With the development of the zircaloy-2 clad uranium fuel element, it was necessary to develop a method of closing the end of the element after the extruded tubes were cut to the desired length. Regardless of the ultimate design of the closure, a satisfactory zircaloy-2 fusion welding technique had to be worked out. The first fully successful welding was performed with electron beam welding in a vacuum chamber. To make satisfactory welds, the electron beam welding involved time and equipment, plus undue maintenance on the equipment.

The decontamination of the present Hanford reactors involves a once-through cleaning operation. Considerable interest has been shown in determining the feasibility of this once-through technique for cleanup of certain portions of the NPR system. This is the second interim report of a series that covers tests performed in the 242-B Single Pass Flow Facility. The first was distributed in January, 1960.

Theoretically aqueous hydrazine will react with dissolved oxygen for form only nitrogen and water. Most of the experimental evidence, however, indicates that the reaction proceeds rather slowly in low-temperature systems. Tests are currently being conducted to determine whether or not it is feasible to use activated carbon to catalyze the reaction in filtered water. A system of this type would be useful in high temperature reactors when it becomes necessary to convert to single-pass operation.

Thermal oxidation of graphite in flowing CO2 is being studied at 650 to 850 C, in a single-pass gas system at atmospheric pressure, by observing weight loss rates. The method is used to provide comparative data for candidate reactor graphites. The effects on oxidation rates of graphite purity, structure, coke type, graphitization temperatures and other manufacturing variables are determined. In addition, the effects of gas flow rates and graphite surface to volume ratios are observed.

This document reports the circumstances surrounding the failure of sheathed thermocouples during a test being conducted in the KAPL-120 Loop. The report is prepared to provide a record of these events and to acquaint those who use these thermocouples for testing of other applications with the difficulties that are sometimes encountered.

Operating plant experiences in restoring to useful service failed equipment contaminated through exposures to radioactive processes is of international interest to the nuclear industry. In accordance with a request from the Hanford Operations Office of the United States Atomic Energy Commission this report of the various measures taken in rehabilitating for re-use expensive engineered equipment has been compiled by the General Electric Company. This report is a review and summary of the disposition of contaminated major processing equipment at Hanford Atomic Products Operation during 1958-1959 and a listing of 1) equipment buried, 2) equipment stored, to be buried or decontaminated, and 3) equipment decontaminated and returned to service.

Accurate sampling of particulate in gaseous effluents is required for auditing and control of radioactive wastes released to the environment at installations generating or processing radioactive materials. Over the years a variety of sampling probe configurations, sampling velocities, lengths and sizes of sample delivery lines have been used locally to obtain these samples. Efforts to properly evaluate the validity of samples in most sampling installations have been hampered by a lack of basic knowledge of particle behavior under the various conditions imposed. Important variables about which minimal knowledge is available are those of particle impaction and retention on and re-entrainment from the walls of sampling lines. In some sampler configurations the effect of these parameters on sampling validity may be made negligible, but in lines already in place. or where long sampling lines are required, the degree to which deposition affects the sampling validity must be established. Deposition and rebuild up, then rapid release to the air stream. Research has been initiated in Hanford Laboratories Operation to provide the required data relative to deposition and retention on conduit walls and to eventually arrive at approved sampling system configurations.

Over the last decade, several computational methods have been developed and used to examine reactor flow transients caused by pump outage. The variations in system character which have been analyzed are sufficiently diverse that it appears worthwhile to compile them into a single report.

One of the problems involved in the design of NPR is the method to be used for decontamination, Considerable effort has been made in both laboratories and pilot plants in developing and evaluating decontamination processes under ideal conditions. Promising processes must be tested under prototypical conditions of velocity, water quality, manner of make-up, type and degree of contamination, addition of decontaminating solutions, and so on.

Although the corrosion of resistance of Zircaloy--2 clad fuel elements in high temperature water is excellent, some concern has been expressed in regard to the resistance against fretting corrosion. Since this form of corrosion can proceed quite rapidly it could induce fuel element failure through penetration of the cladding. Fretting corrosion if it occurred, would take place either where the fuel element contacted the process tube or where portions of the fuel element contacted each other, e. g. wire-wrapping around a cluster of cylindrical fuel rods. This form of corrosion is defined as corrosion occurring at contact areas and as such, fretting of Zircaloy-2 could take place in many reactor concepts. This report details the results of testing performed to induce fretting corrosion of Zircaloy-2 and the direction of the future tests.

Judging scratch depth or surface roughness by unaided visual inspection under controlled conditions, while rapid and popular, is not quantitative. Comparison methods improve reproducibility but are generally not applicable to evaluation of depths of single widely spaced scratches. Stylus-type contour recorders yield valuable scratch contour data but may themselves plow through soft materials and fine details. Depth measuring microscopes are particularly applicable to measurement of pinhole depth but do not graphically reveal profiles and provide only a small field of view. The comparatively large field of view and graphic display of contour provided by profile microscopes make them particularly suitable for evaluation scratch depth as well as surface roughness. A HAPO-constructed instrument has demonstrated an accuracy of +/- 50 micro inches in the range of 50 to 15,000 micro-inches scratch depth. It is a pocket-sized, portable, and can be used on horizontal and vertical surfaces by untrained persons with only brief instruction.

The monocarbide and the mononitride of uranium are potentially useful ceramic nuclear fuel materials. This paper reports the results of exploratory investigations of the reactions of uranium monocarbide and uranium mononitride with boiling water. Uranium dioxide, chemically stable in deoxygenated boiling water, was used as a control.

The purpose of this procedure is to present a detailed, chronological presentation of the preliminary decontamination and post decontamination steps necessary to fulfill the requirements of the Production Test Authorization IP-239-N. The procedure attempts to present the required operation in sufficient detail to successfully accomplish the intent of the test. Certain procedures involve operations of a standard nature and have not been elaborated upon to any great extent, as it is expected that the reactor operations and radiation monitoring personnel will implement these instructions according to standard operating procedures.

Nuclear safety in the dissolution of irradiated 0.95 U235 enriched fuel has been investigated. In particular, critical conditions of fuel of this enrichment in a 52-inch diameter dissolver crib were studied. Since a crib this size is not safe by geometry, dissolution procedures as well as maximum safe batch sizes were analyzed. Uranium-water lattices are normally studied in systems in which rods are uniformly dispersed in the moderator. The results of such a study for 1.34-inch diameter solid rods as well as I. and E. fuel having a 1.37-inch O.D. by a 0.48-inch I.D. have already reported.

Examination of Al- 1.65w/o Pu and Al- 12 w/o Si- 1.65 w/o Pu capsules irradiated 55- 60% burnout of the plutonium atoms revealed a 1.4% volume increase and no apparent microstructural changes. A four rod cluster containing Al-8 w/o Pu and Al-12 w/o Si-8 w/o Pu alloy cores is currently under irradiation in Loop 3 of KE Reactor at a water temperature of approximately 230C. A second cluster has been fabricated an is scheduled for charging late in 1958. Two seven-rod clusters for irradiation in KER are also being fabricated.

In solvent extraction purification processes such as are used at Hanford, the fuel elements or "slugs" from the reactor containing uranium, plutonium, and fission products are dissolved in nitric acid, adjusted to the required feed composition, and pumped to the solvent extraction columns. Figure 1 in a schematic diagram of such a solvent extraction process. In the A column, the uranium and the plutonium are extracted into an organic phase while the bulk of the fission products remain in the aqueous phase and leave as waste with the column raffinate.

It is anticipated that neptunium will be recovered in the Purex process by solvent extraction or ion exchange methods as a nitric acid solution of greater than 0.1 g. Np/1 and containing varying amounts of fission products, plutonium, uranium, and thorium, including Th234 (UX1). At the present time this solution is thermally concentrated in the Purex L-cell package to several grams of neptunium per liter. In this operation the solution is contaminated rather badly with plutonium and stainless steel corrosion products. The present specifications are for the neptunium final product to contain less than 0.1 weight percent plutonium, to be relatively free of gross metallic contaminates, and to be low enough in fission product game activity and Th234-Pa234 (UX1-UX2) beta activity to be handled without resorting to remote techniques.

PuO2-UO2 Irradiation Capsules. Four capsules of Zircaloy-clad, sintered PuO2-UO2 mixed crystal oxides in a UO2 matrix are awaiting irradiation in the NTR.

Whenever fissile materials are handled in significant quantities such as in fuel element fabrication, separation processes, or in exponential and/or critical experiments a potential criticality hazard exists. The usual procedure which is followed by those persons conducting critical mass experiments is to either place the potential reactor in a heavily shielded cell or to conduct the experiments remotely in which case distance provides a measure of safety in the event of an unscheduled radiation outburst. In considering potential critically incidents, especially for the personnel not specifically engaged in critical mass studies, it is very likely that at the time of the incident neither the conditions of shielding nor distance will prevail for the personnel involved.

Previously, W. S. Figg and T. W. Ambrose (HW-51767 Rev) have investigated the problem of flow decay following electrical power loss to the PRTR primary coolant pumps. However, since the time of their study many reactor piping changes have been made in the design; therefore, it has become advisable to re-examine the problem incorporating these changes.

The fixation of aqueous radioactive wastes in a stable solid media by means of calcination has been the subject of considerable research and development effort. Several methods of doing this on a continuous basis have been devised and a few have been demonstrated to be feasible for the handling of non-radioactive or low activity simulated wastes. Currently an investigation of calcination by means of radiant-heat spray drying is being carried on by the Chemical Research Operation of the Hanford Laboratories Operation. The process consists of atomizing the liquid to be treated into the top of a cylindrical column, the walls of which are maintained at a high temperature. The resultant suspension of droplets in the water vapor formed by evaporation passes through successive zones of drying, calcination, possible chemical reaction or melting, and partial cooling as it proceeds down the tower. Separation of the resultant solids, steams, and uncondensable gas is made by conventional methods.

A perspective drawing of typical hood cells arranged in series for an assembly line operation is presented. Advantages of this improved enclosure for low level radiation work are listed which recommend its use on new facilities in preference to more conventional designs.

A preliminary soil column experiment with a waste sample from the 207-S-11 well, which monitors the 216-S cribs, indicated that cesium was absorbed almost completely by the soil but that strontium breakthrough to ground water in the near future seemed likely. Accordingly, it was suggested that the 216-S wastes be discharged to a new disposal site, and that samples of the wastes which are currently being discharged to the 216-S cribs be obtained for soil absorption tests. The primary purpose of these tests was to obtain data which could be used to suggest ways and means of improving the absorption of strontium by soil from the process condensate stream (D-2_ and the cell drainage stream (D-1), both of which have been discharged to the 216-S cribs for the past several months.

The use of process-solution-lubricated sleeve bearings in rotating equipment is quite extensive at H.A.P.O. The difficulty or impossibility of providing contact maintenance, the poor lubricating qualities and corrosive natures of most of the process solutions, in addition to radioactivity, impose stringent restrictions on the selection of materials of construction of these bearings. Prototypical evaluation of materials indicating suitable characteristics in preliminary testing, both in the Corrosion Laboratory and in the bearing test machines, is necessary to establish behavior and compatibility under actual or simulated process conditions. These preliminary tests showed that gold and gold alloys might be used as satisfactory materials for pump bearings under certain conditions. This report presents the test results obtained while testing bearings in pumps prototypical or identical with process plant equipment.