ORNL area.
b) Economically near the heavy-duty roadway to 7503.

c) At a location that is economically feasible with respect to ORNL reactor instal-
lations (present and future) and with respect to access by the construction con-
tractor.

d) Economically near power and water service and preferably near steam service.

 

 
e)

g)

b)
i)

j)

Either near an available tall stack or at a location where it is feasible and permis-
sible to erect one, if necessary, for either the GTHC or the ADC,

On terrain and soil economically suitable for a large, heavy structure with under-
ground facilities.

Either economically near the tank farms or on terrain and in a locale where release
of contaminated wastes is feasible (or include in the design an economically fea-
sible method for a large holdup volume with provision for pumping or transporting
appreciable yolumes of contaminated liquids).

At a location available for construction July 1, 1957.

At a location where transport time would be negligible as compared to loading and
unloading problem of small contaminated parts.

At a location away from heavy traffic so as to minimize contamination liability.

Firm up physical layout in regard to:

a)
b)

c)

d)
e)
)
g)
)

i)
i)
k)
)

Cell dimensions in plan and elevation.

Tooling and equipment layout, including special manipulators, instruments, pit-
mounted pedestal turntable. [s there economical advantage in pit-mounting the
pedestal turntable?

Receiving and setup areas — is the truck access and tool storage area sufficient
and not excessive?

Underground transfer and storage facility.

Access requirements and cell doors for personnel and equipment.

Office and laboratory space — what groups must be housed in the facility?
Personnel decontamination rooms.

Building services area for ventilation, air conditioning, pumps, valve stations, etc.

Layout requirements for sleeves and penetrations through cell wall, including mi-
croscopy viewing ports.

Roof hatches.
Provision for future alterations.

Knockout- or block-type construction around windows.

Firm design criteria.

a)
b)

c)
d)

e)

Shield criteria for walls, windows, doors, and roof in various areas.

Temporary or otherwise partitions or enclosures (dry boxes, hoods, etc.) to isolate
particulates.

Viewing arrangement and requirements.

Decontamination system and permanently installed equipment — chemicals, materials
of construction, volumes, services, holdup, drainage, and disposal arrangement.

Ventilation and exhaust requirements.

(1) Ventilation for functional areas — air changes?
(2) Vacuum cleaning system.

(3) High-velocity vacuum system.

(4) Filtration requirements.

59

 
60

/)

(5) Exhaust stack - what are dimensional requirements of stack for ADC, if re-
quired?

(6) Pressure differentials for areas.

Building services and equipment criteria.

Lighting and electrical services,

)

(2) Emergency power.

(3) Heating.

(4) Cranes.

(5) Water.

(6) Steam.

(7) Sanitary waste.

(8) Process water waste.

(9) Air.
(10) Air conditioning.
(11) Demineralized water. -
(12) Drainage.
Lost-tool transfer scheme. -

Cell liner and wall inserts.

Cell-to-cell transfer device.

Floor loading.

Criteria for underground transfer and storage facility.

(1) Dimensions and weights of items stored.

(2) Conveyor devices.

Safety and fire protection.

Supporting facilities and services,

(1) Intercommunications — telephone, PA system, cell communications, alarms.

(2) Instrumentation — radiation and ventilation.

D. Disassembly program and equipment.

1.

Evaluate the conditions specified in IIA] above that may hold for the reactor as re-
ceived at ADC,

a)
b)
c)
d)
e)
/
g)
h)

Is the water bag in place and empty?

Will the pumps be in place?

Will the control rod drive be removed?

Will the nuclear activity counter pods be in place?

Will the snow trap under the support bridge be in place?

Will dump valves and actuators be in place?

Will all instruments within the water bag outer skin be in place?

Will all lines and leads that have been severed be dangling and possibly dusty with,
or dripping, radicactive or other hazardous materials?

 

 
2. Movement of reactor into disassembly cell.

a) Will the operation be reverse to the 7503 movement? Must this operation be done
remotely?

b) Will the reactor be held on the 30-ton crane for stripdown operations, or set on a
rigid fixture using the bridge support?

3. Stripdown operations.
a) Establish methods for removal of the following external components and parts:
(1) Water bags.
2) NaK pipes.

3) Manifolds.

4) Snow traps.

5) Dump valves and actuators.

6) Nuclear counter pods.

7) Lead shield — How will it be removed? Can it be unbolted?

8) Superfluous portions of bridge support that may be removed.
9 All other items.

b) What provisions must be made for stripdown in midair to facilitate maneuverability
and to avoid setting reactor on its bottom until shield weight is removed?

(
(
(
(
(
(
(
(

c) Will these tools be adequate for stripdown — wrenches, torches, cutoff wheels, and
pipe cutting shears worked from Oman-type manipulator?

d) Will suspended reactor hold steady if an antitorque device is used?
e) Will a dropcloth scheme for contamination control be feasible?

f) Will bosses on top and bottom of reactor pressure shell be suitable for mounting of
the stripped reactor on a mating turntable fixture?

g) Remove pumps — will wrenches, with perhaps a persuader worked from a manipu-
lator, accomplish this?

h) Remove remainder of bridge support structure — will wrenches and persuader worked
from a manipulator do this?

4. Disassembly operations.

a) Type of information needed from specimens — detailed list of all visual and meas-

 

vrement information and specimens required — will investment material reduce visual
and measurement examination?

b) Type of disassembly operations required ~ core drilling vs component removal vs
. section sampling — as outlined in following sections. Evaluate each as to suita-
bility for providing required information and specimens. Establish advantages and
disadvantages of each method.

c) Core drilling.

(1) Evaluate core drilling as one approach to reactor disassembly ~ is it a feasible
method for obtaining any of the information sought in the ART disassembly?

(2) Would core drilling the equator (if a suitable tool is available) be desirable
whether or not investment material is used?

(3) If core drilling cannot be done, will a trepanning scheme with some means of
popping out the B,C tiles and B,C~copper be feasible?

61
62

d) Component removal.

(1)

(2)

(3)
(4)
(5)
(6)

(7)
(8)
(9)

As the second approach to reactor disassembly, evaluate the methods and tools
required to obtain complete components from the reactor.

Can suitable tools and techniques be employed in reverse to the assembly
process so as to free the top half of the pressure shell at the north head where
assembly welds occur such as the four auxiliary NaK lines and around the con-
trol rod thimble?

Can the various shell layers be freed in this type of disassembly?
Can all components required for study be obtained?
How will reactor be held rigid when the need for tilting arises?

Could this disassembly be done with such tools as grinder, large circular saw,
and milling tool?

As a last resort, would use of a cutting torch be permitted?
How will handling devices be influenced by the cutting tools used?

Would any of the reactor assembly fixtures be useful for this disassembly
method?

e) Section sampling.

(1)
)
(3)

(4)
(5)

(6)
(7)

As a third approach to reactor disassembly, evaluate the methods and tools re-
quired to obtain limited portions of severed and dismembered components by use
of large-diameter, deep-cutting tools.

Will dismembered pieces of components be adequate?

Could this disassembly be done with a milling tool or slow-speed saw, or per-
haps a grinding wheel?
Would cutting limits be fixed by tool size and cutting methods?

Would the cutting method be particularly influenced by the scheme for removal
of B,C tiles and B ,C~copper?

How will handling devices be influenced by the cutting tools used?

Would any of the reactor assembly fixtures be useful for this disassembly
method?

5. Tooling requirements.

a) Establishment of the disassembly tooling program, with evaluation of the following
possible tools:

(1)

Cutting devices.

(a) Horizontal cutting tool.

() Vertical cutting tool.

(¢) Interchangeable heads for both cutters.

i) Grinder head (large diameter disk).

ii) Miller or slow-speed saw.
iii) Boring head.
iv) Trepanning head.

(d) Electric discharge cutter.

(e) Ultrasonic cutter.

 

 
(f) Cutting torch with accessories, including water jacket cutting tools.
(g) Do-All band saw.
(2) Manipulators.
(@) Oman type with General Mills unit.
() Wall-mounted General Mills unit.
(c) Argonne-type mod. 8.
(3) Optical measuring devices.
(a) Periscope ~ Kollmorgan type.
(6) Optical rectilinear device — Lenox type.
(c) Binoculars and mounts.
(d) Gages and measuring tools.
(e) Microscope.
(f) Stereomicroscope.
(4) Tumntable rig.
(a) Main lift and turntable for reactor.
() Tool mounting ring for cutters.
(5) Miscellaneous.
(a) Portable tools, including saws, impact wrenches, shears, etc.

(b) Portable storage racks for tools, gages, etc.

E. Decontamination.

1.

What decontamination fluids should be used?

2. Techniques of decontamination.

a)
b)

c)
d)
e)

f

Are methods such as dipping or hosing likely to give satisfactory results?

Type of contamination removed — what will be its nature and what particular prob-
lems can be anticipated?

What checking methods should be planned? Should scanning probes movable by
manipulators be planned?

Identify the fluid handling problems. Can the wash fluid be recirculated? What
transfer, storage, and disposal problems should be anticipated?

Are there chemical hazards that can result from unremoved sodium, NaK, fuel, or oil
that must be considered?

Should methods for cleaning large parts from NaK, sodium, or fuel systems be pro-
vided to aid visval inspection?

F. Contaminated parts transfer and storage.

1.

2,
3.
4

Transport procedure.

Viewing methods.

Access arrangements.

System for parts identification.

a)
b)

Photographs.

ldentification plates.

63

 

 
64

c) Storage location identification.
d) Record system.
Future handling and disposal of parts.

a) Will all parts be passed through storage to GTHC? [f not, how are parts to be
handled for disposal? What are the dimensional and activity limitations?

b} Should the lead from the shield be washed for disposal instead of stored?

G. Experimental program requirements.

1.

Tools and gage development.
a) Establish requirements for and possibility of measurements during disassembly.

b) Evaluate cutting methods as they affect every material in the reactor — grinding,
milling, circular saw, etc.

c) Evaluate measurement methods — need for coordination of planning for ‘‘before’’ and
*“‘after’’ measurements.

d) Establish development contracts for gages, optical and measuring devices — Manco,
Lenox.

Decontamination development.

a) Techniques and fluids for decontamination of parts.

b) System and technique for cell, tool, and equipment decontamination.
Hot cell examination development.

a) Development of laboratory procedures and techniques for hot cell examination of
reactor parts and materials.

(1) Macroscopic and microscopic inspection.
(2) Physical testing.
(3) Metallurgical examination.

(4) Chemical analyses.

H. Testing and training requirements.

1.

2.

3.

Test disassembly equipment and procedures in a mockup facility prior to availability of

ADC.

For this purpose establish location, arrangement, and preliminary planning for the func-
tion.

Plan procedures and training program sufficiently to establish criteria for architect-
engineer design.

|. Design program requirements.

1. Verify the fact that the reactor design will satisfy requirements for its movement and

2.

3.
4,

placement with remotely controlled equipment. Will lifting arrangement be adequate?
Can reactor be affixed to disassembly turntable?

A preliminary design of the trailer shield should be prepared to ascertain feasibility of
transporting reactor.

Firmly establish location of facility.

Prepare layout and required design sketches and design criteria suitable for use by
architect-engineer for both facility and tools.

 

 
Prepare a preliminary proposal for the project.

Procurement specifications for disassembly tools, giving functional and operating con-
ditions, by architect-engineer.

Pictorial representations of disassembly operations, by architect-engineer.
Inspection tools — specifications suitable for procurement.
Architect-engineer design of ADC facility and mockup facility.

Make model of disassembly facility,

 

65

 
APPENDIX C. RDHC HOT CELL EQUIPMENT

Introduction

The equipment tobe installed and used in the dis-
assembly cell may be grouped into five general cate-
gories:

A, Handling Equipment

B. Cutting Tools

C. Observation Tools

D. Measurement Tools

E. Cell Service Equipment
The tools and equipment will be listed along with
the criteria for each, This outlines the plans for
the equipment at this time, Where only the name of
an item is given it indicates arequired tool for which
criteria had not yet been developed. The equipment
is based upon facility dimensions given in “ART
Disassembly Cell Facility Criteria.’*?

A. Handling Equipment (All Remotely Operable)

1. 30-Ton Crane, ~ Remotely operable with con-
trols at viewing windows or by easily attached pend-
ant; hook travel from 3 f+ above floor of lowest pit
to highest retracted position available with stand-
ard crane; adequate high and low speeds on bridge,
trolley, and lifting motion to permit accurate posi-
tioning and rapid equipment removal — use 7503
crane speeds as a guide; the crane track and power
supply shall permit the crane to pass through the
large shieldingdoors (a hinged track is envisioned);
a method is required for retrieving the crane should
it fail while the cell is hot,

2, Overbead Manipulator (Bridge Type). - Re-
motely operable from any viewing window; tele-
scoping support such as used on Farrell-Birmingham
or General Electric manipulators (this support would
carry a General Mills or a Borg-Warner type arm);
two of these units would be mounted on a single
bridge; each on a separate trolley; manipulator hand
would have to reach floor and retract to 21 ft above
cell floor or higher; coverage of full cell floor area
desirable,

3. Bracket for Support Structure. — Assume sup-
port structure plus reactor weighs 30 tons; bracket
to extend from wall far enough to support end of
bridge support; bracket to be readily removable
with manipulators.

4. Turntable and Lift. — The lift platform shall
be 8 ft in diameter; the lift capacity shall be 20

 

ll""’relimim:lry report by V. J. Kelleghan dated January
28, 1957.

2Appendix O of this report.

66

tons plus turntable; the lift shall lower the top of
the reactor 5 ft below the cell floor and raise the
bottom of the platform 3 ft above it; the lift pit
shall be drainable and a wiper shall seal the plat-
form edge to the pit wall; a locking device such as
opposed hydraulic cylinders shall lock the lift plat-
form in position; the turntable mounted on the lift
platform shall have a high and low speed to permit
its use for rough turning or accurate angular posi-
tioning; table diameter to be 5]/2 ft; table to have
self-centering 3-jaw chuck traversing from 60 in. to
30 in. circle,

5. Pump Gripper. — This tool will resemble ice
tongs or a gear puller and will be used for with-
drawing the fuel or sodium pumps after they are
freed by their jack bolts; the tool will be hung from
a crane hook on the manipulator.

6. Model 8 Manipulator. — A number of Argonne
National Lab Model 8 type manipulators will be re- -
quired; American Machine and Foundry is one sup-
plier of this type unit,

7. Radisphere. — A self-propelled and shielded -
vehicle for safe man entry into the hot cell is de-
sired; shielding equivalent to 1 ft of high density
concrete; integral air supply; two manipulator arms;
one-man capacity; communication; adequate viewing
to permit maintenance work; safety cable for re-
trieving car.

8. Holding Vise. — A number of positioning and
holding vises will be required for machining specific
parts,

9. Special Slings and Bails, — In order to pick up
some equipment with the head room available, special
slings will be required (this applies also to delicate
equipment with poor weight distribution); special
bails which fit the 30-ton crane hook and which can
be engaged remotely will be required.

10. Dollies for Lead Shield. — Dollies are required
to hold the sides of the lead shield while they are
disengaged. It is expected that the dollies used for
attaching the lead shield will be available for its
removal,

11. Jigs and Fixtures. — A number of drilling and
cutting jigs will probably be required for such things
as removal of the control red,

12. Handling Cans for Storage, — In the general
disassembly plan each piece removed will be decon-
taminated and placed in a large can. For smaller
parts, small cans will be filled and then placed in
the large cans., Two sizes of large cans are planned,

 

 
both 6 ft tall. One will be 3 ft in diameter and the
other 6 ft. There will be storage for 36 three-foot
cans and 3 six-foot cans. When a large can is filled,
a lid will be attached and the can placed in the stor-
age facility., The cans will be stainless steel and
designed to be readily decontaminated. The bail on
the can should facilitate remote handling.

13. Decontamination Equipment, — Decontamination
of severed reactor parts shall be accomplished in a
stainless steel pan. The pan shall be 8 ft in di-
ameter and have a 3-in. raised lip at the periphery.
It should have a low spot from which a small pump
can recirculate it through a nozzle for raising or
dumping it into a hot drain, The suction to the pump
shall be filtered so that large chips, etc., will re-
main in the pan, It should be possible to remove the
pan from the cell remotely. This may only require
appropriately placed lifting eyes.

B. Cutting Tools (All Remotely Operable)

1. NaK Line Saw. -~ A cut-off tool for the main
and auxiliary NaK lines is required, These are 3]/2
and 2" -in. Sch. 40 Inconel lines which must be cut
without distortion since the lead shield and shells
will be slipped over them. A saw, cutting wheel, or
end mill appears to be the most satisfactory tool for
this job.

2. Drill Head, — Drilling has been adiudged the
best means of removing large chips with minimum
tool rigidity while cutting irregularly shaped pieces
from the reactor, For this operation a Bridgeport
drilling head was chosen with means for positioning
it to be provided,

3. Drill Head Mounting and Positioning Unit. —
The unit for mounting the drill head shall carry the
head to the center of the lift platform. The head
should have vertical and horizontal travel of 5 in,
It should be possible to rotate and lock the drill
head at any angle from vertical to horizontal and
drill at that angle., Maximum drill size is 1 in, The
range of travel of the drill head positioning unit
shall permit drilling through a range of from 50 to
60 in. above the cell floor,

4. Coolant and Circulating System, — A cooling
fluid will be used in the drilling and cutting opera-
tions. A catch pan, filter, and return pump shall be
provided at the turntable to recirculate this fluid,
The catch pan shall not be larger in diameter than
the pit in which the lift table operates.

5. Guillotine, — A number of small lines and
instrument connections will have to be sheared off.

A Manco unit to be carried by a crane and operated
remotely will be used, One-inch Sch. 40 Inconel
lines will be cut with this unit, In addition, a large
shear with a 3Y-in. IPS capacity will be available,

6. Sealant Injector, - A tool similar to a stud
driver has been developed. This unit will shoot a
hollow needle into any of the Inconel pipes from the
reactor. A sealing medium will then be injected into
the line through this hollow needle much like a hypo-
dermic needle injection. The unit should be adjust-
able for 31;-in, to 3/B-in. Sch. 40 Inconel pipe. The
injector wi:il be used to seal a line before it is cut
off and thus contain contamination.

7. Impact Wrench. — The impact applied to the
shaft should be adjustable from that required to
loosen the smallest bolt to a maximum force capable
of shearing the largest bolt used in the reactor as-
sembly. The adjustment of torque to be applied by
the hammer should be suited to regulation with a
manipulator,

8. Cutting Torch and Accessories. -~ The torch
should be adapted to handling with a manipulator.

It will be used to cut Inconel as well as steel, so
necessary auxiliaries should be provided,

9. Do-All Bandsaw, - A Do-All bandsaw model
26 or equivalent shall be provided. Controls shall
be remote, and the unit will be located in the equip-
ment maintenance cell,

10. Portable Tools. — A group of portable tools
equivalent to those available to a maintenance me-
chanic shall be provided, These would include
hand tools, drills, grinders, cut-off wheels, impact
wrenches, etc.

11. Pinch-Off Shears, ~ A pinch-off shear similar
to a bolt cutter shall be adapted to remote operation,
This will be used to cut instrument tubing, ]/4-in. by
0.065-in,-wall stainless steel, and lead wires,

12. Special Cutters. ~ A group of special cutters
may have to be developed for disassembling the
sample and chem tech tanks.

13. Cutting Wheel and Mounting. - A pneumati-
cally or electrically driven cutting whee! shall be
designed. The mounting for this wheel shall be in-
stalled near the main turntable but only if operation
shows that a wheel of this type is required.

14. Remotely Operable Center Punch, ~Since one
method for cutting out of planes, etc., is by means
of drilling a series of closely spaced holes, a spring
loaded center punch is required, It should be possi-
ble to space the drilled holes by adding a locating
pin to this unit. In this way a group of equally

67

 
spaced centers can be located, The punch will be
set and used by a manipulator hand. Minimum hole
spacing ]/4 in,, maximum 1 in,

C. Observation Tools

1. Shielding Windows. — The shielding afforded
by these windows shall be equivalent to 5 ft of ba-
rytes concrete (230 Ib/cu ft}, The cold face of the
window shall be approximately 3 x 4 ft. |f a combi-
nation of glass and zinc bromide will give adequate
shielding at less cost than all glass, the combina-
tion window is acceptable,

2. Periscope. —~ The periscope will penetrate a
S5-ft-thick shielding wall. The floor on both sides
of the wall will be at the same elevation, The peri-
scope should extend to permit viewing from floor
level to 7 ft above the floor. It is expected that the
periscope will be used to look through a microscope
and to take pictures of small objects. Kollmorgan
Optical Corp. makes a number of acceptable peri-
scopes. The radiation level in the cell will be
6500 r/hr . Periscope lenses shall be non-browning.

3. Binoculars and Mounting. ~ The binoculars
will be mounted on the cold side of the observation
windows. A flexible support similar to BX cable
shall be provided. The two eyepieces of the bin-
oculars should be easily separated so that either
section could be used as a telescope. 8X binocu-
lars are acceptable,

4, TV Equipment. —A TV camera will be mounted
on the 30-ton crane. This camera would be capable
of viewing the hook through its full travel and also
pan around the cell for viewing operations on the
floor. The camera shall be remotely operable and
have one normal and one high-magnification lens,

5. Photographic Equipment. — A still camera for
use outside the windows and through the periscope
is required. The camera shall be of the reflex type
which permits viewing the image seen by the lens.
A movie camera is also required for taking pictures
of the disassembly methods and procedures to aid
others working on similar problems,

6. Borescope. — Borescopes for looking into small
diameter {0.210 in.) and larger diameter (3% in,) pipe
are desired, These should be approximately 36 in,
long and suitable for viewing through the periscope.
The glass used in these units shall be non-browning
in a radiation level of 6500 r/hr,

7. Portable Lights. -~ A free standing group of
sodium vapor and fluorescent lights is required,
These units should be readily lamped and balanced

68

for handling with a crane hook. These lights will
be used for picture taking and increased illumination
where required,

D. Measurement Tools

1. Coordinate Scope. - In measuring irregular
shapes such as shells it is felt that a telescope
viewed through a periscope could be developed. This
telescope would be carried on accurately calibrated
lead screws moving the scope in a vertical and hori-
zontal direction, |f the scope is always perpendicu-
lar to the piece to be measured, it can be sighted on
points and their coordinates determined. A travel of
60 in. is required in both directions. An accuracy
of $0.001 in. is desired in 6 to 12 in, dimensions
and +0.003 in. in the 50 to 60 in. range.®

2., Mechanical Measuring Device. — A mechanical
measuring device consisting of three vertical posts
is envisioned, Long travel dial indicators would be
attached to these posts and parts measured in re-
spect to the post spacing. Vertical measurements
could likewise be taken.

3. Photographic Measuring Unit, — An adaptation
of aerial mapping and lofting as used in the aircraft
industry is envisioned. In this procedure a picture
would be taken normal to the part to be measured,
perhaps with a grid background. The picture would
then be projected on a flat surface and measured,
An accuracy of 0,001 in, is desired. This photo-
graphic technique should also be extended to include
stereoscopic pictures for information purposes.

4, Gages and Measuring Tools, — It may be de-
sirable to have available a group of gages for par-
ticular measurements. These may be ‘‘go or no-go'’
gages, plug gages, depth gages, micrometers, cali-
pers, etc,

5. Portable Gage Storage Racks. — |t is felt that
any gage racks for storing gages, etc., within the
cell should be portable, so that definite areas will
not be required and they can be placed in available
space,

6. Crane Scale, — A dynamometer type crane scale
(010,000 Ib) is required. |t will be used to check
part weights and to make sure that a piece being re-
moved has been cut free,

7. Radiation Instruments. — Detectors which give
the radiation level in the cells are required. A port-
able unit is desired for inside the cell, Other de-
tectors will be located in the operating and other
areas for personnel protection.

 

3This system and others which have been studied are
reviewed in Sec 4.4.

 
 

E. Cell Service Equipment

The items listed in this category were intended to
cover the special features which are necessary to
meet hot cell requirements in addition to the gener-
ally accepted services.

These are listed as follows:

1. Shielding, — Adequate shielding is required
to handle the activity levels anticipated.?

2. Decontamination, - Facilities are necessary
to wash down all internal cell areas, giving consider-
ationto a complete spray system capable of remote
operation,

3. Contaminant Holding System. -~ Provision
will be necessary for all wash water to be held until
it is sufficiently low in count to be disposed of, or
otherwise safely handled,

4. 1lumination, — Several types of lamps will be
required, such as sodium vapor for general lighting
and mercury vapor for flood lighting. Lamp cooling
and ventilation are required in addition to accessi-
bility plugs for lamp changes.

5. Handling Equipment. ~ Provision must be
made to remove and replace the wall manipulator
shielding plugs, by means of a portable crane in
the operating area. This crane is also used to
handle master-slave manipulators when changing
them.

6. Crane Rails. — Both the main crane and the
overhead manipulator crane rails should be provided

 

4Described completely in Sec 5.

 

with swing-out sections to permit closing the main
doors of the main and intermediate cell, yet allow
direct travel of the cranes to the receiving bay.

7. Access Doors, -~ Personnel access doors to
both the main and intermediate cell will be required
from the ‘warm’’ areas,

8. Access Roof Plugs. ~ Special removable roof
plugs and means for handling them will provide a
cell of greater usefulness and enable it to handle a
wide variety of future work,

9. Shielded Cable Ways. — Adequate provision is
required for shielded cable ways, pipe tunnels, and
conduit paths to maintain the integrity of the shield-
ing, and to provide necessary drainage and decon-
tamination,

10. Lost Tool Transfer Schemes. ~ Provision for
bringing miscellaneous tools and samples to and
from the cell are required to reduce the need for
opening the large doors,

11. Miscellaneous Services, — Convenient outlets
will be required both inside the cell and in the oper-
ating area for 220-v ac, 110-v ac, air, water, intercoms,
etc,

12. Ventilation and Filtration System. — Contami-
nated cell air will be required to be filtered before
recirculating or being sent up the stack. Rough
filters which will hold the bulk of activity, chips,
etc., must be located inside shielded areas and
capable of remote handling and disposal. The air
cleanup filters must be accessible for remote han-
dling in case they become highly active during un-
usval conditions.

69
APPENDIX D. ABRASIVE GRINDING INVESTIGATIONS'

This memo describes two separate Inconel grinding
tests performed on two machines, one at a vendor’s
plant and the second at the ORNL SF Machine Shop,
Bldg. 3044,

Avisit was made to the Ty-Sa-Man Machine Co. on
May 22, by Frank McQuilkin, L. W. Love, and the
writer to observe their cutting and grinding machine.
A sample piece of Inconel plate was provided for
them to cut off, The object was to learn more about
their cutting methods and its possible adaptation to
our hot cell requirements.

The person contacted was James L. Hensley, their
chief engineer. He gave us a short tour of the plant
in order to familiarize us with the type of machine
they build. Most of them are custom-built units with
rather large travels intended for specialized heavy
cuts on plate. In general, the wheels and motor are
mounted on a carriage which moves back and forth
across the work, Cross travel is provided with trav-
erse tracks, like an overhead crane. The machine
which was used for our test was a 40-hp machine
using a Manhattan type 714 wheel of 24“dia. The
wheel operated at 1560 rpm with a rim speed of 9800
fpm. Water cooling was used. The selection of this
wheel was made on the basis of grinding studies
Ty-Sa-Man Co. had recently completed for Interna-
tional Nickel Company. The maximum motor capac-
ity of 40 hp was not utilized, but by means of an
ammeter it was observed that about 15 hp was the
maximum power used during the cut which they
made. The plate was Inconel of ¥/ thickness and
12" wide. The entire width of the cut was made in
2V, minutes, including a preliminary scoring cut
about ‘/N" deep. These results indicate that grind-
ing could be adapted to hot cell use with good speed
and precision, but the type of mounting would re-
quire redesign. The motor is mounted overhead and
drives the wheel spindle through multiple V-belts,
The belts follow a general ‘L'’ shape so that the
weight of the wheel and the spindle determines the
load on the cutting surface. This load can be varied
by means of counter weights, By oscillating the
wheel it was observed that no burning had occurred
at the edges of the cut, The finish is excellent,
and from the cutting rate it can be seen that this
method must be seriously considered in any tool
evaluation program.

 

]Memo from A. A, Abbatiello to F. R, McQuilkin dated
May 29, 1957,

70

Further work should be done to determine whether
a spray of water would be permissible in the shell
area and whether the metallic particles would spread
contamination throughout the cell to an intolerable
amount, This study should determine whether this
contamination is serious enough to warrant the extra
cost of an air circulating and filtering system, and
if so this could be weighed against the reduction in
cell time which such a grinding method would permit,

It is the writer's opinion that abrasive grinding as
a basic cutting tool would be practical but would re-
quire a change in philosophy in regard to contami-
nation within the cell. Although opinions differ on
this point, it has been proven, especially in the high
level cells at 4501, that activity as spread by such
a grinding operation may be washed out by a direct
rinsing method, and more serious thought should be
given to this as compared to the extreme difficulty
of manipulating a drill or end-milling operation to
produce all the devious cuts which must be made.
it is true that such a grinding wheel would make
necessary longer cuts (because of arc length) in
order to remove specific sections of the reactor, but
by using a wheel of about 24" dia. the depth of cut
which this type would permit would make practically
every area of the shell accessible. This should be
particularly useful in the areas around the Na ex-
pansion joint, the pump barrels, and the girth cut,

In case such a design is to be built, Ty-Sa-Man
Co. have prefabricated spindles available which
could be used as a basic element. The mounting of
this spindle in our case is primarily vertical, with
an adjustment to permit the rotation of the wheel
through an arc all the way from vertical to hori-
zontal, The wheel mounting must also be arranged
in such a manner that the wheel can travel in the
plane of the blade. This means that the entire drive
would be mounted so that it would be on a radial
arm to permit travel of the wheel in the direction of
the cut. This is particularly important in cutting off
the NaK headers, since the wheel must be mounted
at a 45°angle. These machines are controlled from
a central push-button control panel which would lend
itself to remote operation,

During the discussion which followed, Mr. Hensley
suggested a method for mounting wheels in a cell
for easy remote removal and changing. This con-
sists of mounting a Stewart-Warner type magnetic
clutch on the spindle flange and using a steel
bonded wheel which would then be held against the
face by a magnetic force. Two pins mounted on this
surface would drive the wheel, yet would permit easy
removal of the wheel in the event of breakage or
other reasons for changing. |t was his opinion that
in our case, where perhaps 5 hp might be used, we
might get by with dry wheels. For Inconel he sug-
gested a resin-bonded wheel,

A second grinding test was made May 28 on an
Inconel NaK header mockupusing a type M-75 Stone
saw made by the Stone Machinery Co. of Manlius,

N. Y. This machine is located at the SF Machine
Shop at Bldg. 3044,

This is a manual feed radial arm saw, The piece
cut was an assembly of three concentric pipes (3]/2','
3", and 2‘/2" Sch. 40 Inconel) mounted and welded
at a 45° angle to simulate the NaK header. The part
was clamped in the table vise, and the wheel pulled
down through the work. It is estimated about 10
pounds pull was used at the end of the lever arm.
Several times the cutting was stopped in order to
remove the cut portions of the pipes, yet in spite of
these slight delays, the first cut was made in about

2 minutes and the second cut was made in about 1
minute,

These cuts were made dry with a Carborundum Co.
Aloxite wheel No., A-243B-T36 operating at 2520
rpm. The wheel was 16" in dia, and % ” thick.
Wheel wear was about ]/32" on the radius for the first
cut and almost ]/16” on the second cut.

The radial type mounting of this motor and spindle
would lend itself easily to the type of mounting out-
lined previously. An eccentrically mounted built-in
gear head gives a clean exterior with adequate depth
of cut using the 16" wheel. Maximum depth of cut
with a new wheel is about 5” with this arrangement.

With this dry grinding, the spread of particles over
large areas is apparent, and emphasizes the need
for decontamination studies previously discussed.

A comparison of the two grinders investigated to
date points to the advantages of the Stone machine
saw with regard to type of drive, power available,
type of mounting, and maneuverability. When design
work for the grinding fixture proceeds, the use of
the Stone machine saw should be considered.

71

 

 
APPENDIX E. HELIARC TORCH CUTTING '

Introduction

The evaluation of cutting methods for hot cell
use has covered drilling, end milling, wet and dry
grinding, vltrasonic, and electric disintegration, A
Heliarc torch cutting method which was recently
made available was tested on Inconel.

There are two specific applications for this tool,
First, a torch capable of remote manipulation is
desired for use in the hot cell to reach difficult
areas of a reactor, and second, in cutting apart the
ETU, a manually operated torch would expedite
access to reactor internal regions, which it is de-
sired to study before ART assembly proceeds.

Description of Heliarc Torch

The Heliarc cutting process is a high tempera-
ture constricted arc between the tungsten electrode
and the work. The molten metal is blown out with
a mixture of hydrogen and argon to form a kerf. An
auxiliary circuit is used for arc starting. It has
been used successfully in stainless steels, Inconel,
and aluminum, The inert atmosphere prevents the
walls adjacent to the kerf from hardening, The
torch is capable of sufficient control to permit weld
preparation of thick plates with the minimum of
machining, which, combined with its high speed,
make it highly desirable in fabricating nonferrous
alloys.

The equipment which was used for this test was
a model FSH-6 installed at the Lucey Boiler and
Manufacturing Corp., Chattanooga, Tenn. In their
installation the arc voltage was obtained with two
400-amp welders connected in series to hold a
minimum of 115 volts on open circuit. Gas flows
of 40-60 cth of argon and hydrogen are required.
The hydrogen is 20 to 35% of the total flow. A
minimum of 2 quarts of water per minute is required
for adequate torch cooling.

Test Runs

A type 302 stainless steel plate 3/8" thick by
3 ft wide was cut through its full length in about
3 minutes, using the mechanized head.

Next, our piece, an Inconel plate 1/2" thick by
12" wide, was cut, leaving a small connecting
strip to indicate the width of the kerf, as shown in
Fig. E-1. This plate was cut in about 1 minute,

 

TMemo from A. A. Abbatiello to F. R. McQuilkin dated
July 5, 1957,

72

During this test the stainless steel plate used in
the test above was placed about ‘}4" below the
Inconel plate, Sufficient energy remained in the .
cutting stream to pierce and produce a slot in the
stainless steel plate. Although ali observers were
surprised, it was a welcome development because
a cut of multiple layers is desired for some appli-
cations,

The third test was on a section of three con-
centric pipes, 3'/2", 3", and 2‘/2", all Sch. 40
Inconel pipe. The cut was arranged for the axial
direction to permit a setup under the mechanized
head, which can only cut a straight line. The
torch successfully penetrated all three pipe walls
simultaneously. The rate of travel was about the
same as for the preceding cuts, about 1 ft per
minute. Slag and *‘icicles’’ were formed in large
quantities, but they were knocked off without too
much difficulty. See Fig. E-2. The molten ma-
terial which was blown out of the kerf solidified
on the opposite wall of the inner pipe, but did not
adhere, It was possible to raise one end of it
with a thin chisel, as may be seen in Fig, E-2.

Results

The results of this test indicate the following:

1. This type of cutting torch has high cutting
rates,

2. The control would be adaptable to remote hot
cell operation,

3. Large volumes of molten metal would be re-
leased into the reactor and hot cell areas, but the
harm which this might do is not obvious, without
better cold mockups and hot testing. Although this
slag is not too adherent, it will present a problem
merely to clear it away.

From these observations, it appears such a torch
would be a useful tool for both the ETU disassem-
bly and the ART. It may be considered versatile
and maneuverable in close quarters, but is probably
not a cure-all. Problems of arc starting and manip-
ulation under remote conditions will have to be .
worked out. The large quantity of molten metal
removed from the kerf will be detrimental regarding
activity spread.

In general, this torch appears to be sufficiently
useful to warrant its purchase, The first applica-
tion could be the girth cut on the ETU, which would
be a formidable job under conventional machining

 

 
UNCLASSIFIED
PHOTOQ 29112

SRR |
& ot

 

 

Fig. E-2. Three Concentric Inconel Pipes Cut by Heliarc Torch.

73
techniques; for instance, using a boring mill and
standard lathe point tool. Grinding would also be
a suitable method for this cut,

It is recommended that this equipment be pur-
chased and development started on special tooling
and training personnel in its use. At the very
least, it may be looked upon as the ‘‘fireman’s ax’’
type of emergency measure when all other types of
cutting devices still leave cuts necessary.

74

Acknowledgments

The idea of using this type torch was first pro-
posed by Mr. M. Bender. Arrangements for the use
of the installation at Lucey Boiler and Mfg. Corp.
for this test were made by Mr. Earl Woods of the
Linde Company in Knoxville, Tennessee. The co-
operation of Mr. R. C. Trane, Jr., Manager, and
R. S. Lane, Plant Superintendent, of Lucey Boiler
Corp. was most helpful.

 

 
 

APPENDIX F. ULTRASONIC CUTTING (ALSO CALLED lu"n;l!t(:"rl*n[ETllZISTRICTI'L'.II'J]I1

Evaluation of cutting methods for cutting Inconel
which might be applied to hot cell conditions has
continued. Interlocked drilled holes, grinding, and
Elox cutting have been previously reported. Ultra-
sonic cutting was also considered because of its
potential value in cutting hard materials, but since
large amounts of Inconel would also have to be cut,
severing rates on Inconel were important. This
test was an evaluation on cutting Inconel only.

The equipment used was the Cavitron, made by
the Sheffield Corporation, of Dayton, Ohio. The
machine is located in Bldg, 2525, in the Central
Machine Shop Facilities.

The process may be described as a cutting action
produced by flowing an abrasive fluid over the sur-
face to be cut and accelerating the abrasive par-
ticles by means of a high frequency (about 20 kc)
imparted by a ram which travels about 0,0005" and
is attached to the driving member, The fluid con-
taining the abrasive also serves to wash away the
particles removed in the cut,

The cutting tool was a narrow stainless steel
blade, '/16" X 156" in section, The machine was
operated at frequencies of 19.5 to 20.5 ke with a
vertical load of 3 |b 6 0oz. The cutting fluid is a
suspension of water and 280 grain size boron
carbide, called Norbide, made by the Norton
Company. The Inconel sample was the same
piece as had been used for the Elox test, a partly
curved section about I,Q" thick by ];&” wide,

Conclusions

1. After operating the machine for one hour, a
notch about 0.025 “ deep had been started near the
upper corners of the Inconel bar, which had con-
tacted the blade. See Fig. F-1.

2. The results are unsatisfactory on Inconel,
which is considered relatively soft.

 

1Mumo from A. A, Abbatiello to F. R. McQuilkin dated
June 25, 1957.

UNELASSIEIED
BMEOTE 20087

 

 

 

Fig. F-1.

Ultrasonic and Elox Cutting of Inconel.

3. This process is better adapted to the hard,
brittle materials, like quartz and B ,C, which are
difficult to cut with ordinary cutting methods,
Under these conditions the low cutting rate is
acceptable for these hard materials.

Recommendations

Based on the above test, no action is recom-
mended on ultrasonic disintegration for hot cell
use, unless it is necessary to cut material which
is too difficult for ordinary means. Interior sur-
faces of the B ,C tiles appear to be one of the
spots where the process could be applied, but it
is proposed that these tiles might be chipped to
expose these surfaces.,

Acknowledgments

We are indebted to Merle Brown and Dick Fox of
the Central Machine Shop Facilities for the use of
this equipment,

75
 

APPENDIX G, ELOX CUTTING'

The problems of severing active pieces during
disassembly require the development of a number
of cutting methods. Grinding, drilling, and Heliarc
torch cutting have been considered. One process
which has been suggested but has not yet been
evaluated is the Elox cutting process (also called
electrical disintegration).

An Elox machine was made available to us
which had been used for experimentally cutting
apart fuel elements, A test was arranged to cut
Inconel plate in this machine.

The machine used is located in Bldg. 4505 in the
Unit Operations Section of the Chemical Technology
Division, and is a model M-500, serial 149, To de-
scribe this process simply, one might say that it
operates like a welding machine, except that the
material is vaporized by means of an electric arc
and washed away instead of fused. A current is
passed through the electrode, which can be of any
shape to make a particular cut desired, and then to
the work to complete the circuit. Usually, the en-
tire area to be cut is submerged; or it may be sprayed
with either a conducting oil or in our case a de-
mineralized water was used. The electrode wears
away at about the same rate as the material which
is removed in the cut. The process has the ad-
vantage of making any odd-shaped cut which can be
made using a plunge-type movement, and producing
a cut close to the dimensions of the electrode. The
material removed by the arc is vaporized into tiny
globules and is floated away by means of the circu-
lating fluid.

Tests Run

Four test runs were made, three of them using
Inconel, and the last one, as a check, was made
with stainless steel. The Inconel plate was about
12" % 1% " in section and was slightly curved, See
Fig. G-1. It was clamped into the vise and placed
below the solution level, The electrode was a
brass plate about 0,030" thick and was mounted
from a vertical head, The rate at which the blade
or electrode is advanced depends on a device built
into the head which automatically maintains the arc
gap. In the first test a cut of about !"3 " deep was

 

IMumo from A. A, Abbatiello te F. R. McQuilkin dated
June 20, 1957,

76

made in about 3 min, After this period, some errati
operation was encountered and the operation was
stopped without completing the cut.

The other end of the Inconel plate was then set
up and the test repeated using a new section of the
electrode, This time it was permitted to run about
9 min, but the depth of cut was approximately the
same as before with erratic operation during about
the last half of the peried.

The first test was made with the test piece sub-
merged but no forced circulation, The second test
was approximately the same except that the circu-
lating pump was started and the liquid forced
across the cut section to remove the particles in
an attempt to obtain steady operation. This was
not successful,

The third test consisted of a hollow brass elec-
trode about % ” in hexagonal end section with a
V™ hole through it. The object was to force liquid
through the electrode and thereby wash the particle
out from the arc area. In this test it operated for
about a total of 9 min, but again the last half was
erratic in operation and the depth of cut was only
about %32#.

In order to determine whether the Inconel was
causing this difficulty, a fourth test was run using

URCLATSEFIED
PHOTO 19088

 

 

Fig. G-1. Inconel Plate Cut by Elox Process.

 
the same hexagonal vertical electrode but the ma-
terial was changed to stainless steel. After about
7 min operation the depth of cut was about the
same (3/32") as had occurred in the Inconel plate.

In none of the four tests was complete severance
obtained.

The conclusions which might be drawn from this
test are as follows:

1. The cut proceeds at a relatively slow rate but
makes quite a clean-cut edge, therefore would be
desirable for thin, light sections.

2. The electrode is consumed at approximately
the same rate as the cut is made,

3. The particles which are removed from the cut
are confined to the liquid solution, which might be
desirable for limiting contamination,

4, The erratic operation which was noted was
not fully explained. It may be possible to improve
the operations which were noted here, using the
following suggestions:

a) A wider electrode, perhaps '/]6” thick, might
give higher current density and better alignment.

b) A higher velocity and better flow of water
through the gap might prevent some of the erratic
operation,

c) It is suggested that the manufacturer be asked
to tell us what was being done incorrectly in this
test, or whether there was something basically
wrong with this particular machine.

d) An electrode of trapezoidal section, wider at
the base, might be used to automatically increase
the clearance as the cut is deepened. The same
effect might be produced by applying an electri-
cally insulating paint to the side walls of the elec-
trode.

In trying to determine where this process could
be applied, it is apparent that submerging a com-
plete reactor in order to put the electrodes in a
submerged position is impractical, However, it
may be possible to use the Elox process in one of
the auxiliary hot cells. |t could be used for the
removal of specific smaller specimens after the
major elements have been taken off the reactor,
especially in cases where the part is fragile and
sawing or grinding might damage the specimen
(such as the heat exchanger bundle). As a side
comment this method has been used at the G-E hot
cell at the MTR for severing their thin-wall fuel
elements. It has been used successfully, but in a
discussion with Mr. Dave Durrill (in charge of the
G-E hot cell) he mentioned that they were no longer
using this process, but were shearing their fuel
elements instead.

Two other previous tests might also be noted
here. A piece of B4C could not be cut on an elec-
trical disintegration type machine, apparently be-
cause of insufficient electrical conductivity, How-
ever, a piece of Cu—-B ,C was successfully pene-
trated using this method.

Sawing may also be used on Cu~B ,C but it is
impossible to saw B ,C. The precision cuts made
with the electrical disintegration method make this
process attractive for Cu~B C in spite of its slow-
ness.

Acknowledgments

We wish to acknowledge the courtesy of Mr. C. D,
Watson for the use of this equipment, and for its
operation to Mr. George A. West.

77

 

 
APPENDIX H. A COMPARATIVE CONTOUR MEASURING SYSTEM'

In hot cell operation, it is desired to compare
critical reactor parts before and after they have
been operated. To do this, photographic records
have been considered. One of the early systems
which was proposed was a grid projecting system
whereby a cross-section grid would be projected
on a spherical surface from an angle. The photo-
graph of this grid shadow on this spherical surface
would cause a contour to be produced, Any varia-
tion from the normal would cause the curved lines
to deviate from a circular arc. One problem with
this system is that it is too difficult to project a
series of lines on a surface with sufficient defi-
nition to make them readable to the accuracy re-
quired,

2

 

IReporf by A. A. Abbatiello dated May 31, 1957,

2M. G. Willey, Lofting, memo to A, A, Abbatiello, dated
March 6, 1957,

OBJECT TO BE MEASURED 1S PLACED HERE

VERTICAL LINE LIGHT SOURCE

A system has recently come to our attention
which overcomes this objection, |t has been de-
veloped by K. B. Jackson? and is described in
Photogrammetric Engineering.* The system con-
sists of a wire grid placed close to the object to
be measured. A vertical light source at a 45°
angle from the side produces a shadow of this wire
grid on the surface being studied (see Fig. H-1).

A camera directly in front of the object to be meas-
ured photographs both the grid and its shadow, thus
the difference between the two lines as measured
in the photograph will give an indication of the
space between the grid and the contour surface.
Since the grid consists of a series of vertical
wires accurately spaced and stretched taut, it
represents a true grid, and by making the light

 

3Depf. of Applied Physics, University of Toronto,
Toronte, Canada.

4Plsotograr."zr;rze1.'rz'c Eng. 21, 71-76 (March 1955).

UNCLASSIFIED
ORNL-LR-DWG 35472

  
   
   
 

BUMPER TO CENTER ON
MOUNTING LUGS

GRID, 3 x 3ft

 

 

CAMERA, LIGHT SQURCE, GRID, AND LEVELS
ARE MOUNTED ON ONE DOLLY, CAPABLE OF
BEING MOUNTED DIRECTLY ON FIXED POINT
TO BE MEASURED.

Fig. H-1. Contour Measuring System.

78
 

source angle 45° it is possible to directly measure
on the film surface the deviation between the verti-
cal line and its shadow.

This scheme might be adapted to cur require-
ments as follows:

A dolly would be built upon which would be
mounted the grid, camera, and the light source
arranged at three corners of a 45-90° triangle.
The front end of the triangle (at the grid) would
carry a bumper stop which would be adjusted to fit
the machining lugs of the shells, By aligning the
dolly in front of the reactor it would be possible
to make a photograph of the projected grid lines
and the grid in the manner used by Jackson. By
taking this series of photographs at each of the
lug locations, the generai contour of the reactor
can be produced. |t would probably be impractical
to take in the area beyond the NaK connections,
but this might be adequate. These would be pre-
served, and a similar set of photographs could be
made after the reactor had been set up in the hot
cell, using the same rig. It would be possible to
move the rig by means of the crane and shield the
camera with a lead box up until the time the ex-
posure was to be made. The complete rig could
then be raised and brought into the auxiliary cell,
where the film could be removed and a new one
set, or change plates in the camera remotely.

Such a system would have the advantage of
being a totally self-contained unit capable of being
carried to the reactor as it was assembled and the
original record photographs made. The same unit
would then be available for use in the hot cell. It
does not require an extremely accurate camera, as
would be true with the photo-lofting process, since
the grid wire and its shadow becomes the item of
measurement,

As shown in Fig, H-1, the dolly becomes the
carrier and the mounting unit for the camerq, the
light source, and the grid. The position of each of
these units is critical and therefore should be
fixed on the mounting device and retained. A level
in both directions should be added, so that all the
photographs taken would be level regardless of
slight variations in the floor. The base line pro-
duced by the lower edge of the reactor mounting
lug would be the point from which the unit would
be indexed. This device would be used to make
photographs of the reactor as it is assembled.

In the hot cell a similar arrangement using the
same points of reference on the reactor surface
would be used to get the second set of pictures.
The photographs could then be compared and dif-
ferences noted and measured. A correction may
be required for the possible shift in lug reference
point.

Briefly, this contour measuring system appears
to be a simplified version of photo-lofting which
could be directly applied to our requirements. |t
is particularly attractive because the entire de-
vice can be mounted as one unit, carried about
both during the reactor assembly and in the hot
cell, Its cost should not be excessive because
the camera need not be an accurate item and the
light source is merely a vertically aligned tube,
The grid consists of a set of thin wires arranged
on a framework, with the entire unit placed on a
structural steel dolly capable of being transported
and retaining the three-element relationship.

This scheme is submitted for consideration and
possible construction of a test setup designed to
evaluate it.

79

 

 
APPENDIX I. FLAME SPRAYED REPLICAS'

Preliminary trials to determine a suitable method
of making replicas were made using a rejected
Shell | as the surface to be reproduced. Scribe
lines were placed every 30° around the shell and
2" apart vertically. The scribe lines were located
with an accuracy of 0.001".

The first spraying trial was made at X-10 Metal-
lurgy with a metalizing gun assigned to Mr, H.
Inouye.

The first trial was made with aluminum wire.
Aluminum would not build up on the Inconel sur-
face. It was dislodged by the air blast of the gun
as fast as formed.

The second trial was with Spramold wire, a lead
alloy. The lead adhered readily and showed good
detail but could not be removed in a reasonable
thickness without bending. Some blistering of the
lead occurred during spraying, but thorough clean-
ing with acetone of the Inconel surface stopped the
formation of blisters,

The third and fourth trials were made with an
estimated 0,020" thickness of lead backed with
0.005" to 0,010" of aluminum. There was con-
siderable variation in thickness from point to point
on the surface due to the impossibility of judging
accurately, during spraying, the thickness already
applied.

The aluminum backing caused the replica to curl
away from the surface. While this facilitated re-
moval of the replica, it made impossible the accu-
rate measurement of distances between points on
the replica.

A sixth trial was made at the main Y-12 machine
shop with the cooperation of Mr. W. C. Collins.

In this trial the surface of Shell | was carefully
waxed and polished with Simoniz wax. Spramold
wire " in diameter was used. An area covering
approximately 120° x 8" at the small end of the
shell was delineated with pressure sensitive tape
folded to produce a parting ridge about 3/8" high.
The area thus marked out was sprayed with the
Spramold wire to a maximum depth of 0,170".
There was considerable variation in thickness,
with a minimum of perhaps 0,125”. The spraying
operation required about 25 minutes. The shell
heated up during spraying to an estimated 200°F.

 

]Memo from L. W, Love to F, R, McQuilkin dated
April 23, 1957.

80

The replica and shell were allowed to cool to
room temperature before attempting removal of the
replica. The pressure sensitive tape (cloth backed)
was pulled away, which permitted the replica to
fall off. No prying or rough handling was required.
The reproduction obtained was excellent. There
were some blisters, which were thought to have
been caused by excessive wax. Fortunately none
of the blisters occurred on a scribed line.

The replica was then measured with a radius
sweep gage, with the following four results:

Radius of Radius of Difference
Locatien Shell Replica .
(in.) {in.) (in.)
Station 7 (top) 3.407 3.4035 -0.0035
Station 6 3.432 3.4445 +0.0125
Station 5 3.598 3.6108 +0.0128
Station 4 3.898 3.9109 +0.0129

Measurements of the 2 vertical distances be-
tween the circumferential scribed lines were meas-
ured on the contour projecting gage with the fol-
lowing results:

Inches
Distance from station 7 to 6 2.0000
Distance from station 6 to 5 2.0000
Distance from station 5 to 4 2.0006
Distance from station 4 to 3 2.0003

The sixth replica, prepared at the Y-12 machine
shop, is quite rigid and with reasonably careful
handling will not bend out of shape. The radius
measurements indicate that the replica was warped
somewhat either during spraying or while cooling.
It is believed that the lack of warping at the top
was caused by the flow of molten lead over the top
edge of the shell, which tended to hold the replica
to the shell at that point.

The operation of the metal spraying equipment
required considerable adjustment and trial before
satisfactory spraying could be accomplished. How-
ever, at neither X-10 or Y-12 had the operator a
previous experience in spraying lead.

 
A, A, Abbatiello and L. W. Love visited the
Osborne Equipment Company in Knoxville to try
the spraying of gypsum cement with Bondact
cement spraying equipment,

The equipment consists of a mixing gun in which
water and cement are combined and sprayed on a
surface with an air blast, a hopper for feeding the
cement into the air stream, a pressurized water
tank, an air compressor, and suitable hoses.

About 25 |b of Ultracal 30, a trade name of the
U.S. Gypsum Co. for a low-expansion gypsum
cement, was taken to Knoxville for the trial spray-
ing.

The Ultracal 30 was sprayed on a part of a re-
ject Shell I, One half of the shell was oiled with
30W lubricating oil applied with a rag in a light
to moderate coat. The other half of the shell was
not coated. Separating strips of plywood ]/2" X l/2 !
were taped to the shell 180° apart to provide a

means of separating the two halves of the cast.

The equipment with which the trial spraying was
carried out was old, with an unsatisfacotry design
for controlling the flow of cement into the air
stream, At least it was unsatisfactory when used
with Ultracal 30. The equipment operated errati-
cally due to variations in the rate of flow of the
gypsum cement. The operator was unable to ad-
just the flow of water to correspond to the flow of
cement, with the result that the mix was either too
wet and flowing or too dry, which caused it to blow
away as dust., It is estimated that about one-fourth

 

1
Memo from L. W, Love to F, R, McQuilkin dated May 28,
1957.

 

APPENDIX J, SPRAYING OF GYPSUM CEMENT'

   
 

of the 25 Ib taken to Knoxville was actually ap-
plied to the shell. The remainder was splattered
or dusted over the environs.,

After a few minutes' operation the Ultracal 30
hardened in the gun, which then had to be dis-
mantled and cleaned before work could continue,

The coating applied varied from 3/16” to /8”'
it is believed that a more uniform coating could
have been applied if the operator had been able to
give his attention to the spraying operation rather
than to continual adjustment of the equipment.

The replica from the oitled side of the shell was
removed without difficulty. There was clean sepa-
ration except for one spot about 1 sq in. in area,
This replica showed some detail but did not com-
pare in clarity with the flame-sprayed lead. The
surface was somewhat dusty,

The replica from the side of the shell which had
not been oiled was removed with somewhat greater
difficulty but was nonetheless removed without
breaking. This cast adhered over the principal
part of the surface, leaving an irregular thin coat-
ing of gypsum cement, This replica does not show
fine detail but does conform closely to the con-
tours of the shell. Both replicas are sufficiently
rigid and strong to withstand handling.

It was concluded as a result of this test that the
spraying of gypsum cements was not practical for
a hot cell operation. This conclusion was based on
(1) production of excessive splatter and dust,

(2) erratic operation of the equipment, (3) plugging
of the gun with gypsum cement,

It is recognized that (2) and (3) above could
probably be overcome with further trials or rede-
sign of parts of the equipment, but the final result
to be expected would not justify the time and
money required.

 
APPENDIX K. CAST GYPSUM CEMENT REF’LICASl

In order to evaluate gypsum cement as a replicating material, four types were ordered from the

U.S. Gypsum Co. These cements have the following properties as reported by the manufacturer:

Type Name Setting Time Setting Expansion Dry Compression Strength
of Cement (min) (in./in.) (Ib/sq in.)
Ultracal 30 2535 0.0003 7,300
Ultracal 60 75-90 0.0002 7,300
Hydrocal B-11 2025 0.0005 3,800
Hydrostone 20-.25 0.002 11,000
The first cast was made with Ultracal 30. Into a box of suitable size a mix of 181/2 Ib of

water and 50 |b of Ultracal 30 was poured. A rejected Shell | with Lucite end plates was
pushed down into the box until it rested on wooden stops previously located. A second mix was
prepared of ]23/4 Ib of water and 35 Ib of Ultracal 30 and poured on top of the first to bring the -
final level up to the point where half the shell was immersed. Silicone Valve Seal ‘‘A’" was used
as the mold release agent. In addition, ha!f the immersed area of the shell was coated with -
sprayed lacquer. The cast was removed by striking the free side of the shell a few blows with a
hammer, using a block of wood to prevent damage to the shell.
The replication was only fair in this first case. There were a considerable number of air
bubbles trapped in the cement on the underside of the shell, too much mold release agent was used
causing poor detail, and the shell apparently shifted slightly during the second pour.
It was decided that a different pouring arrangement was necessary. A mold box was prepared
so that the cement could be poured over the top side of the shell rather than immersing the shell
in the cement. Four replicas were prepared of Shell | using the four types of gypsum cement listed

above and the improved mold box. Results of these trials were as follows:

Ml . . .
Cement oo Como Ié Mold Release Quality of Esfli;n:;:::dlli);:::s;?nal
ater ement : ;
(Ib) (Ib) Agent Replication 2" Grid Lines
Ultracal 30 18.5 50 D.C. Valve Poor - too much mold Could not measure .
Seal “‘A”’ release agent
Ultracal 60 19.0 50 D.C. Valve  Improved - too much 2.00"
Seal “'A"’ mold release agent .
Hydrocal B-11  20.0 40 D.C. Valve Satisfactory 2.00"
Seal ‘A"’
Hydrostone 16.5 35 D.C. Valve Satisfactory 2.01°
Seal “‘A”’

 

IMemo from L. W. Love to F. R. McQuilkin dated May 27, 1957.

82

 

 
The estimate of dimensional reproduction was made visually with a scale marked in 1/64" gradu-
ations. Appearance of the replicas indicates that in all four cases too much mold release agent
remained on the shell. The Dow Corning Valve Seal ‘A"’ is too viscous and thus hard to wipe
off. It is believed that Dow Corning Mold Release Emulsion 35B, which has recently been re-
ceived, would improve the replication detail.

It is reported that D-C Valve Seal ‘““A’’ can be dissolved with methylchloroform but not many
other solvents. D-C 200 fluid, which is believed to be the base for Emulsion 35B, can be removed
by amy! acetate, gasoline, perchloroethylene, and trichloroethylene, among other solvents. There
thus appears to be considerable advantage to using Emulsion 35B. [t should work also with the

flame-sprayed lead.

 

 
84

APPENDIX L. OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS
(ZINC BROMIDE)'

One of the principal objectives in hot cell operations is the accurate measurement of parts by
remote means. Optical methods have been considered but have not been evaluated on their basic
accuracy. In order to clarify this point a test was set up at the Solid State Division Hot Cell in
Bldg. 3025, using available equipment.

The basic instrument used was a Gaertner Scientific Co. cathetometer No. 2832 borrowed from
the Solid State Division. A piece of accurately finished dowel pin 0.437" dia by 4" long was
used as the test specimen. To show the effect of surface reflection, one end was left shiny and
the other was painted with Dykem. An oxidized surface might have been a better nonreflecting
surface, however.

In order to get a comparison of the dimensions obtained with no window and then through the
window, a set of readings was first obtained with the cathetometer and the sample set up outside
the cell about five feet apart. The specimen was then brought inside the ceil and the cathetometer
set up directly in front of and normal to the window. When these readings were completed, the
cathetometer was moved to test the effect of looking through the window at an angle. Two sets of
angular data were taken, the first being at an angle of 15° looking up at the specimen and the sec-
ond at an angle of 30° from the side. Several individuals were used to take different readings in
order to determine the possible variations which might be expected. The data are presented at the
end of this memo.

The conclusions which may be drawn from this test are preliminary, but are sufficient to
change some original concepts and to warrant further work.

1. An examination of the data indicates there is no marked difference in accuracy between the
readings taken with the specimen outside and those taken with the specimen inside the cell.

2. The reflected highlights from both the clear and darkened end of the sample tend to give
low readings. As the operator becomes more experienced in knowing what to look for, this error
becomes less, Oxidized surfaces would also tend to reduce this error.

3. Angular readings through the zinc bromide window do not reduce the accuracy, but the
angle increases the chromatic aberration. However, this effect appears tolerable if the telescope
used is limited to 3 or 4 power.

4. This system has an inherent disadvantage in that it is slow and requires pre-established
reference points. The points must be easily identifiable.

5. The results obtained with zinc bromide windows indicate such a measuring system would
be feasible if it were decided to use it.

6. Further checking to determine the limitations of such a system working through multilayered

lead glass windows appears as a next step, to check for effect of density and surface variations.

 

lMemo from A. A, Abbatiello to F. R. McQuilkin dated April 15, 1957,

 
7. It appears feasible for a good operator, with a little practice, to obtain readings of the order

of +0.000” to ~0.007" using this method.

Data Taken

The first set of data was taken outside the cell, with both sample and cathetometer set up

about five feet apart. Normal diameter of specimen is 0.437" as measured with direct readin
9

micrometer calipers. (Note: 0.437” dia = 11.07 mm as the cathetometer was calibrated in milli-

meters. All readings were taken in millimeters and converted to inches.)

Readings Outside Cell

Diameter Reading

Operator Location ,
(in.)
A Dark end 0.436
W Light end 0.431
SwW Light end 0.421

Operator Location

Dark end
Light end
Light end
Dark end
Dark end
Dark end
Light end
Dark end
Light end
Dark end

> > > > 0 Vv x> » > >

Reading with Sample Placed Inside Cell

Angle (in.)
Normal 0.426
Normal 0.430
Normal 0.434
Normal 0.428
Normal 0.422
Normal 0.424
15° up 0.436
15° up 0.426
30° side 0.425
30° side 0.432

Variation

(in.)

Diameter Reading

Notes

-0.001
—-0.006
--0.016 His first try

Variation

(in.)

Notes

-0.011
-0.007
-0.003
-0.009
-0.015 His first try
-0.013
-0.001
~0.011
-0.012
~0.005

85
APPENDIX M. OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS
(EARLY DESIGN LEAD GLASS)! -

The purpose of this memo is to report the results
obtained by measuring a piece of Inconel in a hot
cell through a lead glass window. The object was
to repeat the test made on the zinc bromide win-
dows and reported on April 15.2 The evaluation of
measuring through lead glass will determine the
feasibility of optical tooling instruments mounted
outside cell windows,

The same cathetometer as used for the previous
test was set up in Bldg. 4501 B cell, lower win-
dow. The window in this cell is about 20" square
and 3 ft thick, Unfortunately this window is one of
the first lead glass windows installed, and there-
fore its quality is not representative of present day
windows. However, for the purpose of this test it
was desired to make the conditions as severe as
might be met in practice to determine what the
upper limits might be,

The sample was a piece of %" Sch. 40 Inconel
pipe which had a dull oxidized surface finish simi-
lar to what is expected in our hot cell. The pipe
was mounted in a ring stand and placed in the cell.
The cathetometer was placed on the outside of the
cell window on a table, The pipe diameter was
0.831" -0.832" and was quite uniform, although
the pipe was slightly curved — about 24" radius.

Since the cathetometer is calibrated in milli-
meters, the conversion of the 0.832" diameter of
the pipe becomes 21.13 mm, and this is taken as
the normal reading for the pipe diameter. It will
be observed that in the data sheet the diameters of
the pipe as recorded will vary in location depend-
ing on which section of the glass area was used
when the measurement was made,

Measurements (Table M-1) were made in approxi-
mately five places. Position A was on the lower
right-hand corner (4" from each edge) of the glass,
perpendicular to the surface. Position B was on
the lower left-hand comer, also perpendicular to
the surface. Position C was approximately the
same as Position A, i.e., on the right-hand side,
but looking through the window at an angle of 15°
to the normal. Position D was taken from the left

 

IMemo from A. A. Abbatiello to F. R, McQuilkin dated
May 17, 1957,

2A. A Abbatiello, Optical Measurements Through Hot
Cell Windows (Zinc Bromide ), memo to F. R. McQuilkin
dated April 15, 1957 (Appendix L of this report).

86

side of the window (near B), looking at an angle
of about 22° from the normal. Position E is the
same as Position D except that it was lowered
4", and therefore this line of sight is paralle| to
D but 4" below it, still 22° from the normal.

As in the previously reported experiment, several
observers were used to take readings in order to
determine the variations between individuals. The
conclusions which may be drawn from this experi-
ment are as follows:

1. The groups of readings which are taken
through the particular zone of the window will show
reasonable agreement (about 10,003 ).

2. Rather wide differences were found at the
different points measured, +0.007", +0.020",
+0.013", +0.020", +0.012”., Since this window is
one of the first built, it is expected that it would -
have rather wide variations, A newer window
about 4 ft thick is on order but will not be de-

livered until about another month, |f desired, the =
test could be repeated, but this is not felt neces-
sary,

3. These tests could be repeated from the newer
window, but it may be stated generally that meas-
urements through the lead glass will be limited in
usefulness to the long dimensions,

4. It will be noted that the angluar measure-
ments did not introduce the higher inaccuracies
which might have been expected, or the high chro-
matic aberration which was noted through the zinc
bromide windows. This may be partially explained
by the lights used in the two different cells. Less
chromatic aberration was noted in this window, The
type of light used is fluoride mercury vapor. For-
tunately, this effect will make it possible to use
higher power telescopes, if desired. (The test in-
strument was only 3 to 4 power.)

5. Another conclusion which may be drawn is
that in practically all cases the measurements
read oversize, whereas the previous measurements
through the zinc bromide windows were all under-
size, It is believed that the basic cause for this
difference is the color of the finish on the speci-
men., The rather shiny surfaces on the specimen
tested in the zinc bromide windows tended to pro-
duce highlights which caused the observer to read
the lighter edge, which would result in a low read-
ing.

 
6. Because of these oxidized surfaces and also
because of the light colored background in the
cell, it was possible to establish the edge of the
specimen with good precision, |t may not be pos-
sible in all cases to duplicate this condition when
the work starts in the hot cell, but this method
may be an aid, that is, to provide a light back-
ground surface so that any darker object which
would be placed before it would produce a shadow-
graph type of image.

The general results of this test seemed to indi-
cate there is a possibility of using the Brunson
optical tooling bar or similar equipment for limited

applications from outside the cell wall, This is
not recommended for the small high accuracy di-
mensions, |t may, however, be suitable for the
large dimensions which are required across the
major reactor proportions., |f the error which lead
glass introduces is a constant, a variation of
0.010" to 0.020” may be tolerated in the longer
dimensions,

Acknowledgment is made to Oscar Sisman and
George Parker for assistance in arranging for the
use of the 4501 cell, and to W, E. Brundage of the
Solid State Division for the use of the cathetom-
eter.

Table M-1. Data on Lead Glass Window at Bldg. 4501

Window:

Bldg. 4501, cell B, lower, 19" x 19", 3 ft thick

Specimen: pipe, diameter 0.832" = 21.13 mm

 

 

 

Reading Reading Difference Deviation
Run Position By Top Bottom . Notes
(mm) (in.)
(mm) (mm)
1 A WK 87.03 65.53 21.50 +0.017
2 A AA 89.96 65.68 21.28 +o.oo71 View normal to surface;
3 A AA 87.26 65.87 21.39 +0.010 , _ o
specimen tilted about 5
4 A WK 87.05 65.77 21.28 +0.006
5 A AA 86.91 65.38 21.53 +0,016
6 A AA 83.13 61.62 21.53 +0.016 )
7 A AO 83.45 61.63 21.82 +0.027
8 A AA 81.71 60.09 21.63 +0.020 View normal 1o curface:
9 A WP 81.63 60.00 21.63 +0.020 > o loveled ’
10 A WP 81.90 60.15 21.75 +0.024 specimen fevele
1 A WP 81.58 59.88 21.70 +0.022
12 A WP 81.80 60.18 21.62 +0.020 |
13 B AA 80.94 59.09 21.85 +0.028
14 B AA 75.49 54.40 21.09 ~0.002 At left side of window,
15 B AA 77.81 56.35 21.46 +0.013 normal to surface
16 B AA 77.70 56.33 21.37 +0.010
17 C AA 76.47 55.01 21.46 +0.013
18 C AA 76.54 55.08 21.46 +0.013 At right side, 15° off
19 C AA 76.45 55.01 21.44 +0.013 normal to surface
20 C AA 76.95 55.64 21.31 +0.007
21 D AA 75.38 53.75 21.63 +0.020 . 5
22 D AA 75.49 53.86 21.63 +0.020 Left side, 227 off
23 D AA 75.41 53.78 21.63 +0.020 normal to surface
24 E AA 51.13 29.81 21.32 +0.007
25 E AA 51.03 29.49 21,54 +0.016 Left side, 22° off normal
26 E AA 50.99 29.55 21.44 +0.012 but 4" lower than D
27 E AA 50.91 29,47 21,44 +0.012

 

87
APPENDIX N.

OPTICAL MEASUREMENTS THROUGH HOT CELL WINDOWS

(CURRENT DESIGN LEAD GLASS)‘

The first in this series of tests measured the
optical qualities of a zinc bromide window in the
Solid State Division, Bldg. 3025, for the purpose
of taking measurements from outside, and was
dated April 15.2 The second test was done on
measurements taken through an early lead glass
window at the High Level Laboratory in Bldg. 4501
and was dated May 17,3 This memo, the third in
the series, presents the test data taken on one of
the new lead glass windows which have been pur-
chased for the High Level Chemical Development
Facility, Bldg. 4507, but have not yet been in-
stalled. The work was done while they were still
in storage at Bldg. 7005.

When the new lead glass windows which are to
be installed in the HLCD were made available to
us, a set of data was taken to compare this win-
dow with the earlier lead window previously re-
ported.

The window is 4 ft, thick, 20 in, high, and 36 in.
wide at the outside of the cell, It is composed of
the following pieces of glass, starting from the
outside surface: 1 piece of plate glass, density
2.5 g/cc, 1 in. thick; 5 pieces of lead glass,
density 3.3 g/cc, each 8 in, thick; 1 piece of lead
glass of the same density, 6 in. thick; for a total
of 46 in. of lead glass. The inside of the cell
window is covered with a piece of 1 in, thick non-
browning plate glass of 2.7 g/cc density. The
spaces are filled with a mineral oil to cut down re-
flections. These windows were built by the
Corning Glass Works at their Harrodsburg, Ky.,
Plant, and are shown on their drawing 12931-1480
and on ORNL drawing D-25357. Four of these
windows are available and one of them was select-
ed for this test at random.

The equipment which was used was the same as
that used previously, i.e., a Gaertner Scientific
Co. cathetometer borrowed from the Solid State
Division and placed on the front side of the win-
dow. A piece of ]/2 in, Sch. 40 Inconel pipe with

 

]Memo from A, A, Abbatiello to F. R. McQuilkin dated
June 11, 1957,

2A. A. Abbatiello, Optical Measurements Through Hot
Cell Windows (Zinc Bromide), memo to F. R. McQuilkin
dated April 15, 1957 (Appendix L of this report).

3A. A. Abbatiello, Optical Measurements Through Hot
Cell Windows (Early Design [.ead Glass), memo to F. R.
McQuilkin dated May 17, 1957 (Appendix M of this report).

88

a dull finish was placed on the cell side of the
window and mounted in a horizontal position,
Readings (Table N-1) were taken at five points
through the window. Three of them were normal to
the surface, at points A, 12 in, from the right edge
of the window, B, about at the center, and C, at

4 in, from the left edge of the window. All three
of these readings were taken at the approximate
horizontal centerline, Two readings, D and E,
were obtained at an angle to the surface. Position
D was at an angle of 25° from the normal entering
at a point 4 in. from the left edge, looking toward
the right. Position E was taken at a point about
12 in. from the right edge of the window facing the
glass at an angle of about 23° from the normal, but
looking toward the left.

Because these windows were located in a storage
area, the only available illumination was daylight.
A door open to the exterior of the building was
raised and the object to be measured was illumi-
nated by natural daylight.

Conclusions

1. As can be seen by examination of the data,
the dimensions obtained through this window are
better than any of those obtained heretofore, either
with the zinc bromide or through the earlier lead
glass window in Bldg. 4501, The results indicate
that there is closest agreement between all the
readings of any data taken to date. There were no
marked differences between any of the specific
points on this window as measured.

2, The deviations noted from the true diameter
were both on the plus and minus side, indicating
that these readings gave better dispersion about
the mean.

3. Because the cathetometer could not be fo-
cused on the longer distances (Positions D and E),
some parallax was encountered which could not be
removed (parallax is the apparent shifting of the
cross hairs on the image as the eye is moved
across the field of view and means the cross hairs
are not located at the exact focal point of the
eyepiece). A telescope designed for the range of
distance at hand would have avoided this handi-
cap.

4, Nevertheless, in spite of the problems of
trying to adapt the available equipment to this
 

Table N-1.

Window:

natural daylight illumination

Data on Lead Glass Window for HLCD
20 X 36 in., 4 ft thick, tested while in storage at Bldg. 7005, May 31, 1957,

Specimen: pipe, diameter 0.832 in, = 21.13 mm

 

 

Reading Reading Difference Deviation
Run Position Top Bottom . Notes
(mm) (in.)
(mm) (mm)
A 80.77 59.49 21.28 +0.006
A 80.84 59.69 21.15 +0.001 Normal to surface at position A
A 80.77 59.82 20.85 -0.01
4 B 80.37 59.39 20.98 -~0.006
5 B 80.51 59.33 21.18 +0.002
6 B 80.47 59.52 20.95 —0.007 Normal to surface at position B
7 B 80.59 59.25 21.34 +0.009
8 B 80.44 59.49 20.95 -0.007
9 cC 89.10 67.98 21.12 —0.0004
10 C 89.29 67.92 21.37 +0.010 N | ¢ o C
11 C 88.96 67.82 21.14 +0.0004 ormal te surtace at position
12 cC 89.12 67.86 21.26 +0.005
13 D 89.50 68.25 21.25 +0.¢05
14 D 89.44 68.36 21.18 +0.002
A le of 25° to righ
15 D 89.42 68.32 21.10 ~0.001 Pangle of 297 to right
16 D 89.51 68.22 21.29 +0.006
17 E 78.62 57.10 21.52 +0.015*
18 E 78.51 57.50 21.01 -0.005 o
19 E 78.84 57.85 20.99 ~0.006 At angle of 237 to left
20 E 78.86 57.71 21.15 +0.001

 

* Probably due to parallax.

test, the results are most encouraging. The test
setup was made and about 20 readings were taken
in a 2-hour period, which indicates that an ac-
ceptable rate for obtaining data is possibie.

5. The available range of accuracy and repro-
ducibility using this system appears adequate to
justify its use, as determined by the 0.1 to 1%
change in dimensions expected as suggested by
the Power Plant Design Department.*

6. Since these readings compare favorably with
the first set of readings taken in air only (see my

 

4Erom personal notes of a meeting at 9201.3, Jan. 31,

1957

April 15 memo), it is apparent that the lead win-
dow has little effect and that we have reached the
accuracy obtainable with this type of experimental
setup. It should be noted that this test was impro-
vised from available equipment and that a larger
power scope with a longer focusing range would
have provided better results, However, in spite
of these minor difficulties it is felt that lead win-
dows as presently produced and indicated by this
example, which will be used at the HLCD, will be
adequate to give the type of measurements needed.
All the plus values averaged out to +0.0052 in.,,
and all the minus values averaged -0.0054 in,
The object which was measured was placed
about 2 ft inside the cell, i.e., from the window.

89

 
When the reactor is placed in the cell it is ex-
pected that it will be about 10 ft from the window.
Our equipment did not permit this long range test.
Had the equipment been available, which would
have focused properly at these longer ranges, it
would have been preferable to make this test to
determine whether the angular deviation varies as
the distance. However, since such small devia-
tions were found with the present readings, it is
expected that as the distance becomes greater the
variation will not increase appreciably.

90

Acknowledgments

We are again indebted to W. E. Brundage of the
Solid State Division for the use of the cathetom-
eter, to H. C, Duggan of E & M Division for the
information and specifications on this new lead
glass window, and to Frank Ring, Jr., for per-
mission to use these windows.
APPENDIX O. ART DISASSEMBLY CELL (ADC) FACILITY CIRITERIAI'2

1. Introduction

Continued study and experimentation in the field of nuclear energy by the Oak Ridge National

Laboratory (ORNL) has progressed to the stage where facilities are necessary for handling

large, highly radioactive assemblies and disassembling these units to obtain engineering data.

1.1. Document Definition
These criteria outline the requirements for construction of an ART Disassembly Cell
(ADC) at the Oak Ridge National Laboratory, Oak Ridge, Tennessee. In preparing the
drawings and construction specifications the prime consideration has been to acquaint
the Architect-Engineer (A-E) with general facility requirements without restricting his
normal freedom of choice as to engineering and construction details, The benefit of the
Architect-Engineer’s experience on similar structures, to amplify and improve the design
criteria, is solicited,

1.2. Location
The ADC shall be located on the site shown in Fig. O-1. This site is within the X-10
plant security area.

1.3. Completion Considerations
Special consideration shall be given to the design and construction schedules to insure
transfer of the ADC to ORNL by June 1, 1958, Maximum use shall be made of standard
equipment and prefabrication to minimize procurement and construction time,

1.4. Special Considerations
Construction within the Laboratory is subject to certain special conditions covering
operations such as blasting. These conditions shall be included in the specifications.
Information of this nature will be furnished by ORNL.
1.4.1. Provision for Additions

It is definitely planned that an addition will be made to the building, This addi-
tion may be equal to or larger than the ADC, Figure O-2 shows the proposed

 

location of this addition, The addition is not included in this design, except that
a study shall be made to determine the additional utilities required. ORNL will
collaborate in determining these requirements.

1.4,2. AEC Construction Requirements
The A-E will be expected to provide estimates and services as required to fulfill
AEC requirements as to bid evaluation, construction reports, and procedures.
Standard AEC construction requirements which are required to be a part of the
ADC specification will be furnished to the A-E.

 

 

]Preliminary report by V. J. Kelleghan and F. R. McQuilkin dated December 20, 1956.

2The title for this proposed facility was later revised to Reactor Disassembly Hot Cell (RDHC). The
facility has been referred to elsewhere in this report by the revised title.

91

 
UNCLASSIFIED
ORNL—-LR—DWG 35473 “

ADC “
4 N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OLD CHEMISTRY BUILDING \ 3852 3551 - —t
CHEM. EVAP //
35Doeo O O /
O O O 3515 3550 // \500
3579
3505 WETAL __I O . [_3;5_;1
RECOVERY //////4 —
BUILDING

 

 

 

CHEM. ISOLATION 1:]
MULTI-CURIE | LAB.

 

FISSION 3592 ] 3587
PRODUCTS [:I s5e7
PLANT

 

 

 

 

 

 

3308 STORAGE AREA

3504 SOLV. OPER, "
SOLV. OPER.
OFFICE

 

 

 

 

 

H.P. WASTE 3502
RESEARCH 3503 "
NOTE: INCREASE SCALE AND SHOW
TOPOGRAPHY AND UTILITIES
3500 -~ 3999

 

 

0 100 200 300

SCALE (N FEET

N

{ FOR DRAWING ONLY)
Fig. O-1. ADC Facility Site.

1.5. Security
No security clearance will be required for contractor’s personnel, inasmuch as the con-
struction area will be isolated from the X-10 security area by security fencing and pro- .
vision will be made for free access to the construction area from a road open to public
travel, .
1.5.1, Exterior Doors
All exterior doors shall be of l%-in. insulated metal construction, They shall
have concealed hinges and pins or the approved security equivalent. All exterior
swinging doors shall have panic hardware. All exterior doors, swinging and roll-up,
shall be equipped with approved security eyelets. The roll-up door shall be op-

erable from the interior of the building only.

92

 

 
UNCLASSIFIED
ORNL-LR-DWG 35474

 

 

 

 

 

 

 

 

 

 

 

 

  

 

 

   

 

 

 

 

      
  

 

 

  

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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NOTE;
CELL WINDOWS NOT SHOWN

—TUNNEL TO STORAGE AREA

Fig. 0-2. ADC Floor Plan.

1.5.2. Locks
All cylinders for locks and exit bolts shall be Best Universal Lock Company's
]932-in. cylinder bore, 7-pin core No. 1E74 or approved equivalent, Cores shall
be uncombinated. Cores and blank keys shall be supplied to ORNL for combinating

and cutting of keys. Panic hardware, locked type, to accommodate the above

cylinder will be used where required.

 
1,5.3. Access to Underground Storage Facility
The underground storage facility is accessible via a tunnel from the ADC. A
secondary entrance from ground level shall be provided and suitably shielded.
This entrance shall have a metal door equal to or stronger than the exterior doors
for the ADC, with similar locks.
1.6. Special Studies To Be Made by the A-E
ft is desired that the A-E study the building exhaust requirements and make recommenda-
tions as to the cost of erecting a new stack to elevation _____ or use an existing
stack with necessary modifications, A study of a storage facility as outlined in Section
2.3.11 shall be made.
2. Description of Facility
2.1. General Description
The ADC shall be arranged generally as shown on Figs. 0-2 and 0-3. It shall be approx-
imately 125 ft wide by 85 ft long by 36 ft high. Windows will be located in the offices
only. Adjacent to the ADC will be an underground storage area for radicactive materials.

A tunnel will connect the two buildings. Design of the underground storage should be

such that it may be enlarged to serve the planned building addition.

UNCLASSIFIED
ORNL-LR-DWG 35475

   

 
 
 
    

 
      

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PARTITION

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HYDRAULIC LIFT TUNNEL TO STORAGE AREA

5 0 5 10 15 20

SECTION A-A

Fig. 0-3. Sectional View of ADC Building.

o
2.1.1,

2.1.2,

2.1.3.

Type of Building

The building shall be of structural framing with reinforced concrete floors, metal
roof panels, built-up roof, and exterior walls of concrete block faced with brick

to conform to the appearance of existing permanent laboratory buildings. One
wall of the ADC shall not be brick faced but shall be designed with provision for
the future additions. Building and construction shall be such that low level air-
borne contamination is contained and decontamination is facilitated,

Floor Plan

Figure O-2 shows the proposed floor plan. The layout chosen is intended to show
general area requirements and other operating features. Structural considerations,
location of utilities, economy of layout, etc., may necessitate its revision.

Site Location

Figure O-1 shows the site chosen for the ADC and the adjacent buildings. Loca-

tions of utility tie-in points are shown.

2.2, Building Areas Required

&~ 2.2.].

2.2.2,

2.2.3,

2.2.4,

2.2.5.

2.2,6.

Unloading Area

An area is required in front of the cell sliding doors where large equipment
trucked to the ADC can be unloaded and transported into the building, This area
is in effect a truck unloading dock.

Set-Up Area

This area is a hot (possibly radioactively contaminated) area. It is the staging
area where small tools and equipment to be placed in or removed from the cell
are prepared. Personnel going into and out of the cells will operate from this
area,

Personnel Decontamination Area

This is a locker room where contaminated clothing is removed. Personnel are
required to wash any contaminated dust, etc., from their persons before leaving
this area and entering the cold locker room,

Locker Room

A locker room where operating personnel can leave their clean clothing before
entering the hot locker room and donning their coveralls is required, It will also
provide toilet facilities for other personnel in the building.

Operating Area

This area is located adjacent to the cell. It is the working area from which the
disassembly tools and manipulators will be operated during disassembly. All
viewing of operations and measurements will be made from this area.

Office and Laboratory Area

The business of keeping track of the disassembly operation will be conducted
here. Any work of a minor nature involving need for laboratory equipment will

be handled in this area.

95
2.2.7. Mezzanine
Access to viewing windows at an upper elevation is necessary. Additional »
offices and storage space for health physics instruments, etc., are to be avail-
able at this level,
2.2.8, Building Service Equipment Area
It is intended that all service equipment such as air conditioning units, hot
water heater, electrical cabinets, etc., be located in one single area separate
from the rest of the areas.
i 2.2.9. Disassembly Cell
A cell is required where large equipment may be sectioned and examined to
obtain engineering information. Due to the biological hazard the area where this
is done must be heavily shielded. Special provision must also be made for ready
decontamination.
2.2.10. Maintenance or Temporary Reactor Storage Cell
A cell is required where the equipment from the disassembly cell can be repaired
while disassembly operations are still in progress. It will permit such mainte- .
nance without the necessity of decontaminating the large cell. Such an areaq, if
adjacent to the disassembly cell, can also be used for temporary storage of large -
radioactive components when access is required to the main cell.
2.2.11. Storage Facility
As large radioactive components are disassembled, it is desirable to have some
area where their parts may be safely stored. Since these parts will in turn be
studied in great detail, it must be possible to withdraw specific ones from
storage. This storage facility will be common to the ADC and the future building
addition.
2.3. Requirements for Areas
2.3.1. Unloading Area
2.3.1.1. Dimensions
The unloading area will be an 18-ft roadbed passing in front of the
sliding doors for the cell. [t shall be depressed 6 in. below the
leve| of the cell floor. This will tend to contain any spillage in
this area.
2.3.1.2. Overhead Crane
A 30-ton crane shall extend out over the unloading area for use in
unloading heavy components. Tracks for both O-man manipulators
shall extend out over the unloading area farther than the crane so
that the crane can be between the building and one of these manipu-

lators when it picks up a load.

96

 
 

2.3.13.

2.3.1.4,

2.3.1.5.

Contaminated Fluid Drain

A drain which connects to the contaminated fluid drainage system
shall be provided in the unloading area. It shall be valved off and
used only when decontamination of the unloading area is required.
Storm Drain

Because the unloading area is depressed below surrounding areas, a
storm drain will be required, Provision shall be made for ¢closing this
drain during decontamination operations.

Load Requirements

The roadbed in this area must be suitable for heavy duty trucking. It

should have a load capacity equal to the roads in the X-10 plant area.

2.3.2. Set-Up Area

2.3.2.1.

2,3.2.2,

2.3.2.3.

2.3.2.4.

2.3.2.5.

2.3.2.6.

Dimensions

This area should be approximately 40 x 40 ft. Ceiling height should
be sufficient to permit set-up of portable lifts, etc., to load and unload
light trucks. A ceiling height of approximately 20 ft is desirable,
Floor Load

The floor load in this area should be adequate to permit use of a
3/4-'ron pick-up truck or a smail fork lift.

Roll-Up Door

An exterior roll-up door is required to provide truck access to the
set-up area. This door should be operable from the set-up area only,
with an external buzzer or bell to request admittance.

Flooring and Painting

The floor in this area shall be concrete covered with a vinyl coating
equivalent to Amercoat No. 33 applied as recommended by the manu-
facturer, Color scheme and paints for walls and ceiling shall conform
to ORNL standards.

Access from Other Areas

Access to the set-up area will normally be through the hot locker
room. The set-up area will be classed as a hot area since entrance
into the cells will be from this area, The roll-up door will be used
for access into this area only when special precautions have been
taken.

Tool Decontamination Table and Sink

A mechanics’ work table shall be provided in the areq, with a sink at
one end suitable for decontaminating small tools. This sink should
connect into the contaminated fluid drain system. A contominated

fluid floor drain is required in this area.

97
<

98

2.3.2.7. Safety Shower

A safety shower is required in this area,
2.3.3. Personnel Decontamination Area

2.3.3.1. Access from Other Areas
This is the hot locker room. It shall connect with the setup area
through a swinging door with a door closer. Connection from this
room to the cold locker room shall be by means of a pass-through
shower or a swinging door. The locker room should be sized to accom-
modate six men per shift on a three-shift basis.

2.3.3.2. Equipment and Hardware
The general types of equipment required in this area are shown on
Fig. O-4. Toilet hardware shall be brass, chrome plated, and all

brackets, bolts, and screws shall be chrome plated.

UNCLASSIFIED
ORNL-LR—DWG 35476

COLD LOCKER ~-«——— HOT LOCKER

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CC  CLEAN CLOTHES
MC  HAND AND FOOT COUNTER
CSC CLEAN SHOE COVERS —  N—
DSC DIRTY SHOE COVERS
S SHOWER
H HAMPER

Fig. 0-4. Locker Rooms.
2.3.3.3.

2.3.3.4.

2,3.3.5.

Contaminated Fluid Drains

All drainage including floor drain, lavatory, and showers shall be to
the contaminated drain system. The toilets shall drain to the sanitary
drain system.

Flooring and Painting

The floor in this area shall be concrete covered with a vinyl coating
equivalent to Amercoat No. 33 applied as recommended by the manu-
facturer. Color scheme and materials for walls and ceiling shall con-
form to ORNL standards.

Floor Load

Floor load in this area shall be normal for this type of service,

2.3.4, Locker Room

2.3.4.1.

2.3.4.2,

2.3.4.3.

2.3.4.4,

2.3.4.5.

Design Operating Crew

The locker room should be sized on the basis of six men per shift on
a three-shift basis. Two additional people will normally be in the
building on the day shift,

Access from Other Areas

The cold locker room shall be accessible from the hot locker room

by means of a pass-through shower. A swinging door with door closer
shall be the access to the operating area. If convenient, access to

the locker room is desirable from the street,

Equipment and Hardware

The general types of equipment required in this area are shown on
Fig. 0-4. Toilet hardware shall be brass, chrome plated, and all
brackets, bolts, and screws shall be chrome plated.

Flooring and Painting

The floor in the locker room shall be steel troweled concrete finished
with hardener, The paint shall be consistent with ORNL standards as
to color and type.

Floor Load

The floor load shall be standard for this type of area.

2.3.5. Operating Area

2.3.5.1.

2.3.5.2.

Access from Other Areas

The operating area shall be accessible from the laboratory, offices,
building service equipment room, locker room, and the street,
Emergency exits shall be provided from this area where required.
Janitors' Closet

A janitor’s closet with sink is required either in this area or in the
locker room, The space under the stairs to the mezzanine would be

an acceptable location,

99

 
100

2,3.5.3.

2 .3. 5.4.

2.3.5.5.

Stairway to Mezzanine

It is desired that access to the mezzanine be provided by a staircase
leading from the operating area.

Flooring and Painting

The flooring in the operating area shall be grease-proof asphalt tile
equivalent to Kentile., Walls and ceiling shall be painted in accord-
ance with ORNL standards; however, special effort shall be made to
use flat paints which will minimize reflection,

Floor Load

The floor load in this area shall be standard for halls where large

numbers of people may congregate.

2,3.6. Office and Laboratory Area

2.3.6.1.

2.3.6.2.

2.3.6.3.

2.3.6.4.

2.3.6.5.

2.3.6.6.

2.3.7. Mezzanine

2.3.7.1.

Access from Other Areas

Access to the office and labs shali be from the operating area or the

street, depending upon location. .
Office Equipment

All desks, chairs, and other office equipment will be supplied by .
ORNL.

Laboratory Equipment

The laboratory shall be equipped with a laboratory table with a hood

at one end and a sink at the other end. This shall be an acid sink and

for this reason should drain into the contaminated fluid drainage

system. Provision shall be made for installing bottled gas near the

table.

Dimensions

The office shall be sized to accommodate two desks, file drawers,
etc. The laboratory should accommodate a desk and storage cabinets
as well as the work table,

Flooring and Painting

These areas shall have grease-proof asphalt tile with walls and
ceilings painted to conform to ORNL standards. .
Partitions

Room division shall be accomplished with movable metal partitions

similar to those manufactured by the Mills Co.

Access from Other Areas
Access to the mezzanine shall be by staircase from the operating area.

A secondary means of egress shall be provided in case of emergency.

 

 
 

2.3.7.2.

* 2,3.7.3.

2,3.7.4

2.3.7.5.

Rooms

Rooms on the mezzanine shall be sized and provided with fixtures so
that they may be readily usable for office space.

Floor Loading

The floor of the mezzanine shall be designed to permit storage of
light equipment or assembly of groups of approximately 15 people,
Flooring and Painting

Flooring and painting in this area shall be similar to that used in the
office and laboratory area,

Partitions

Room division shall be accomplished with movable metal partitions

similar to those manufactured by the Mills Co.

2.3.8. Building Service Equipment Area

2.3.8.1,

2.3.8.2.

2.3.8.3.

2.3.8.4.

2.3.8.5.

Access from Other Areas

This area shall be accessible from the operating area or from the
street. The street access shall be sufficiently large to permit in-
stallation or removal of equipment in this area,

Equipment

It is desirable to have all of the building service equipment located
in a single place. It is expected that the building air conditioning,
hot water heater, lighting and power panels, etc., will be located
here.

Floor Loading

The floor in this area shall be designed for the heavy loads of the

equipment located in it.

Floor Drain

A floor drain shall be provided in this area to which any drainage
from the equipment can be directed. This drain should tie into the
building storm drain system,

Flooring and Painting

The floor in this area will be steel troweled concrete, hardened.

Painting of walls and ceiling shall conform to ORNL standards.

2.3.9. Disassembly Cell

2.3.9.1,

 

Dimensions

The approximate inside dimensions of the disassembly cell (Fig. O-5)
shall be 52 ft long by 20 ft wide by 34 ft high, The shielding walls
shall be 4]/2-ft-thic|< high-density concrete of at least 230 pounds per
cubic foot. The roof shall be 2-ft-thick high-density concrete.

101
Z0l1

 

 

 

 

 

 

 

 

 

 

UNCLASSIFIED
ORNL- LR—DWG 35477

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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PORTAB%E PLATFORM —) Cfi C CONDUIT AND PIPE, SLEEVE PANEL
| | S D DECONTAMINATION NOZZLE CONNECTION
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| Prmm==ss S SPOTLIGHT
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FEET

Fig. 0-5. Cell, South Elevation.
 

2.3.9.2.

2.3.9.3.

2.3.9.4.

2.3.9.5.

2.3.9.6.

Cell Liner

The interior surface of the shielding wall and floor shall be lined
with stainless steel to facilitate decontamination operations,
Viewing Windows

The shielded viewing windows shall be approximately 3 x 4 ft (viewing
area on operating side), glass with oil laminations or zinc bromide
tanks. They shall be the tapered type and be sized by the A-E for
maximum vision to all parts of the cells, The A-E shall investigate
the possibility of using a “*package’’ window as manufactured by
Corning Glass Works, or approved equivalent, The shield wall sur-
rounding the windows shall be high-density solid concrete blocks
suitably installed to permit easy revisions to hole size and placement

in these areas.

Bridge Crane

A 30-ton bridge crane shall be provided in the disassembly cell, The
tracks for the crane shall extend from the disassembly cell, through
the maintenance cell, and out over the unloading area. Crane rails
shall pivot out of the way where the crane passes through the large
doors. Slow travel and hoisting by the crane are desirable to permit
accurate positioning of equipment. The maximum hook to floor
clearance shall be 26 ft. The lift of the hook shall be from 3 ft above
the floor of the lowest pit to at least 26 ft above the cell floor.
Controls for the crane shall be located in the operating area. Pro-
vision shall be made for quickly attaching and detaching a pendant
control with which the ¢crane may be operated from the cell floor.
Wash Down Facilities

A spray system shall be installed in the hot cell rooms which will
handle detergent and hot or cold water for decontaminating purposes.
The system shall be supplied from a pump and tank. The cell.rooms
are to be individually valved. Consideration should be given to the
use of dilute nitric acid (approx. 6%) in this system.

Large Shielding Doors

The wall between the disassembly cell and the maintenance cell
shall be movable. Split type doors are preferred consisting of 4]/2 ft
of high-density concrete covered with a stainless steel skin, The
doors shall be motor operated with controls located in the operating
area. Where necessary, an air seal shall be provided between the cell

and the operating area,

103

 
104

2.3.9.7,

2.3.9.8.

2.3.9.9.

2.3.9.10.

2,3.9.11,

2.3.9.12.

2.3.9.13.

O-Man Tracks

Two sets of tracks suitable for O-man manipulators shall be provided
in the cell. These tracks shall be located to permit the manipulators
to pass the crane and each other,

Manipulator Holes

There shall be two holes above each viewing window for manipulators.
The holes shall be sized and spaced for the Argonne Model 8 type
manipulators,

Lost Tool Transfer Scheme

There shall be incorporated in the design of hot cell rooms a device
with appropriate shielding which will allow an operator to transfer
small objects into and out of the hot cell rooms after the rooms are
radioactive. This system shall be designed and located so that con-
tamination is confined to the cell rooms or is otherwise controiled.,
Maximum dimension of objects to be transferred are 6 in. dia. by

18 in. long. Transfer devices, if mechanized, shall also be manually
operable from operating area side.

Access Door

A suitably shielded door shall be provided to permit entrance into the
cell from the set-up area. The door shall be mechanized or counter-
weighted in such a way that one man may move it, The penetration
of the cell liner shall be developed by the A-E. A hole 4 x 5 ft is
suggested,

Contaminated Fluid Drain

Four contaminated fluid drains shall be provided in the cell and shall
tie into the contaminated fluid drain system, These drains should each
have a closure which can be actuated from the operating area. One of

these drains shall be located in the bottom of the elevator pit.

Wall Inserts

Stiffeners shall be attached to the outer surface of the cell liner at
suitable spacing to permit attachment of shelves and storage racks
for instruments, tools, gages, etc. These stiffeners may be attached
to the concrete, but relative expansion problems should be studied
to prevent buckling the cell liner.

Microscopy Yiewing Posts

There shall be installed in the disassembly area two microscopy
viewing portholes, size and positioning of holes to be furnished by

ORNL.

 

 
2.3.9.14,

2,3.9.15.

2.3.9.16.

2.3.9.17.

Transfer Hatch to Storage Area and Cover

There shall be a transfer system from the disassembly cell to an
underground storage area as shown on Figs. 0-2, 0-3, and O-6. This
system shall be designed to allow specimens to be lowered from the
crane or a manipulator onto a mechanized dolly in an underground
tunnel. The dolly shall run on tracks and be controlled remotely.
When the dolly is in position under the hot cell hatch, specimens may
be lifted out with manipulators. The hatchway shall have an 8 x 8-ft
cover which shall be motor driven and controlled from the operating
area, This is not a shielding cover but an air seal,

Floor Loading

The floor in the disassembly area shall be designed for a possible
maximum uniform load of 3000 pounds per square foot, However,
foundation pads capable of carrying the tool equipment loads plus
working loads shall be provided where fixed tools will be installed
as indicated on Figs, O-2 and O-3.

Elevator Pit and Plug

A hydraulic lift will be located in a pit in the cell as shown on
Figs,0-2 and 0-3. A shielding plug for the pit (thickness by ORNL)
shall be provided and provision made for storing it within one of the
cells. Design should permit the 30-ton crane to pick the plug up and
cover the pit when the lift is depressed. Pit design shall facilitate
maintenance and decontamination,

Parts Decontamination

Parts will be decontaminated where indicated on Fig. 0-2; therefore

the floor shall be sloped in this area to a contaminated fluid drain.

2.3.10. Maintenance of Temporary Reactor Storage Cell

2.3.10.1.

2.3.10.2.

2,3.10.3.

Dimensions

This cell will have one wall common to the disassembly cell and will
be approximately 20 ft wide by 20 ft long by 34 ft high, The shielding
walls shall be high-density concrete, at least 230 pounds per cubic
foot, 4]/2 ft thick,

Cell Liner

The interior of this cell shall be lined with stainless steel as in the
disassembly cell,

Viewing Windows

The viewing windows in this cell shall be similar to those in the dis-

assembly cell,

105

 
 

 

 

 

 

 

 

 

 

 

UNCLASSIFIED
ORNL~-LR-DWG 35478

 

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OPERATING EXPERIENCE MAY DEMONSTRATE
THAT REMOTE OPERATION OF CRANE 15

NOT NECESSARY.

106

Fig- 0'6.

Storage Area.

 

 
2.3.10.4, Bridge Crane
The same 30-ton crane which serves the disassembly cell will serve
this cell. Where the crane passes through a large shielding door it
must be possible to separate the track and pivot it out of the way

to permit the door to close,

2,3.10.5. Wash Down Facilities
This system should be the same as that in the disassembly cell,
2.3.10.6. Large Shielding Doors
The maintenance cell shall have motor operated split doors at each
end, one pair in common with the disassembly cell and the other pair
opening to the loading area. Both doors shall be motorized and con-
trolled from the operating area.
2.3.10.7. O-Man Tracks
The manipulator tracks will pass through this cell and will have to be
handled in the same manner as the crane tracks where door inter-
ference will be encountered,
2.3.10.8, Manipulator Holes
Requirements are the same as in the disassembly cell.
2.3.10.9. Access Door
An access plug and door in the cell liner shall be provided giving'
access from the set-up area into the cell. A hole 4 x 5 ft is suggested.
The requirements are the same as for the access door into the dis-
assembly cell.
2.3.10,10. Contaminated Fluid Drain
At least two such drains shall be located in the maintenance cell,
These drains should each have a closure which can be actuated from
the operating area,
2.3.10.11. Wall Inserts
Requirements are the same as in the disassembly cell.
2.3.10.12, Floor Loading
The floor of the cell shall be designed for a maximum uniform loading
of 3000 pounds per square foot,
2.3.11. Storage Facility
2.3.11,1, Location and Dimensions
The storage facility shall be located as near to the ADC as con-
struction and shielding will permit. This will reduce the cost of
extending the tunnel and utilities into the storage area, Location of

the storage area shall permit extension of the building at some future

107

 
108

2.3.11.2,

2.3.11.3.

2.3.11.4,

2.3.11.3,

2.3.11.6.

2.3.11.7.

2.3.11.8,

date. The storage area shall be planned to accommedate thirty-six

3 ft dia by 6 ft high drums and six 5 ft dia by 6 ft high drums, These
drums must be positioned remotely, so area for this handling equip-
ment will be required.

The storage facility shielding will be determined by ORNL, but for
preliminary studies 5 ft of high-density concrete or its shielding
equivalent shall be assumed for personnel protection,

Mechanization

Because of the biological hazard from the stored materials, the stor-
age facility shall be completely mechanized for remote handling,
ORNL intends to propose a number of acceptable methods and request
the A-E to study these methods from a design and cost standpoint and
make recommendations. Prime considerations in evaluating these
methods shall be simplicity, reliability, ease of maintenance, safety,
minimum cost, and possibilities for increasing the storage capacity.
Provisions for Additions -
It is definitely expected that the storage facility will have to be in-
creased. The design and layout shall be such that this expansion of
the facilities can be accomplished without seriously interfering with
the operation of the existing storage. Any expansion of the facilities
shall also be possible without exposing construction personnel to

radiation hazards.

Floor Loading

The floor loading in the storage area shall be no less than that in the
cells but may be any higher loading which might be necessitated by
the method of storage chosen,

Painting

The storage facility interiors shall be painted with an acid resistant
paint equivalent to Amercoat No. 33 applied as recommended by the
manufacturer, This paint shall be used for all areas upon which con-
taminated materials may be spilled or dropped.

Contaminated Fluid Drain

The entire storage facility shall be provided with adequate floor
drains which tie into the contaminated liquid drainage system for the
area.

Storage Methods

Engineering studies shall be conducted by the A-E to evaluate the
following methods of storage on the basis of simplicity, reliability,
ease of maintenance, safety, minimum cost, and possibility for in-

creasing storage capacity,

 

 
1. Storage in a Large Shielded Room
Cans stored in a single room; light overhead crane, remotely
operated; no shielding between cans; operator outside looking
through shielding window; method for crane removal and repair.

2. Plug Storage
Cans stored in holes in ground with shield plugs; cans separated
from one another and shielded to make radiation from can being
handled the main problem; shielded carrier, cans can be remotely
drawn up into it like inverted tumbler; heavy crane, remotely
operated; light building which can be held at a slightly negative
pressure.

3. Underwater Storage
Water for shielding; method for pressurizing cans with inert gas
and sinking under water in single large pool; light crane; water
treatment scheme.

4, Conveyor Belt
Heavy shielding; conveyor hooks carrying cans on circular or

elongated system; conveyor mechanism readily accessible; cans

 

in @ common tunnel not shielded from one another.
2.4, Building Utilities
2.4.1. Heating
The heating system for the ADC shall be steam to be supplied from an existing
central steam plant, The A-E shall design the temperatures for the various areas
in accordance with good engineering practice. There shall be no temperature or
humidity control in the cell. The remainder of the building shall be air con-
ditioned.
| 2.4.1.1. Combination with Air Conditioner
With the entire building air conditioned it appears desirable to provide
the air conditioning unit with a steam coil and in this way heat the
building.
2.4,2, Lighting
2.4,2.1. Lighting Requirements by Areas
1. Entrance Doors
. Incandescent industrial type fixtures, reflector type units, heavy
duty, weatherproof, located above doors and switched locally.
Red incandescent exit fixtures shall be located above doors where
applicable in complying with fire and safety codes, no local

switching,

109
2, Stair Well
Incandescent, 10 foot-candles, locally switched.

3. Safety Shower
Green incandescent, no local switching.

4, Grounds
Incandescent, conforming to security and ORNL standards as to
type and intensity.

5. Set-Up Area
‘ Fluorescent or incandescent, vapor tight, 50 foot-candles,

switched at panels.

6. Hot and Cold Locker Rooms
Incandescent, industrial type diffusing fixtures, switched at
doors, vapor proof in hot locker room, 20 foot-candles.

7. Offices and Laboratory Area
Fluorescent, commercial office diffusing type, symmetrical
arrangement, switched at doors, 40 foot-candles.

8. Operating Area
Incandescent or fluorescent, industrial type diffusing fixtures,
50 foot-candles, switched at panels. Special emphasis on the
area immediately in front of the windows.

9. Equipment Room
Incandescent, industrial type diffusing fixtures, symmetrical

arrangement, switched at door, 30 foot-candles.,

10. Disassembly and Maintenance Cells
Incandescent and sodium vapor, industrial type diffusing fix-
tures, vapor proof, panel switched, 300 foot-candles total. In
addition, a mercury arc spotlight shall be provided at each
window. Special emphasis shall be placed upon making the
lamps in this area readily replaceable.
2,4,2.2, Emergency Lighting
An emergency lighting system is to be provided to supply low level
lighting in cells, stairs, exits, and other critical areas.
2.4.3. Ventilation and Air Conditioning
2.4.3.1. Basic Philosophy
It is intended that the flow of air leakage resulting from the pres-
sure levels within the building should be into the building and, within
the building, from uncontaminated areas to areas of higher contamina-
tion. In this way, the spread of air-borne contamination to cold areas

should be minimized. Temperature levels should be maintained such

110

 

 
 

2.4.3.2,

2.4.3.3.

that operators performing difficult disassembly operations with manipu-
lators will be in a comfortable environment.

Design Conditions

Areas other than the cells shall have approximately seven air changes
per hour, with the air migrating to the cell area. The hot cells shall
have approximately twenty air changes per hour and be at a greater
negative pressure than any other areas in the ADC, Ali of this air
shall be cleaned and exhausted to the atmosphere through a stack.
The A-E shall determine whether a new stack will be required or
whether an existing stack can be utilized, The cells shall be main-
tained under a negative pressure at all times to prevent radioactive
particles from migrating to colder areas. When the cell doors are
opened, an indraft shall result through the openings which prevents
radioactive particles from migrating to colder areas. The A-E shall

locate the filters in the cells for easy replacement with manipulators,

Cell ventilation shall be separately controlled so that it can be shut
off, if desired, without affecting the ventilation of the remainder of
the building. Downdraft ventilation is desirable in the cells. No
temperature or humidity control is required for the cells. The re-
maining areas shall be maintained at 78°F, 50% relative humidity
with control in accordance with good engineering practice.

Special Filter Considerations

No filters shall be used which are not of a replaceable type. All
filter installations should feature ease of replacement in the event
air-borne contamination deposits material with an appreciable activity
in the filters. Building occupancy and operations will be discussed
with the A-E.

2.4.4, Electrical Facilities

2.4.4.1,

2.4.4.2.

Building Service Entrance

The building power transformer or tie-in to existing lines shall supply
480-volt 3-phase 60-cycle power to the ADC., The A-E will size this
equipment to accommodate a 25% future load increase in the ADC,
Interior Distribution

A new 480-volt 3-phase load center shall be installed in the ADC.
Feeders shall radiate from this load center to individual 480-208/120-
volt 3-phase transformers where lower voltages are required. Load
centers and breaker panels shall be sized to accommodate a 25% future

load increase,

111
2.4.4.3.

2,444,

2,4.4.5.

2.4.4.6.

2.4.4.7.

2.4,.5. Water
2.4.5.1,

Conduit

Conduit to accommodate wiring shall be run to all permanently located
equipment and shall be embedded in floors, ceilings, or walls, which-
ever is the most feasible, Conduit shall be installed for wiring to all
outlets for lights, receptacles, transformer locations, etc. Approxi-
mately six conduit sleeves shall be installed in the cell walls at each
viewing window. ORNL will provide layouts showing size and posi-
tions for conduits,

Grounding

An adequate grounding system shall be extended throughout the facility
for equipment and building grounding.

Receptacles for Areas

The A-E shall specify receptacles in areas as functionally required.
ORNL will provide information on receptacles required for opérations
functions.

Emergency Power Requirements

An emergency power supply shall be provided. This will power the
emergency lighting system, In addition, 120-volt a-¢ single-phase
emergency power receptacles are required in both cells, in the set-up
area, and in the equipment room.

Motors

Motors above l/2 horsepower shall be rated at 480 volts, 3 phase,

wherever possible.

Distribution

All water to the building will be from the plant sanitary water system.
It will be distributed in the facility to sinks, equipment, fountains,
etc., as required. Drainage will be to the sanitary drain system

except where otherwise specified.

2.4.6. Communications

2.4.6.] .

2.4,6.2.

112

Intercoms for Areas

A complete intercommunication system shall be provided which per-
mits contact between all areas except the equipment room and locker
rooms.,

Commercial Telephone

Provision shall be made for extension of the existing commercial
telephone system into the ADC. Phones will be installed in all
offices and laboratories, the operating area, and the set-up area.
Wiring installed shall permit addition of phones if offices are added

on the mezzanine.
 

2.4.7. Sanitary Drainage

Sanitary waste lines from the ADC shall tie into the existing waste system for

ORNL.

2.4.8. Storm Drains

2.4.9,

2.4,10,

2.4.8.1.

2.4.8.2,

2.4.8.3.

Roof Drains

Roof drainage shall be provided and connected to existing area storm
drains.,

Unloading Area Drains

Because the unloading area is depressed below the surrounding
ground level, a storm drain which can be closed off shall be provided
which connects into the storm drain system,

Building and Tunnel Drainage

Adequate drainage for all underground construction such as founda-

tions, tunnels, etc., shall be provided.

Contaminated Fluid Drainage

2.4.9.1,

2.4,9.2,

Requirements

Where drains for radioactively contaminated fluid are specified, they
shall connect into a drain system which ties into a holding drum,
Flow from this tank will be regulated at a preset value, and discharge
will be to the existing ORNL contaminated waste disposal tank
system,

Shielding Requirements

ORNL will supply the shielding criteria for this system, Piping

materials shall be chosen to withstand dilute nitric acid solutions (6%).

Compressed Air

2.4.10.1.

Requirements
A connection shall be made with existing plant compressed air lines
or a compressor provided, Lines for 90 psig air shall be provided in

both cells, the set-up areq, and the unloading area.

2.4.11, Utilities Identification

All vtilities in the buildings shall be clearly labeled. The standard laboratory

color scheme shall be followed in painting, and self-adhesive labels such as the

Quik-Label manufactured by the W. H. Brady Company or an approved equal shall

be specified.

2.5, Alteration, Removal, or Relocating of Existing Building or Equipment

Any existing equipment such as piping, manholes, drain ditches, fire hydrants, etc.,

which the A-E may find necessary to alter, remove, or relocate for the ADC shall be

subject to approval from ORNL. A building now exists on the site planned for the ADC,

 
The A-E shall study removal of designated portions of this building which can be vacated
at an earlier date than others. This study should include necessary protection for por-
tions of the building left standing. The necessary construction consequences of this re-
striction should be presented for ORNL evaluation, "
2.6. Special Supporting Services
2.6.1. Yacuum Cleaning System
A manifold vacuum clean-up system shall be installed to service the cell rooms
and set-up area. There shall be at least five connections in the disassembly
area. The facility maintenance area and set-up area shall have two connections.
This system shall have not less than 60 inches w.g. vacuum at each of the indi-
vidual connections and adequate flow for dust pick-up when it is assumed that
three connections may be in use at one time. All particulate matter in the cell
rooms shall be removed by a bag and filter located in each room for ease of dis-
posal, The discharge header for the vacuum system shall terminate into the stack.
2.6.2. High Yacuum System
A manifold high velocity vacuum system having four connections shall be in-
stalled to service the disassembly cell and maintenance cell, two connections
per cell, for removal of cutting tool chips. The pump for this vacuum system
shall be specified by the A-E.
2.6.3. Radiation Detection
A radiation detection system shall be provided to measure levels in certain
areas. A hand and foot counter will be required in the cold locker room, Other
requirements of this system will be specified by ORNL.
2.6.4. Fire Alarm System
A Gamewell or approved equal fire alarm system shall be provided for the build-
ings. A smoke detection system shall be provided for the storage facility and in
the cell exhaust ducts.
2.6.5, Cell Decontamination System
A spray system shall be installed in the hot cell rooms which will handle de-
tergent, dilute nitric acid (6%), and hot or cold water for decontaminating purposes.
System design shall permit washing down either cell independently.
2.6.6. Service Roads v
Service road construction shall be governed by AEC design standards except as
modified for increased vehicular wheel loads. Roads shall be consistent with .
existing heavy duty ORNL roads in the vicinity of the ADC,
2.6.7. Container for Contaminated Trash
Provision shall be made to place a Dempster Dumpster type container near the
ADC. This container will be provided by ORNL, but a space allocation with
road access shall be provided by the A-E.

114

 

 
2.7. ORNL Furnished Equipment

2'7. ] o

2.7.2,

A-E Specitied

The A-E will be expected to specify all equipment required for completion of
the building and placing it in operational readiness. This includes such items
as cranes, viewing windows, air conditioner, etc, Any equipment so specified
which cannot, in the A-E’s opinion, be obtained by the contractor before June 1,
1958, shall be procured by ORNL for installation at a later date by others,
ORNL Specified

A list of equipment to be supplied by ORNL will be provided to the A-E along
with dates when the items will be available for installation. Equipment such as

manipulators, tools, furniture, instruments, etc., will be in this category.

115
APPENDIX P. SITE INVESTIGATIONS — REACTOR ENGINEERING HOT CELL FACILITIES!*?

A survey has been made of the Bethel Valley and Melton Valley areas for a suitable site loca-
tion for the Reactor Engineering Hot Cell Facility (REHCF). Findings of this study and recom-
mendations by the survey team are reported below and on the attached tabulation and drawing.
This study was made by Mr, S, E. Dismuke of the Solid State Division and the writer of ARED
with the helpful aid of Mr. C. M. Carter of the Engineering and Mechanical Division's Civil Engi-
neering Section and Mr. W. E. Thompson of the Buget Office. The information and recommenda-
tions presented herein were reviewed in the Reactor Disassembly Planning Meeting on October 3,
1956, and this letter is being submitted with the endorsement of and at the instruction of that
meeting.

Assuming that the final plans will require an area approximately as indicated by the sketches
included in the recent proposal® to the AEC, the search was for a site that would ultimately
accommodate a facility approximately 190 ft by 320 ft or 60,800 sq ft, plus allowances for con-
tractor working and storage space. On a three phase construction basis, the gross area require-
ment would be about (1) 60,000 sq ft by July 1, 1957, (2) 70,600 sq ft by July 1, 1958, and 85,800
sq ft at such time that construction of the 20 ‘“future’’ cells should be started. In addition to
space, the locations were studied with respect to utilities, services, center of reactor installa-
tions, center of hot cell operations, public roads, stack installations, soil conditions, accessi-
bility from 750Q area, contractor accessibility, current use of space, and planned future use of
the space.

Table P-1 lists findings for the eleven most promising sites studied. The approximate loca-
tion of each site is shown on Fig. P-1. A summary of advantages and disadvantages for each
site, along with recommendations, is given below. You will note that Sites 4, 8, and 11 are

recommended as suitable locations for the Reactor Engineering Hot Cell Facility.

Site 1 ~ 7500 area
Advantage: Adjacent to Bldg. 7503

Disadvantage: Remote from center of Laboratory operations, hot cell personnel, and
services; remote from hot waste drain system; on semipublic road; outside
ORNL security fence; if required, a discharge stack would have to be con-

structed

Recommendation: Not recommended for REHCF

Site 2 — 1500 area

Advantage: Readily available construction space

 

lMerm:o from F. R. McQuilkin to S, Cromer dated October 10, 1956.

2The title for the proposed facility was later revised to Reactor Disassembly Hot Cell (RDHC)., The
facility has been referred to elsewhere in this report by the revised title.

3 . .
Oak Ridge National L.aboratory Proposal for Reactor Engineering Hot Cell Facilities, ORNL CF-56-8-96
(Aug. 20, 1956).

116
LLL

Table P-1. Site Investigations: Reactor Engineering Hot Ceil Facility (REHCF)

 

Criteria [tem

A, Site location
B. Requirements to make area available

C. Area possibly available 7/1/57:
Dimensions
Area
Sufficient?

D. Area possibly available after 7/1/57:
Dimensions
Area
Sufficient?

E, Is the site:

1. within ORNL security area?

2. near heavy-duty road to 75037

3. away from public or semipublic road?
4, near Lab. area reactor installations?
5, near present Solid State Bldg.?

6. near power service?

7. near potable water service?

8, near steam and air service?

9. near natural gas service?
10, near sanitary sewer?
11. near process sewer?
12. near hot waste drain?

13, near process water?
14. near existing stack?
15. near available stock?
16. near feasible stack construction site?
17. easily accessible for contractor?

F. 1s underground storage and transfer facility
feasibie?

G. Are terrain, soil, and subsoil suitable?

H. General site rating: composite evaluation

Site |

7500 area
(300 ft E of 7503
on 7500 Road)

Clear land of

timber

400 x 500 ft
200,000 f12
Yes

400 x 500 ft
200,000 f+2
Yes

No
Yes
No
No
No
Yes
Yes
Yes
No
No
No
No
No
No
No
Yes

Yes

Site 2

1500 area
(600 £t S of 1000
Bldg. on 1st St.)

N. R.

400 x 600 1
240,000 ft2
Yes

400 x 600 ft
240,000 12
Yes

No
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
No

Yes
No
No
No
Yes

Yes

Fair

Site 3

2500 area
(500 ft SW of Steam
Bldg. on Ist St.)

N. R.

200 x 500 ft
100,000 f2
Yes

200 x 500 ft
100,000 #+2
Yes

Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
No
No
Yes
No
No
Doubtful
Yes

Site 4

3500 area
(present site of
3550 Bldg. on
Central Ave.)

Relocate offices
and labs of 4
divisional groups;

roze Bldg. 3550

250 x 400 f
100,000 f+2
Yes

250 x 400 1
100,000 f+2
Yes

Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Doubtful
Yes
Yes

Yes

Yes

Good

Site 5§

3000 area

{present site of
3026 Bldg. on
Central Ave,)

Relocote lab,

function; raze

Bldg. 3026

150 x 250 ft
37,500 12
No

150 x 250 ft
37,500 f#?
No

Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Doubtful
Doubtful
Doubtful

Doubtful

Doubtful

Poor

 

Site 6

3000 area
(150 f+ W of 13.8 kv substa-
tion on Bethel Valley Rd.)

N. R.

300 x 300 ft
90,000 f12
Yes

300 x 300 ft
90,000 ft2
Yes

Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
No
No
No
Yes
Yes
Yes
N. R.
Yes

Yes

Doubtful

Fair
8Ll

Table P-1 (continued)

 

 

 

Criteria [tem Site 7 Site 8 Site ¢ Site 10 Site 11
A, Site location 5500 area 2000 area 2500 area 3000 area 4000 area
(500 ft E of (immediately W of old (present site of Bldg. {present site of Bldg., 3022) (north of 4500 and
4500 Bidg.) steam plant, Bldg. 2011) 2506} 4501 Bidgs.}
B. Requirements to make orea available N. R. Relocate 2018 shop; re- Relocate poymaster and Relocate E & M Div. offices N. R.
locate 2012 H.P. lab; storeroom; raze bldg. and dwg. rooms; raze bldg.
relocate 2011 Lig. Met,
lab.; raze vacated bldgs,
C. Area possibly available 7/1/57:
Dimensions 300 x 400 ft 190 x 290 ft 200 x 275 ft 100 x 300 ft 200 x 500 ft
Area 120,000 f12 55,000 2 55,000 ft2 30,000 ft2 100,000 ft2
Sufficient? Yes Yes Yes Neo Yes
D. Areg possibly available after 7/1/57:
Dimensions 300 x 400 ft 190 x 500 £ 200 x 275 ft 100 x 300 ft 200 x 500 ft
Area 120,000 §+2 95,000 f+2 55,000 f+2 30,000 12 100,000 2
Sufficient? Yes Yes No No Yes
E. Is the site:
1. within ORNL security area? No Yes Yes Yes Yes
2. near heavy-duty road to 7503? No Yes Yes Yes Yes
3. away from public or semipublic road? No Yes Yes Yes Yes
4, near Lab. area reactor installations? No Yes Yes Yes Yes
5. near present Solid State Bldg.? No Yes Yes Yes Yes
6. near power service? Yes Yes Yes Yes Yes
7. near potable water service? Yes Yes Yes Yes Yes
8. near steam and air service? Yes Yes Yes Yes Yes
9. near notural gas service? Yes Yes Yes Yes Yes
10. near sanitary sewer? Yes Yes Yes Yes Yes
11. near process sewer? Yes Yes Yes Yes Yes
12. near hot waste drain? Yes Yes Yes Yes Yes
13. near process water? Yes Yes Yes Yes Yes
14, near existing stack? No Yes Yes Yes No
15, near ovailable stack? No Yes Yes Doubtful No
16. near feasible stack construction site? Yes N. R. N. R. Doubtful Yes
17. easily accessible for contractor? Yes No Yes No Yes
F. |s underground storage and transfer facility Yes Yes Yes (rock) No Yes
feasible?
G. Are terrain, soil, and subsoil suitable? Yes Yes Yes Yes Yes
H. General site rating: composite evaluation Fair+ Good Fair - Poor Good
- e 1 ] .
 

 

 

- e
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///
4
///
/, ///
/
/
pamy /.
7 7
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e R

o/
% /
%
000 -1499 % (
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3
W

N

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T

' 2000-2499
o 4 I DR

i

.

N
-

......

o (il
LB |
Bl

i
o
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X
D

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7500 - 7999

 

 

 

 

 

 

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5500 - 5999

 

 

 

 

 

 

Fig. P-1. Site Investigations for Reactor Engineering Hot Cell Facility.

119

 
Disadvantage:

Recommendation:

Site 3 ~ 2500 area
Advantage:

Disadvantage:

Recommendation:

Site 4 — 3500 area

Advantage:

Disadvantage:

Recommendation:

Remote from center of Laboratory operations, hot cell personnel, and services,
while at the same time is removed from 7500 area reactor installations; remote
from hot waste drain system; on semipublic road; outside ORNL security fence;
if required, a discharge stack would have to be constructed in a location that

is upwind of the Laboratory prevailing wind direction

Not recommended for REHCF

Readily available construction space

Remote from center of Laboratory operations, hot cell personnel, and services,
while at the same time is removed from 7500 area reactor installations; remote
from hot waste drain system; on semipublic road; if required, a discharge stack
would have to be constructed in a location that is upwind of the Laboratory

prevailing wind direction

Not recommended for REHCF

Located near center of Laboratory operations, hot cell personnel, utilities,

and services, including hot waste drain system

To vacate Bldg. 3550 on the site requires relocation of offices and labs of
personnel from four divisions (this can be done in three phases to correspond
with new construction phases); if required, a discharge stack would have to be
constructed, or possibly arrangements could be developed for limited use of the

No. 3039 stack
Recommended for REHCF

Site 5 — 3000 area (3026 Building site)

Advantage:

Disadvantage:

Recommendation:

Located near center of Laboratory operations, hot cell personnel, utilities, and
services, including hot drain; five existing cells could be incorporated in the

small building design

Site is much too small for a facility of the dimensions proposed; the sloping
terrain and subsoil rock conditions would affect the building usage and con-
struction cost; to replace Bldg. 3026, limited operations by two divisions would
be disrupted; if required, a discharge stack should be constructed, or possibly
limited use of No. 3039 stack could be arranged

Not recommended for REHCF

Site 6 — 3000 area (this is the site adjacent to Bethel Yalley Road that was described in the proposcll)3

Advantage:

Disadvantage:

Recommendation;

Site 7 — 5500 area

Advantage:

120

Readily available construction site; near an existing and available stack

No. 3020 v

Somewhat removed from center of Laboratory operations, hot cell personnel, and
services; remote from hot waste drain system; on public road; the sloping terrain
and subsoil rock conditions would affect the construction cost; future expansion

possible only if substation or water mains are relocated

Not recommended by the survey team for REHCF

Readily available construction site; near the 4500 area scientific personnel;

future expansion to the east would be feasible

 

 
Disadvantage: Somewhat removed from center of Laboratory operations, hot cell personnel, and
services; outside ORNL security fence; if required, a discharge stack should be

constructed; near public road

Recommendation: Not recommended for REHCF

Site 8 ~ 2000 area (2018 Building site)

Advantage: Located near center of Laboratory cperations, hot cell personnel, utilities, and
services, including hot waste drain; adjacent to existing and available discharge

stack No. 2061; future expansion toward the west would be feasible

Disadvantage: To vacate site the Central Machine Shop Annex in Bldg. 2018 (scheduled to
move to Bldg, 2525 in spring 1957), Liquid Metals Laboratory operations in
Bldgs. 2011 and 2017, and Health Physics Laboratory Monitoring operations in
Bldg. 2012 all must be relocated and the buildings razed (this can be done in
three phases to correspond with new construction phases); the sloping terrain

on the north side would somewhat affect building layout and construction cost

Recommendation: Recommended for REHCF

Site 9 — 2500 area (2506 Building site)

Advantage: Located near center of Laboratory operations, hot cell personnel, utilities, and
services, including hot waste drain; near existing and available discharge stack
No. 2061

Disadvantage: Site is small for the facility as proposed and therefore future expansion would

not be feasible; to vacate site the paymaster’s office and tool stores must be
relocated and the building razed; known rock in the area would affect construction

cost

Recommendation: Not recommended for REHCF

 

Site 10 —~ 3000 area (3022 Building site)

Advantage: Located near center of Laboratory operations, hot cell personnel, utilities, and

services, including hot waste drain; near existing discharge stack No. 3020

Disadvantage: Site is much too small for the facility as proposed; to vacate site the E & M
Division offices and drafting rooms would have to be relocated and the building
razed; the terrain on the north side of site would affect building layout and con-

struction cost

Recommendation: Not recommended for REHCF

Site 11 — 4000 area

Advantage: Located near center of Laboratory operations, hot cell personnel, utilities, and

services, including hot waste drain; is readily available construction site

Disadvantage: If required, a discharge stack should be constructed, or possibly limited use of
No. 3039 stack could be arranged; adjacent to former radioactive waste burial
ground No, 606B

» Recommendation: Recommended for REHCF

Suppiementary to the above summary we wish to amplify the findings as to requirements for
making the sites ready for construction:

Sites 1, 2, 3, 6, 7, and 11 are readily available and require relatively minor site preparation

work,

 
Site 4 in the 3500 area requires vacating and razing Bldg. 3550. Relocation of the lab and
office groups imposes certain problems that would have to be resolved. Where it might be reason-
able to vacate and raze the center (office) wing first and later remove the outer (lab) wings, the
present plans for such relocation call for transferring only a portion of the Bldg. 3550 activities in
calendar year 1959,

Site 5 in the 3000 area cannot be released for a building site until present commitments for the

Rala project in Bldg, 3026 expire March 31, 1957, and after arrangements are made to relocate hot
cell activities in the west end of the building.

Site 8 in the 2000 area is the present site of temporary buildings 2011, 2012, 2017, and 2018,
As pointed out above, the Central Machine Shop Annex in Bldg. 2018 is scheduled to move to

‘ Bldg. 2525 in the spring of 1957, The writer understands that the activities of the Health Physics

i Laboratory Monitoring Group in Bldg. 2012 are now such that relocation problems would be minor
and probably could be worked out on short notice. Also, it is understood that the Liquid Metals
Lab, which recently occupied the former steam plant Bldgs. 2011 and 2017, will require the
building until the Metals and Ceramics Building is available in early calendar year 1960.

Present plans for Site 9 call for relocation from Bldg. 2506 of the paymaster's office in the
summer of 1958 and removal of the tool stores activity to an undetermined place at about the same
time. The building is subsequently scheduled to be razed for construction of a permanent plant
protection headquarters building as a fiscal year 1959 capital project.

Site 10 is scheduled for release as a permanent building area after the E & M Division offices
and drafting rooms are relocated in a second floor addition to be constructed on Bldg. 2525 as a

fiscal year 1959 project.

122

 
ORNL-2464
UC-80 Reactors-General
TID-4500 (15th ed.)

4
INTERNAL DISTRIBUTION
1. A. A. Abbatiello 39. R. S. Livingston
2. S. E. Beall 40. R. N. Lyon
3. M. Bender 41. W. D. Manly
4. D. S. Billington 42. E. R. Mann
5. E. P. Blizard 43. H. G. MacPherson
6. C. J. Borkowski 44. F. R. McQuilkin
7. W. F. Boudreau 45. R. P. Milford
8. G. E. Boyd 46. A. J. Miller
9. E. J. Breeding 47. K. Z. Morgan
10. R. B. Briggs 48. J. P. Murray (Y-12)
11. W. E. Browning 49. G. Morris
12. F. R. Bruce 50. A. R. Olsen
13. T. J. Burnett 51. G. W. Parker
| 14. A. D. Callihan 52. P. Patriarca
| 15. R. S. Carlsmith 53. A. M. Perry
* 16. C. E. Center (K-25) 54. P. M. Reyling
17. R. A. Charpie 55. F. Ring, Jr.
18. R. L. Clark 56. A. F. Rupp
° 19. W. B. Cottrell 57. H. W. Savage
| 20. F. L. Culler 58. R. P. Shields
21. S. E. Dismuke 59. Oscar Sisman
22. H. G. Duggan 60. M. J. Skinner
23. W. K. Eister 61. A. M. Smith
24. L. B. Emlet (K-25) 62. J. A. Swartout
25. D. E. Ferguson 63. D. B. Trauger
26. A. P. Fraas 64. A. M. Weinberg
27. E. A. Franco-Ferreira 65. G. D. Whitman
28. E. J. Frederick 66. G. C. Williams
29. J. H. Frye, Jr. 67. C. E. Winters
30. W. R. Grimes 68. Health Physics Library
31. C. S. Harrill 69. Biology Library
32. W. R. Harwell 70. Reactor Experimental
33. T. Hikido Engineering Library
34. W. H. Jordan 71-72. Central Research Library
35. G. W. Keilholtz 73-75. ORNL -~ Y-12 Technical Library,
36. C. P. Keim Document Reference Section
37. Eugene Lamb 76-95. Laboratory Records Department
j 38. R. B. Lindaver 96. Laboratory Records, ORNL R.C.
* EXTERNAL DISTRIBUTION

97. Division of Research and Cevelopment, AEC, ORO
98-681. Given distribution as shown in TID-4500 (15th ed.) under Reactors-General
category (75 copies — OTS)