j^ i^ aubl)b 1996 1. edt

j

AUbl

^ i

)b 1996 ENGINEERING DATA TRANSMITTAL 1. EDT

of 1

2. To: (Receiving Organization)

Distribution3. From: (Originating Organization)

Spent Nuclear Fuels Project4. Related EOT Ho.:

N/A5. Proj./Prog./Dept./Div.:

Spent Nuclear Fuels Project6. Cog. Engr.:

C. R. Miska7. Purchase Order No.:

N/A

8. Originator Remarks: 9. Equip./Component Ho.:

N/A

10. System/Bidg./Facility:

N/A

11. Receiver Remarks: 12. Major Assm. Dug. No.:

N/A13. Permit/Permit Application No.

N/A14. Required Response Date:

July 30, 1996DATA TRANSMITTED (H)

(AlItem (B) Document/Drawing No.

IDIRev.No.

(E} Title or Description of DetaTransmitted

ApprovalDeato-

Reatofor

Origi-nator

Dispo-sition

Dispo-sition

WHC-SD-SNF-CDR-007

Hot ConditioningEquipment ConceptualDesign Report

SQ

Approval Designator (F) Reason for Tra Disposition (H) & |

E, S, Q, D or N/A(see WHC-CM-3-5,Sec. 12.7)

1. Approval 4. Review2. Release 5. Post-Review3. Information 6. Dist. (Receipt Ac km '. Required)

1. Approved 4. Reviewed no/comment2. Approved w/commont 5. Reviewed w/comment3- Disapproved w/comment 6. Receipt acknowledged

SIGNATURE/DISTRIBUTION(See Approval Designator for required signatures)

[] Approved[] Approved w/comments[] Disapproved w/comnents

D-7400-172-2 <04/94) GEF097

KAtit 1 01

WHC-SD-SNF-CDR-007, Rev. 0

Hot Conditioning Equipment Conceptual DesignReport

UC:Charge Code: LH002Total Pages:

Herrick and AssociatesWestinghouse Hanford Company, Richland, HA 99352U.S. Department of Energy Contract DE-AC06-87RL10930

EDT/ECN: 616136Org Code: 2C400B&R Code: EH3135040

Key Words: Spent Nuclear Fuel, N Reactor Spent Nuclear Fuel, SinglePass Reactor Spent Nuclear Fuel, Hot Conditioning System Equipment,Canister Storage Building, K-Basins, Cold Vacuum Drying System

Abstract: This report documents the conceptual design of the HotConditioning System Equipment. The Hot Conditioning System will consistof two separate designs: the Hot Conditioning System Equipment; and theHot Conditioning System Annex. The Hot Conditioning System EquipmentDesign includes the equipment such as ovens, vacuum pumps, inert gasdelivery systems, etc. necessary to condition spent nuclear fuelcurrently in storage in the K Basins of the Hanford Site. The HotConditioning System Annex consists of the facility to house the Hotconditioning System. The Hot Conditioning System will be housed in anannex to the Canister Storage Building. The Hot Conditioning Systemwill consist of pits in the floor which contain ovens in which the spentnuclear will be conditioned prior to interim storage.

TRADEMARK DISCLAIMER. Reference herein to any specific commercial product, process, or service bytrade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply itsendorsement, recommendation, or favoring by the United States Government or any agency thereof orits contractors or subcontractors.

Printed in the United States of America. To obtain copies of this document, contact: WHC/BCSDocument Control Services, P.O. Box 1970, Mailstop H6-08, Richland WA 99352, Phone (509) 372-2420:Fax (509) 376-4989.

Companies whose information is photocopied and included in this documenthave been contacted to verify that the information is not copyrighted orcompany sensitive in anyway. Attached are 2 letters of permission to usethat companies copyrighted information.

Date

Approved for Public Release

DATE:

A-6400-073 (10/95) GEF321

o f 3SUPPORTING DCC'JMiNT COVERS^;"WHC-SD-SNF-CCR-007, Rev. 0

Westlnghouse Hanford Companyf.a. lot 1970Blcl lUnd, WA WSSJ

To: EG&G ROTRON

APPLICATION FOR PERMISSION TO USEYOUR COPYRIGHTED MATERIAL !

Date: B/l/96

Permission Is requested t ° reproduce the following copyrighted materiel from:

EG&G ROTROH Cutsheets for The MD 10]

Selection, from text (specify by date of Issue, page, paragraph, or Illustration; If desired, attach acopy of the material In question):

The attsehed pages Include a brief Introduction to our document and the EG4Gcutsheets our author would l ike to include in his Conceptual Design Report.

Title of work or project In which this material will be Included:

Hot Conditioning System Equipment

Estimated publication date: 8/1/96

Publisher (if applicable): N/A

-VK-Basin Spent Nuclear Fuel Project

Author: Herri ck and A$soc.andW.L. Wi l l isWestlnghouse Hanford Co.

if the copyrighted material Is not to be used In a published work, pleas* provide a brief description ofhow it Is to be used:

Name: Kara M, B'O' ^

Slonaturer^=9^c/^t ~-&!*S&*~' J'•t S

Application approved by;

Name: \ \ lACL UJ*TS

Company Name: P-&' , fa O-'o' tio^ -:

Signature: j /^-* - -V v,— -^^

MSIN: R1-29 Date: 8/1/96

Westlnghouse Hanford Company

Date: tlbfol,. ' ' ~TiJfl Ow Slonatory's Position:

(on behalf of)

A-M00.4J? (0J/9S) UEF220

SUPPORTING DOCUMENT COVERS":PAGE 3 of 3 WHC-SD-SNF-CDR-0O7, Rev. 0

TELECOPYfrom

PALL ADVANCED SEPARATIONS SYSTEMSPall Trinity Micro Corporation 3643 Route 281, PO Box 2030

CortlanJ, NY 13045Phone, (607) 753-6041

Fax: (607) 753-8525

X Pages Total (Including Cover Sheet)

(If you do not receive this entire facsimile, please call (607) 753-6041 Ext. 1811)

TO: Kara Broz - Westinghouse Hanford Company

Fax.- (509) 373-7739

FROM: Paul Dittman

SUBJECT: Design Data Report

DATE: Augu.t 2,1996

I am writing to inform you that it is acceptable for you to include Pall Corporation's

Literature UAF-100 (Pall Ultramet /Air Filters/Systems Brochure) in your report that

discusses the use of Pall niters for the subject of HCSE Specification.

You may also use Pall Proposal Number: BP7ACDR96-129PDI for Santa Fe Engineering,with the exception of the pricing and delivery sections.

if you have any questions or need further information, please do not hesitate to call me at

(607) 753-6041 Ext. 1680.

Regards,

Pall Advanced Separations Syitams

QcuAPaul DittmanSenior Applications Engineer

lotut notei/iyping/diiiman

TT:ET 9661-20-90

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning Syrttm Equlpmtnt AdnncadTtchnology S«ctorContract »MW5-SWV-310416,TMk #17 _ Project No. 30012318

WHC-SD-SNF-CDR-007, Revision 0

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION PAGE

TABLE OF CONTENTS i

ACRONYMS Hi

DEFINITIONS ix

1.0 INTRODUCTION

2.0 PROCESS

2.1 HCSE MODEL OPERATION SEQUENCE 2-1

2.2 MAIN PROCESS SYSTEMS 2-112.3 COMBINED VENTILATION SYSTEM (CVS) CONFIGURATION 2-292.4 PROCESS CONTROL 2-312.5 OVEN ASSEMBLY DESCRIPTION 2-332.6 PROCESS MODULE 2-362.7 SERVICE MODULE 2-412.8 PROCESS ENCLOSURE DESCRIPTION 2-442.9 SOLID WASTE 2-56

3.0 FACILITIES/UTILITIES SUPPORT

3.1 HCSE LAYOUT 3-13.2 HCSE/HCSA INTERFACES 3-6

3.3 AUXILIARY FACILITIES 3-10

4.0 INTERFACES

4.1 HCSE INTERFACES 4-1

5.0 COST AND SCHEDULE

5.1 METHOD OF ACCOMPLISHMENT 5-1

5.2 SCHEDULE 5-25.3 SUMMARY COST ESTIMATE 5-2

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning Syrtwn Equipment Adnncad Technology SectorContract«MW6-SWV-310416,Tnk#17 Project No. 30012318


TABLE OF CONTENTS

APPENDICES

A. DRAWINGSB. ALARA IMPLEMENTATION PLANC. SHIELDING AND RADIATION EXPOSURE ANALYSISD. OPERATIONS AND MAINTENANCE PHILOSOPHYE. PERFORMANCE SPECIFICATIONS REPORTF. COST ESTIMATE BACKUPG. CALCULATIONSH. VENDOR CUT SHEETSI. CRITERIA EVALUATIONJ. OPERABILITY AND MAINTAINABILITY ASSESSMENTK. COMMENT DATABASEL USE OF COOLING WATER IN THE HOT CONDITIONING SYSTEM

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WESTINGHOUSE HANFORD COMPANYHoi Conditioning Sy*am EquipnwitContl«ct#MWS-SVW-310416, Twk#17

MERRICK&COMPANYAdwnod Tachnoiogy Sactor

Project No. 30012318


ACRONYMS

ACRONYMS

acfm Actual cubic feet per minute

ACGIH American Conference of Governmental Industrial Hygienists

ACI American Concrete Institute

Al Residual Gas Analyzer Indicator

ALARA As Low As Reasonably Achievable

ANS American National Standard

ANSI American National Standards Institute

ASHRAE American Society of Heating, Refrigeration, and Air ConditioningEngineers

ASME American Society of Mechanical Engineers

BFD Block Flow Diagram

BLO Blower

CAM Continuous Air Monitors

cc/sec Cubic centimeters per second

CDR Conceptual Design Report

CFR Code of Federal Regulations

CH Chiller

CHW Chilled Water System

CLR Cooler

CM Control Manual

Co Cobalt

Cs Cesium

CSB Canister Storage Building

CVDM Cold Vacuum Drying Module

CVDS Cold Vacuum Drying System

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WESTINGHOUSE HANFORD COMPANYHot CondWoning Syitam EquipmentContr»ct#MW6-SWV-310416, T t t k * 1 7

MERRICK&COMPANYAdvincsd Technology Soctor



ACRONYMS

CVS Combined Ventilation System

DBA Design Basis Accident

DE Design Earthquake

DNFSB Defense Nuclear Facilities Safety Board

DOE Department of Energy

DOP Dioctylphthalate aerosol

DOT Department of Transportation

EDE Effective Dose Equivalent

ERDA Energy Research & Development Administration

ES&H Environmental Protection, Safety and Health

EWS Engineering Work Station

F Filter

Fl Flow Indicator

FIC Flow Indicating Control

FOB Free On Board

FQIC Totalizing Flow Indicating Control

FSF Fuel Stabilization Facility

ft/min Feet per minute

GDC General Design Criteria

GOCO Government Owned Contractor Operated

GOV Gas Operated Valve; flow, ball

gpm Gallons per minute

H Hydrogen

HC2 Hazard Category 2

HC3 Hazard Category 3

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WESTINGHOUSE HANFORD COMPANYHot Conditioning System EquipmentContract #MW6-SWV-310416, Task#17

MERRICK&COMPANYAdvanced Technology Sector



ACRONYMS

HCL

HCS

HCSA

HCSE

He

HEPA

HLAN

HSRCM

HVAC

HVCE

I

I/O

ICRP

IEEE

IFMSF

ISA

ISFSI

kg

Kr

LAN

LCP

Ipm

LPT

MCO

MCS

Electric Heater

Hot Conditioning System

Hot Conditioning System Annex

Hot Conditioning System Equipment

Helium

High Efficiency Particulate Air

Hanford Local Area Networks

Hanford Site Radiological Control Manual

Heating, Ventilation, and Air Conditioning

Hot Vacuum Conditioning Equipment

Iodine

Input/Output

International Commission on Radiological Protection

Institute of Electrical & Electronics Engineers

Irradiated Fissile Material Storage Facilities

Instrument Society of America

Independent Spent Fuel Storage Installation

Kilogram

Krypton

Local Area Network

Local Control Panel

Liters per minute

Liquid Penetrant Test

Multi-canister Overpack

MCO Cooling System

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WESTINGHOUSE HANFORD COMPANYHot Conditioning System EquipmentContract #MW6-SWV-310416, Task #17




ACRONYMS

Mg Magnesium

MHM MCO Handling Machine

MMI Man-Machine Interface

MSHA Mine Safety and Health Administration

N Nitrogen

NFPA National Fire Protection Association

NGS Non-Government Standards

NIOSH National Institute for Occupational Safety and Health

NQA Nuclear Quality Assurance

NRC Nuclear Regulatory Commission

O Oxygen

OIS Operator Interface Station

ORA Operational Readiness Assessment

ORR Operational Readiness Review

OSHA Operational Safety and Health Administration

P&ID Piping and Instrument Diagram

PC Personal Computer

PCS Process Control System

PCV Constant Pressure Regulator Valve

PE Process Enclosure

PFD Process Flow Diagram

PFR Purifier

PG Process Gas

PGS Process Gas System

PHA Preliminary Hazards Analysis

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WEST1NGHOUSE HANFORD COMPANYHoi Conditioning Syittm EquipmentContract #MW6-SWV-31(M16, T u k * t 7




ACRONYMS

PHS Process Heating System

PI Pressure Indicator

PIC Pressure Indicating Control

PID Proportional Integral Derivative

PLC Programmable Logic Controller

PNL Pacific Northwest Laboratory

psia Pounds per square inch absolute

psig Pounds per square inch gauge

PTFE Teflon based solid lubricant

PV Process Vent

QA Quality Assurance

- QAP Quality Assurance Plan

RAS Radiation Air Sampler

RCW Revised Codes of Washington

SAR Safety Analysis Report

SCADA Supervisory Control and Data Acquisition

scfm Standard cubic feet per minute

SDD System Design Description

SMACNA Sheet Metal and Air Conditioning Contractors' National Association, Inc.

SMCS System Monitoring and Control System

SNF Spent Nuclear Fuel

SNFP Spent Nuclear Fuel Project

SOV Gas Operated Valve, solenoid

SSC Structure, System and Component

SSF Staging and Storage Facility

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WEST1NGHOUSE HANFORD COMPANYHoi Conditioning System EquipmentContract #MW6-SWV-310416, Task #17




ACRONYMS

STD Standard

TBD To Be Determined

TCP/IP Transmission Control Protocol/lntemet Protocol

TEDE Total Effective Dose Equivalent

Tl Temperature Indicator

TIC Temperature Indicating Control

TSR Technical Safety Requirements

UL Underwriter's Laboratory

VAC Vacuum

VPS Vacuum Pumping System

WAC Waste Acceptance Criteria

WAC Washington State Administrative Codes

WBS Work Breakdown Structure

WHC Westinghouse Hanford Company

Xe Xenon

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WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot CondHoning Syitom Equipment Advwwtd Technology StdorCoot™ct#MW6-SWV-310416, TMk#17 Preset No 30012318


DEFINITIONS

DEFINITIONS

Annular Space Cover

A ring (that now will be 3-in thick to provide shielding) with a bellows to seal the topof the annular space between the Oven and the MCO. When not is use, theAnnular Space Cover can be stored in the Process Enclosure or in a room next tothe solid waste storage room. Since the cover will not normally becomecontaminated, it can be transferred in and out of the Process Enclosure by a heavyduty tray that slides goes in and out of the Process Enclosure. A fork lift can put iton the tray and the manipulator can place it on the MCO. This will require a largermanipulator with more lifting capability.

Cold Trap (a.k.a. "Cs/I Trap")

A water cooled unit that will be located in the Trench and that will be used toremove Iodine, Cesium and participate from the gases being circulated through orremoved from the MCO. The water cooling will be accomplished by wrapping atube around the Cold Trap body such that a double leak would be required for waterto contact the process gases (i.e., the tubing would have to leak and the Cold Trapbody would also have to leak.) The Cold Trap will be changed when the ProcessEnclosure is positioned over the Process Pit (and thus also over the Trench Cover).The Trench Cover will be raised and the manipulator will be used to disconnect thespent Cold Trap, blank the Cold Trap end connections, place the spent Cold Trapin a shielded waste drum, and install a new Cold Trap.

Connection Valves

The valves that will be used to connect the equipment on the Process Module to theinterior of the MCO. There are two such valves on each MCO, one that isconnected to a dip tube that extends to the bottom of the MCO and one that isconnected to a sintered metal filter that is located at the top (interior) of the MCO.The exact configuration of the Connection Valves is TBD.

Insulation Cover (a.k.a. "Insulated MCO Top Cover")

The cover that is placed on top of the MCO after all of the connections are made.Its purpose is to limit the heat loss from the top of the MCO during the heatingcycle. The cover will be handled in the same manner as the Annular Space Coverexcept that it will be lighter in weight.

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WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning System Equipment Advanced T*chnology SKIOTContract #MW6-SWV-310416TMk #17 . Project No. 30012318


DEFINITIONS

MCO Process Heater

The electrically heated unit that will be used to heat the air that is circulated aroundthe MCO when it is in the Oven. This unit is currently conceived as an in-duct typeheater that will be located in the Process Module.

Oven (a.k.a. "furnace" and "dewar")

The vacuum insulation around the Oven is also referred to as the Oven Jacket.The current concept of the Oven is a vacuum insulated sleeve in which the MCOis placed. The annular space between the sleeve (Oven) and the MCO isconnected by vacuum insulated piping to the MCO Process Heater. During theheating cycle, air is circulated between the Process Heater and the Oven to heatthe MCO. Collection rings are located at the top and bottom of the Oven todistribute and collect the heating gases.

Port Covers

The covers that are on the MCO to protect the Valve Connections when the MCOarrives at the Process Pit.

Process Enclosure (a.k.a. "Cell" and "Hole Portable Operations Cell")

A shielded enclosure that is equipped with a manipulator, HEPA filtration, operatorwork station, personnel entry door, waste drum bagport, welder, CCTV, lighting,shelves, hangers, air monitor and radiation monitors. The Process Enclosure willbe moved from Process Pit to Process Pit by a cable that is manually attached tothe Enclosure. It will have limited, manual, steering capability so that it can bepositioned over a Process Pit. Potentially outlines of the Process Enclosure couldbe painted on the floor to allow sufficiently accurate placement. Its height will beless than 10 feet so the MHM top rail can pass over it without interference. If it isnecessary to move it out of the center line of the Process Pits when the MHM ispresent, then a floor level transfer tray can be provided for this purpose. TheProcess Enclosure would be parked on the transfer tray and then the tray wouldtransport it to the South and out of the path of the MHM.

Process Module (a.k.a. "Process Bay Skid")

This is skid where the bulk of the hot vacuum conditioning process equipment islocated. There will be one Process Module per Process Pit. The Process Modulewould contain the vacuum pumps, heat exchangers, valving, instrumentation, andother hot conditioning process equipment that does not have to be located in theProcess Pit or the Trench.

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WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning Sy««m Equipment Advanced Technology S«ctorContract #MW6-SWV-310416, Task #17 _ Project No. 30012318


DEFINITIONS

Process Pit (a.k.a. "furnace pit" "vault")

This is a hole in the CSB Annex floor that will be approximately 4-ft diameter and20-ft deep. The oven will be located in the Process pit. It is anticipated that sixProcess Pits will be required with a space provided for a seventh to allow weldingor active neutron interrogation of the MCO to determine residual water content.

Process Pit Cover (a.k.a. "Oven Top" and "6-in Thick Steel Covers")

A two piece unit consisting of the Process Pit Cover and the Shield Plug. TheProcess Pit Cover is hinged on one end and will be pivoted out of the way to allowaccess to the top of the MCO after the Process Enclosure has been positioned overthe Process Pit. As currently envisioned, the Process Pit Cover will include a HEPAfilter that is capable of allowing 150 cfm of air to be drawn from the CSB Annexoperating space to the Process Pit.

Shield Plug

A unit that is centered in the Process Pit Cover and that is removed by the MHMwhen a MCO is placed in the Process Pit. This unit is intended to look like astorage position plug to the MHM and thus be handled by it in an identical manner.The plug will probably have to be mechanically locked to the Process Pit Cover sothat it will not fall out of the cover then the Process Pit Cover is raised. The detailsof this mechanical interlock are TBD.

Trench (a.k.a. "Process Trench")

A rectangular cross-section space that is located below floor level and thatconnects the Process Pit with the Process Module. The piping that connects theMCO and Oven with equipment that is located in the Process Module is located inthe Trench.

Trench Cover

A removable shield that will be located over the Trench to provide shielding shouldradioactive constituents from the SNF plate out in the piping or be trapped in theCold Trap.

Vent Cover

The cover that will be placed over the HEPA filtered MCO vent port. That port mustbe plugged during the hot conditioning process."

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHoi Conditioning Systwn Equipment Advanoad Technology SectorContract JWW6-SWV-310416, Task #17 Project No. 30012318


1.0 INTRODUCTION

The K Basins Spent Nuclear Fuel Removal project has been undertaken for the purposesof decommissioning K Basins, stabilizing the SNF, and placing the SNF into dry storage.The project will retrieve Spent Nuclear Fuel (SNF) elements from their storage canistersin the basins, package the SNF into vessels called Multi-Canister Overpacks (MCOs),drain and vacuum dry the MCO contents, condition (degas) the MCO contents at hightemperature, and place sealed MCOs into dry storage. This Conceptual Design Reportaddresses the processes and equipment systems required to perform the hot conditioning.

The mission of the Hot Conditioning System Equipment (HCSE) project is to degas andpassivate the SNF that has been dried by the Cold Vacuum Drying System (CVDS), andthat has been stored temporarily in the Canister Storage Building (CSB) awaitingavailability of a hot conditioning process station. The hot conditioning will assure that thehydrogen production arising from uranium - water vapor reaction, water radiolysis, anduranium hydride breakdown during storage will be less than the design threshold so thatthe MCOs can be permanently sealed. The degassing is to be accomplished by bakingthe SNF at a temperature of 300°C and evacuating the MCO. This recipe will releasechemically bound water (waters of hydration) and also the readily releasable fraction of thehydrogen that is contained in uranium hydride. The passivation of exposed uranium willbe accomplished by oxidizing with a low concentration oxygen/inert gas blend.Performance requirements for the HCSE that contain the process parameters are foundin Performance Specifications for the Spent Nuclear Fuel Hot Vacuum ConditioningEquipment (WHC-S-0460, Rev 0). The hot conditioning sequence of operations and theprocess system design are found in Chapter 2 below.

The hot conditioning equipment is to be installed in an annex to the CSB. Theconstruction of the annex, Hot Conditioning System Annex (HCSA) is being provided bythe CSB project. This arrangement will allow the MCO Handling Machine (MHM) toperform MCO interchange between the hot treatment process stations and the CSBstorage vaults. The CSB storage vaults are vertically oriented, below grade, tubes thatprotect the SNF from external threats such as tornadoes, earthquakes, and industrialaccidents that might be initiators for an SNF release and that also provide concrete andearthen radiation shielding. The MHM is designed to lift the MCO from a below grade tubeand to place the MCO into a below grade tube. Therefore, the ovens used to heat theMCO in the HCSE must be located in below grade tubes to that they emulate a storagetube to the MHM. The design requirements that define the interfaces between the HCSEand the annex conceptually are given in Chapter 3.

The hazards associated with Hot Conditioning will be described in a Preliminary HazardsAnalysis (PHA). The initial conclusion of the PH are that there are both process upset andnatural phenomena hazards that could cause the primary confinement to fail resulting insignificant radiological consequences. Therefore, the Hot Conditioning process will bedesignated as a Hazard Category 2 (HC2) system per the guidance of DOE STD 1027.

1 -1

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Sy*tem Equipment Advanced TechnoloBy SectorContract #MW6-SWV-310416, Task #17 Project No. 30012316


1.0 INTRODUCTION

The CSB building structure was not designed to act as an accidental nuclear materialrelease confinement barrier. It does not have a nuclear grade ventilation system that willmaintain a negative pressure and collect released material in HEPA filters, nor does ithave "safety class" features that might be needed to mitigate a release from the HCSE.The HCSA will not provide any secondary confinement capability to support the HCSEsince it is an extension of the CSB structure. The responsibility of providing secondaryconfinement and of creating the safety structures, systems, and components (SSCs) thatmitigate the postulated accidental release from the Hot Conditioning process is assignedto the HCSE project. This means that HCSE will include structures to provide a secondarybarrier at all steps of the process that is resistant to the action of Design Basis Accidents(DBAs) including natural phenomenon events, and that traps releases. The HCSE willalso include a ventilation system with HEPA filters and stack to hold the secondaryconfinement volume at a negative pressure. Localized "hardening* will be included in theHCSE design to provide the protection required to assure that the secondary confinementfunctions during and after a DBA as required by DOE 6430.1 A.

The project has agreed to a policy of "Nuclear Regulatory Commission (NRC) Equivalency"in addition to satisfying the DOE criteria. For the most part the DOE criteria are morerestrictive than the equivalent NRC criteria. The major impact on the HCSE project is thatthe NRC requires that the DBAs include a tornado that is not deemed credible in the DOEcriteria for the Hartford Site.

Radiation exposure management is a key issue in the HCSE design as well as it isthroughout all phase of the K Basins SNF Removal project. Because the MCO is notcontained in a shield cask, the radiation exposure would be quite large in the HCSE unlessspecial design features are implemented. The design incorporates a combination ofshielding, remote operations, and automation to absorb radiation, to provide distancebetween the source and operator, and to minimize operator exposure time. These actionsare taken in accordance with the requirements of an ALARA Plan included in the AppendixB. The radiation exposure in the HCSE has been calculated using the CDR sequence ofoperations (see Chapter 2) and geometry, and radiation exposure maps for the bare MCOdesign provided by WHC analysts. The resulting dose estimates are reported in AppendixC of this CDR.

The designs and supporting analysis presented in the CDR have been selected using thefollowing reasonableness judgments which the designers believe does lead to a designthat will support the specific acceptance criteria whenever they become available.

1. The geometry of the CSB, HCSA, and MHM supports a row of HCSE processstations spaced according to the requirement to avoid interference with the MHM.Seven HCSE stations can fit reasonably in this space.

1 -2

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHoi Conditioning Syitom Equipnwnt Advincad Tachnotogy SadorContnct*MW6-SWV-310416,Tuk*17 Projoct No. 30012318


1.0 INTRODUCTION

2. The majority of the times in the process sequence can be reasonably estimatedincluding the heat-up and cool-down times. Although the heat-up and cool-downtimes are quite model dependent (flows are complex), the conservative results canbe selected to assure that the design is robust enough.

3. The evacuation time is unpredictable. However, the vacuum pump selected for theCVDS where off gas rates (water evaporation) are high is a reasonable choice forthe HCSE. The time estimates for the CVDS evacuation (which are highly uncertainbecause of unknown sludge content) have been assumed to be reasonable for theHCSE since the amount of off gas mass removed in the CVDS will certainly exceedthe amount of gas drawn off by the CVDS.

4. The worst credible accidental release scenario will be limited by the amount of SNFpowder that a burst of gas can carry out of the MCO. This amount is dependent onthe mass of gas in the release and is not affected by excess powder in the MCO.Therefore the HCSE safety systems designs are not affected by the amount ofpowder in the MCO.

5. Six (6) HCSE stations were selected because process time is expected to be similarto the CVDS processing time.

The design has been selected to be a robust design that fits within the constraints of theMHM access area. If the process times turn out to be shorter than anticipated then the HotConditioning of the SNF will be completed early. Conversely, if the time is longer thananticipated then the Hot Conditioning will take longer than specified.

A cost estimate has been developed for the HCSE. The details of the estimate arepresented in Appendix F.

1-3

WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHot Conditioning S y i i m Equipment Advancwi Twhnology SwlorContract «MW6-SWV-310416, T i»k*17 Project No. 30012318


2.0 PROCESS

2.1 HCSE MODEL OPERATING SEQUENCE

A model operating sequence has been developed and depicted in an Overall BlockFlow Diagram (BFD) (See Drawing SK-2-300411). Rough time estimates havebeen assigned to each block in the sequence for the purposes of estimatingequipment quantities, equipment utilization, and radiation exposure estimates. Thesequence assumes the following general description of the HCSE configuration:

Treatment will take place in ovens that are located in process pits below the facilityfloor. An oven will essentially be a thermos bottle placed within the process pit. TheMCO will be placed inside the oven. A cover ring will be placed so that hot airblown through the annular space between the MCO and the oven interior wall is notlost into the process pit. Heating will be accomplished by blowing hot air throughthe oven. An insulation cover will be placed over the MCO top. The process pit andoven assembly is shown in Drawing SK-2-400417.

There will be six (6) ovens in the HCSE. The number of oven stations has beendetermined by calculating the process duration for a single oven using theconceptual sequence of operations as a basis, and by imposing a total annualprocess demand of 200 MCOs.

Transactions where an MCO is either inserted into, or pulled from, an oven will beaccomplished by the MCO Handling Machine (MHM) which is part of the CanisterStorage Building (CSB). The HCSE will be housed in an annex of the CSB that isaccessible to the MHM and that is referred to as the HCSA.

The process pits will have top covers that serve as secondary confinement andradiation shields. These covers will be different from the storage hole plugs in theCSB because the oven will have a larger diameter than the storage holes. Thedesign incorporates a two part cover ( plug within a cover) so that the plug will havethe same diameter as the CSB storage hole plugs. This will allow the MHM to makethe transactions while maintaining the double confinement of the SNF using thesame procedure already planned in the MHM and CSB designs.

There will be a process equipment module associatedjwith each oven. This modulewill contain a heater and fan that will supply hot (300°C) air to the oven. The MCOwill be heated externally by this air. The process module will contain a vacuumpumping system and an inert gas purge system to handle the gas within the MCO.The oven insulation will be a vacuum jacket that is supported by a vacuum pumpin one of the process modules. A service module will contain an exhaust fan and

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air cleaning equipment for the air in the process pits and trenches. The exhaustswill pass through air cleaning equipment before being discharged from the facilitythrough a stack.

Process lines that connect the process module and the oven will run below floorlevel in a trench. The hot air lines will be insulated. The trench cover will be thicksteel plate to shield radiation arising from condensation of volatile radioactivematerials in the lines. The lines have a "cold trap" or "adsorber trap" containedwithin the trench.

The radiation exposure associated with making and breaking the MCO connectionsmanually and with changing the trap is anticipated to be unacceptable.Furthermore, the connections will be made a few feet below the floor level wheremanual reach will be awkward. A portable process enclosure will be provided. Thisenclosure will be parked above the oven when needed. It will offer some shieldingand it will contain a hoist and tele-operated manipulator. The hoist will be used tohandle the process pit cover and the manipulators will be used to make and breakthe MCO connections. It has been assumed that the MCO has been designed tosupport remotely manipulated connections and valves. The enclosure will beventilated so that it provides secondary confinement while the MCO top is exposedand while the MCO ports are manipulated.

The final closure of the MCO will be made by welding a cover piece on the MCOwhile the MCO is in the oven after the hot conditioning has been completed. Thisscheme has not been defined by the MCO design project. It is assumed that theweld will be similar to the multiple pass weld that holds the MCO top plug to thebody and that the procedure for the two welds will be approximately the same (rootpass, root pass LPT, 5 cover passes, LPT last pass). The new cover will bedesigned to mate with the MHM.

Given these assumptions the overall sequence is given on Drawing SK- 2-300411.The sequence description is:

ID1.0

NameSelect Oven

DescriptionChoose an oven to receive the MCO. Inspectthe process module, instruments, gassupplies, etc. Verify Readiness.

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2.0 PROCESS

102.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

NameMove-in MHM

Lower MCO

Remove MHM

Move-in ProcessEnclosure

Connect ProcessEnclosure

Open Process Pit

Place Annulus Cover

Attach AnnulusCover

Remove Port Covers

Install Vent Cover

Install Valves

Open Valves

DescriptionPosition the MHM over the chosen processPit.The MHM executes a sequence where it pullsthe center piece from the process pit cover,lowers the MCO into the oven, and replacesthe process pit cover piece.

The MHM is undocked and moved out of thearea.

The process enclosure is moved from itsparking place into its operating position abovethe process pit.

Make the electrical and instrumentationconnections that operate the processenclosure equipment.

Actuate the process pit cover openingmechanism and expose the oven.Get the annulus cover from its storagelocation in the enclosure and place it on theoven top using the manipulator.

Use manipulator and drill motor driven socketto tighten the bolts.

Use the manipulator and drill motor drivensocket to loosen port cover bolts. Usemanipulator and suction device to remove thecovers.

Use the manipulator to get a cover from itsstorage location in the enclosure and place itin the vent port. Use the manipulator and drillmotor driven socket to tighten the bolts.

Use the manipulator to pick the valves fromtheir storage ports and plug them into theMCO ports. Use the manipulator and drillmotor driven socket to tighten the bolts.Use the manipulator and drill motor drivensockets to drive the valve operator screws.

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ID14.0

15.016.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

NameEvacuate MCO

Fill MCO With He

Leak Check Ports

Pass Leak Test ?

Close Bad Valve

Disconnect Valve

Clean Port

Install Reserve Valve

Install InsulationCover

Close Process pit

Perform Heat-upCycle

Description

Remove old gas from the MCO using thesystem vacuum pump.

Fill the MCO with helium.

Use the manipulator to move the the snifferhose attached to a helium leak detector (partof the process enclosure equipment) aroundthe MCO ports.

Determine if corrective action is requiredbefore proceeding.

Use the manipulator and drill motor drivensockets to close the leaking port.

Use the manipulator and drill motor drivensocket to loosen the valve attachment bolts.Use the manipulator to pull the valve out ofthe port.

Use the manipulator and drill motor drivencloth pad to clean port.Use the manipulator to re-install the valve orto install a reserve valve. Use the manipulatorand drill motor driven socket to tighten thebolts. Open the valve using the manipulatorheld drill motor and sockets.

Use the manipulator to get the insulationcover from its storage location in theenclosure and place it on top of the MCO.Actuate the process pit cover operatingmechanism.

Hot air flows through the oven. The airtemperature versus time profile will becontrolled by the system PLC. The heliumatmosphere will be circulated and analyzedcontinuously. A pressure actuated valve willrelieve gas as the pressure builds due toheating. Periodic evacuation and helium refillwill be triggered by build-up of water orhvdroaen content.

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ID25.0

26.0

27.0

28.0

29.0

30.031.0

32.0

33.034.035.0

36.0

37.038.039.0

NameSurvey Process

Enclosure

Disconnect ProcessEnclosure

Remove ProcessEnclosure

Purge Vacuum Cycle

Perform AcceptanceTest

Accept?Additional PurgeVacuum Cycling

Cool For Passivation

Evacuate MCOPassivation Gas FillPassivation Period

Cool Down

Evacuate MCOFill With He


Description

Use the manipulators to swipe selected spotsin the enclosure. Pass bottled swipes out ofthe enclosure for counting.

Disconnect the electrical and instrumentationservices.Return the enclosure to its parking place.

When the conditioning temperature has beenreached the MCO will undergo a sequence ofevacuation and purge cycles.An acceptance test (unknown at this time) willbe performed to determine that the hotconditioning has met acceptance criteria(undetermined at this time).Determine if more conditioning is needed.Acceptance was not achieved. Continue thepurge vacuum cycle.Circulate cooled air through the oven. The airtemperature versus time function will becontrolled by the system PLC. Stop when thepassivation temperature is achieved.

Remove the conditioning gas from the MCO.

Fill the MCO with inert gas/oxygen blend.Allow uranium oxidation to proceed. Addmake-up gas to replenish oxygenconcentration as needed.Circulate cooled air through the oven. The airtemperature versus time function will becontrolled by the system PLC.Remove the passivation gas from the MCO.Fill the MCO with Helium.The process enclosure is moved from itsparking place into its operating position abovethe process pit.

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ID40.0

41.0

42.0

43.0

44.0

45.0

46.047.0

48.0

49.050.0

51.052.0

53.0

54.0

NameConnect Process

Enclosure

Open Process Pit

Remove Insul. Cover

Close MCO Valves

Place Weld-OnCover

Install Welder

Weld Root PassVisual Inspect

Clean Weld

Repair

Grind

Repair WeldApply Dye

Soak

Remove Dye

Description

Make the electrical and instrumentationconnections that operate the processenclosure equipment.

Actuate the process pit cover openingmechanism and expose the oven.Use the manipulator to grab the insulationcover and return it to its storage location in theprocess enclosure.Use the manipulator and drill motor drivensockets to close the valves.Use the manipulator to get the weld-on coverfrom its storage location in the processenclosure. Place it over the MCO.

Use the hoist and manipulator to get theautomatic welder from its storage location inthe process enclosure. Install the welder onthe top of the MCO.Turn on the welder. Make the root pass.Inspect the weld using a television camera onthe manipulator arm.Clean the weld using a rotary stainless steelwire brush and the manipulator held drillmotor.

Is weld repair required?Grind out the defect area using a small grinder(dremel tool) held by the manipulator.Use the welder to reweld the ground out area.Apply liquid penetrant dye using a speciallydesigned applicator held by the manipulator.Wait the prescribed time for the dye to seepinto weld defects.

Using a specially designed applicator applythe cleaning fluid and wash off the dye. Finishwith a cleaning fluid soaked rotary buffing paddriven bv the manipulator held drill motor.

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ID55.0

56.0

57.0

58.0

59.0

60.0

61.0

62.063.0

64.0

65.0

66.0

67.068.0

69.070.0

71.072.0

73.0

74.0

NameApply Developer

Bleed

Inspect

Clean

RepairGrind

Repair Weld

Weld Pass 1

Visual Inspect

Repair

Grind

Repair Weld

Weld Pass 2Visual Inspect

RepairGrind

Repair Weld


Repair

DescriptionApply the developer using a specially designapplicator and the manipulator.Wait the prescribed time for the dye to "blotout" of weld defects.

Inspect the developer coated weld using themanipulator mounted camera.

Using a specially designed applicator applythe cleaning fluid and wash off the developer.Finish with a cleaning fluid soaked rotarybuffing pad driven by the manipulator held drillmotor

Is weld repair required?Grind out the defect area using a small grinder(dremel tool) held by the manipulator.

Use the welder to reweld the ground out area.

Turn on the welder. Make the weld pass.

Inspect the weld using a television camera onthe manipulator arm.Is weld repair required?

Grind out the defect area using a small grinder(dremel tool) held by the manipulator.



Inspect the weld using a television camera onthe manipulator arm.Is weld repair required?




Inspect the weld using a television camera onthe manipulator arm.

Is weld repair required?

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ID75.0

76.0

77.0

78.0

79.0

80.0

81.0

82.083.0

84.0

85.0

86.0

87.0

88.0

89.0

90.0

91.0

92.0

NameGrind

Repair Weld

Weld Pass 4

Visual Inspect

Repair

Grind

Repair Weld


Repair

Grind

Repair Weld

Apply Dye

Soak

Remove Dye

Apply Developer

Bleed

Inspect

DescriptionGrind out the defect area using a small grinder(dremel tool) held by the manipulator.



Inspect the weld using a television camera onthe manipulator arm.




Turn on the welder. Make the weld pass.Inspect the weld using a television camera onthe manipulator arm.




Apply liquid penetrant dye using a speciallydesigned applicator held by the manipulator.Wait the prescribed time for the dye to seepinto weld defects.

Using a specially designed applicator applythe cleaning fluid and wash off the dye. Finishwith a cleaning fluid soaked rotary buffing paddriven by the manipulator held drill motor.

Apply the developer using a specially designapplicator and the manipulator.

Wait the prescribed time for the dye to "blotout* of weld defects.

Inspect the developer coated weld using themanipulator mounted camera.

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ID93.0

94.095.0

96.0

97.0

98.0

99.0

100.0

101.0

102.0

103.0

104.0

105.0

106.0

107.0

NameClean

Repair

Grind

Repair Weld

Remove Trap

Install New Trap

Connect WasteDrum

Remove Top Shield

Dispose Hot Trap

Insert Top Shield

Tie BagClose Drum

Undo Annulus Cover

Remove AnnulusCover

Close Process Pit

DescriptionUsing a specially designed applicator applythe cleaning fluid and wash off the developer.Finish with a cleaning fluid soaked rotarybuffing pad driven by the manipulator held drillmotor



Use the welder to reweld the ground out area.Use the manipulator to disconnect the trapand set it aside.

Use the manipulator to get the new trap fromits storage location in the enclosure. Make thenew trap connections using the manipulator.Use a cart to place a shielded waste drumbelow the process enclosure bag port.Connect the drum and port.

Open the bagport door. Lower a hoist into thedrum and pull the top of the shield into theenclosure. Set it out of the way.

Use the manipulator to place the trap into thedrum.

Use the hoist to replace the shield to in thedrum.

Tie off and cut the bag.

Place the top on the drum and attach it. Movethe drum cart to the waste management area.

Use the manipulator and drill motor drivensocket to release the annulus cover bolts.

Use the manipulator to remove the annuluscover and place it into its storage location inthe enclosure.

Actuate the process pit cover mechanism toclose the cover.

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ID108.0

109.0

110.0

111.0

112.0

113.0

114.0

NameSurvey Process

Enclosure

Disconnect ProcessEnclosure

Remove ProcessEnclosure

Move-in MHM

Lower MCO

Remove MHM

Prepare For NextMCO

Description

Use the manipulators to swipe selected spotsin the enclosure. Pass bottled swipes out ofthe enclosure for counting.Disconnect the electrical and instrumentationservices.Return the enclosure to its parking place.

Position the MHM over the chosen processpit.The MHM executes a sequence where it pullsthe center piece from the process pit cover,lowers the MCO into the oven, and replacesthe process pit cover piece.

The MHM is undocked and moved out of thearea.Perform activities such as suppliespreparation to prepare for the system for itsnext use.

This sequence was used to model the HCSE throughput using an industrialmodeling program (WITNESS Release 7.0). This model uses a random numbergenerator to simulate real events (such as which branch paths are followed atdecision points in the sequence). The calculation details are given in Appendix G.A run of 10 MCOs indicated that the average process time for an MCO is 101 hrs.This suggests that 505 oven hours are required in average week to produce thenecessary average of 5 MCOs per week. Assuming a 7 day, 3 shift, operatingschedule each week an average of 3.0 ovens will be occupied 100% of the time.Reasonable allowance for statistical fluctuations, maintenance, and so forthsuggests that six stations is appropriate for processing 400 MCOs in two years.

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2.2 MAIN PROCESS SYSTEMS

The hot conditioning process is schematically depicted by the Process FlowDiagram (SK-2-300412), which has the Material & Energy Balance on sheet 2 andthe Piping and Instrument Diagrams (SK-2-300413) of which there are 5 sheets.The hot condition process is comprised of the Vacuum and Gas Pumping System,the MCO Heating System, and the MCO Cooling system.

2.2.1 Vacuum & Gas Pumping Systems

2.2.1.1 System Function

The vacuum system function is to evacuate the MCO and connected process pipingin order to remove:

A. Chemically bound water;

B. Hydrogen when the hydrides of uranium are decomposed, and

C. Oxygen following the hot conditioning sequence prior to cool-down of theMCO.

The gas pumping system provides for circulation of the helium heat transfer gasduring steps in the process where the MCO and its contents are being either heatedor cooled.

2.2.1.2 System Design Requirements

The vacuum system must be able to remove gaseous fission products during thetreatment of the SNF as well as support the conditions necessary for optimum heattransfer during heating and cooling of the MCO. Operation at 13 psia heliumpressure is the base case for this conceptual design. However the process iscapable of operation at elevated pressure up to 24.7 psia should that be requiredto achieve the desired heat transfer rate.

2.2.1.2.1 Vacuum Operations

The system, shall be capable of evacuation of the MCO during the following threesteps in the HVCS operation:

A. The initial evacuation of the MCO, as received from cold conditioning, priorto system filling with fresh helium to the prescribed pressure,

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B. Evacuation at elevated temperature for removal of the decompositionproducts of uranium hydrides and chemically bound water, and

C. The evacuation of residual oxygen and gaseous fission products followingthe hot conditioning process.

The vacuum system provides a means of system evacuation in preparation for fillingwith helium prior to heat transfer operations. A pressure of approximately 10 torris sought prior to the introduction of a helium gas charge. This provides removalof over 98 percent of the constituents of the previous MCO atmosphere.

The system also provides an MCO vacuum of 5 torr which is conducive to thedisassociation of chemically bound water and uranium hydrides at temperatures of300°C and above (see Figure 2.2-1 for the Van't Hoff curve for the uranium-hydrogen system). The Van't Hoff curve shows that the vapor pressure of hydrogenover uranium hydride is about 28 Torr at 300°C. The vacuum system is held at thiscondition for approximately 48 hours, sufficient time to allow for water release,hydride decomposition and for hydrogen diffusion to the gas space of the MCO.

During the lower temperature partial oxidation phase of the hot conditioningprocess, low concentrations of oxygen are introduced into the MCO in an inertcarrier gas stream. This low concentration of oxygen consumes highly reactivesites on the fuel inside the MCO, reducing the chemical reactivity of the damagedfuel matrix that may be present in the MCO. Not the reactive sites consumed bythis partial oxidation may include small fuel fragments, high surface area uraniumhydride particles, and high surface area uranium metal particles created by thethermal decomposition of uranium hydride. During oxide formation, gaseous fissionproducts diffuse through the oxide and are released to the gas phase. Thesefission products, which are radioactive, are removed in a product purifier by eithersorption, reaction, or condensation. Equipment for gas purification is part of thevacuum system.

During vacuum operations as well as during operations with gas circulation, fissionproducts are removed from the gas phase.

2.2.1.2.2 Gas Circulation

Helium gas is charged to the MCO void space to promote heat transfer from theMCO wall to the fuel elements. The rate of this heat transfer may be the limitingfactor which determines the time for MCO heating and cooling. To increase thelikelihood of heat transfer operations taking place at a rate which is conducive toachieving a faster throughput, forced convective heat transfer from the MCO wallto the fuel will be used. The characterization of this heat transfer operation is quite

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definitive design, advanced thermal analysis using finite element techniques will beuse to predict the composite internal heat transfer coefficient for MCO to fuel heattransfer. This conceptual design provides a vacuum system that is capable ofheating the MCO and SNF with recirculating helium at pressures ranging from 13psia to 24.7 psia. The baseline pressure for the CDR is 13 psia.

Helium circulation is employed in all heat transfer operations, so that heat can beadded or removed from by transfer in external heat exchangers. Fission productsare removed in a cold trap during gas circulation.

Table 2.2-1 provides key design parameters for the Vacuum System.

ParameterEvacuation prior to helium fillDesign pressure rangeMaterial of constructionMaximum design temp, for:

vacuum pumpcirculation blowerheat exchangers

Operating temperature for:vacuum pumpcirculation blowerheat exchangers

Time at vacuum:pre He fill prior to heat-up

hydride removalpre He fill following O2passivation

Time at He circulationheating to 300°Ccooling to 150°C

He circulation rate

UnitstorrpsiaNA

°C°C°C

°C°C°C

min.hrs.min.

hrs.hrs

ACFM

Specified Rating10

0.1 to 24.7304 or 316 SS

40

375

25100

40 to 300

154815

1212

<10

Table 2.2-1 Vacuum & Gas Pumping System Design Specifications

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Figure 2.2-1

Van't-Hoff Curve

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 xiO

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The vacuum and gas pumping system will interface with the following otherprocess systems:

A. the MCO heating system

B. the MCO cooling system

C. the process gas system

D. the process module system

E. the combined ventilation system

F. the HVCS control system

2.2.1.3 Equipment Arrangement and Response to Design Requirements

Equipment required for the HCSE is identified on the Piping and InstrumentDiagrams (SK-2-300413). The following major equipment components comprise theMCO vacuum pumping system on each of the six process modules or in each of thesix MCO trenches:

A. VPS-VAC-1104, the scroll-type vacuum pump.

B. VPS-BLO-1106, the Rotron recirculation blower.

C. VPS-PFR-1101, the purifier/cooler/filter containing copper gauze andactivated charcoal.

D. VPS-CLR-1103, the cooler, a plate-type heat exchanger.

E. VPS-HCL-1105, the electrical heater.

F. VPS-F-1102, VPS-F-1107 HEPA filters.

2.2.1.3.1 Gas pumps

Two gas pumps are used in the vacuum system, one a vacuum pump and the othera circulating blower. Vacuum pump VPS-VAC-1104 is a scroll-type pump, capableof pumping 500 liters per minute at inlet pressures above 1 torr with reduced

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pumping rates at higher vacuum levels. When properly installed and operated, thispump has an expected life of 6,000 hours before minor maintenance is required forshaft bearing replacement and of 12,000 hours before requiring major maintenance.With an MCO total process cycle time of 150 hours and an expectation of up to 68MCO process events per bay over the life of the campaign, the vacuum pump willhave to be either idled during portions of cycle, operated to an estimated 10,000hours without performing the minor maintenance suggested by the manufacturer,or replaced once during the life of the MCO hot vacuum conditioning program.Because the level of vacuum required ofVPS-VAC-1104 is moderate in comparisonto its capability, it is likely that the pump will be operated without minor maintenancefor the required period without serious impact to ongoing operations. Once avacuum pump is taken out of service, it will be discarded as radioactive waste.

Helium circulation blower VPS-BLO-1106 is a magnetically coupled regenerativeunit capable of operating under vacuum or at pressure up to 10 psig. The unit isconstructed for intrinsically safe operation. The magnetic drive provides freedomfrom seal leakage worries.

2.2.1.3.2 Heat Exchangers

Proper operation of VPS-VAC-1104 requires precooling during the 48-hour vacuumphase of chemically bound water and hydride removal which takes place at orabove 300°C. To accomplish this, two stages of cooling are provided. The firststage is the cold trap which serves as the vent purifier VPS-PFR-1101. This unitreduces temperature from a nominal inlet temperature of 300°C to 100°C. Furthercooling is provided by a plate-type heat exchanger VPS-CLR-1103 which achievesan intended outlet temperature of 38°C. Both exchangers are cooled with streamsof exhaust air from the ventilation the MCO pit before it is passed to the centralprocess ventilation system for HEPA filtration and discharge through the stack.

The exchangers of the vacuum system are designed to accommodate heat transferoperations with helium atmospheres from 13 to 24.7 psia.

2.2.1.3.3 Cold Trap & Gas Purification Equipment

Cold trap VPS-PFR-1101 contains copper gauze to react with iodine fissionproduct, chilling to capture cesium fission product and activated carbon for bothcesium and iodine secondary capture. The cold trap may become contaminatedwith high level fission products and thus is installed in the MCO trench where it willbe serviced by the process enclosure. It is anticipated that this unit may have to bechanged for each MCO which is processed. Included in the purifier is a HEPA filter.

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2.2.1.3.4 Instrumentation and Control Requirements

The module control configuration and logic are shown on the P&IDs and arediscussed in the Operating Sequence Section. Programmable Logic Controllers,one at each process module, are used to assure proper operation and reliability.Each communicates with each instrument element via local connection and with thecontrol center via one line on which signals are multiplexed. Several interlocks areprovided to assure the proper sequence is followed. While direct operatorintervention for many operating steps is available to override control logic, theareas where serious safety implications are involved cannot be overridden withoutthe approval from a second authority. Data logging as well as process control isavailable.

2.2.2 MCO Heating System

2.2.2.1 System Function

The MCO heating system heats the MCO and its fuel contents to a processingtemperature of above 300°C within the required cycle time. Heating is indirect, viahot air circulation around the MCO and circulation of the helium contained in theMCO through an external electric heater. The system must be able to heat theMCO at a rate which does not exceed 50°C/hr. It must also function through a widerange of internal helium pressures. Heating is to be electrically powered.

The system shall be designed so that it has little if any impact upon the air balancein the HCSA.

2.2.2.2 System Design Requirements

There are several restrictions on the heating of the MCO as specified by WHC-S-0460, revision A and summarized in Table 2.2-2.

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Parameter

Maximum MCO temperature

Minimum MCO temperatureMaximum MCO heating rate

Maximum temperaturechange over MCO

Duration for MCO heating

Units

°C°C

°C/hr

°Chrs

Specified Rating375

300

50

100

-12

Table 2.2-2 MCO Heating System Design Specifications

2.2.2.3 Equipment Arrangement

It was originally conceived that the MCO would be heated with clamping band-typeelectrical resistance heaters. Upon further consideration of this method it becameapparent that it would be difficult to assure even heating and the ability to staywithin the 50°C/hr limitation. Also, the mechanical complexity of direct contactconductive heat transfer was significantly greater than alternative options usingconvective transfer. On this basis the determination was made to proceed withforced convection for heating of the outer shell with supplemental heating of thecirculating helium stream via circulation through an electrical resistance heatingelement.

2.2.2.3.1 Heating of the MCO Shell

Heating the MCO with forced hot air is a two stage process. The shell is heatedand the hot shell transfers its heat to the internal SNF. Transfer from the shell tothe SNF occurs principally through convection of the internal gas. Helium is chosenfor the heat transfer fluid because, next to hydrogen it has the highest thermalconductivity and unlike hydrogen it is safe to handle, at all concentrations.

Primary heating of the MCO was chosen to be via forced air convective heattransfer. Air is circulated and heat is applied at each pass with an electricallypowered unit called the MCO Process Heater. The clearance between the ovenwall and the outer surface of the MCO is one inch. The air flow rate is 750 acfmwhich is sufficient to produce turbulence in the annular space.

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Calculation of the MCO outside and inside heat transfer coefficients indicated thatheat transfer from the shell to the fuel would be the limiting factor with sub-atmospheric internal helium pressure. Heat transfer coefficients are shown in thefollowing equation:

Q = U * A * ( T i - T 2 )where: Q = heating rate in Btu/hour

U = heat transfer coefficient in Btu/hour * sq. ft. * °FA = area of heat transfer in sq. ft.(T-| - T2) = temperature difference between the heatsource and the heat sink in °F

The outside coefficient was calculated, using the Colburn j factor, and found tobe 5. The inside coefficient was calculated from a modified Nusselt number forconvection in annular spaces and found to be 1.77 which was discounted to 1.0due to the complex internal geometry. These two transfer coefficients were usedin calculating both heating and cooling temperature profiles. At sub-atmosphericpressure there is less than a 10 percent contribution to heating from the heatapplied to the circulating helium. This contribution would increase if a pressureof 24.7 psia were used for the circulating helium.

The temperature profile for a MCO helium pressure of 13 psia is shown asFigure 2.2-2. It does not account for the minor contribution by heating of thecirculating helium, but does allow for internal heating due to nuclear decay. Itshows that heating to above 300°C may be accomplished in under 14 hours froma starting temperature of 40°C. The actual starting temperature is expected to beabout 140°C since the precooling step that was initially thought to be required isnot necessary. Thus the heat up time will be about 10 hours. When the SNFremoval project was originally conceived it was though that connections to theMCO would be made manually so the MCO would have to be cooled from itsequilibrium storage temperature to 40°C. All remote operations from theProcess Enclosure are now planned so the connections can be made at 140°C.

As shown on the heating temperature profile, incrementally changing thetemperature of the heating air is necessary to assure that the MCO heating ratedoes not exceed the 50°C per hour specification. The control is accomplishedvia a programmed ramping function. Feedback to the controller is obtained bymonitoring the temperature of the circulating helium gas. The ramping rate canbe revised based on experience with the first MCOs that are processed.

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2.2.3 MCO Cooling System

2.2.3.1 MCO Cooling System Design Description

2.2.3.1.1 System Function

The MCO cooling system is to cool the MCO from 300°C to 150°C within anapproximately 12 hour period, while not exceeding the 50-degree per hourspecification.

2.2.3.1.2 System Design Requirements

The design requirements are presented in the table below:

ParameterMaximum MCO cooling rateMaximum temperaturechange over MCO

Duration for MCO cooling

Units°C/hr

"C

hrs

Specified Rating50

100

12

Table 2.2-3 MCO Cooling System Design Specifications

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Figure 2.2-2

Heating Temperature Profile

h(out)=5 / h(in) = 1 / 750 ACFM air rate

0 1 2 3 4 5 6 7 8 9 10 111213 14 15 16 1718 19 20Hours

Hot Air in —<— MCO Wall - * - MCO Rate - s - Fuel Rods

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2.2.3.1.3 Equipment Arrangement

2.2.3.1.3.1 MCO Shell Cooling

Air that circulates through the oven is cooled by exchanger MCS-CLR-1153. Thecooled air is recirculated back to the MCO. MCS-CLR-1153 may be supplied withchilled water coolant from either or both of the central chillers CHW-CH-2023 andCHW-CH-2024. The temperature of the air exiting the cooling system isprogrammed to allow MCO cooling without exceeding the 50°C per hourtemperature change specification.

The largest influence on MCO cooling will be the interior film coefficient. The basecase design assumes an interior film coefficient on/when the internal heliumatmosphere is 13 psia.

Cooling air is circulated to the MCO shell at a minimum temperature of 40°C.Should a lower temperature be desired, it is easily achieved.

The cooling temperature profile is shown as Figure 2.2-3 on the following page.

2.2.3.1.3.2 Helium Circulation Cooling

Cooling of the circulating helium stream takes place in two stages. The cooling isprimarily used to allow low temperature operation of the vacuum pump andcirculating blower. The first stage cold trap, VPS-PFR-1101, provides a degree ofpurification as well as provides cooling to 100°C or lower so that VPS-BLO-1106may safely operate within its temperature limit.

The second stage of cooling allows the scroll vacuum pump, VPS-VAC-1104 tooperate below its maximum inlet temperature of 40°C. Chilled water cools thecirculating helium to 25°C before its introduction to the vacuum pump.

During the MCO heating cycle, the cooled helium is electrically reheated by VPS-HCL-1105 prior to its introduction back into the MCO, however in the cooling cycleit is introduced at the temperature at which it discharges from VPS-BLO-1106. Thetemperature rise through this blower is nominally 2"C.

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Figure 2.2-3

Cooling Temperature Profile

h(out)=5 / h(in)=1 / 750 ACFM air rate

o

0 1 2 3 4 5 6 7 8 9 10 111213 14 15 16 1718 1920Hours

Hot Air in MCO Wall MCO Rate - e - Fuel Rods

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2.2.3.1.3.3 Instrumentation and Control Requirements

Ramped temperature control is also used for MCO cooling for staying within therate of temperature change specification. This is pre-programmed in the units PLC.Suggested ramping temperatures are shown on the temperature profile of thefollowing page.

Control interlocks assure that heater PHS-HCL-1152 remains off during the coolingcycle.

2.2.4 Sequence of Operation

The sequence of operation for the HCSE is as follows. Please refer to P&IDdrawing SK-2-300413 sheet 2, Appendix A to follow these steps.

A. MCO vault ventilation air flow is initiated by selecting and starting eitherProcess Vent Blower (PV-BLO-2043 or PV-BLO-2046), if not alreadyrunning, and drawing air through the MCO vault and the vault trench, andchecking that the flow is about 1000 cfm on FI-1174;

B. The MCO is placed into the oven by the MHM and the process enclosure ispositioned over the oven.

C. The block valve for the Oven (PHS-OVEN-1154) is opened if not alreadyopen, holding a vacuum of less than 10"4 torr measured on PIC-1181. TheHCS Oven Vacuum System, VAC-VAC-3041,3042, should be functional;

D. The MCO is connected to process gas piping by swinging the connectionvalves and quick disconnects into place over the valve ports and fasteningremotely. Anytime the MCO valves and quick disconnects are beingmanipulated, vacuum should be applied by running the MCO Vacuum Pump(VPS-VAC-1104), closing GOV-1112,1120 and opening GOV-1105,1121.Once the quick disconnect is secured, the valves are opened followed byimmediate evacuation using MCO Vacuum Pump. The MCO Vault Cover isre-seated. During the evacuation, the MCO Vacuum Pump is exhaustedthrough PV-1109, GOV-1112,1120,1121 are closed, GOV-1105 is openedand GOV-1136 is opened to allow a small process gas (He or N2) purge.Once a vacuum of 10 torr (PI-1102) is achieved, PV-1109 is closed, GOV-1105 is closed, MCO Vacuum Pump stopped, GOV-1120 is opened, GOV-1133 is opened and process gas is added through FIC-1134 at 280 Ipmuntil PIC-1115 reaches ~ -0.1 psig;

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E. The MCO process heating system is changed from "STARTUP" to"HEATING" mode by closing GOV-1155, maintaining about a 750 cfmProcess Heating Loop flowrate with FIC-1153 and the Process Heating LoopBlower (PHS-BLO-1151) operating. TIC-1154, which now controls the MCOProcess Heater, (PHS-HCL-1152), is setting FIC-1122 to "AUTO" (processgas added only for pressure control and water hydrogen dilution) with asetpoint determined by a prescribed temperature rise profile;

F. Circulating helium is heated using the MCO Circulating Heater(PG-HCL-1105). Temperature exiting the heater is controlled by TIC-1119according to a prescribed temperature rise profile. The MCO exit gas ispassed through a Cold Trap (VPS-PFR-1101), where the gas is cooled to~100°C to protect downstream equipment and to adsorb volatile componentssuch as H2O, iodine, cesium, etc.;

G. Pressure and composition control of the MCO process gas loop isaccomplished during heat-up by maintaining PI-1115 at about -0.1 psig bybleeding MCO gas through SOV-1118, and by adding purge helium througheither FI-1136 (preset to -0.9 ipm) or through FIC-1134 at higher rates.Helium purge may be needed to control H2O, O2 or H 2 levels as measuredby AI-1117 residual gas analyzer;

H. Once the MCO core has reached approximately 300°C, as indicated by thetemperature of the MCO exit gas, TI-1101, and the patterned heat transfercalculations, the helium is evacuated from the system to a pressure of -5torr using the MCO Vacuum Pump with GOV-1112,1120,1121 closed andGOV-1105 opened. FI-1136 is used to bleed helium in at a rate of 0.9 Ipm(10 acfm MCO internal gas rate). The MCO is maintained at -5 torr and300-350°C for a period of 48 hours. H2 and H2O are monitored usingAI-1117. When H2 and H2 generation ceases, it is assumed that allhydrides anc chemically bound water have been decomposed.

I. During withdrawal of the water and hydrogen with the vacuum pump, severalfission products may be extracted. These could include gaseous C s 1 3 7 andI2129 a n c | ( ^ 5 a s w e | | a s jSotopes of magnesium and cobalt which are inparticulate form. Cs 1 3 7 and l2129 are adsorbed in the Cold Trap. The Kr85

passes through to the stack via the HEPA filters. Particulate Mg and Co arecaptured in the HEPA filter (VPS-F-1102).

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J. The MCO heating and cooling system is changed to "COOLING' mode witha TIC-1154 setpoint of 300°C and GOV-1155 opened. A prescribed cooldown rate is followed until the MCO core temperature is reduced to 150°C(TI-1101). The MCO process gas loop is returned to loop flow during thistime, and the process system pressure adjusted to --0.1 psig, PIC-1115,using purge helium as above. The MCO Process Heater, is disabled duringthe cool down period;

K Oxygen sufficient to bring the composition of the MCO process gas to ~2 %is through an open GOV-1142 and FQIC-1141. The oxygen totalizer willclose when the calculated amount of oxygen has been added, or theanalyzer, AI-1117, indicates >2.5% O2 or the system pressure, PIC-1115,has risen to a greater gas pressure that calculations permit. Once theoxygen has been introduced, the process gas loop is circulated at 150°Cuntil the oxygen level drops below 0.5% (the system pressure should recorda calculated pressure drop in rough agreement). The process is repeateduntil the oxygen level fails to decrease appreciably below 2%. At this pointthe system is held for an additional 12 hours with the oxygen concentrationcontinuously monitored;

L. Following the 12 hour passivation period, the oxygen is displaced by heliumby purging as above and evacuating the MCO to a pressure <50 torr, andrefilling with helium. Once O2 levels have been verified to below 0.1%,process is complete.

The MCO vault cover is removed. The MCO valves and quick disconnectsare disconnected.

M. The MCO ports are covered and seal-welded according to procedures;

N. The welds are inspected.

O. The top of the MCO is surveyed and decontaminated as necessary prior totransfer to a storage position in the CSB;

P. The cold trap will need to be periodically replaced according to proceduresbetween MCO runs. The replacement schedule will depend upon thequantity of material that is collected in the trap as determined by radiationreadings.

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2.2.5 DESCRIPTION OF SAFETY SYSTEMS

Overall, the PLC control system will provide a high degree of non-passive controland coordination. Interlocks will include these important loops:

A. All operations will be structured to allow PLC computer control ofsequencing, valve positioning and other important parameter setting.Operators will interact with the system by changing the sequencing mode tovarious allowed states such as "IDLE", "STARTUP", "HEATUP","VACUUM_PURGE", "COOLDOWN", "PASSIVATE", etc. Within each ofthese states, are allowed valve positions, controller states, processconditions, etc. If these conditions are not correct progress through theprocess is held. The control system will normally function without operatorintervention. If operators wish, they can override most PLC functions.Exceptions are required interlocks.

B. All operations will be tied into the utilities status. If utility systems includingthe oven vacuum, process vent, process gases and cooling water systemsare malfunctioning, operation of the HCSE system will be limited to essentialoperations.

C. Oxygen addition during passivation is set up with several layers ofprotection. The first is that the addition controller, FQIC-1131 is a totalizingcontroller which feeds only a pre-calculated amount of oxygen into knownconditions, the second is the protection of the gas analyzer, AM 117, and thethird is the secondary check of rising system gas pressure beyond thebounds of a 2% pressure rise. Any violation of these checks will cause theisolation valve, GOV-1142 to close and the output mode of the controller,FQIC-1131 to change to "MANUAL" with an output of 0.0.

D. To avoid excessive dust migration within the MCO, the flow rate ofcirculating gas is limited to 10 scfm at ambient pressures and 10 acfm at lowpressures. This is accomplished using FIC-1114 to control the flowrate(calculated flow internal to MCO).

E. MCO gas composition control is accomplished by using analyzer, AI-1117,to sense high levels of hydrogen or water. When these gas levels reach athreshold, purge gas is added using either FIC-1134 or FI-1136. Excess,pressure is then bled off through SOV-1118. The MCO could also beevacuated and refilled at this point.

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F. In the event of an electrical or instrument air failure, FI-1136 will purge theMCO system with process gas up to a pressure of 0.5 psig. This protectsthe situation when a full vacuum is being held on a hot MCO and the controlsystems fail. If a leak were to develop, air would begin leaking into the MCOleading to rapid oxidation reaction. This system prevents this by purging theMCO with inert gas.

G. In the event that the internal MCO filter becomes plugged, a blowbacksystem exists to clear the blockage. An accumulator holds sufficient gasinventory to supply a pulse of inert gas through GOV1132. In order toprevent gas bypassing or passage of dust into the draw tube, valves GOV-1105,1112,1120,1121 will be closed during blowback operations.

H. FI-1136 is a rotameter set at 0.9 Ipm. This rate is equivalent to 10 acfmthrough the MCO at 5 torr and 300°C.

I. The MCO heating system uses flow control, FIC-1153, in the circulation loop.This allows for a wider range of heating and cooling situations to be met.Additionally, the heating system used temperature control, TIC-1154 tocontrol the heater input while holding TV-1154 wide open. The coolingsystem uses TIC-1154 to disable the heater while modulating coolingtemperature with TV-1154.

J. Pressure control of the heating system is by bleeding pressures over 0.1psig, PCV-1159, into the process vent system (usually during startup andduring heating cycles) and by allowing air into the system through PCV-1156set at -0.1 psig. Air inlet will be required during cooling and when airleakage from between the MCO/OVEN annulus into the vault is excessive.

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2.3 COMBINED VENTILATION SYSTEM (CVS) CONFIGURATION

The conceptual design for the HCSE exhaust gas system consists of a HEPA filterintake, ducted manifold for up to six bays, isolation nuclear grade dampers, twostage testable HEPA filter plenum with pre-filter, variable speed drive exhaust fan,static pressure senors, and exhaust stack.

2.3.1 Reference Standards

ERDA 76-21ACGIHASHRAESMACNANFPAASME40CFR61

2.3.2 System Design Parameters

The CVS shall:

Minimize particulate hold up by use of smooth duct transitions and maintaining aminimum duct velocity of 2000 fpm.

Minimize contamination spread and prevent the backfiow of gases and particulate.

Provide a constant stack flow for proper stack discharge velocity and for stackmonitoring.

Provide sufficient volume for dilution of the process gas system to 25 % of the lowerexplosion limit for hydrogen.

Limit particulate discharge through the use of a two stage HEPA filter plenum.

2.3.3 Process Description

The CVS is designed to exhaust six process pit/trench spaces and the process gasexhaust from six MCOs. Air is drawn through a HEPA filter into the process pitspace at a nominal rate of 150 CFM per process pit. The HEPA filter serves as anisolation, backdraft and filtering device. The air moves through the process pit andtrench space to the exhaust duct inlet manifold, through an isolation damper, pre-

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filter and two stages of HEPA filters with isolation dampers, exhaust fan, and finallyexits the HCSA through a dedicated stack. Twenty CFM of process exhaust gasfrom each of the six MCOs may enter the process exhaust stream at any time.Variable speed drives on the exhaust fan motors, with control based on pressuresensors will adjust air flow to keep the exhaust flow in the stack constant.

Motorized dampers on the exhaust from each process pit will be modulated usingpressure sensors with integral controllers to maintain a nominal 150 CFM flow rate.

2.3.4 Equipment description

2.3.4.1 Exhaust Fan

Backwardly inclined, class III centrifugal fan, standard application for hot gases to200 degrees F, intrinsically safe construction, with belt drive and variable frequencymotor controller.

2.3.4.2 HEPA Filter Housing

Type 304 stainless steel, bag in/out type, transition on both ends, assembled in thedirection of air flow as follows: prefilter section, test section, first stage HEPA filtersection, test section, second stage HEPA filter section, and final test section.

2.3.4.3 HEPA Filters

24 x 24 x 11.5 inches thick, UL Class 1, 99.97% efficiency per DOP test, andstainless steel frame.

2.3.4.4 Prefilter

24 x 24 x 6 inches thick, UL Class 1, 65% efficiency per ASHRAE standard 52-76.

2.3.4.5 Isolation Dampers

ANSI class 150 butterfly valves with motorized actuators and will meet therequirements of ASME N 509-1989, leakage class I.

2.3.4.6 Centrifugal Pumps

Nominal 24 GPM each.

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2.4 PROCESS CONTROL

2.4.1 Control System Design

The System Monitoring and Control System (SMCS) design is based on integratedProgrammable Logic Controllers (PLC's), Personal Computers (PC's), and Man-Machine Interfaces (MMI's). The SMCS Architecture is based on Supervisorycontrol and Data Acquisition (SCADA) type of control system. The SMCS will becapable of handling all process controls, data acquisition, reporting, and archiving.Process control, supervisory, and Management Data Communications will behandled via standard ethemet with Transmission Control Protocol/Internet Protocol(TCP/IP). TCP/IP is the standard communications protocol used by the Internet andHanford Local Area Networks (HLAN).

The recommended hardware are IBM compatible PC's with a 200 MHZ PentiumPro, 64 MB ram, 2.5 GB of hard drive primary, 2.5 GB hard drive backup, 3.5"floppy drive, 6x CD-ROM drive, 21" SVGA monitor. A Laser Printer will be requiredfor report printing. The operating system platform will be on the Windows NT.Each PC will have a dynamic graphical display of process parameters and othersystem variables. The MMI will animate the process variables to show processstates such as an open valve or flow through a pipe. There will be a total of 3 PC's,one Operator Interface Stations (OIS), one Process Enclosure (PE) Local ControlPanel (LCP), Operator, and one Engineering Work Station (EWS).

2.4.2 Programmable Logic Controllers

The process control will be handled by the PLC processors which will be locatedin a panel that will be installed in the control room. Each Process Module and theService Module will have remote I/O stations that communicate to the PLC. Thecontrol system provides redundant PLC controllers which will be located in a controlroom PLC panel. The primary processor maintains independent control of theprocess and monitoring. The hot standby processor maintains a mirror of theprimary PLC program and a real time data image table via a fiber optic link. Shouldan upset occur within the primary processor, the hot standby will immediately takecontrol within a few milliseconds. The availability of real time data and quickresponse time by the hot standby will allow for a bumpless transfer of control. Alsoprovided are redundant communications cabling to the remote I/O racks in eachbay/skid.

All Local Process Modules and Service Module and skid I/O points will be fieldterminated at the respective remote I/O panels. The system HVAC, Chiller, Air

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Monitor, and other system I/O will be field terminated at the control room PLC I/O.The PE will have a remote I/O rack which will communicate to the PLC processorvia radio modem. The radio modem will take advantage of Spread-Spectrumtransmission technology.

2.4.3 PLC Programming Interface

Logic diagrams and PLC programming will be configured by graphical methodsusing AutoCAD with pre-designed blocks having pre-configured attributes.Examples of logic and control blocks are, but not limited to; AND, OR, Analog I/O,Sequential Step, PID, and Digital I/O Blocks. A commercially available softwarepackage will be used to compile the AutoCAD drawing into a function block whichcan be downloaded to the PLC. There will be no PLC relay ladder logic to program.As such, when the logic changes, the drawing follows suit and the programrecompiled. The program will have a supporting I/O data base and program de-bugging tools. Run-Time simulations and PID Control Loop Tuning tools will beavailable.

2.4.4 Man-Machine Interface

The OIS will handle concurrent processing of the Modules. The OIS and the EWSwill have the capability of handling full operation of all six Process Modules and allother system controls including, but not limited to, archiving, reporting andalarming. The EWS will normally show the System HVAC process and systemalarming. Generating alarm, event, graphic, and analysis reports will normally bean EWS task. The EWS will be used by the Operations System Engineer tofacilitate run-time and enhancement changes to the MMI and PLC.

2.4.5 Communications

Communications will be through an ethernet network using Microsoft (MS) TCP/IPprotocol. This ensures compatibility for communications to Hanford Local AreaNetwork (HLAN). Communications from the PLC to the PC's will be via a separateLAN to isolate the process communications from the management and HLANsystem. Printing communications will be handled through the ethernet network.

The PMC will communicate to the PLC using a spread spectrum radio modem. Theinterface to the control system network will be standard ethernet with TCP/IPprotocol. The radio modem communications design will facilitate control,interlocking, and alarming requirements from the PMC while maintaining mobility.

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2.5 OVEN ASSEMBLY DESCRIPTION

The MCOs will be heated in six(6) ovens which will be installed in process pits thatwill be located below the HCSA floor level. As indicated in the P&IDs (SK-2-300413), the MCO will be heated by forced hot air that is blown through the oven.The heater and blower will be located on the process module and the pipes thatcarry the circulating air will run from the process module through a below gradetrench to the oven. The general arrangement of the oven in the pit, the trench, andthe connecting piping is shown on SK-2-300422.

The oven will be an insulated stainless steel cylinder with an insulation jacket. Theproposed insulation is vacuum. In other words, the oven will be constructed as athermos bottle. The outer vessel will be stainless steel and super insulation will beattached to the inside surface of the outer vessel. The space between the inner andouter vessel will be constantly evacuated by a vacuum pump so that gas releasepromoted by the heating of the vessel will be drawn away. Two variations of theconcept that are under consideration are given Drawings SK-2-300417 and SK-2-300418. The selection will be made once the MCO neck design has been settled.

This basic design concept was selected for a number of reasons:

A. The rate of temperature rise of the MCO is limited to 50°C per hour. Theheat transfer from the MCO into the SNF is slow because the transfer iseffected by a nearly static gas. Therefore the MCO wall is easily heated.Radiation from heaters could easily overwhelm the heating rate limitation,whereas heat transfer from forced air is easy to control. Furthermore, therewould be no simple way to measure the MCO surface temperature if it wasexposed to radiation from heaters. Measurement of the inlet and outlet airtemperatures in the proposed design is simple and is a good measure of theMCO temperature because heat transfer is effected by convection and gasconduction.

B. There are no heaters and no electrical distribution in the oven. This meansthat there is no opportunity to have a heater failure that would take the ovenout of service or cause it to be pulled from the pit for repair.

C. Vacuum insulation was chosen because it is effective. It makes the oveneasily constructable as a single stainless steel assembly. It is the lightestinsulation choice which will make the assembly easier to install. And, mostimportantly it has few contamination traps and smooth and hard surfacesthat can be decontaminated.

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In both design alternatives, the hot air enters into a ring contained in the upperportion of the vacuum jacket. This ring distributes air to three downcomer pipes thatcarry the hot air to an insertion ring located in the bottom of the vacuum jacket. Thedistribution ring allows the air to enter into the oven uniformly around the base ofthe MCO through perforations into the oven interior. The downcomer pipes containbellows expansion sections and are mounted to allow for vertical motion.

The MCO concept where the vessel has straight walls from top to bottom is shownon Drawing SK-2-300417. The MCO rests on a ring which transfers the load to aring between the inner and outer oven vessels. The oven outer vessel rests on animpact limiter that transfers the load to the pit foundation. The impact limiter, whichis for the purposes of protecting the MCO in the event of an accidental drop, will bethe same one used in the CSB storage vaults. Both the ring between the MCO andthe oven and the one in the vacuum jacket will be perforated to allow for airflow.The air will flow upward through the annulus between the MCO and the oven. Heattransfer calculations (see Appendix G) indicate that a 1" annulus with an airflow of750 CFM will be appropriate. When the air reaches the top of the annulus it isblocked by an annulus cover piece that will be installed after the MCO is loweredinto the oven. The cover side wall will be a bellows to allow for differentialexpansion between the MCO and the oven. The top plate of the cover will be 3"thick to create some shielding for the radiation stream coming up through theannulus. It will also provide enough weight to hold it against the MCO top as theoven grows faster than the MCO. The air will flow through perforations into acollection ring located in the top of the vacuum jacket. The collection ring feeds thereturn pipe to the process module. The air circulation pipes run within a vacuumjacket in the trench. The outer vessel of the oven will have a bellows to allow forthermal expansion of the oven. This bellows will have a restraint so that the ovencan be lifted during installation. The top ring of the oven that holds the inner anouter vessels of the vacuum jacket will be thick stainless steel in order to shield theradiation stream rising from the MCO.

Air flowing through the top of the oven pit and through the trench will be divertedfrom the MCO top by an insulation cover so that the MCO top temperature is notsignificantly cooler than the body.

The oven concept shown on Drawing SK-2-300418 assumes an MCO design wherethe upper part of the MCO has a small flare. In this case, the MCO flare rests on abeveled flange on the top of the oven. There is no support at the bottom of theMCO. The weight is carried though the inner vessel of the oven to a ring in thevacuum jacket base and then to the impact limiter. There is no need for a special

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2.0 PROCESS

annulus cover. Otherwise the design is the same. With this design the thermalgrowth of the MCO is accommodated by the space between the MCO bottom andthe oven.

The final closure of the MCO will be accomplished by welding a cover over theMCO top. This weld will be made while the MCO is in the HCSE oven after the hotconditioning process has been completed. The geometry of the cover, weld, andwelding machine have not been defined at this time. This means that the relativevertical dimensions of the oven top and the MCO top cannot be defined at this timeand assembly concept sketches cannot be developed for the welder/oven interface.Resolution of this interface will be required to complete the detailed design of theoven.

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2.0 PROCESS

2.6 PROCESS MODULE

2.6.1 Process Module Description

The process module contains most of the equipment shown on the piping andinstrument drawing sheet #1. With the exception of central and combined serviceequipment, the MCO, its oven and the cold trap, all equipment servicing an MCOis part of this module.

Module equipment includes:

A. Vacuum pump (VPS-VAC-1104).

B. Recirculation blower (VPS-BLO-1106).

C. The vacuum system cooler (VPS-CLR-1103).

D. The vacuum system heater (VPS-HCL-1105).

E. The MCO cooling system cooler (MCS-CLR-1153).

F. The MCO heating system heater (PHS-HCL-1152).

G. The MCO heating system circulating blower (PHS-BLO-1151).

H. The process vent HEPA filter (PV-F-1171).

I. A control panel for the module which includes input/output interfaces to acentral programmable logic controller.

The module measures six feet by nine feet in the plan dimension and is eight feethigh. Some equipment items are vertically installed to conserve space. Except forthe module's vacuum pump, rotating mechanical equipment is mounted on one sidefor accessibility and ease of maintenance. The skid is placed in the CSB annexwith ample accessibility to all its sides. It is located behind the service crane's areaof influence so as not to be of concern.

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2.0 PROCESS

Process piping to and from the module proceeds in the trench to the MCO. Serviceutilities are run to the module above grade.

Structural elements for its fabrication are standard AISC shapes. Deck platingcovers the service area. It is intended that the process module be fabricated andassembled in a local shop and then shipped to the site where it is to be leveled andaffixed to steel plates imbedded in the CSB annex floor.

The module requires operator attention only for maintenance. All controls areaccessed from a remote central control station which is capable of monitoring andcontrolling each of the six process modules plus the central utilities.

The operation of the process module equipment is described in Section 2.2. Cutsheets for the equipment are available in Appendix H.

While each module, trench and vault unit have three HEPA filters, only one isinstalled on the process module. That filter provides suction air to its associatedMCO. Installation at the MCO was considered but abandoned when it wasapparent that the filter would have to be installed at grade elevation and would thusbe subject to contamination from the adjacent floor area. Its installation on theprocess module allows longer life and ease in servicing the filter. The piping fromthe filter to the MCO vault is accommodated in the trench.

HEPA filters VPS-F-1102 and VPS-F-1107 are the bag-out type and are pressurerated to 100 psig. This rating increases the cost of these units considerably. It ismade necessary because of the current uncertainty about heat transfer rates in thesub-atmospheric MCO. Should this issue become resolved prior to detailed designand pressure operation not be required, these filters can be simplified considerablywith a commensurate reduction in module cost. At this time they are showninstalled in the trench.

2.6.2 Equipment Description

2.6.2.1 Vacuum Pump Selection (VPS-VAC-1104)

This section discusses the basis for selection of the scroll type vacuum pump forthe HCS project. The starting point for this discussion is the alternatives studyperformed for the Cold Vacuum Drying System (CVDS) project. That study

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2.0 PROCESS

evaluated eight alternatives involving different pump combinations. The rotaryscroll pump was selected on the basis of operational simplicity , cleanliness and thewide pressure range covered by a single stage of pumping. A staged Roots blowerwas the second choice. The intent of the current study is to expand upon theearlier work by focusing on germane operating conditions in the CVDS anddetermining if changes in these conditions are required for the Hot VacuumConditioning System (HVCS) project are required and if so, are the changesdetrimental to the pump. Germane operating conditions which could compromisethe reliability of a rotary scroll pump are:

Elevated TemperaturesPresence of ParticulatesWater Vapor Condensing Within the PumpMaterials Incompatibility

During the CVDS development testing program, the scroll pump's ability to operatefor long periods while pumping water vapor at temperatures in excess of 100 C willbe demonstrated. The concern is that bearings within the pump may fail at theelevated temperature. Discussions with the manufacturer's representative identifiedthat the stated operating limit of the pump (40 C) is a limiting condition only whencombined with high vacuum at the pump inlet. Under these conditions, cooling ofthe pump bearings relies mainly on conductive heat transfer to the pump body.When pumping at higher pressures the situation is relieved due to convectivetransfer on the bearings directly. As part of the CVDS, a pump will be tested todemonstrate long term pumping of water vapor at 100°C or above to verify thatpump life is not compromised. If this demonstration is assumed to be successful,utilization of the pump for the HVCS process does not present any increase inseverity as regards the operating temperature.

Particulates are a concern for a rotary scroll pump because of the close toleranceswithin the interleaved scrolls which could bind if subjected to particulates in the gasstream. Filters will be installed upstream of the pump inlet to protect the pumpingsurfaces. Additionally, the scroll pump that was selected for the CVDS has Teflontip seals that are more tolerant of particulate than an all metal design. If necessary,the pump can be repaired should damage due to particulate be incurred. Routinereplacement of some pump parts is recommended at 6,000 and 12,000 hourintervals. The development testing program will demonstrate pump life underparticulate conditions that are comparable to the actual pumping environment.

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2.0 PROCESS

For the CVDS application, a heater was provided immediately upstream of thepump to ensure that the pump inlet temperature was high enough to precludecondensation of water vapor as the pressure increased within the pump housing.Since the pressure at the pump exhaust is atmospheric, condensation can beavoided by maintaining the pump inlet temperature above 100 C. As for the HVCSprocess, that concern is reversed. With cask temperatures of up to 350 C and verysmall quantities of residual water after cold vacuum drying, the possibility of watercondensing within the pump is remote. The water which is pumped will mix withhelium purge gas so that, after compression, the relative humidity is still low.

The wetted surfaces of the scroll pump are hard coat anodized aluminum and aTeflon compound. The gases being pumped, helium, hydrogen, water vapor, andtrace quantities of tritium, air and fission gases are all compatible with thesematerials. Bearings are housed in a separate chamber and are lubricated withinorganic PTFE. The gases being pumped during hot vacuum conditioning shouldhave no detrimental effect on the pump. Radioactive gases and participate thatmay be released by oxidation of the SNF during the HVCS process ( I , Cs, Mg) willbe removed before they reach the pump.

It is recommended that the rotary scroll pump that was selected for the CVDSprocess be used for the water HVCS process. No changes in operating conditionshave been identified that would be deleterious to pump operation. If it is assumedthat pump performance will be satisfactory during development testing for the CVDSproject, then the transition to the HVCS process presents no risk relative topumping performance. As in the CVDS, the fall back pump for HVCS is amultistage Roots pump.

2.6.2.2 Recirculation Blower (VPS-BLO-1106)

The recirculation blower is a magnetically coupled regenerative-type blower whichcirculates helium through the MCO and through external treatment in the trench andthrough heat exchange units on the process module. It has been specified tohandle 13 to 25 psia of helium pressure. The blower has no seal and consequentlyno leakage. The pump can deliver 20 ACFM of helium against a 4-inch WC statichead

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2.0 PROCESS

2.6.2.3 Vacuum System Cooler (VPS-CLR-1103)

The cooler is a plate-type unit. Its duty is highly dependent upon the pressure inthe helium recirculation system; the duty increases with increasing pressure.

The system is sized at a duty of 2,000 Btu per hour at pressure service.

2.6.2.4 Vacuum System Heater (VPS-HCL-1105)

As with the cooler, the duty of the heater increases significantly with increasinghelium pressure. The heater is electrically powered and is sized at 3 kW.

2.6.2.4 MCO System Cooler (MCS-CLR-1153)

The cooler is an air to water heat exchanger. It is sized at 83,000 Btu per hour toremove the appropriate amount of heat during the MCO cooling cycle.

2.6.2.5 MCO Heating System Heater (PHS-HCL-1152)

The heater is an electrically powered 25 kW unit. It is normally operating at lessthan half of its capacity during the major portion of the MCO heat up process.

2.6.2.6 MCO Heating System Circulating Blower (PHS-BLO-1151)

The blower is designed to work at the high temperature (375 C) that will beencountered in heat up. It is powered by a 5-horsepower motor which draws itsmaximum load at ambient temperature during startup.

2.6.2.7 Process Vent HEPA Filter (PV-F-1171)

This filter draws air from the building in the area of the process module and afterpassing it through the HEPA, pipes it to the MCO vault. Installation of this filter onthe process module avoids problems which are inherent in mounting this filter at theMCO at floor level.

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2.0 PROCESS

2.7 SERVICE MODULE

The service module contains all utility systems which are common to each of theprocess modules, with the exception of the chiller system, the process gas systemand the vent stack, all of which are outside the CSB. These outside systems aredescribed in Section 3.3 as auxiliary facilities.

The service module is located at the mezzanine level in the southwest corner of theHCSA. It contains the following components:

A. Chilled water pumps, expansion tank and heat exchanger;

B. Cooling water pumps, expansion tank and heat exchanger;

C. Combined ventilation system blowers and HEPA filter;

D. MCO oven vacuum pumps; and

E. Instrument air system

The equipment, piping and instrumentation that are in the service module areidentified on the P&IDs (SK-2-300413).

2.7.1 Chilled Water Systems

The chilled water system provides cooling for the MCO cool down cycle and forprotection of gas circulation and vacuum pumps during other portions of the HCSEoperation.

In order to achieve adequate confinement from the radioactive systems whichrequire cooling, a chiller system is used which provides three levels of isolationfrom the process heat load. The first level exchanges heat directly with the Freon®loop of the package chillers and the atmosphere. Inside the HCSA the Freon® loopexchanges heat with a chilled water loop that provides cooling for the water loop.The cooled water loop extends to each of the modules and exchanges heat directlywith the process heat exchangers. This multiple level system provides multiple

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2.0 PROCESS

barriers to prevent radioactive material from contaminating either the chilled waterloop or the Freon® loop. Redundant pumps piped in parallel will be provided onthe water side of each heat exchanger in order to provide operating flexibility duringmaintenance periods.

The chiller equipment is described as follows:

Compressor/Condensing Unit: Scroll compressor, air-cooled condensing unit,single circuit with 2 steps of capacity. Nominal 25 ton capacity at 105°F. Supplywith 25 ton evaporator chiller.

Centrifugal Pumps: Nominal 24 GPM each.

2.7.2 HCSE Process Vent System

The process vent system discharges to the combined ventilation system asdescribed in Section 2.3. Process exhaust gases include those vented frompressure relief valves and discharge from the vacuum pumps, the pressure reliefvalve vents and vacuum pump exhaust are located at the process modules. Acollection manifold extends from the combined ventilation system on the servicemodule to each of the process modules. All of the process ventilation gases passthrough HEPA filters that are located in the Trench before they are vented to thefinal set of HEPA filters in the combined ventilation system.

2.7.3 MCO Oven Insulating Vacuum System

Insulation for the MCO ovens is provided by a vacuum jacket that is designed intoeach oven. This vacuum jacket is evacuated by a central MCO Oven InsulatingVacuum system. The function of the MCO Oven Insulating Vacuum System is tomaintain a vacuum of 10"4 torr in the oven jackets and in the jackets of the processpiping that is vacuum insulated. Two vacuum pumps, operating in series, serve allMCO ovens. The fore pump is the same scroll pump unit used on each processmodule. It is used to bring the vacuum to the operating range of the turbomolecularpump. The turbomolecular maintains the vacuum system at approximately 10"4

torr. Installed spares are not provided for these vacuum pumps. The pumpsdischarge to the combined ventilation system.

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2.0 PROCESS

2.7.4 Instrument Air System

The instrument air system consists of a 45 CFM compressor, an air receiver, anda molecular sieve dryer. The compressor is powered by a 10 horsepower electricmotor and produces air to the 200 gallon ASME-stamped receiver at 100 psi. In-line between the receiver and the dryer is a deoiler. The air dryer has twomolecular sieve columns, one which is on-line while the other is regenerating.Regeneration is accomplished on a timed cycle.

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2.0 PROCESS

2.8 PROCESS ENCLOSURE DESCRIPTION

Each HCSE oven will be imbedded in a process pit so that the top of an oven willbe a few feet below the facility floor. It is necessary to access the top of the MCOto make and break connections, to assemble and disassemble oven top pieces, tochange the Cs/I trap, and to weld the final cover over the MCO . This accessrequires that the process pit cover (shield) be opened and that a means ofmanipulating items inside the process pit be provided.

A portable process enclosure is to be used while working in the open process pit.When not in use the enclosure will be parked out of the way. When access isrequired to an oven the enclosure will moved over the process and lowered so thatit seals against the facility floor. An actuator located within the enclosure will beused to open the process pit cover. An operator using a tele-operated manipulatorarm and a variety of tools and fixtures carried in the enclosure will perform a list ofoperations to either prepare for conditioning or to tear down after conditioning iscomplete as detailed in the HCSE Model Operating Sequence (see Section 2.1)

The enclosure performs the following basic functions:

A. Secondary Confinement: It acts as the secondary radioactive materialconfinement structure when the process pit cover is open. It will preventaccidental releases from the MCO during connect/disconnect operationsfrom spreading into the HCSA.

B. Radiation Exposure Management: It removes the operator a reasonabledistance from the radiation area immediately above the process pit and itprovides shielding in front of the operator.

C. Remote Operations Tool Chest: It provides manipulation capability neededfor a number of specific activities and it provides the structure required tomount the manipulators, hoists, and auxiliary tools and equipment.

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2.0 PROCESS

The process steps to be performed with the process enclosure are:

ID

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

Name


Connect Process Cell

Open Process Pit

Place Annulus Cover

Attach Annulus Cover

Remove Port Covers

Install Vent Cover

Install Valves

Open Valves

Evacuate MCO

Fill MCO With He

DescriptionThe process enclosure is moved fromits parking place into its operatingposition above the process pit.

Make the electrical andinstrumentation connections thatoperate the process enclosureequipment.

Actuate the process pit cover openingmechanism and expose the oven.

Get the annulus cover from its storagelocation in the enclosure and place iton the oven top using the manipulator.

Use manipulator and drill motor drivensocket to tighten the bolts.Use the manipulator and drill motordriven socket to loosen port coverbolts. Use manipulator and suctiondevice to remove the covers.

Use the manipulator to get a coverfrom its storage location in theenclosure and place it in the vent port.Use the manipulator and drill motordriven socket to tighten the bolts.

Use the manipulator to pick the valvesfrom their storage ports and plug theminto the MCO ports. Use themanipulator and drill motor drivensocket to tighten the bolts.

Use the manipulator and drill motordriven sockets to drive the valveoperator screws.Remove old gas from the MCO usingthe system vacuum pump.

Fill the MCO with helium.

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2.0 PROCESS

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

25.0

26.0

27.0

Leak Check Ports

Pass Leak Test ?

Close Bad Valve

Disconnect Valve

Clean Port

Install Reserve Valve

Install Insulation Cover

Close Process Pit

Survey Process Cell

Disconnect Process Cell

Remove Process Cell

Use the manipulator to move the thesniffer hose attached to a helium leakdetector (part of the processenclosure equipment) around theMCO ports.

Determine if corrective action isrequired before proceeding.

Use the manipulator and drill motordriven sockets to close the leakingport.

Use the manipulator and drill motordriven socket to loosen the valveattachment bolts. Use the manipulatorto pull the valve out of the port.

Use the manipulator and drill motordriven cloth pad to clean port.

Use the manipulator to re-install thevalve or to install a reserve valve. Usethe manipulator and drill motor drivensocket to tighten the bolts. Open thevalve using the manipulator held drillmotor and sockets.

Use the manipulator to get theinsulation cover from its storagelocation in the enclosure and place iton top of the MCO.

Actuate the process pit coveroperating mechanism.

Use the manipulators to swipeselected spots in the cell. Pass bottledswipes out of the enclosure forcounting.

Disconnect the electrical andinstrumentation services.Return the enclosure to its parkingplace.

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39.0

40.0

41.0

42.0

43.0

44.0

45.0

46.0

47.0

48.0

49.0

50.0

51.0

Move-in Process Cell

Connect Process Cell

Open Process Pit

Remove Insul. Cover

Close MCO Valves

Place Weld-On Cover

Install Welder

Weld Root Pass

Visual Inspect

Clean Weld

Repair

Grind

Repair Weld

The process enclosures moved fromits parking place into its operatingposition above the process pit.

Make the electrical andinstrumentation connections thatoperate the process enclosureequipment.

Actuate the process pit cover openingmechanism and expose the oven.Use the manipulator to grab theinsulation cover and return it to itsstorage location in the process cell.Use the manipulator and drill motordriven sockets to close the valves.Use the manipulator to get the weld-on cover from its storage location inthe process cell. Place it over theMCO.

Use the hoist and manipulator to getthe automatic welder from its storagelocation in the process cell. Install thewelder on the top of the MCO.

Turn on the welder. Make the rootpass.

Inspect the weld using a televisioncamera on the manipulator arm.

Clean the weld using a rotarystainless steel wire brush and themanipulator held drill motor.


Grind out the defect area using asmall grinder (dremel tool) held by themanipulator.

Use the welder to reweld the groundout area.

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2.0 PROCESS

52.0

53.0

54.0

55.0

56.0

57.0

58.0

59.0

60.0

61.0

62.0

63.0

64.065.0

Apply Dye

Soak

Remove Dye

Apply Developer

Bleed

Inspect

Clean

Repair

Grind

Repair Weld

Weld Pass 1

Visual Inspect

RepairGrind

Apply liquid penetrant Dye using aspecially designed applicator held bythe manipulator.

Wait the prescribed time for the Dyeto seep into weld defects.Using a specially designed applicatorapply the cleaning fluid and wash offthe Dye. Finish with a cleaning fluidsoaked rotary buffing pad driven bythe manipulator held drill motor.

Apply the developer using a speciallydesign applicator and the manipulator.

Wait the prescribed time for the Dyeto "blot out" of weld defects.

Inspect the developer coated weldusing the manipulator mountedcamera.

Using a specially designed applicatorapply the cleaning fluid and wash offthe developer. Finish with a cleaningfluid soaked rotary buffing pad drivenby the manipulator held drill motor




Turn on the welder. Make the weldpass.

Inspect the weld using a televisioncamera on the manipulator arm.Is weld repair required?Grind out the defect area using asmall grinder (dremel tool) held by themanipulator.

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Pniect No. 30012316


2.0 PROCESS

66.0

67.0

68.0

69.070.0

71.0

72.0

73.0

74.075.0

76.0

77.0

78.0

79.080.0

81.0

82.0

83.0

Repair Weld

Weld Pass 2

Visual Inspect

Repair

Grind

Repair Weld

Weld Pass 3

Visual Inspect

RepairGrind

Repair Weld

Weld Pass 4

Visual Inspect

Repair

Grind

Repair Weld

Weld Pass 5

Visual Inspect

Use the welder to reweld the groundout area.Turn on the welder. Make the weldpass.Inspect the weld using a televisioncamera on the manipulator arm.Is weld repair required?


Use the welder to reweld the groundout area.Turn on the welder. Make the weldpass.





Turn on the welder. Make the weldpass.Inspect the weld using a televisioncamera on the manipulator arm.



Use the welder to reweld the groundout area.Turn on the welder. Make the weldpass.


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2.0 PROCESS

84.0

85.0

86.0

87.0

88.0

89.0

90.0

91.0

92.0

93.0

94.0

95.0

96.0

97.0

Repair

Grind

Repair Weld

Apply Dye

Soak

Remove Dye

Apply Developer

Bleed

Inspect

Clean

Repair

Grind

Repair Weld

Remove Trap

Is weld repair required?Grind out the defect area using asmall grinder (dremel tool) held by themanipulator.


Apply liquid penetrant Dye using aspecially designed applicator held bythe manipulator.

Wait the prescribed time for the Dyeto seep into weld defects.

Using a specially designed applicatorapply the cleaning fluid and wash offthe Dye. Finish with a cleaning fluidsoaked rotary buffing pad driven bythe manipulator held drill motor.

Apply the developer using a speciallydesign applicator and the manipulator.

Wait the prescribed time for the Dyeto "blot out" of weld defects.

Inspect the developer coated weldusing the manipulator mountedcamera.

Using a specially designed applicatorapply the cleaning fluid and wash offthe developer. Finish with a cleaningfluid soaked rotary buffing pad drivenby the manipulator held drill motor




Use the manipulator to disconnect thetrap and set it aside.

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2.0 PROCESS

98.0

99.0

100.0

101.0

102.0

103.0

104.0

105.0

106.0

107.0

108.0

109.0

110.0

Install New Trap

Connect Waste Drum

Remove Top Shield

Dispose Hot Trap

Insert Top Shield

Tie BagClose Drum

Undo Annulus Cover

Remove Annulus Cover

Close Process Pit

Survey Process Cell

Disconnect Process Cell

Remove Process Cell

Use the manipulator to get the newtrap from its storage location in thecell. Make the new trap connectionsusing the manipulator.

Use a cart to place a shielded wastedrum below the process enclosurebag port. Connect the drum and port.Open the bagport door. Lower a hoistinto the drum and pull the top of theshield into the cell. Set it out of theway.

Use the manipulator to place the trapinto the drum.

Use the hoist to replace the shield toin the drum.

Tie off and cut the bag.

Place the top on the drum and attachit. Move the drum cart to the wastemanagement area.

Use the manipulator and drill motordriven socket to release the annuluscover bolts.

Use the manipulator to remove theannulus cover and place it into itsstorage location in the cell.

Actuate the process pit covermechanism to close the cover.

Use the manipulators to swipeselected spots in the cell. Pass bottledswipes out of the enclosure forcounting.

Disconnect the electrical andinstrumentation services.

Return the enclosure to its parkingplace.

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2.0 PROCESS

In order to accomplish these process steps the enclosure must have the followingfunctions and capabilities:

FunctionID

F1

F2

F3

F4

F5

F6

AffectedSequence

Steps5,27,39,110

6,26,40,109

7,23,41,107

8,9,105,106

10,11

8,9,10,11,12,13,16,18,19,20,21,22,25,42,43,44,45,47,48,50,52,54,55,57,58,60,

63,65,68,70,73,75,78,80,83,85,87,89,90,92,93,95,97,98,101

,105.106.108

Description

The enclosure must be movable with x, yaxis motion. It must be able to move overeach of the HCSE process pits and to astorage location where it does not interferewith the MHM. It may be either selfmotivated or towed.

The enclosure must have vertical motionso that it can be lifted while traveling andlowered to rest on the floor when over aprocess pit. An elastomer seal is requiredbetween the enclosure base perimeter andthe floor.

The enclosure must contain a mechanismfor opening and closing the process pitcover. The cover weight estimate is 5,000lbs.

The enclosure must have a position forstoring one annulus space cover.

The enclosure must have positions forstoring three port covers.

The enclosure must have dextrous tele-operated hydraulic manipulator with forcefeedback controls. The manipulator mustbe able to reach the MCO top surface, thetrap, the drum output port, and the varioustool and accessory storage locations in thecell. The largest and heaviest item that itmust be able to lift and place will be theannulus space cover. It must be able tohold a wide variety of tools.

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2.0 PROCESS

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

9,10,11,12,13,18,19,21,43,105

16

20,48,54,58,89,93

48

50,60,65,70,75,80,85,95

47,48,50,51,52,54,55,57,58,60,61,63,65,66,68,70,71,73,75,76,

78,80,81,83,85,86,87,89,90,92,93,

95,96

7,23,41,107

52,87

55,90

99,103

A drill motor and socket attachments areneeded to drive various bolts. There mustbe a manipulator friendly system and theremust be a storage rack in the enclosure forthese items.

A helium leak detector equipped foroperating in the sniffing mode must bemounted to the cell. The manipulator mustbe able to direct the sniffer hose aroundthe MCO port connections.

A rotary buffing pad that can be attached tothe drill motor is required in the toolstorage rack.

A rotary stainless steel wire brush that canbe attached to the drill motor is required inthe tool storage rack.

A small grinder (dremel tool) that can bemanipulator held is required in the toolrack.

A manipulator mounted television camerais required to perform visual inspection ofthe weld and the liquid penetrantdeveloper. A monitor is required at theoperator station.

A process pit cover actuator is required toopen and close the process pit.

A liquid penetrant dye applicator that canbe remotely handled with a manipulator isrequired in the cell.

A liquid penetrant developer applicator thatcan be remotely handled with amanipulator is required in the cell.

A waste drum bag port connection isrequired.

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MERRICKt. COMPANYAdvanced Technology Sector



2.0 PROCESS

F17

F18

F19

F20

F21

F22

F23

F24

100,102

45,46,51,61,62,66,67,71,72,76,77,81,82,86,96

22,42

98

A hoist to pull the shield from the wastedrum is required.

An automatic tube welder and fixture isrequired. The head and fixture must bestored in the enclosure and themanipulator must be able to place andattach it. the power supply should bemounted on the outside of the cell.

Television cameras that can see the top ofthe MCO and into the waste drum arerequired. The operator station monitor mustbe able to display multiple cameras.

The enclosure must be able to store aninsulation cover.

The enclosure must be able to store a newtrap.

The enclosure must have a pass throughdoor that allows the insulation cover,annulus cover, trap, and variousmiscellaneous supplies to be passed.

The enclosure must have shielding builtinto the walls and ceiling as determined bythe radiation exposure analysis.

The enclosure must have an operatorstation with a shielded viewing window, TVmonitor, manipulator control, motor control,valve control, welder control, andcommunication with the process controlPLC.

A process enclosure concept that incorporates these functions is shown on DrawingSK-2-300420. The enclosure will be a floorless steel plate enclosure with a comeroperator station and a recess for the drum bag port. The viewing station will havea leaded Lexan window. The enclosure will contain a hydraulic manipulator similarto the Schilling Titan VII depicted. The drum bagport system will be the CentralResearch system. The enclosure vertical motion can be accomplished withmanually pumped hydraulic jacks. The enclosure rides on an open frame supportedon four wheels. There is limited turning capability for positioning the cell. The

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2.0 PROCESS

enclosure will be moved along the process pit centerline by towing with a handoperated electric tow motor. A battery charging station for the tow motor will beprovided at the enclosure parking station. As indicated on the HCSE floor plan theparking space will be to the (Southeast) of the process modules. A shuttle table willmove the enclosure from the process pit centerline to the parking location.

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning system Equipment Advanced Technology SectorContract*MW6-SWV-310416,Task#17 Project No. 30012318


2.0 PROCESS

2.9 SOLID WASTE

The solid waste handling system and requirements will be designed in accordancewith the requirements outline in WAC 173-303, Dangerous Waste Regulations andWHC EP 0063, Waste Acceptance Criteria. This system shall provide theequipment and local storage necessary to prepare all solid waste produced by theHot Conditioning Equipment System (HCSE) for transfer to the appropriate storageand or treatment facility.

The sources of solid routine waste generated by the HCSE fall into two categories.The first is waste generated as a direct result of operating the conditioningequipment (i.e. HEPA filters, iodine traps, and filters used by the radioactivemonitoring equipment) and the second is from general cleaning and inspection (i.e.welding rods, kirn wipes, swipe tests, etc.). If a accidental breach occurs additionalsolid waste would be generated from the decontamination operations such asabsorbent materials, swipe test papers, kirn wipes, etc.

The amount of solid waste expected to contain potentially low levels ofcontamination has been estimated as follows:

A. Contaminated HEPA Filters (adjacent to the exhaust stack)Changed on average 2 times yearly

B. Contaminated HEPA Filters (inlet to the process trench)Changed on average 4 times yearly

C. Getter and Charcoal Beds (HVAC), if requiredChanged on average 2 times yearly

D. Filters Incorporated in the Radiation MonitorsChanged on average Monthly

E. Filters Used by the RAS MonitorsChanged on average Weekly

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2.0 PROCESS

F. Process Filters VPS-PFR-1101 and VPS-F-1107Changed on average Monthly

G. Vacuum Pump FiltersChanged on average Monthly

H. Spent Welding RodsApproximately V4 lbs per MCO

I. Kim Wipes for General CleaningApproximately 15 per MCO

J. Swipe PapersApproximately 10 per MCO

K. Soiled Protective ClothingApproximately 1 per Operator per month

L. Dye Penetrant Testing MaterialsApproximately 1/4 lbs per MCO

The amount of solid waste expected to contain potentially moderate to high levelsof contamination has been estimated as follows:

A. Iodine/Cesium TrapsApproximately 1 per MCO

Failed equipment can potentially fall into both low and high levels of contamination.The process equipment that is used to pump the gases and moisture from the MCO(vacuum pumps and blowers), the piping used to convey these gases, and thevalves and fittings in this portion of the system have the potential to becomemoderately contaminated if the MCO internal filter fails. Other equipment such asradiation monitors, gas supply system components, and heating elements do nothave a potential to become moderately or highly contaminated. An analysis of theaverage expected lifetime of the process equipment will be performed as part of the

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Advanced Technology SectorContract #MW6-SWV-310416, Task«M7 Project No. 30012318


2.0 PROCESS

detailed design effort to estimate the frequency of equipment failure and thus theamount of waste generated as a result of the failure.

The Hot Conditioning System Annex will be provided with appropriate storagecontainers for both low level.waste and moderately contaminated wastes. Failedequipment will be disposed of appropriately based on a radiation survey. Thewaste storage area will also provide functions for characterizing the waste materialsbefore shipment to storage (i.e., burial ground, WRAP, etc.).

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equlfxntnt AdV»ne«d Technology SectorContract *MW6-SWV-310416,TMk #17 Pro)«ct No. 30012318



3.1 HCSE LAYOUT

3.1.1 Functions and Requirements

The function of the HCSE layout is to configure the process equipment and othercomponents to best support maintenance and operation of the system. Thisincludes providing; sufficient access to each component, optimizing the flow ofprocess materials, and matching the requirements for interfacing with the MHM. Asecondary requirement is to configure the system to be compatible with future SNFstorage in a vault that could be constructed on the south end of the Annex.

3.1.2 HCSE Layout Description

The HCSA will be located on the south end of the CSB. The layout of the processpits, trenches, process modules, service module and solid waste storage area areshown on Drawing No. SK-2-300421.

The six process pits and the spare are aligned in a row to facilitate access by theprocess enclosure. The pits must also be accessed by the MHM so they arelocated between the MHM rails. Clearance distances for the MHM are maintainedfrom the MHM rails and between the centerline of the pits and the edge of theprocess modules. The distance between pits is mainly driven by the access arearequired around the process modules. This distance is larger than the distancebetween CSB storage holes so it is compatible with the MHM space requirements.

The trenches join the process pits with the process modules where the bulk of theprocess equipment is located. The trenches are required because a flat floor isrequired for all areas serviced by the MHM. It is anticipated that the trenches willbe 24-in wide and 51-in deep. The length is dictated by the MHM clearancerequirements.

The process modules will be 6-ft wide by 9-ft long by 8-ft. high. They are laid outwith a 4-ft wide aisle all around to provide access for maintenance. A module is notshown for the spare process pit but space is provided for it. The process modulesare located as close to the process pits as allowed by the MHM to minimize the sizeof the HCSA.

The service module will be in the southeast corner of the CSB annex at floor level.An aisle way is provided all around the service module to allow access formaintenance.

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The bottom surface of the MHM bridge will be 9 feet off the floor. This will allow thebridge to clear the process enclosure. The process enclosure will be parked overan MCO pit when it is not in use.

All of the HCSE components that will be located outside of the HCSA are classifiedas auxiliary facilities. These include the ventilation stack, the refrigerant condenserfor the chilled water system, the gas bottles, and the tube trailers.

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WESTINGHOUSE HANFORD COMPANYHot Conditioning System EquipmentContract #MW6-SWV-310416, Tesk #17

MERRICK COMPANYAdvanced Technology Sector


WHC-SD-SNF-CDR-007, REV. 0

INTERFACE

General Arrangement - Oven

General Arrangement - ProcessModule

General Arrangement - ProcessModule Mounting Plates

General Arrangement - TrenchGeneral Arrangement - TrenchCover

General Arrangement - ProcessPit

General Arrangement - ProcessPit Cover

General Arrangement - ProcessPit Impact LJmitersGeneral Arrangement - ServiceModuleGeneral Arrangement - ProcessEnclosure

General Arrangement - Floor

Process Piping

Process HVAC

Building HVAC

HCSEOvens including self-containedinsulation & shielding, will beinstalled in process pit by HCSE.Process Modules will be installed.Size to fit within 6-ft wide by 9-ftlong by 8-ft 6-in high space.

HCSE to provide installation detailsto weld process modules tomounting plates.

HCSE to provide all supports,conduits, piping, insulation,instrumentation and equipment thatwill be located in trenches.Trench cover to be 6-in thick withmetal edges and sealing surfaces.HCSE to provide design details forinstalling ovens and associatedpiping and instrumentation in theprocess pits.Process pit cover to be 6-in thickwith metal edges and sealingsurfaces.HCSE to design impact limiters thatare essentially identical to overpackstorage hole impact limiters, H-2-120142.Service Module will be installed byHCSE.Process Enclosure will be installedby HCSE.

HCSE design team to developequipment and module loads and todetermine locations for ProcessPits, Trenches and Mounting PlatesProcess piping and piping supportsn process pit, trench and onprocess skids to be provided byHCSE.

HCSE to provide all ventilationsystems required to support HCSEncluding stack, ductwork andmonitoring equipment and solidwaste handling area ventilation.

No HCSE design team involvement.

HCSA

No HCSA design team involvement.

No HCSA design team involvement.Mounting plates are to be cast in HCSAfloor to support Process Modules. Platesto be located as shown on HCSE layoutDwg No. SK-2-300430 Sheet 1.

Trenches to be formed in HCSA floor andlocated as shown on HCSE layout DwgNo. SK-2-300430, Sheets 1 and 2.Dimensions will be standard for 7Trenches.

No HCSA design team involvementSeven identical process pits to be formedin HCSA floor and located per HCSElayout Dwg No. SK-2-300340, Sheetsland 2.





HCSA to develop drawings, specificationsand design analysis for HCSA floor.


HCSE system will draw approximately1500 cfm from HVSA. Heat load will befrom air convection cooling of electricmotors (TBD) Btu/hr.HCSA to develop drawings, specificationsand design analysis for annex HVACsystem.

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WESTINGHOUSE HANFORD COMPANYHot Conditioning Systam EquipmentContract #MW6-SWV-310416, Task #17


MERRICK COMPANYAdvanoad Tachnolagy Sector


INTERFACE

Electrical Power - Normal

Electrical Power - UninterruptibleElectrical Power - Standby

Grounding Systems

Lighting

Process Gases

Instrument Air

Instrumentation & Control -Process Modules and ServiceModule

Process Cooling System

Safety Signals such as StackMonitor and Radiation Monitoring

MHM Interface

HCSE

HCSE to provide all electrical gearrequired to interface the 480 vacsupply with the connected loads.HCSE to provide dedicateduninterruptible power to allequipment that requires it.Not required

HCSE design team to connect togrounding systems from processequipment and instrumentation.

No HCSE design team involvement.HCSE to provide any requiredspecialty gases and the pads, tanks,piping, instrumentation, wallpenetrations, etc. required to storeand distribute them.HCSE to provide any instrument airrequired for the HCSE processincluding distribution piping.

HCSE to provide hardware andsoftware required at both ends oflie Ethernet cables.HCSE to provide process coolingsystem including outside airexchanger, wall penetrations,transfer fluid piping, pumps,nstrumentation and other heatexchange equipment.

HCSE provides monitors and signalgenerators and conductors, cablesand conduits to transmit signals tocommon point in proximity of southside of Service Module. HCSE toprovide hardware and software incontrol room to process signals.HCSE to provide process pit coverwith MCO access cover thatemulates storage hole cover.

HCSA480 vac, 3-phase provided to 8 boxeslocated on south HCSA wall (7 processmodules, 1 service module) in closeproximity to modules as shown on HCSElayout Dwg No. SK-2-300421, Sheet 1. 40kW connected load per box. Totaldemand load is 175 kW.

No HCSA design team involvement.Not required

Two grounding systems, one for powerand one for sensitive instruments. Accesspoints to be provided in proximity tomodules. On south end of HCSA.HCSA to provide general building lightingand outdoor lighting.

No HCSA design team involvement


HCSA design team to provide one conduitper module from HCSA control room toproximity of modules as shown on HCSElayout Dwg No. SK-2-300321, Sheet 1.Conduit to contain two Ethernet cables perEEE 802.3, cable type (TBD).

Mo HCSA design team involvement

HCSA to provide cable with 50 conductorsto hard wire safety signals to CSB controlroom from south wall in proximity ofsen/ice module.


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WEST1NGHOUSE HANFORD COMPANYHot Conditioning System EquipmentContract #MW6-SWV-310416, Talk #17




INTERFACE

Water

Occupancy

Equipment Installation

Sewer

Access Roads

HCSE Ventilation Stack

Staging Areas

Auxiliary Crane

MHM Rails

Doors

Communications, Fire Alarms,Security Alarms

HCSENot required, water not allowed instorage vaults and combustibles notpresent in HCSE. If water is used inclosed loop cooling systems it willbe trucked in. Spills will becontained by HCSE and moppedup.

No HCSE design team involvementHCSE responsible for installing allhot conditioning systems andequipment.


No HCSE design team involvement.HCSE to provide ductwork, wallpenetrations, stack monitors,support structure and ventilationstack for HCSE exhaust gases.HCSE to provide any staging areasrequired for solid waste, serviceequipment, samples and othermiscellaneous items.Not required for HCSE process orequipment, fork lifts can handle alltransfer duties.


HCSE to design equipment andmodules to fit through doors fornrtial installation.


HCSA

No HCSA design team involvement.CSB change room and lavatory facilities toaccommodate 4 additional people pershift, 21 shifts per week to supplementCSB staff who will also operate andmaintain the HCSE.Building access to accommodate thelargest HCSE unit which will be theProcess Enclosure, SK-2-300420.

HCSA to provide if necessaryHCSA to provide roads and truck apron onwest side of annex.



Not required.HCSA design team to extend MHM railsfrom CSB to annex.HCSA design team to provide all accessdoors to HCSA. Door on west wall ofannex must be large enough to allow theProcess Enclosure (SK-2-300420) to passthrough.HCSA design team to provide allcommunication systems, fire alarmconnections and interties to the sitesecurity system.

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3.2 HCSE/HCSA INTERFACES

The HCSE project is being developed as a project separate from the HCSA of theCSB that will house it. This is because the HCSA interacts structurally with the CSBand services must be extended from the CSB, while the HCSE is a processequipment development activity that is not dependent on the detailedcharacteristics of the HCSA building. The HCSE will be stand-alone processsystems designed to operate as independently from the HCSA as possible. TheHCSA will be a building with properties that are similar to the CSB. It will be opento the CSB storage area to allow the MCO Handling Machine (MHM) to move MCOsbetween the storage vaults and the HCSE. Therefore, the criteria for the CSBregarding design features such as structure, ventilation, radiation monitoring, andso forth that define the nuclear facility characteristics of the building apply to theHCSA. The existing CSB design and partially complete construction assumecriteria that do not require the building envelope to act as a nuclear material releaseconfinement structure. In principle, the HCSE will be a miniature nuclear systemwith confinement and safety class SSCs housed within the HCSA shell. Generallythe HCSA will be a minimal building shell and the HCSE will provide its ownamenities after the HCSA is completed. This approach allows the HCSA to catchup with the CSB so that it can be built as part of completing the CSB constructionwhile the HCSE progresses through its design and safety analysis activities withoutimpacting the construction of the CSB. The HCSA must provide a number ofservices that are to be connected to the HCSE. In addition, the HCSE will generateloads such as heat and weight on the HCSA. The HCSE also requires service bythe MHM in order to make MCO input/output transactions. This discussiondescribes the basic interfaces.

The HCSE/HCSA interfaces and responsibilities are given in Table 3.2-1.

3.2.1 General Arrangement

The general arrangement of the HCSE is given by Drawing SK-2-300421 (BuildingLayout). The HCSA project will be responsible for providing the process pits(without covers), trenches (without covers), floor, mounting pads, and other featuresneeded to obtain this arrangement.

3.2.2 Process Station Arrangement

A process station consists of the process pit, oven, and process trench. Theprocess station plan and elevation views are given in Drawing SK-2-300422. TheHCSA project will be responsible for providing the vaults (without covers), trenches(without covers), mounting pads, and other structural features required to attain this

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WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Advanced Technology SectorContract#MvV6-SWV-3104l6,T«»k#17 Project No. 30012318



arrangement. The HCSA project will perform the structural design, such as concretespecification, while preserving the critical dimensions called out on the Drawings.

3.2.3 Oven Interface

The oven will be a jacketed vessel with a smooth stainless steel skin. The processpit in which it will reside shall have cast concrete walls and bottom. The interiordimensions shall be as given on Drawing SK-2-300422. The concrete surfaces shallbe sealed with an epoxy paint. The oven outer skin temperature will not exceed50°C. The empty oven weight will not exceed 5,000 lbs. The weight of the loadedoven will not exceed 25,000 lbs. The estimated weight of the vault cover is 5,000lbs. The foundation shall support these loads. The 20,000 Ib MCO may beaccidentally dropped onto the bottom of the oven from a height of 14 ft. The holeassembly will contain the same shock absorber utilized in the CSB overpackstorage holes. The HCSE project shall provide these shock absorbers. Thefoundation design shall be able to absorb the drop load without sustaining structuralfailure.

The HCSE will provide and install the oven, process pit cover, process trenchcover, other items contained within the process pit and process trench, the processenclosure, and the process module.

3.2.4 Process Piping Interface

The HCSA project shall provide a trench with interior dimensions as given onDrawing SK-2-300430. The trench floor and sides shall be cast concrete sealedwith epoxy paint. The exterior temperature of the pipes in the trench will not exceed50°C. Mounting hardware for the pipes and conduit will be attached using concreteanchors to be located at the time of installation by the HCSE project. The estimatedweight of the piping is 75 lbs per foot. The trench design shall support a cover thatwill weigh approximately 500 lbs per foot.

The HCSE project shall supply all piping, conduit, supports, and trench covers.

3.2.5 HVAC Interface

The HCSA is not required to provide any nuclear material confinement capability.Nuclear material confinement will be provided within the HCSE.

The HCSE will contain its own exhaust fans, ducts, and nuclear grade filtrationsystems. Intake air will be drawn from the HCSA volume, through HEPA filters(provided by the HCSE) into potentially contaminated pit space, through thepotentially contaminated vault and process trench, through an HCSE provided

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HEPA filter, through an HCSE provided fan, and out a stack provided by the HCSE.This scheme assures a negative pressure in the potentially contaminated pit andprocess trench. Hardening of the HVAC system to protect it from adverse effectsarising from Design Basis Accidents (DBAs) and its safety features will be theresponsibility of the HCSE project.

The HCSE will design and construct its own exhaust stack for the potentiallycontaminated exhaust generated by the HCSE process. Penetration in the pre-existing HCSA structure for the stack, stack, pipe, stack foundation, stack support,stack feed ducting, and so forth will be part of the HCSE scope. The air volumedrawn from the HCSA will range from 1000 to 1500 CFM.

The estimated heat load of the HCSE equipment that will be discharged to theHCSA will be (TBD) BTU. This heat will be from the process modules where motorsand heat exchangers will be located.

The HCSE will provide safety interlock signals, such as HVAC flow loss, to be usedin the CSB control room when monitoring the facility.

3.2.6 Electrical Interface

3.2.6.1 Normal Power

The HCA shall provide 480 VAC three phase power for use by the HCSE. Thepower shall be provided to eight (8) disconnect switches (one for each processmodule, including the spare and one for service module). The HCSA providedpower will terminate in these eight boxes to be located on the HCSA wall near eachof the process modules. The HCSE will be responsible for transformation anddistribution of power within the HCSE systems.

The power requirements are:

A. Process Module Supply: Average Demand = (TBD) Amps, Peak Demand= (TBD) Amps

B. Central Service Supply: Average Demand = (TBD) Amps, Peak Demand =(TBD) Amps

3.2.6.2 Grounding

Two grounding systems shall be provided. An isolated ground that is not connectedto power circuits shall be provided for use by sensitive instruments. The HCSA shallprovide ground and isolated ground connections near each process module.

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3.2.7 Process Gas Interface

The HCSE will require a source of Helium and Inert Gas/Oxygen Blend. These areto be provided from tube trailers parked immediately outside the HCSA. The HCSAproject shall provide aprons for truck access. The HCSE will be responsible forpenetrating the HCSA wall and for distribution of the gases within the facility.

3.2.B I&C Interface

Each skid will contain its own PLC and data collection capability. The HCSA willprovide cabling only to support Ethernet connection of the HCSE processors(located on the process modules) and the process monitoring station to be locatedin the CSB control room. All computing equipment, control logic, sensors, etc. arethe responsibility of the HCSE.

Safety signals, such as stack monitor signals, fire detectors, and radiation monitors,will be hard wired to the CSB control room. The HCSA shall provide 50 conductorsfor these signals that will be collected on the central services skid. The patterns,"rules of thumb", and instrument models selected in the CSB design shall befollowed by the HCSE project. CSB data collection and facility monitoringequipment will accept the safety system detector signals.

The HCSE will provide all radiation monitoring. The HCSE will provide the stackmonitoring system.

The HCSA will provide security systems components such as TV cameras. TheHCSA shall provide cabling between a collection box located in the HCSA and theCSB control room. The HCSA shall coordinate provision of TV monitors andsecurity alarm monitoring equipment in the CSB control room.

3.2.9 MHM Interface

The HCSE will design the process pit cover so that it simulates the top of a storagehole in the CSB. The MHM will not have to take any special actions when loadingor unloading the HCSE ovens.

The MHM collision avoidance system must allow the MHM to load or unload anoven when the process enclosure is located over another oven. The box beam ofthe MHM will be located at 9-ft above the floor to allow this.

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3.2.10 Water

No process water connection will be required by the HCSE. The chilled watersystem will be filled from a portable water tank.

No fire water will be required in the HCSE.

3.2.11 Occupancy

Occupancy will be 4 additional people per shift to the CSB operating staff workingthree shifts per day and 7 days per week. CSB facilities such as change rooms andbathrooms must be able to accommodate this staff in addition to CSB operationsstaff.

3.2.12 Equipment Installation Interface

The HCSA shall provide an equipment access door with an opening large enoughfor the process enclosure to pass through. The maximum estimated module weightis (TBD)) lbs. Equipment movement and placement will be accomplished usingforklifts. No overhead crane will be required in the HCSA. The process skids will bemounted to imbedded steel floor plates. Attachment will be made by welding theequipment skid steel to the floor plates. The floor plates are located on Drawing SK-2-300430. The HCSE will be responsible for installing the equipment.

3.2.13 HCA Structural Requirements

The HCSA will be a structure designed to meet the same load, earthquake, wind,missile, criteria as the CSB to which it is attached. The HCSE shall provide localsecondary confinement that shall meet the necessary safety class/safety significantcriteria.

3.3 AUXILIARY FACILITIES

Auxiliary facilities are defined as those that are located outside of the HCSAbuilding. These include the tube trailers and gas bottles for the process gassystem, the stack for the combined ventilation system and the refrigerant to airportion of the chilled water system.

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3.3.1 Process Gas System

3.3.1.1 Function and Requirements

The process gas system includes items necessary for the storage, pressurereduction and manifolding of all process gasses for the HCSE. The system shouldfunction on demand from each of the individual process modules.

3.3.1.2 Process Gas System Description

The equipment and instrumentation used in the process gas system is identified onthe P&IDs, SK-2-300413. The following major equipment components comprise theprocess gas system:

The process gas system is installed on a pad located outside of the HCSA. Thesystem consists of the following gases:

A. Helium

B. Nitrogen

C. Oxygen/inert gas blend

Nitrogen and helium are supplied by tube trailers while oxygen is supplied atpremixed concentrations in cylinders. Oxygen and an inert gas wili be preblendedto an oxygen concentration of 2 percent for fuel oxidation. Pressure from eachstation is reduced to 5 psi above the internal pressure of the MCO prior tointroduction to the process area.

3.3.2 Stack

3.3.2.1 Functions and Requirements

The function of the ventilation stack is to exhaust the HEPA filtered effluent from thecombined ventilation system to the atmosphere. The stack is to be provided withan isokinitic sampling system as described in Section 2.3 and shall be 1-14 timesthe HCSA height. Effluent from the stack is to have a minimum exit velocity of 3000ft/min.

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3.3.2.2 Stack Description

The stack is anticipated to be 90-ft high with an internal diameter of 8-inches. It willbe construction of steel and will be located on concrete pad. Guy wires will beattached as appropriate to stabilize it such that it will withstand the postulatedDBAs.

3.3.3 Water Chiller

3.3.3.1 Functions and Requirements

The function of the water chiller system is to provide cooling to the processequipment. The requirements for the system are shown in Section 2.7 since partsof the system are located in the service module. The system is also discussed aspart of the auxiliary facilities because the refrigerant condenser will be located ona pad outside of the HCSA to allow air cooling.

3.3.3.2 Water Chiller Description

The refrigerant condenser will be a 25-ton unit designed for exterior air cooling. Aconcrete pad will be provided for mounting of the condenser. Electrical power forthe condenser will be supplied from the HCSE and refrigerant piping will connectthe condenser with the service module.

3 - 1 2

WESTINGHOUSE HANFORD COMPANYHVCE Conceptual DesignContract #Mv\»-SvW-310416, Ta«k#17




4.0 INTERFACES

4.1 HCSE INTERFACES

The HCSE will interact primarily with three subprojects. These are the HCSA,the MHM, and the MCO. The HCSA interfaces are required to define the facilityand services that must be provided to house the HCSE. They are described inthe Section 3.2 of the facility chapter. The MHM interface is required becausethe MHM will perform the MCO input / output transactions with the HCSE. TheMCO interfaces are defined by the physical mating of the MCO and the ovenassembly, by the need to have a scheme for connecting the HCSE to the MCO,by the need to make the final closure of the MCO in the HCSE ovens, and bythe operating temperature and pressure design limitations of the MCO. Theinterfaces are given Table 4.0-1 below.

InterfaceNumber

MC01

MC02

MC03

MC04

Name

MCO BodySize

MCO NeckShape

MCO Weight

Draw Tubeand Head

Space PortCover

Description

The MCO diameter andheight are important fordetermining the ovendimensions.

The MCO neck shapeis not finalized. If theflared design is selectedthe MCO will hang froma beveled flange and noannulus cover will berequired. If the MCOneck is straight, theMCO will rest on itsbase and an annuluscover will be required.The MCO weight mustbe constant after ovendetail design iscomplete. The ovenstructure and shockabsorber are dependentupon the weight.

The ports are coveredby a bolted identicalbolted plates whichmust be removed foraccess to MCOconnectors.

Requirement

Dimensions must beconstant after ovendetailed design is completeor after HCSA design iscomplete.If flare design is selected -flare dimensions and ovenflange dimensions mustagree. If the straight bodydesign is selected the topsurface must allow theannulus cover to sitwithout interference.

None

Bolts must be hexheadtype. Bolts must becaptured and spring loadedso that they cannot fall outand so that they pop-upwhen disengaged.

4 - 1

WESTINGHOUSE HANFORD COMPANYHVCE Conceptual DnignContract#MW6-SWV-310416, Task#17

MERRICK& COMPANYAdvanced Technology Sector

Project No 30012316


4.0 INTERFACES

InterfaceNumberMC05

MC06

MC07

Name

Draw Tubeand Head

SpaceConnections

Final ClosureDesign

TemperatureRestraints

Description

The connectors allowthe HCSE process linesto be connected to theMCO.

The final closure of theMCO will be a coverwelded in the HCSE.

The MCO has designratings for maximumoperating temperature,rate of temperature rise,and point to pointtemperature difference.

Requirement

Connectors must beremotely (manipulator andtools) operable.Connectors should have aflow cross sectional areaas close to 0.8 sq. in. aspossible. Connector sealsmust be capable ofoperating at 350°C.Connector must be heliumleak tight. Connector mustbe tolerant to dirt (SNFcorrosion dust). Theconnector must be heliumleak tight measured with ahelium sniffer (max leakrate 10E-06 std. cc/sec at100PSI).Weld must becircumferential so that itcan be accomplished withthe same welding head/fixture as used in theCVDS. Weld procedureusing ultra-sonic inspectionis preferable to LPTbecause remote executionis easier. The cover mustinclude features to allowthe MHM to lift the MCOout of the oven.The limits are 325°C, 50°Cbetween any two points,and 50°C per hour.

4 -2

WESTINQHOUSE HANFORD COMPANYHVCE Conceptual DnignContact #MW6-SWV-310416, Task #17

MERRICK & COMPANYAdvanced Tachnology Sector



4.0 INTERFACES

InterfaceNumberMCO7

MC08

MHM1

MHM2

MHM3

MHM4

Name

OperatingPressure

Head SpaceVent Filter

MCOAlignment

Plug Docking

MHM -Process

EnclosureCollision

Avoidance

MHMLockout

Description

The MCO pressure islimited by its designpressure and its rupturedisk.

Dust entrained in thehelium flow must befiltered inside the MCO.The angular position ofthe port pattern on thetop of the MCO cannotvary form MCO to MCObecause the HCSEprocess connectionshave a limited range ofmotion.The MHM will locateabove the process pitcenter plug. Its grapplewill lock onto the plugand pull it. After thesequence is completedit will replace the plug.The MHM may requireaccess to one ovenwhile the processenclosure is over theother. The MHM bridgeand enclosure cannotcollide.The MHM should not beable to access a hotoven by error.

Requirement

The HCSE desires to havethe ability to operate at 25psia at 300°C so that it hasthe flexibility to improvethe heat transfer rate if itproves to be necessary tomeet processing timebudgets.Micron type filter. Capableof operating at 300°C.

No more than + /- 15degrees.

Plug top must be a replicaof the CSB storage vaultcovers that the MHM iscapable of handling.

Can be administrativelycontrolled.

HCSE to provide anactuator that indicatesvisually to MHM operatorthat the oven is active.HCSE to provide actuatorthat prevents MHM grapplefrom attaching to plug.

4 - 3

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Condttoni^ Sylttm Equipment Adnncad Ttchnotogy S*dorConWct*MWMWV-310416,TMk#17 Prej«a No. 30012318



5.1 METHOD OF ACCOMPLISHMENT

The HCSE project will be a joint effort between the DOE as the owner, WHC as theoperator, Merrick as the architect-engineer, and a yet to be determined primeconstruction contractor. The responsibilities of each organization are as follows.

Department of Enerov

DOE will furnish overall project coordination, review all conceptual design anddefinitive design documents and based on their review authorize the definitivedesign, construction and operation of the HCSE. DOE administers the WHC primecontract to operate the Hanford facilities.

Westinohouse Hanford Company

WHC will provide design criteria and engineering management services during theconceptual design, definitive design and construction project phases. WHC willreview all design documents and based on this review recommend to DOE that thedefinitive design, construction and operation of the HCSE be authorized. WHC willaward and administer the architect-engineer and prime construction contracts. Ifit is determined that government furnished equipment is required, WHC will beresponsible for procuring this equipment and providing it to the prime constructioncontractor. Following construction of the HCSE, WHC will be responsible for HCSEoperations.

Merrick & Company

Merrick is under contract to WHC to perform all conceptual engineering services.Engineering required to develop the definitive design packages and constructionsupport engineering are options under this contract. Merrick will be responsible foridentifying and recommending to WHC items that should be classified asgovernment furnished equipment. Merrick administers the subcontracts of thespeciality design firms that support the architect-engineering work.

Prime Construction Contractor

A prime construction contractor will be selected and placed under contract to WHCto construct the HCSE. This contractor will be responsible for procuring materialsand supplies and constructing the HCSE in accordance with the definitive designpackages. The contractor will also be responsible for installing any governmentfurnished equipment and administering the subcontracts of the speciality firms thatwill support the construction activities.

5-1

WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment AdMnced Technology SectorContract#MW6-SWV-310416,T»«l<#17 Project No. 30012318



5.2 SCHEDULE

The key milestones in the HCSE design and construction schedule are as follows.

Conceptual Design Complete July 31, 1993

Authorization to Proceed with Definitive Design August 1, 1996

Definitive Design Complete March 25, 1997

Authorization to Proceed with Construction October 2,1997

Construction Complete June 30, 1998

Beneficial Occupancy September 30,1998

5.3 SUMMARY COST ESTIMATE

The project cost estimate has been developed by the individual designers andutilizes a factored approach where the installed cost is based upon the cost of theequipment. The costs for the process modules and the central service module havebeen developed with the following criteria:

A. The cost estimate is developed for the pressure system, operating at aninternal helium pressure of 25 psia. This was done because this option isthe more expensive of the two cases. For an atmospheric system, deduct$60,000 from the overall cost.

B. All installed costs are factored to equipment cost. All equipment cost isobtained from a vendor unless otherwise noted on the equipment list.

C. Cost factors are taken from the method of Miller (Perry, Table 25-51) forbattery-limit installations. As skids will be factory assembled, the lowerrange of factors is normally used. In the event of significant complexity, thefactor is adjusted to the higher end of the range. When extraordinary costsare involved for support equipment, as in the case of specificinstrumentation, these items will be costed separately.

D. The structural estimate is applied once for each skid assembly.

E. Installed cost assumes FOB Richland, WA. A local skid fabricator isassumed.

5-2

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Advanced Technology SectorContnKt*MW6-SWV-310416,Taak#17 Project No. 30012318



Contingency, Engineering, Project Management, Insurance, etc. are factored toConstruction Cost Estimate.

The auxiliary area estimate was developed from Means Construction CostEstimator. The cost estimate for the Process Enclosure was developed from theexperience of Paul Smith on like projects. Engineering cost and contingency arefactored to the constructed cost of the equipment.

Backup information used to develop the estimate is found in the Appendix F.

The summary of the construction cost estimate is shown in Table 5.3 below:

Table 5.3Project Cost Estimate(all costs in thousand $)

Construction CostsProcess ModuleService ModuleProcess EnclosureAuxiliary FacilitiesProcess Pit Compnts

Subtotal Const. Cost

Project Management(8%)Eng. Design & Insp.(22%)Bond & Insurance (2%)Contingency (30%)

TOTAL PROJECTCOST

Item No.Cost Items

300150550130210

61116

TotalCost

2,318328620622

1.6355,523

442

1,215

1101.657

8,947

5 - 3

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHo» Conditioning Sy*t»m Equiprr-nt Advmo«d Toehnology SKtorCortnBt«MW8-SWV-3l0416.TMl<#17 P r o j K t N o W M Z M B


APPENDICES

APPENDIX A

DRAWINGS

A - i


DftAMNGNUMBER

SK-I -3004IO

SX-2-300411

SK-2-300412SK-2-300412

SK-2-300413SK-2-300413SK-2-300413SK-2-300413SK-2-300413

SK-2-300414

SK-2-300417

SK-2-300418

SK-2-3O0420

SK-2-300421SK-2-300421SK-2-300421

SK-2-300423

SK-2-30O4U

SK-I-30O42SSK-2-300429

5K-2-300426

SK-2-300430SK-2-300430

SHEETNUMBER

1

1

12

234S

1

1

1

1

23

1

1

12

1

12

DEsenPnoN

DAAWiNG M E X

BLOCK FLOW OUCRAM

PROCESS FLOW DIAGRAM

HCSE P * » LECCNOHCSE PROCESS MODULE PUDHCSE PROCESS MODULE PUDHCSE PROCESS MODULE P * »HCSC PROCESS MODULE PUD

CONTROL SrSTO* DWGRAU

OVEN ASSEMBLY OPT 1

OVEN ASSEMBLY OPT 2

PROCESS ENCLOSURE

BULDMG LAYOUTAUX PROCESS LAYOUTCENTRAL PROCESS LAYOUT

OVEN MSTAUADON

PROCESS MOOULE

ELECTRICAL ONE-UNES {BAYS 1-4)ELECTRICAL ONE-UNES {BAYS * - • )

COMBMES VENTUATION SYSTEM

PROCESS PTT A TRENCH LAYOUTPROCESS PfT * TRENCH PLAN AW

DCPAITTUENT OF (MERCY

HOT CONDITIONING SYSTEMEQUIPMENT

DRAWING INDEX

I \at»i/

A-l


I Issj'fl w nVMWffaiiAaMiiaaiAP] |

I I B

S. KPAffTMEMT Of EMOtCT


BLOCK FLOW DIAGRAM

• ISK-2-:7003 ISK-2-3004H I A

A-2


HOT VACCUUM CONDITIONINGPROCESS FLOW DIAGRAMMCO CELL OPERATIONS

A-3


Operating Cycle

Stream DescriptionStream No.

Temp. C f )

Press Ton (psio )Flow rate std I/sec sfcfm )Vac rale l/mlnH , kg/hr loVhr )0 , k g / h r Itjs/hr)N , kg/hr IKi /hr )He kg/hr l l s /h r )I111 gram/hr las/hr)K r " gram/hr Hfc/hr)C s " ' gram/hr Ibs/hr)

Max heat rate kcol/hr e > / h r )

Process Duration (Note 4)-Approx. Total DurationWater Removed kgHydrogen Removed kg

Ongoing

UWI \ Dewar vacuum draw1 1

! 20-375I[ 1.00E-04I nilI

2 i32 I28 i4 i

131 186 1137 1

j

68-707

1.93E-06nil

i ongoingi ongoingt

!

utility"~

UCO area hood vent2

20

76066

68

14.7140

13 hr130 hr

Preparation forInitial vacuum

evacuation3

40

100.067

3

6.8015

104

0.1930.142

0

min.min.

heating cycle

Helium filling of UCO4

20

9315.32

3.42

12.9515

68

1811.29

7.55

min.min.

UCO heating air

375M * 3

760149

17,640

13.2 hr14

707

14.7316

70,000

(Note 3)hr.

Helium heating(Healer Inlet)

6A

102

68111.90

1.22

13.214

216

13.34.037

2.70

hr.hr.

" H e l i u m(Heater

Hedtlfigol BC0~(<K to^OO+C) "~heatingoutlet)

6B

325

6721.90

1.22

142

13.214

617

134.037

2.70

562

hr.hr.

F>erloolc fiellumpurging to 200 C

7A

200

6880.005

0.003

0.002

I8

392

13.30.011

0.007

0.007

hr.hr.

Helium purging 200 Cto 300 C

7S

300

6880.003

0.002

0.001

5.36

572

13.30.006

0.004

0.004

hr.hr.

1.8140.165

Helium fur purgeduring heat-up

8

20

9310.004

0.003

13.3

68

180.009

0.006

hr.

Purifier Outlet9

100

1.90

212

4.037

Operating Cycle


emp. C f )

Press Torr (pjlu )

Vac rate l/mlnH, kg/hr IH>/hr)O,kg/hr Ifjs/hr)N, kg/hr IbS/hr)He kc/hr lls/hr)l u l aram/hr 116/hr)Kr" qrom/hr laVhr)Cs I J ; gram/hr Up/hr)

Max heal rale kcol/hr ( tu /hr )

Process Duration (Note 4)ApjO/ox. Total DurationWater Removed kgHydrogen Removed kg

UWt

232284

13186137

vacuum condition

Vacuum draw10

300

5

3.0.0005

0.135

7.948

572

0.097

IO

0.001

0.298

minhr.

0.056O.OO3999375

Inert gas purgeduring vacuum

I I

20

931

0.135

4848

68

18

0.298

hr.hr.

• ~ "Cooling - o m a n b n so c

Coding air12

80

760

|

18,144

1414.5

176

14.7

_ 5 4 2 _

72,000

hr.hr.

Helium added forcool-down.

13

20

931

3.423

0.95715

68

18

7.547

min.min.

Helium coolingt4A

100

6723 ' ° 5 i

2.006

13I3.S

212

13

-ML—

3.143

hr.hr.

Helium cooling148

102

688

2.006

1313.5

216

13.3

3.143

hr.hr.

Kitrogen added15

20

931

M2_

15.668

1212

68

18

34.548

hr.hr.

Oxygen passivation

Oxygen added16

20

931

1

0.365

1212

68

18

1

0.806

hr.hr.

Circulating passivationgas17

150

688

1212

302

13.3

hr.hr.

Inert Gas Kecking

Oxygen Evacuation18

150

5

3.

7.9015

302

0.097

>0

min.min.

Helium Fill19

150

1137

3.000

1.95815

302

22

6.615

min.min.

Notes:

1. Although hydrogen moy be present at coKitttrdlona greater thon 51 . . H b Inherently M l . because Hs concantrotlon whan diluted would be lass than IX, tlgnlflcontly bain Hi L£L

2. Run 23 data assumed to be at MCO operating conditions.

3. Heofing rate Is determined with on Moral neat transfer coefficient of I Btu / pound degree F sq. ft. hr end onomol heal transfer coefficient el 5 9tu / pound degree F K ft. hr.

4. Moss rote times process duration equals mass. Approximate total duration Is for cycle time datermlnaHon only.

5. This Is Mwjaxlmum of o programmed temperature schedule

«. This Is lleHmurn of a programmed temperature schedule VACUUM CONDITIONING SYSTEMEQUIPMENT

MASS BALANCE TABLE

- 3 0 0 4 1 2 I

A-4


MISCELLANEOUS

Vt -utm ma

(•7:5

LINE § DESIGNATIONS EQUIPMENT i DESIGNATIONS

REFER TO W H C - S Q - O G S - 0 0 2 REV 0

ELECTRICAL I DESIGNATIONS INSTRUMENT I DESIGNATIONS

XlOOGOC—KJUU—XXjrioaoac-xxxx-xx

REFER TO KHC-SD-DCS-002 REV 0 REFER TO WHC-SD-DCS-003 REV 0

GENERAL PAIO NOTES:

1 . REFER TO W H C - S D - O C S - 0 0 2 REV 0 . APPENDCES FOR ACCEPTABLE ACRONWS

Z ALL PRESSURE MSTRUUEffTS USE A PRESSURE W U G C ROOT VALVE (NOT SHOWN ON P U T S )

3 . ALL MSTRtMENT MTROCEN (AIR) USERS ARE SEPARATED FROM HEADER WTH t / « * « U VALVE

(NOT SHOWN ON P M T S )

4 . REFER TO EQUIPMENT SPECIFICATIONS FOR SPECIALITY EOUPUENT DESCRPTIONS

3. 1W1CAL O f ALL H C LOOPS:

tor M — Maura KJOGK w y c r WMIM

6. PPINC FTTTMGS CONFORM TO PIPMC SPECIFICATIONS (CONF0RUN6 FTTTMGS NOT SHOWN ON P * » ^ }

7 . SEQUENCING AND MTERLCCKING NOT SHOWN ON P U T S (REFER TO LOCK AND LOOP DIAGRAMS)

S. MOST ALARMS NOT SHOWN ON P M T S . ONLY ALARMS WITH MTERLOCKS ARE MOCATED

REFER TO NSTRUMENT UST FOR COMPLETE LOOP COMPONENTS MCLLONG HSTftUMENTS, VALVES, ALARMS,S E T - P O M S . THRESHOLDS, ETC.

FLOW SHFFT SYMBOLS INSTRLMENT SYMBOI S

t

o

mlii

SffiSta

o

—1|(— - # « »

0IT

T

e

n m

Q S"

'SSF1

ssssr-

MSnOMEHT SOCIETY OF AUERCA. E A - S S . 1 . 1B9S

I INF IFGFNn

HOT CONDITIONING SYSTEMPAID

HCS P&ID LEGENO

A-5


VPS-CLR-II03 VPS-VAC-1104 VPS-HCL-1105 VPS-BLO-1106 VPS-F-1107 PG-ACC-1131 PHS-BLO-II51 PCS-HCL-115? MCS-CLR-1153 PHS-OVFN-1154UCO VAC PUMPWC SY5 MCO VAC PUMPWG SYS MCO V « P U W W C SYS

MJ TWP POP. C» / l HEPA H L E H CO(X£R SC8OU. WOAIM PUMP WCO CWCULATION HCATtR RECWCUATTON BLOWER MCO SUPPLY HEPA MCO F I T BLOWBK ACCUM CIRCULATING BLOWER ELECTRICAL HEATER COOLER3C00 BTU/HR <1.0 *WC • 100 ACFM JOOO BTU/MR 430 LPM • 3 TORR 1 K W 30 SCFM OCSKM <1 .0 "WC • 100 SCFM 10 UTERS 21000 LPM • T WC $P 25 KW SO.OOO BTU/HR

NOTESvps-PfR-noiMCO WC PUMPING SYS MCO WC PUMPING SYS UCO WC PUMPING SYS UCO W C PUMPING SYS K M WC PUMPWC SY5 UCO WC PUUPING SYS UCO W C PUMPING SYS MEUUU SUPPLY SYSTEM UCO HEATWG SYSTEM UCO HEATWG SYSTEM UCO COOLIWC SYSTEM MCO HEATING SYSTEM PROCESS VEWT '" *" • i/0 °* n£^°-°i-tMWPJVRJrt ...HEW_fUW « ~ 5 l _ S^T ^ W W J E S T «C0 CIRCULATION HCATER K O R U U n O N M N n _.uO._?JPn.r"EPA _ MCO F W a W W ACCUU ..OHCUiTWC BLOWEH__ ELECTRICALHEATER „ .COOLER _ MO M U M OWN HEPA • / PW-FWOI . J. MnVMEHT WnNGEN .SUPPLIED

HOT CONDITIONING SYSTEMP*IO

HCS PROCESS MODULE

"I "^ 15" lsK-2-30O413jI

A-6


COOUNC WATER SYSTEM HCSCMCUUTION PUMP

72 GPM

HCS COOUNC WATER SYSTEM HCSLOOP EXPANSION TANK

SO LTTERS

COOUNC WATER SYSTEMORCUUTION PUMP

73 CPU

HCS COOUNC WATER SYSTEM HCS CULLED WATERSECONDARY HEAT EXCHANGE LOOP EXPANSION TANK

240,000 BTU/HR 90 LTTEftS

HCS CHLLED MATER SYSTEMORCULM10N PUMP

U CPU

HCS CHILLED WATQt SYSTEMCIRCULATION PUUP

€ 0 CPU

HCS PROCESS VENT SYSTEMHEPA FLTER

1000 CFU • I" WC

CULLED WATER SYSTEMCHILLER

340,000 STU/HR

HCS PROCESS VENT SYSTEMPROCESS VENT BLOWER

1000 CHI • AT WC SP

HCS PROCESS VENT SYSTEMHEPA HLTER

1000 CFM • 1* WC

HCS PROCESS VENT SYSTEMHEPA FITER

1000 CFM • 1" WCPROCESS VENT BLOWER

1000 CFU • IT WC SP

VENDOR SUPPLIED CHILLER SYSTEMHEAT EXCHANGER LOCATED INSIDECONDENSOR LOCATED OUTSIDEASSOCIATED EQUIPMENT NOT SHOWN

py-f -2041 PV-F-2042

HOT CONDITIONING SYSTEMPAID

HCS PROCESS MODULE

A-7


VAC-VAC-3041 VAC-VAC-3043

HCS ( M M WCUUH SYSTEM5CR0U. WCUUU ROUGHER PUMP

600 U>W

l_Jas*Bvw/»i t\M

HOT CONDITIONING SYSTEMP4ID

HCS PROCESS MODUUE

ISK-2 -300413 I

A-8


3" THK *1T SHIELD 3T TKK 4Tf SHIEUJ I t 5" THK 41T


HCSE PROCESS MODULE PAID

A-1000eCTA/CMMA PWTCULATE,K » M E - 1 » . * NOBEL O S

MONITOREBCRUNE "P1NC-3e"

A-2000I00INE-I29. * NOBEL GAS

MOMTOftEBERUNE 'PINC-3GT

A-5000ALPW/BCU PtfTJCULATE.

MOMFTOREBERUHC " S A - W

A-5001TWTttJM

OCRHOFF TECH. UOOEL "32X SEBIi

A-4000ALPHA/BETA PilRTICUlATE.

MOHTTOft3 " EBESUHE ' M - 4 A "

A-4001TRITIUM

I PROCESS STACK"

A-9


FF

MANIPULATOR PORTABLE CELL

LEGEND

X X H HrJr

VACUUM CONDITIONING SYSTEMEQUIPMENT

CONTROL SYSTEM DIAGRAM

? lsK-2-ion I S K - 2 - 3 0 0 4 U I

*i*ati>m \

A-10


FLEXIBLE CXPANSltM

KH3INC/CEXILJH TRAP

KIT AIR RETURN

HOT AIR SUPPLY

EVACUATED PIPE

-EXPANSHW KLLOVS

EXPANSION BELLOWS

J J . DEPARTMENT OF CNOI


OVEN ASSEM8LY OPT1

A - l l

' • - ' " ' - I

i £ o

\\\


MASTER MAWPUATORw / CCTV. « • D e r e c i wAND RMMTtON DETECTOR

DROP TABLE FORMSULATION COVERN O BELLOWSSEOTOf*

FDR TRENCH

S/ACCESS LOCKOUT

VJi

i i n i l"-H » 3/4'

ELEVATIONFRONT

TOOL ACCESS DOCK

DROP TABt£ FORM5UUTXM COVERAM> K U i M S SECTION(SHOW* W U» POSITION) = >

* HLTEB ~S

HOT CONDITIONINGSYSTEM EQUIPMENT

PROCESS ENCLOSURE

A-13


NOTFS:

1. SEE DRAWING "HOT CONDITIONING SYSTEM EQUIPMENT""PROCESS PIT & TRENCH" SK-1-3CXM30 SHEET 2 FORPIT AND TRENCH DETAILS

ELECTRICAL-'


BUILDING LAYOUT

-300421

A-14-


JHEUUU BANKS

PROCESS CHILLER

NITROGEN BANKS

CT T )

AUXILIARY PROCESS EQUIPMENT - SKID PLAN AUXILIARY PROCESS EQUIPMENT - SKID ELEVATION

i >Vuraa«M3i^at«ii«


AUX PROCESS LAYOUT

A-15


CENTRAL SERVICES PROCESS EQUIPMENT - SKiD ELEVATION

CHW-P-2022 CHW-P-2022 - i CW-HX-2013 -v

CW-«C-2011 ->. \CHW-ACC-2021 -v \ \

-20,2-^ \ X \ \ \ /

- CHW-HX-7???

CENTRAL SERVICES PROCESS EQUIPMENT - SKID PLAN

-PV-BLO-2043


CENTRAL PROCES LAYOUT

A-16



OVEN INSTALUTION

l_U3JV3V»«

A-17


tCS-lll-SS-4

MCS-101-SS-*'

COOLER BODY CONTAINS AMYFIN-TUBE COOLING WATER IREACH TO

PREVENT WATER FUN INTO OVEN

VPS-103-SS-1*

VAC-101-SS-l*

PHS-103-SS-4*PKS-I01-SS-4'

- VPS-VAC-t104

-CONTROL PANEL

-VPS-HCL- I103

-VPS-B .D-1106

D WITH BUI-T-W CONTAMWENT—.FOR RETENnON OF EXTERN*. \

COOLMS WATER LEAKS \

MCS-1DE-SS-4-

HCS PROCESS SKID - PLAN HC5 PROCESS SKID - ELEVATION

HOT CONDITIONING SYSTEMLAYOUT

PROCESS MODULE

A-18

FPWHC-SD-SNF-CDR-007, Revision 0

- • ' ( '

/ • * "

r l ,8

%

PROCESS BAY-1 SKID ONE-LINE DIAGRAM

T

S 3S/3P J *5/3t

ioi I r^i

PROCESS BAY-2 SKID ONE-LINE DIAGRAMSCALE; NONE

•I.11I

PROCESS BAY-3 SKID ONE-LINE DIAGRAM,

HOT CONDITIONING SYSTEMEQUIPMENT ELECTRICAL

SKID ONE-UNE (BAYS 1-4)

*>1/M l\WraOI0&J1^K419OI1MB

A-19


i

T

PROCESS BAY-5 SKID ONE-LINE DIAGRAMSOLi: NONE

U» W0 "F

"•I?

PR0CESS_BAY-6 SKID ONE-LINE DIAGRAMSCLv NONE

SHARED UTILITY SKID ONE-LINE DIAGRAMSCALE; NOME

— 1 N0.4 * 1 N0 13<Gfi»)

THHN(CU) - 1 - C . (SOS)

i l lCHILLER C H - 2 0 2 5 (25 TON) ONE-LINE DIAGRAM

INST/CONTROL POWER ONE-LINE DIAGRAM

HOT CONDITIONING SYSTEMEQUIPMENMT ELECTRICAL

SKID ONE-LINES (BAYS 5-6)

A-20



COMBINED VENTIUTION SYSTEM

A-21


0

NOTTS:

1. SEE DRAWING "HOT CONDmONING SYSTEM EQUIPMENr'PROCESS PrT 4 TRENCH" SK-1-300430 SHEET 2 FORPIT AND TRENCH DETAILS

0

h

HCSE/HCSA INTERFACEPROCESS PIT & TRENCH

LAYOUT

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Systm Equipment Advanced Technology SectorContract *MW6-SWV-310416, Task #17 Project No. 30012318


APPENDICES

APPENDIX B

ALARA IMPLEMENTATION PLAN

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHoi Vacuum Conditioning Equ ip™* Project Adnncad Twhnology S«lorContract*MW6-SWV-31O416,THk*<7 Project No. 30012318


APPENDIX B • ALARA IMPLEMENTATION PLAN

ALARA IMPLEMENTATION PLANfor the

HOT CONDITIONING SYSTEM EQUIPMENTof the

K-BASIN SPENT NUCLEAR FUEL STORAGE PROJECT

1.0 INTRODUCTION

Approximately 2100 tons of SNF are stored in the K-Basins. The DOE hasagreed to an accelerated schedule to move this material from the basins intointerim dry storage. The project requires the construction of a process facility,called the Cold Vacuum Drying Module (CVDM), to dewater and dry the fueloutside of the basin buildings, before shipment to a distant storage facility. TheSNF elements will be placed within a container called the Multiple CanisterOverpack (MCO) in the basin. The MCO, which will be full of basin water as wellas fuel, will be placed in a shielded shipping cask on a transport trailer at thebasin. This assembly will be transported to the CVDM where it will be drainedand dried by a vacuum process. When processing is complete in the CVDM, theMCO and cask are transported to the Canister Storage Building (CSB) where theMCO is placed in interim storage to await further drying by the Hot ConditioningSystem Equipment (HCSE). The HCSE is located in an annex to the CSB and isserved by the CSB MCO Handling Machine (MHM).

There are two important radiation sources associated with the hot vacuum dryingprocess. The principle source will be the MCO filled with spent nuclear fuel.The shielding integral to the MHM and oven will reduce the dose to relatively lowlevels in the area that the workers will occupy during the hot vacuum dryingprocess. The second source will be the process equipment. Fission productsfrom leaking fuel and activation products will accumulate in the processequipment, creating a source. Controls will be required to protect staff frominhaling or spreading releasable contamination that could be released whenMCO connections are made or broken during the hot vacuum drying process.

The federal law governing design objectives for radiation exposure for this typeof work is 10 CFR 835, Occupational Radiation Protection. This is the code thatestablishes radiation protection standards for the conduct of Department ofEnergy activities. The annual limit for total effective dose equivalent (TEDE) is 5rems. Administrative limits are imposed by DOE Notice 441.1, RadiologicalProtection for DOE Activities. A guide to useful practices for achieving theobjective of the ALARA process is DOE publication PNL-6577, "Health PhysicsManual of Good Practices for Reducing Radiation Exposure to Levels that areAs Low As Reasonably Achievable (ALARA)". The purpose of this plan is to

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Vacuum Conditioning Equipment Project Advineed Technology SectorContr«ct*MW&-SWV-3104i6,T»»l(#17 Project No. 30012318


APPENDIX B - ALARA IMPLEMENTATION PLAN

provide the framework for a design and operations planning program whichassures that the ALARA requirements will be met.

This ALARA Implementation plan provides guidance during the design phase forestimating the expected radiation doses and for selecting appropriate remote orautomated operations and shielding features for the Hot Conditioning SystemEquipment. It also provides input for decision making while writing operationalprocedures.

2.0 ALARA PRINCIPLES

The following documents serve as references for ALARA considerations:

10 CFR 835 Occupational Radiation ProtectionASME NQA-1 Quality Assurance Program Requirements for Nuclear

FacilitiesDOE Notice 441.1 Radiological Protection for DOE ActivitiesDOE Order 6430.1 A General Design CriteriaPNL-6577 Health Physics Manual of Good Practices for Reducing

Radiation Exposure to Levels that are As Low AsReasonably Achievable (ALARA)

WHC-IP-1043 WHC Occupational ALARA ProgramWHC-CM-4-29 Nuclear Criticality SafetyWHC-CM-4-46 Nonreactor Facility Safety Analysis ManualWHC-CM-7-5 Environmental ComplianceWHC-SD-GN-30011 Radiological Design GuideDOE/EH-0256T DOE Radiological Control ManualHSRCM-1 Hanford Site Radiological Control Manual

In combination, the DOE Orders and Guidelines generally require the followingradiological design criteria:

A. Individual worker dose shall be ALARA and should be less than 500mrem per year.

B. Control of contamination should be achieved by containment ofradioactive material.

C. Efficiency of maintenance, decontamination, operations, anddecommissioning shall be maximized.

The basic principles that are to be adhered to in the design of the Hot VacuumConditioning Equipment are to: 1) determine the major contributors to the dose

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and examine methods for making the process more efficient, 2) provide shieldingto reduce the dose, 3) examine the cost-effectiveness of using robotics, and 4)examine the cost-effectiveness of using remote controls where possible. Thesedeterminations should include assessment of normal operations exposure andmaintenance/repair exposure.

3.0 HOT VACUUM DRYING EQUIPMENT MODULE DESCRIPTION

A. Process Description

The purpose of the Hot Treatment Process is to dry the SNF by driving offwater vapor trapped in pores that may remain after Cold Vacuum Dryinghas been completed and releasing chemically bound water (water ofhydration). In addition to completing the drying, the process will breakdown uranium hydride and release the hydrogen. After drying has beencompleted the exposed uranium surfaces will be oxidized by a controlledreaction. These processes are designed to remove hydrogen, eliminatefurther hydrogen production during storage, and reduce the reactivity ofthe uranium surfaces prior to storage.

The process involves heating the SNF to 300 °C with a Heliumatmosphere, then evacuating the vessel to a pressure of 5 torr. The SNFis then cooled somewhat and a Helium / Oxygen mixture is added tooxidize the exposed uranium. When the process is completed a cover isplaced over the MCO ports. The cover is welded in place.

The hot treatment process will be executed in an extension of theCanister Storage Building. This building covers an array ofsubterranean holes into which the Multiple Canister Overpacks(MCOs) are placed for storage. Removal of the MCO from theshipping cask that it arrives in and input / output transactions withthe storage holes is effected with a special remotely operatedmachine (within a shield cask) called the MCO Handling Machine(MHM). The Hot Treatment Process ovens will be located insubterranean holes similar to the storage holes. The MHM will getan MCO from storage, insert it into an oven for treatment, andreturn it to storage after hot treatment is completed.

The key elements of a Hot Treatment Process station will be:

1. An oven will be located below the facility floor level in a hole. Theoven will hold an MCO. Hot air circulated between the oven vessel

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Vicuum Conditioning; Equipment Project Advanced Technolofly SectorContract*MW6-SWV-310416.Tuk*17 Project No. 30012318



wall and the MCO outer surface will heat the MCO to 300 °C. Thebottom of the oven will be approximately 16 ft below grade. The topof the MCO will be about 30" below grade. The hole will be coveredby a thick steel plate which will be selected to control radiationexposure rate above the oven.

2. A process skid containing the hot air source, the vacuum pump andmiscellaneous items will be located on the floor a few feet distantfrom the oven.

3. Hot air and process lines running between the furnace and theprocess equipment skid will be in a trench below floor level. Thetrench will be covered with steel to provide shielding fromradioactivity which may be caught in in-line traps and filters builtinto the MCO exhaust line. These devices will be located in thetrench. Their purpose is to prevent contamination of the processequipment.

4. The space above the oven within the hole will be ventilatedthrough the trench. Thus the covers for the hole and trench willform the secondary confinement barrier for the process.

5. A portable process enclosure will be provided. This enclosure willbe stationed over the oven after the MHM has departed in order toprepare for the Hot Treatment Process and will also be stationedover the oven to remove process connections after the process iscompleted. The process enclosure will also be used to change andpackage hot traps that are in the trench. The process enclosure willcontain tele-operated manipulators so that the operator usingCCTV guidance can reach down into the oven hole to placefixtures, make MCO valve connections, and place insulation coverpieces. The enclosure will contain the hoist required to lift theoven hole lid and place it out of the way. The enclosure will alsoinclude equipment such as a helium leak detector, a welder, drum-out port, etc. needed to complete the process. The thickness of thecell walls and the selection of window materials and thickness willbe determined by radiation exposure analysis. An importantfunction of the enclosure is to provide secondary confinement forthe process when the oven hole top is off. The air drawn throughthe trench will create a negative pressure and airflow in theenclosure when it is parked over the oven.

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WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHot Vacuum CoreStnnino Equipment Project AdvanoKl Tachnology SKtorContract#MW6-SWV-31O416,T«sk#17 Project No. 30012318



It is expected that six (6) of the HTP stations will be required to meet thethroughput requirements.

The overall sequence of operations is given in block flow diagram formon drawing SK-2-300411. A summary of the sequence is :

1. The MHM moves in, opens the hole, places the MCO into the oven,closes the hole, and leaves.

2. The process enclosure is moved in and parked over the hole.

3. The hole cover is pulled and the manipulator is used to install thetop of oven parts and the MCO process connections.

4. The hole cover is replaced and the process enclosure is movedaway.

5. The treatment process is run and controlled from the CSB controlroom via computer.

6. The process enclosure is returned after the process is complete.

7. The hole is opened, the process connections and oven parts areremoved, the cover is placed and welded, the traps are replaced ifnecessary and packaged for waste shipment, and the hole cover isreplaced.

8. The process enclosure is removed.

9. The MHM moves in, pulls the MCO, and places it in storage.

B. Hot Vacuum Drying Equipment Radiation Hazards

There are two important radiation sources associated with the hot vacuumdrying process. The principle source will be the MCO filled with spentnuclear fuel. The shielding integral to the MHM and oven will reduce thedose to relatively low levels in the area that the workers will occupy duringthe hot vacuum drying process. The second source will be the processequipment. Fission products from leaking fuel and activation products willaccumulate in the process equipment, creating a source. This isanticipated to be significantly below the radiation levels at the top of theMCO during the connect/disconnect operations.

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WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHot Vacuum Conditioning Equipment Project Advanced Technology SectorContract#MW6-SWV-310416,T»»k#17 Project No. 30012318


APPENDIX B • ALARA IMPLEMENTATION PLAN

4.0 RADIATION SAFETY DESIGN

DOE Order 5480.11 paragraph 9.j addresses Design and Control. The meansfor maintaining exposures ALARA are to be through physical controls -confinement, ventilation, remote handling and shielding. Administrative andprocedural controls provide supplemental means of controlling exposure andmaintaining exposures ALARA.

In the design phase, the following objectives shall be applied:

A. Optimization. Optimization principles, as discussed in ICRP Publication37, shall be utilized in developing and justifying design and physicalcontrols.

B. External Exposure should not exceed 2.5 mrem/hr on the average.

C. Internal Exposure should be limited to zero under normal operatingconditions.

D. Maintenance. Ease of maintenance, decontamination anddecommissioning shall be considered in the facility design and selectionof materials.

Radiation Exposure shall be monitored, recorded and controlled in accordancewith the Hanford Site Radiological Control Manual, HSRCM-1.

1. Normal Operations Design

Each process step will be analyzed as part of the analysis. Eachstep will be characterized by:

The position of the operator(s)The dose rate contribution from the MCOThe dose rate contribution from the process equipmentThe amount of operator time anticipatedThe total operator dose attributable to performing the stepA description of potential ingestion pathsA description of mitigating features incorporated in the designor recommended

The total dose for the process will be estimated by summing theexpected dose calculated for each step of the process.

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WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHoi Vacuum Conditioning Equipment Project Advanced Technology SectorContnct«MW6-SWV-310416.Teek#17 Project No. 30012318



The dose rates at various distances from the MCO as well as doserates for spots of lesser shielding (MCO nozzle locations) havebeen previously calculated. If the dose rate for any specificlocation has not been determined by the provided calculations,these will need to be calculated using a conservative model for thesource.

The dose to any given worker by the HCSE will be determined bythe staff size, the extent of cross training allowing for rotation oftasks, and the rotation among shifts. An operating staff plan will bedeveloped during detailed design. Radiation exposureconsiderations may be used in developing the plan in order todetermine how tasks will be grouped for training and assignment.Local and temporary shielding features will be planned andimplemented so that the staff is not increased (beyond the amountthat would be planned if there were no radiation exposurelimitation) for the purposes of spreading the dose.

Airborne release may occur when MCO connections are made orbroken. The process enclosure and ventilation design features willbe used to capture any releases that may occur.

2. Maintenance Design

The process flow diagrams and equipment design will be reviewedon a component by component basis during the definitive design toassess likely modes of failure and the implied maintenance/repairactivities. Routine maintenance activities will be addressed aswell. Each of the anticipated activities will be described, exposurerates will be estimated, and activity durations will be estimated.The combination of these estimates will yield a maintenanceexposure estimate for the most likely occurrences. Design featuressuch as temporary shielding, decontamination, or mechanicalassistance/ special tools incorporated in the design to reduce theactivity time will be described. Control of airborne and releasablecontamination will be planned for the maintenance activities. Localor temporary ventilation may be incorporated in the design.

3. Radiation Monitoring Instrumentation

Radiation monitoring and alarm instrumentation will be located atkey locations around the process. The design will include sourcespecific radiation detectors to monitor build-up of material in the

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Vacuum Conditioning Equipment Project Advanced Technology SectorContnKt*MW6-SvW-310416,Taak#17 Project NO. 30012318



system (such as on the filters). These will be used to determinewhen system cleaning or filter changes are required. The designwill include ionization detectors in the area where staff is workingto monitor the radiation field and to warn of unacceptable doserate. The design will include Continuous Air Monitors (CAMs)capable of detecting airborne particles that emit alpha or betaradiation. These will be located at strategic points near potentialrelease points.

5.0 LESSONS LEARNED PROGRAM

One of the greatest potentials for reducing dose is the application of lessonslearned from operational experience. The lessons learned from Duke PowerCompany's Oconee Nuclear Station during the process of loading and storingcasks of spent nuclear fuel into the Independent Spent Fuel Storage Installation(ISFSI) on-site at the station will be considered. Other commercial nuclearfacilities such as Arkansas Nuclear One, Palisades, and Surry that may havelessons learned will be investigated in the design phase of this project. Theexperience at these plants is likely to show system modification andoptimization actions that have reduced radiation exposure. The crewsperforming the operation for the first casks will be debriefed immediately afterthe operation to determine what may be done to improve the efficiency of theprocess. The ideas from these crews will provide the information necessary tomodify equipment and procedures to improve efficiency and thus reduce dose.A video tape of the process will be made. It will be reviewed for additionalimprovements by others not directly involved in the actual process. Video tapinglater cold vacuum drying processes after modifications have been implementedwill also aid in training additional workers.

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Syitom Equipmmt Advwotd Technology SoctorContnct«MW6-SWV-aiO416,TMk#17 Project No. 30CH2318


APPENDICES

APPENDIX C

SHIELDING AND RADIATION EXPOSURE ANALYSIS

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Sy««mEqu!pnMntPro|acl Adnncad Tacnnology SwtorContr«ct#MW6-SWV-310416.Twlc#17 Project No. 30012318


APPENDIX C - SHIELDING AND RADIATION EXPOSURE ANALYSIS

SHIELDING AND RADIATION EXPOSURE ANALYSISfor the



1.0 INTRODUCTION

The purpose of this analysis is to evaluate the radiation exposure received byworkers during each step of the hot vacuum drying process, and to determinethe total cumulative exposure (person-rem) for the process. The results of thisanalysis will be used during the detailed design phase of the Hot ConditioningSystem Equipment (HCSE) to reduce exposure where appropriate, in keepingwith the ALARA (As Low As Reasonably Achievable) principle.

The radiological design of the HCSE will incorporate the criteria specified in theapplicable orders, regulations, and publications listed in the PerformanceSpecification for the Spent Nuclear Fuel Hot Vacuum Conditioning Equipment,WHC-S-0460, Rev. A. Also, the facility will be designed in accordance with thefollowing documents. HSRCM-1, Hanford Site Radiological Control Manual;WHC-SC-GN30011, Radiological Design Guide; 10CFR835, OccupationalRadiation Protection; DOE Order 6430.1 A, General Design Criteria; and theALARA Implementation Plan for the K-Basin Spent Fuel Storage Project.

This analysis will be updated during the detailed design of the HCSE to ensurethat the radiological design criteria for the facility are met.

2.0 SUMMARY

The total exposure received from processing one MCO in the HCSE isapproximately 80 person-mrem (0.080 person-rem). This number is based onthe average shielding source term and assumes one inch of steel shieldingintegral to the hot cell enclosure.

3.0 DISCUSSION

3.1 Methodology

All activities to be performed are listed in Table 1. These activities arefrom the Hot Conditioning System Equipment Block Flow Diagram, SK-2-

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WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHot CoreiitioninsSyitom Equipment Project AdvwMd Technology SectorCoc*Kt#MW6-SWV-310416,TMlt#17 Project No. 30012318



300-411, Reference 1. Each activity was evaluated to determine if thelocation at which the activity is to be performed would result in anyradiation exposure to the personnel performing that specific activity. If itwas determined that there would be exposure from that activity, thelocation and dose rate associated with that location was listed in Table 1for that activity. The estimated dose rate for each location was calculatedfrom source term information from Reference 2. The workforce and timerequired to perform each exposure activity was estimated and thefrequency of each activity was determined from the Block Flow Diagram.These values are listed in Table 2. The exposure (person-mrem) for eachactivity was then calculated and those were summed to determine thetotal exposure from processing one cask.

3.2 Assumptions

It is conservatively assumed that 100% of the duration for each activity isspent in the radiation field.

One inch of steel shielding is assumed to be incorporated in the processenclosure design.

Tasks performed over the top of the Multi-Canister Overpack (MCO) areperformed with manipulators inside the process enclosure. This isrequired because the streaming dose rate directly over the annular spacebetween the cask and MCO is estimated to be on the order of 1500mrem/hr.

3.3 Results

The exposures for each process task are given in Tables 1 and 2.

The total exposure received from processing one MCO in the HCSE isapproximately 80 person-mrem (0.080 person-rem). This number is basedon the average shielding source term and assumes one inch of steelshielding integral to the hot cell enclosure.

The dose budget for the HCSE is 49.0 person-rem (Reference 3). Thetotal dose budget for welding in the K-Basins Spent Nuclear Fuel Projectis 30.0 person-rem (Reference 3). Assuming the welding budget can besplit between the Cold and Hot Conditioning Projects, the total availabledose budget for HCSE is 64.0 person-rem. Assuming a total of 400MCOs, the total exposure for HCSE is approximately 32.0 person-rem.While this is well within the dose budget, it does not include exposurefrom airborne activity in the CSB. This exposure issue must be evaluated

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WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHot CondHoningSytttm Equipment PraiKt Adwnod T«chnotooy S«ctorContraet#MW6-SWV-310416, T«tk#17 Project No. 30012318

WHC-SD-SNF-CDR-OO7, Revision 0


and included in the exposure analysis during the definitive design phaseof the HCSE.

While the calculated total exposure is within the dose budget, it is likelynow as low as reasonably achievable (ALARA) when considering that theoven shielding design is not optimized due to the unresolved interfacedetails with the MCO design. Also, the current analysis indicates that the0.25 mrem/hr general area dose rate criteria for the floor area is not met.Additional shielding will be incorporated into the oven design and theprocess enclosure design during the definitive design to ensure that doserate criteria are met and that exposures are ALARA.

4.0 REFERENCES

1) Drawing SK-2-300411.

2) 3/14/96 Memo from R.A. Schwarz to J.S. Lan regarding Neutron andPhoton Source for Safeguards.

3) 4/30/96 Memo from J.A. Swenson, Manager, Project Integration regardingIndividual Design Project Target Cumulative Dose Values for the SpentNuclear Fuel Project.

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WESTINGHOUSE HANFORD COMPANYHot Conditioning Syittm EqupmmtContract #MC6-SWV-31M16. T n k 17 WHC-SD-SNF-CDR-007, REV. 0

Table 1

Exposure Locations and Dose Rates

MERRICK COMPANYAdnncwl Twhnolody Sactor


Action

Select OvenMove in the MHMLower MCO into OvenRemove the MHMMove in Process EnclosureConnect Process EnclosureOpen Process PitPlace Annulus CoverAttach Annulus CoverRemove Port CoverInstall Vent CoverInstall ValvesOpen ValvesEvacuate MCOFill MCO with HeliumLeak Check PortsClose Bad ValveDisconnect ValveClean PortInstall Reserve ValveInstall Insulation CoverClose Process PitPerform Heat-up CycleSurvey Process EnclosureDisconnect Process EnclosureRemove Process Enclosure3urge/Vacuum CyclePerform Acceptance TestCool for PasivationEvacuate MCOFill with Passivation GasPassivation PeriodCool DownEvacuate MCOFill MCO with HeliumMove in Process EnclosureConnect Process EnclosureOpen Process PitRemove Insullation CoverClose ValvesDisconnect ValvesPlace Weld-on CoverInstall WelderWeld Root PassVisual InspectionClean Weld

ExposureActivity?

NoYesYesYesYesYesYesYesYesYesYesYesYesNoNoYesYesYesYesYesYesYesNoYesYesYesNoNoNoNoNoNoNoNoNoYesYesYesYesYesYesYesYesNoYesYes

ExposureLocation

N/AOven Deck AreaOven Deck AreaOven Deck AreaOven Deck AreaOven Deck AreaProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationOven Deck AreaOven Deck AreaN/AN/AN/AN/AN/AN/AN/AN/AN/AOven Deck AreaOven Deck AreaProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control Station

Dose Rate(mrem/hr)

N/A2.02.02.02.02.05.05.05.05.05.05.05.0N/AN/A5.05.05.05.05.05.05.0N/A5.02.02.0N/AN/AN/AN/AN/AN/AN/AN/AN/A2.02.05.05.05.05.05.05.0N/A5.05.0

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WESTINGHOUSE HANFORD COMPANY

WHC-SD-SNF-OMW.07, REV. o

Table 1


MERRICK COMPANYAdwncad Tachnolotfy Sactor

Prt#ct No. 30013218

Action

GrindRepair WeldApply DyeSoakRemove DyeApply DeveloperBleedInspectCleanGrindRepair WeldMake Cover Pass 1Visual InspectionGrindRepair WeldMake Cover Pass 2Visual InspectionGrindRepair WeldMake Cover Pass 3Visual InspectionGrindRepair WeldMake Cover Pass 4Visual InspectionGrindRepair WeldApply DyeSoakRemove DyeApply DeveloperBleedInspectCleanGrindRepair WeldRemove WelderRemove TrapInstall New TrapConnect Waste DrumRemove Top ShieldDispose Hot TrapInsert Top ShieldTie BagClose DrumUndo Annulus Cover

ExposureActivity?

YesYesYesNoYesYesNoYesYesYesYesNoYesYesYesNoYesYesYesNoYesYesYesNoYesYesYesYesNoYesYesNoYesYesYesYesYesYesYesYesYesYesYesYesYesYes

ExposureLocation

Process Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationN/AProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control Station

Dose Rate(mrem/hr)

5.05.05.0N/A5.05.0N/A5.05.05.05.0N/A5.05.05.0N/A5.05.05.0N/A5.05.05.0N/A5.05.05.05.0N/A5.05.0N/A5.05.05.05.05.05.05.05.05.05.05.05.05.05.0

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WESTINGHOUSE HANFORD COMPANYHoi Conditioning Syitern Equipment WHC-SD-SNF-CDR-007, REV. 0Contract #MC6-SWV-310416, TmK 17

Table 1


MERRICK COMPANYAdvanced Technokxly Sector


Action

Remove Annulus CoverClose Process PitSurvey Process EnclosureDisconnect Process EnclosureRemove Process Enclosureviove in the MHMPull the MCORemove the MHMPrepare for next MCO

ExposureActivity?

YesYesYesYesYesYesYesYesNo

ExposureLocation

Process Enclosure Control StationProcess Enclosure Control StationProcess Enclosure Control StationOven Deck AreaOven Deck AreaOven Deck AreaOven Deck AreaOven Deck AreaN/A

Dose Rate(mrem/hr)

5.05.05.02.02.02.02.02.0N/A

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WESTINGHOUSE HANFORD COMPANYHot CondWoninB Sytfun Equip™* Pn#cf WHC-SD-SNF-CDR-007, REV. 0Contract *MW6-SWV-310416. TMk 17

Table 2

Exposure per MCO

MERRICK COMPANYAoVmetd Technology S«ctor


Action

Select OvenMove in the MHMLower MCO into OvenRemove the MHMMove in Process EnclosureConnect Process EnclosureOpen Process PitPlace Annulus CoverAttach Annulus CoverRemove Port CoverInstall Vent CoverInstall ValvesOpen ValvesEvacuate MCOFill MCO with HeliumLeak Check PortsClose Bad ValveDisconnect ValveClean PortInstall Reserve Valvenstall Insulation CoverClose Process PitPerform Heat-up CycleSurvey Process EnclosureDisconnect Process EnclosureRemove Process EnclosurePurge/Vacuum CyclePerform Acceptance TestCool for PassivationEvacuate MCOFill with Passivation GasPassivation PeriodCool DownEvacuate MCOFill MCO with HeliumMove in Process EnclosureConnect Process EnclosureOpen Process PitRemove Insulation CoverClose ValvesDisconnect ValvesPlace Weld-on CoverInstall WelderWeld Root PassVisual InspectionClean Weld

ExposureActivity?

NoYesYesYesYesYesYesYesYesYesYesYesYesNoNoYesYesYesYesYesYesYesNoYesYesYesNoNoNoNoNoNoNoNoNoYesYesYesYesYesYesYesYesNoYesYes

Workforce

N/A222221111111

N/AN/A1111111

N/A222

N/AN/AN/AN/AN/AN/AN/AN/AN/A22111111

N/A11

Duration(min.)N/A1010101551010101551015N/AN/A15555555

N/A30515

N/AN/AN/AN/AN/AN/AN/AN/AN/A15510515101020N/A1010

Frequency(per Cask)

N/A.0.0

1.01.0.0.0

t.01.01.0.0

1.01.0N/AN/A1.10.10.10.10.11.01.0N/A1.01.01.0N/AN/AN/AN/AN/AN/AN/AN/AN/A1.01.01.01.01.01.01.01.0N/A1.11.1

Dose Rate(mrem/hr)

N/A2.02.02.02.02.05.05.05.05.05.05.05.0N/AN/A5.05.05.05.05.05.05.0N/A5.02.02.0N/AN/AN/AN/AN/AN/AN/AN/AN/A2.02.05.05.05.05.05.05.0N/A5.05.0

Exposure(person mrem

—0.70.70.71.00.30.80.80.81.30.40.81.3——1.40.00.00.00.00.40.4—

5.00.31.0

————————1.00.30.80.41.30.80.81.7

0.90.9

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WESTINGHOUSE HANFORD COMPANYHot Conditioning S y U m Equipment PrajKtContract WUNV6-SVW-310416, Title 17 WHC-SD-SNF-CDR-007, REV. 0

Table 2

MERRICK COMPANYAdvancad Technology SKtor


Exposure per MCO

Action

GrindRepair WeldApply DyeSoakRemove DveApply DeveloperBleedInspectCleanGrindRepair WeldMake Cover Pass 1Visual InspectionGrindRepair WeldMake Cover Pass 2Visual InspectionGrindRepair WeldMake Cover Pass 3Visual InspectionGrindRepair WeldMake Cover Pass 4Visual InspectionGrindRepair WeldApply DyeSoakRemove DyeApply DeveloperBleedInspectCleanGrindRepair WeldRemove WelderRemove TrapInstall New TrapConnect Waste DrumRemove Top ShieldDispose Hot TrapInsert Top ShieldTie BagClose Drum

ExposureActivity?^

YesYesYesNoYesYesNoYesYesYesYesNoYesYesYesNoYesYesYesNoYesYesYesNoYesYesYesYesNoYesYesNoYesYesYesYesYesYesYesYesYesYesYesYesYes

Undo Annulus Cover Yes

Workforce

111

N/A11

N/A1111

N/A111

N/A111

N/A111

N/A1111

N/A11

N/A11111111111111

Duration(min.)

151510N/A1510

N/A5101515

N/A101515

N/A101515

N/A101515N/A10151510

N/A1510

N/A510151515606030101010151010

Frequency(per Cask)


Dose Rate(mrem/hr)


Exposure(person mrem

0.10.10.9—1.40.9—

0.50.90.10.1—0.91.41.4—0.91.41.4—0.91.41.4—0.91.41.40.9—1.40.9—0.50.90.10.11.35.05.02.50.80.80.81.30.80.8

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, REV. 0



Table 2

Exposure per MCO

Action

Remove Annulus CoverClose Process PitSurvey Process EnclosureDisconnect Process EnclosureRemove Process EnclosureMove in the MHMPull the MCORemove the MHMPrepare for next MCO

ExposureActivity?

YesYesYesYesYesYesYesYesNo

Workforce

11222222

N/A

Duration(min.)

5530515101010

N/A

Frequency(per Cask)

1.01.01.01.01.01.01.01.0N/A

Dose Rate(mrem/hr)

5.05.05.02.02.02.02.02.0N/A

Exposure(person mrem)

0.40.45.00.31.00.70.70.7—

Total Exposure per MCO 80.2

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APPENDICES

APPENDIX D

OPERATIONS AND MAINTENANCE PHILOSOPHY

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APPENDIX D - OPERATIONS AND MAINTENANCE PHILOSOPHY

OPERATIONS AND MAINTENANCE PHILOSOPHYfor the



1.0 INTRODUCTION

The purpose of this document is to set forth operating and maintenancephilosophies to guide the Hot Conditioning System Equipment (HCSE) designand operations planning process. In the modern DOE nuclear facility projectenvironment, the transition from the engineering/construction phase of theproject to operations is critical to project success. It is essential that thistransition be planned, that safety documentation including a SAR and TSRs arecomplete when needed, that operations testing procedures be written, that staffis hired and trained before while construction is ongoing so that they are readyto take the reigns when the facility is ready, and that an appropriate OperationsReadiness verification process as required by DOE 5480.31 and guided by DOESTD-3011 is completed smoothly. This philosophy document is a first step inthe process of planning for operations.

The operations and maintenance philosophy for the HCSE should reflect thefollowing facts about the facility:

A. The HCSE is located in the Canister Storage Building (CSB). The facilityis a nuclear facility. It must be operated with the rigor and controlsnormally associated with a nuclear facility. Only qualified, trainedradiation workers shall be allowed into the facility. Workers will wearprotective clothing when required (routine operational activities will notrequire protective clothing). There will be personnel radiation monitoringprograms. Areas of potential contamination or radiation fields will bespecially controlled, etc.

B. The radiation dose of a given worker will be administratively controlledperHSRCM-1.

C. The active processing life of the equipment is scheduled to be 2 yearswith a 10 year design life for the equipment and a 75 year design life forthe HCSE annex to the CSB.

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The project is schedule driven. Payment is determined by meeting work-off milestones. Lost time for responding to abnormal drying conditions orresults, and for repairing essential components must be minimized. Thedesign team needs to attempt to plan for the most likely upsets andincorporate "work arounds* into the design process.

2.0 INDEPENDENCE OF OPERATIONS IN THE HCSE

The HCSE will be designed to have independent process ovens that will allowfor the drying of more than one MCO simultaneously. Each oven will have itsown ventilation system, its own drying system, and its own control station in theCSB control room. Redundancy of key components should be a design strategywhere a central service feeds all ovens (chilled water for example) so that itsfailure could potentially take the entire facility out of service for a durationgreater than a single shift. The decision driver during design of the facilityregarding provision of redundant components should be consideration of lostprocess time.

3.0 EQUIPMENT SELECTION AND DEVELOPMENT

The drying process equipment will be a collection of common commercialcomponents arranged on a skid, connected by pipes and conduits. Theequipment should be selected for operations in a radiation field and acontaminated environment. Typical features of equipment suitable for this type ofservice are:

A. Minimize the use of rubbers, plastics, and polymers that degrade as aresult of radiation damage.

B. Sealed equipment, with secondary seals, where contaminated leakagemay occur.

C. Avoid equipment that requires oil changes or greasing.

D. Smooth, impervious surfaces that allow for decontamination.

E. Easy replacement ( as opposed to repair in place) - flange or unionconnections, clamp hold-downs, electrical and signal cable plugs, etc.

F. Sealed bagging schemes should be utilized where regular change-outswill be required - MCO connectors, filters.

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G. A high degree of reliability should be required. Mean time between failuredata should be requested from potential component vendors. The goalwill be to assure that all components have at least a 90% likelihood ofoperating for the design life without a failure.

H. Components potentially requiring maintenance or replacement in the ovenshould be designed for remote manipulator replacement, if possible.Contact maintenance of this equipment would only be possible afterremoval of the MCO and shielding or removal of accumulated dosecontributors such as contaminated process lines, cold traps, and filters.

The equipment arrangement on the skids should allow for easy accesses tocomponents. Clearances should be checked during the detail design to assurethat reasonable paths for component access and removal exist, that allowancehas been made for bags and tents that may be used to limit the spread ofcontamination when a component is being used, and that lifting aids can accessthe maintenance activity when a component may be too heavy to be liftedmanually. Items requiring frequent access, such as filters should be locatedconveniently near an outer edge of the skid. Shielding that may surround somecomponents (filters for example) should be modular and should be easily movedor swung out of the way (hinged).

Equipment should be selected to minimize manual operation or verification. Aprimary design goal is to minimize the presence of staff in the processing areawhere they may be exposed to radiation. The operation and status monitoring ofthe drying system and components should be accomplished from a remotecontrol room. Sensor failure and repair is a potential negative impact that mustbe considered as the design is developed.

The process equipment system should contain radiation monitors for points inthe system where radioactive material may accumulate, such as filters. Thesemonitors should be used to determine when filters are to be changed.

An important goal is to limit the spread of radioactive contamination to themaximum extent possible. Ideally all contamination would be trapped in the MCOor within the first few feet of process line immediately above the MCO. Filters areto be installed to accomplish this goal. Contamination may be released andspread when MCO connections are made and broken. A connection design thatincorporates an operations within a bag technique are to be implemented tocontain potential releases. The process enclosure will contain any contaminatedair that may be present in the area.

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Ventilation system HEPA filters that may become contaminated shall include abag-in/bag-out filter changing system that will allow filter changes withoutrelease of contamination and without shutting down the ventilation system.HEPA filters will be equipped with DOP test capability so that their efficiency canbe certified while in operation.

4.0 RADIATION SAFETY AND EXPOSURE CONTROL

The administrative radiation exposure limitation for the HCSE will be perHSRCM-1. Preliminary exposure estimates suggest that this can be achievedthrough a combination of shielding near the MCO integral to the oven assembly,and shielding provided by the process pit covers and the process enclosure.Detailed operations recipes need to be written for each activity to assesswhether it is reasonable to reduce exposure estimates. The operations staffmust be thoroughly cross trained so that they can be rotated among all the jobsin the facility. Also, the operations scheduling must distribute the steps wheredoses are received among all shifts and days uniformly (in other words an MCOreceived on Friday evening may be held until Saturday afternoon so that thedose loading of all staff is uniform).

In order to promote cross training of staff so that they can perform severalfunctions, the design should attempt to minimize actions requiring decisions oractions by the staff. The use of Process Logic Controller software andsimplified user friendly control screens are techniques to be used to reducedependence on specialized training. The implementation of a human factorsengineering program in the detailed design (as required by DOE 6430.1A) canalso contribute to increasing operator flexibility.

The following radiation safety features will be provided in the HCSE to aid inoperating the facility:

4.1 Emergency Respiratory Protection

The facility shall be capable of providing as emergency devices onlyrespiratory protection equipment that has been specifically certified orhad certification extended for emergency use by NIOSH/MSHA10 CFR 20.1703©

4.2 Radiological Alarm System

Radiological alarm systems shall be provided in accessible work areas asappropriate to warn operating personnel of radiation and airborneradioactive material concentrations above a given set point and of

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concentrations of radioactive material in effluent above control limits.10CFR72.126(b)

Radiation alarm systems shall be designed with provisions for calibrationand testing their operability.10CFR72.126(a), (b)

Set points shall be established to ensure that exposures are kept belowthe allowable limits.10CFR72.126(a), (b)

4.3 Direct Radiation Monitoring

Areas containing radioactive materials shall be provided with systems formeasuring the direct radiation levels in and around these areas.1OCFR72.126(C)(2)

The facility shall provide capability to monitor the external surfaces of apackage known to contain radioactive material for radioactivecontamination and radiation levels if the package is labeled as containingradioactive material; or has evidence of potential contamination, such aspackages that are crushed, wet, or damaged.10CFR20.1906(b)

4.4 Effluent Monitoring

The facility shall monitor the amount of radionuclides in effluents duringnormal and off-normal conditions.10CFR72.126(c)(1)

Systems designed to monitor the release of radioactive materials shallhave means to calibrate and test their operability.10CFR72.126(d)

4.5 Airborne Radioactive Material Control

The design of the facility shall use, to the extent practicable, process orother engineering controls (e.g., containment or ventilation) to control theconcentrations of radioactive material in air.10 CFR 20.1701

When it is not practical to apply process or other engineering controls tocontrol the concentrations of radioactive material in the air to values

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WHC-SD-SNF-CDR-007, REV.-O


below those that define an airborne radioactivity area, the design of thefacility shall, consistent with maintaining the total effective doseequivalent ALARA, have the capability to increase monitoring and limitintakes by: control of access, limitation of exposure times, use ofrespiratory protection equipment, or other controls.10 CFR 20.1702

4.6 Personnel Dosimeters

The facility shall provide capability for processing and evaluating allpersonnel dosimeters that require processing to determine the radiationdose, and that are used by the facility to comply with 10 CFR 20.1201 orwith conditions specified in the facility license, this capability does notapply to direct and indirect reading pocket ionization chambers and thosedosimeters used to measure the dose to the extremities.10 CFR 20.1501 (c)(1), (2)

4.7 Shielding and Protective Clothing

Normally Occupied Areas. The shielding design basis shall limit themaximum exposure to an individual worker to one-fifth of the annualoccupational external exposure limits. Within this design basis, personnelexposures must be maintained ALARA. Specifically, the shielding mustbe designed with the objective of limiting the total EDE (Effective DoseEquivalent) to less than one rem per year to workers, based on theirpredicted exposure time in the normally occupied area. The EDE is thesum of all contributing external penetrating radiation (gamma andneutron). In addition, appropriate shielding must be installed, ifnecessary, to minimize non penetrating external radiation exposures tothe skin and lens of the eye of the worker. In most cases, theconfinement barrier or process equipment provides this shielding.DOE Order 6430.1 1300-6.2

Intermittently Occupied Areas. Shielding and other radiation protectionmeasures shall be provided for areas requiring intermittent access, suchas for preventive maintenance, component changes, adjustment ofsystems and equipment, and so forth, so that the projected dose ratesbased on occupancy, time, and frequency of exposure do not exceed onerem per year.DOE Order 6430.1 1300-6.2

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Concrete radiation shielding design shall comply with ANS 6.4 and ACI349 where it provides a critical confinement or structural function.ANSI/ANS 6.4 Sec. 1ACI 349 Pt. 1 Sec. 1.1DOE Order 6430.1 1300-6.2

Concrete radiation shielding design shall consider the materialspecifications of ANS 6.4.2 where it provides a critical confinement orstructural function.ANSI/ANS-6.4.2 Sec. 1DOE Order 6430.1 1300-6.2

ACI 318 shall be considered for radiation shields, used for other thancritical confinement or structural function, since ACI 318 is appropriateand provides adequate strength for design earthquake (DE) loads.ANSI/ACI-318 Pt. 1 Sec. 1.1.1DOE Order 6430.1 1300-6.2

Penetrations. Straight line penetration of shield walls shall be avoided toprevent radiation streaming.DOE Order 6430.1 1300-6.2

4.8 Remote Shield Operation

Remote shielded operation (i.e., with remote handling equipment such asremote manipulators) shall be considered where it is anticipated thatexposures to hands and forearms would otherwise approach the doseguidance in Section 3.2.2 or where contaminated puncture wounds couldoccur.DOE Order 6430.1 1300-6.3

4.9 Posting

The facility shall be posted with radiation area, contamination area, andairborne contamination area signs in accordance with federal law.10 CFR 20.1902(a), (b), (c), (d)

5.0 MAINTENANCE PHILOSOPHY

Generally, and to the maximum extent possible, equipment should be selectedthat will not require routine maintenance during the processing lifetime of theHCSE. Equipment with a high degree of reliability should be chosen to reducethe likelihood of breakage. Policy such as requesting warranties and reviewing

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failure data should be instituted when selecting equipment in order to improvereliability. When repair is needed it should be accomplished by replacement ofdefective components (ie, pump) instead of repair in place procedures (ie. Pumpbearing rebuild). Equipment system designers should recommend a sparecomponents list to be kept on site and should attempt to select components thatcan be obtained from manufacturers in 24 hours should an emergency arise.

Maintenance or repair of contaminated items is a particularly hazardous activitybecause it is not a routine operation that can be included in the training programand because it involves opening a path between the contaminated equipmentinterior cavity and inhabited space. Provision must be made in the designanticipating the use of bags and tents for contamination control. Provisionshould also be made for temporary shielding and for lifting assistance.

6.0 OPERATIONS READINESS VERIFICATION

DOE 5480.31 requires that a new nuclear facility undergo an OperationsReadiness verification process (either an ORR or ORA depending on the natureof the facility and its associated hazards). The extent of the verification processis to be determined by the nuclear safety issues associated with the facility. Thefacility will be considered an HC-2 facility with low potential for severe accidents.There are three operations program activities that must be accomplished prior toinitiating the verification process. First, an Operations Readiness plan must bewritten and approved by whatever review agency (DOE - HQ, DOE - RL, WHC)is required to certify readiness. Second, test procedures must be prepared sothat the verification can be conducted. Third, staff must be trained so that theycan demonstrate readiness.

The engineering team should support this process as follows:

A. Write System Design Descriptions (SDDs) with thorough operatingrecipes included.

B. Write the Operations Readiness Plan draft.

C. Write the test procedures.

Writing these documents in conjunction with the design development/constructionwill help to assure that the design has the appropriate features to support thefacility operations.

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7.0 OPERATIONS SUPPORT

The HCSE will share operations support functions with the CSB.

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APPENDICES

APPENDIX E

PERFORMANCE SPECIFICATIONS REPORT

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APPENDIX E - PERFORMANCE SPECIFICATIONS REPORT

UNDERSTANDING OF K-BASIN SPENT NUCLEAR FUELHOT VACUUM CONDITIONING EQUIPMENTPERFORMANCE SPECIFICATIONS REPORT

1.0 INTRODUCTION

The objectives of the Department of Energy (DOE) at Hanford include cleanup ofthe site, protecting the health and safety of workers and the public, and protectingthe environment. The cleanup will be accomplished in accordance with the HanfordFederal Facility Agreement and Consent Order (the Tri Party Agreement), and incompliance with applicable Federal, State, local laws, and American Indian TreatyRights. The Hanford cleanup must also comply with DOE policies and directives.

The Hot Vacuum Conditioning Equipment (HVCE) Subproject is an important stepin the cleanup of Spent Nuclear Fuel (SNF). In order for the HVCE to safely andefficiently accomplish its functions, the equipment designer must have a completeunderstanding of the functions and performance requirements of the equipment.The Performance Specification for the Spent Nuclear Fuel Hot VacuumConditioning Equipment. WHC-S-0460 Rev. A, March 11,1996, states the intendedfunctional design and performance specifications for the HVCE. Thesespecifications provide the basis for the design, operation, and monitoring of theprocess and equipment. The Performance Specification also identifies federal,state, and local regulations that may be applicable to the design basis for theHVCE.

The scope of this evaluation is to: (a) demonstrate Merrick's understanding of theperformance specifications for the HVCE that must be reflected in the equipmentdesign and (b) demonstrate Merrick's understanding of regulations that impactdesign of the HVCE.

2.0 IDENTIFICATION OF FUNCTIONS AND PERFORMANCE SPECIFICATIONS

Hot vacuum conditioning of SNF is the last of several processes to be performedto package the spent fuel for transportation, interim dry storage, and eventual finaldisposition. The HVCE provides the system to remove chemically bound water (byheat and vacuum) from SNF, to condition the fuel (decompose uranium hydrides),and to passivate metal fuel (oxidize exposed uranium metal surfaces). The HVCE,as conceived, is multiple modular structures located in the Canister StorageBuilding. The HVCE consists of a Process Station (heating coils, shielding thermal

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insulation), a cooling system, measurement and control instrumentation, a ProcessModule (vacuum pumps, HEPAs, fans, instrumentation), a Combined VentilationSystem for process off-gas management, and a Solid Waste Handling System. Inthe following paragraphs, each conceptual operating phase is described, on thebases of phase duration, process steps, required subsystems, functions of eachsubsystem, and design points to be controlled.

Receipt. The first operating phase consists of receiving Multi-Canister Overpacks(MCO) from the staging area and placing an MCO into a Process Station (PS). Theduration of the receipt operating phase is 8 hours. The system componentsinvolved in this operating phase are: a) the multi-canister overpack, which providesprimary containment of radionuclides. Allowable external contamination levels forthe MCO are not defined in the Performance Specifications: b) The MCO HandlingMachine (MHM), which provides secondary containment of radionuclides andshielding of direct radiation. Allowable external contamination levels for the MHMare not defined in the Performance Specifications: shielding performance mustresult in general room (Vy doses < 0.5 mrem/hr and contact B/y doses <10 mrem/hr.The MHM also provides the capability to move and manipulate the MCO; however,this capability is not within the scope of this task; c) The MHM Process Station (PS)holds the MCO during processing and provides the support structure for the heatingcoils and thermal insulation, discussed in the Heatup operating phase; and d) TheProcess Control System (PCS), which has four design points for the operatingphase - MCO temperature <140°C as staged or <75°C at receipt, initial H2

concentration <100 volume %, initial O2 concentration < 5 volume %, MCO internalpressure approximately 14.7 psia (vented) or <150 psia (as received).

Cool Down for Connection. The second operating phase consists of cooling eachreceived MCO sufficiently to permit initial connection of process piping to the MCO.The duration of this operating phase is 8 hours. The system components involvedin this operating phase are: a) The MCO Cooling System (MCS), which drawsambient HEPA-filtered air from the CSB across the outside of the MCO. The initialMCO temperature is s140°C and the design point for the final MCO temperatureis 40°C (measured at the MCO head, which is the point of greatest thermal mass).The MCS nominal design cooling rate is approximately 10°C/hour, with a maximumcooling rate of <50°C/hour, and a maximum temperature difference between theMCO head and sidewall of 100°C; b) The Combined Ventilation System (CVS),which receives, filters (redundant HEPAs) and discharges the MCS air flows.

Hookup and Purge. This operating phase consists of connecting the inert andoxidizing gas supplies, connecting the conditioning off gas lines, connecting thevacuum lines, and preparing the Process Heating System. The total phase duration

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is 8 hours. The system components involved in this phase are: a)Process GasSystem, supplying inert and oxygen gases; and b) The Vacuum Pumping System.

Heat Up. The next operating phase is heat up of the SNF in an MCO. The durationof this operating phase is 12 hours. The system components involved in this phaseare: a) The Process Heating System (PHS), which heats, controls and maintains thetemperature of the MCO. The final fuel temperature is 300°C within a range of+50°C, -0°C. The fuel heating rate is 20° C/hour (nominal), 50°C/hour (maximum).The maximum temperature difference between separate points on the MCO is100°C; b) The Process Gas System (PGS), supplying an inert gas purge at up to10 SCFM, maintaining a maximum hydrogen concentration of 2 volume %, anominal oxygen concentration of zero, and a maximum oxygen concentration of 5volume %; and c) the Vacuum Pumping System (VPS), which maintains an MCOinternal pressure of approximately 13 PSIA during this phase.

Drying and L/H, Decomposition. This operating phase holds the fuel at a hightemperature and low pressure for an extended time, thus removing water,decomposing uranium hydrides, and removing the resultant hydrogen. Theduration of this phase is 48 hours. The system components involved in this phaseare: a) The PHS, which maintains an MCO set point of 350°C, an MCO maximumof 375°C, and a fuel temperature of 300+50,-0°C; b) The PGS, which maintains apurge gas flow rate of up to 10 ACFM, a maximum hydrogen concentration of 2volume %, a nominal oxygen concentration of zero, and a maximum oxygenconcentration of 5 volume %; and c) The VPS, which maintains a final pressure of0.1 PSIA and a final hydrogen partial pressure of 0.05 PSI.

Cool Down Prior to Partial Oxidation. This operating phase accomplishes a partialcooldown and partial repressurization of the MCO, to prepare for the next operatingphase of Partial Oxidation. The duration of this phase is 12 hours. The systemcomponents necessary for this phase are: a) The MCS, which cools the MCO from300°C to 150°C at a maximum cooling rate of 50°C/hour. The maximumtemperature difference allowable between any two points on the MCO is 100°C;b) The PGS, with a purge rate of up to 10 ACFM, to maintain a maximum hydrogenconcentration of 2 volume % (nominal zero) and a maximum oxygen concentrationof 5 volume % (nominal zero); and c) The VPS, which achieves and maintains afinal MCO internal pressure of approximately 13 PSIA (the rate of pressure changefrom 0.1 to 13 PSIA is not specified).

Partial Oxidation. This operating phase passivates exposed surfaces of uraniummetal by formation of oxides. The duration of this phase is 12 hours. The systemcomponents involved are: a) The MCS, only if required to prevent the final fueltemperature from exceeding 250°C, as the oxidation reaction heats the fuel; b) The

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PGS, with a gas flow rate of u to 10 SCFM, to maintain a maximum hydrogenconcentration of 2 volume % and to achieve a final oxygen concentration of up toapproximately 20 volume %; and c) The VPS, to maintain an MCO internal pressureof approximately 13 PSIA.

Final Cool Down. This operating phase cools the MCO containing conditioned andpassivated SNF to near ambient temperatures, which allow the final processingphase, Backfill, Disconnect, Seal, to be safely accomplished. The duration of thisphase is 10 hours. The involved system components are: a)The MCS, which coolsthe MCO from s250°C to 40°C, at a cooling rate of 10°C/hour nominal (50°C/hourmaximum, with a maximum MCO temperature delta of 100°C; and b) the PGS,which provides purge gas to achieve final oxygen concentration < 5 volume % andfinal hydrogen concentration of <2 volume %.

Backfill. Disconnect. Seal. This is the last operating phase of the SNF Hot VacuumConditioning and Passivation process. The functions of this step are to backfill theMCO void volume with an inert gas (helium at 99.995 volume % purity) , todisconnect the MCO from process connections, and to weld all MCO openingsclosed. The estimated duration of this phase is 24 hours. The system componentinvolved in this phase is the PGS, which supplies the backfill helium.

3.0 IDENTIFICATION OF REGULATORY REQUIREMENTS

The Performance Specification outlines the HVCE functions and traces therelationship to the Spent Nuclear Fuel Project (SNFP) through the Work BreakdownStructure (WBS) and organizational block diagrams. The technical requirementsand descriptions are organized by WBS number and the associated requirementreferences are listed.

The requirements listed include Federal, State, and local laws and regulations aswell as Westinghouse Hanford Company (WHC) rules and regulations. Thefunctions and requirements in the Performance Specification report implement therequirements set forth in the Spent Nuclear Fuel Program Project ManagementPlan, which requires management, development, and maintenance of baselinedocumentation.

The requirements listed in the Performance Specification report mainly consist ofthe Code of Federal Regulations (CFRs), DOE Orders, Washington StateAdministrative Codes (WACs) including Revised Codes of Washington (RCW),WHC control manuals (WHC-CM), and other miscellaneous documents.

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The Code of Federal Regulations is a codification of applicable regulationspromulgated by an issuing Federal Agency and published in the Federal Register.The Code is divided into 50 titles which represent broad areas subject to FederalRegulations. Each title is divided into chapters which usually bear the name of theissuing agency. Each chapter is further subdivided into several parts to addressspecific regulations. Historically, CFRs have applied to commercial nuclear reactorfacilities but not to Government Owned Contractor Operated (GOCO) sites such asHartford. The Federal Government desires to provide adequate protection of thepublic from radioactive material releases associated with normal operations andaccident/natural phenomena. To this end, the Congress has legislated that this isgenerally the responsibility of the DOE where DOE facilities are involved andgenerally the responsibility of the NRC where commercial facilities are involved.The Congress has further established the DNFSB as the watch dog over the DOE.10 CFR 30.12 indicates that prime contractors of the DOE are exempt from theregulations to the extent that the contractor working under his prime contractmanufactures, produces, transfers, receives, acquires, owns, possesses, or usesbyproduct material for the performance of work for the DOE at a GOCO site. Thewording very specifically says prime contractors because such contractors operateDOE owned facilities on the DOE's behalf. This exemption applies to the HVCE.The DOE established in the K-Basin Spent Nuclear Fuel Project - RegulatoryPolicy, dated August 4, 1995, the requirement for the SNFP facilities to achieve"nuclear safety equivalency" comparable to NRC licensed facilities. An evaluationwas performed to identify any additional requirements that were needed tosupplement the existing and applicable DOE requirements to establish nuclearsafety equivalency with the NRC licensed facilities. The additional requirementswere consolidated into 29 items. All items are to be implemented per the NRCregulations with the exception of the design earthquake which will be implementedin a manner that established equivalence in safety, as opposed to directequivalence to the regulation.

The DOE Orders establish policies, guidelines, and requirements for the safeoperation and maintenance of DOE owned facilities. Historically, these orders havebeen considered to be the governing regulations, and not the CFRs, for the DOEGOCO sites. In addition to DOE orders, several supplemental guidancedocuments, which are specific to Hanford, are also listed in the PerformanceSpecification report.

The Washington Administrative Codes (WACs) and Revised Codes of Washington(RCWs) are compiled by the various agencies of the State of Washington. WACsand RCWs are normally considered to be additional requirements to Federalguidelines rather than as replacements. However, WACs promulgate similar

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requirements as CFRs for many instances. Hence, compliance with either Federalor State regulations is normally considered adequate. Since 10 CFR 30.12exempts the HVCE from the CFRs, in this case it is the State regulations that apply.

The goals of WHC are to make the Hanford site a model for environmentalmanagement, demonstrate and apply advanced and innovative technologies forcleanup, and restore the land for productive use. To accomplish these goals, WHChas created several control manuals (CMs). The purpose of these control manualsis to establish various compliance requirements and guidelines in conjunction withapplicable DOE Orders, and Federal, State, and local laws and regulations.

4.0 CLASSIFICATION OF REQUIREMENTS

DOE Order 6430.1A (General Design Criteria) gives the main requirements neededfor the design. The quality assurance requirements are given in 10 CFR Part830.120. These and other applicable requirements are listed in Appendices A andB. Requirements that do not have any significant direct impact, but may affect thedesign process, are listed in Appendix C. These requirements are maintained forreference. Although these requirements may not have direct influence on the actualdesign of the Hot Vacuum Conditioning Equipment, each requirement may impactthe design process. The extent of impact will be determined later.

5.0 DESCRIPTION OF APPLICABLE REQUIREMENTS

Five requirements listed in Appendix A are judged to be applicable for the HotVacuum Conditioning Equipment design. Of these five, DOE 6430.1 A and 10 CFRPart 830.120 are the two significant documents. Detailed descriptions of each ofthe five requirements are given below.

A. 10 CFR Part 830.120, Quality Assurance

The ten criteria of 10 CFR Part 830.120 prescribe a comprehensivemanagement system for DOE work. The quality management programdescribed in 10 CFR Part 830.120 provides a results-oriented managementsystem that focuses on the customer while providing a method for theorganization to become more efficient through constant processimprovement. The ten criteria are as follows:

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1. Program: The contractor shall develop and maintain a written QualityAssurance Plan (QAP). The QAP shall describe the organizationalstructure, functional responsibilities, levels of authority, and interfacesfor those managing, performing, and assessing adequacy of work.The QAP shall describe the contractors management system,including planning, scheduling, and cost control considerations.

2. Personnel Training and Qualifications: Personnel shall be trainedand qualified to ensure that they are capable of performing theirassigned work. Personnel shall be provided continuing training toensure that job proficiency is maintained.

3. Quality Improvement: The contractor shall establish and implementprocesses to detect and prevent quality problems and to ensurequality improvement. Items and processes that do not meetestablished requirements shall be identified, controlled, andcorrected. Correction shall include identifying the causes of problemsand preventing recurrence. Item reliability, process implementation,and other quality-related information shall be reviewed and the dataanalyzed to identify items and processes needing improvement.

4. Documents and Records: Documents shall be prepared, reviewed,approved, issued, used, and revised to prescribe processes, specifyrequirements, or establish design. Records shall be specified,prepared, reviewed, approved, and maintained.

5. Work Processes: Work shall be performed to establish technicalstandards and administrative controls. Work shall be performedunder controlled conditions using approved instructions, procedures,or other appropriate means. Items shall be identified and controlledto ensure their proper use. Items shall be maintained to prevent theirdamage, loss, or deterioration. Equipment used for processmonitoring or data collection shall be calibrated and maintained.

6. Design: Items and processes shall be designed using soundengineering/scientific principles and appropriate standards. Designwork, including changes, shall incorporate applicable requirementsand design bases. Design interfaces shall be identified andcontrolled. The adequacy of design products shall be verified orvalidated by individuals or groups other than those who performed thework. Verification and validation work shall be completed beforeapproval and implementation of the change.

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7. Procurement: Procured items and services shall meet establishedrequirements and perform as specified. Prospective suppliers shallbe evaluated and selected on the basis of specified criteria. Thecontractor shall ensure that approved suppliers can continue toprovide acceptable items and services.

8. Inspection and Acceptance Testing: Inspection and acceptancetesting of specified items and processes shall be conducted usingestablished acceptance and performance criteria. Equipment usedfor inspections and tests shall be calibrated and maintained.

9. Management Assessment: Management at all levels shallperiodically assess the integrated quality assurance program and itsperformance. Problems that hinder the organization from achievingits objectives shall be identified and corrected.

10. Independent Assessment: Planned and periodic independentassessments shall be conducted to measure items' quality andprocess effectiveness and to promote improvement. The organizationperforming independent assessments shall have sufficient authorityand freedom from the line organization to carry out its responsibilities.Persons conducting independent assessments shall be technicallyqualified and knowledgeable in the areas assessed.

Merrick will develop a QAP that is in accordance with these criteria and thatshows how the criteria will be satisfied. A QA matrix will also be developedto provide a cross walk between the criteria and the Merrick qualityassurance, administrative, and design procedures.

B. DOE 6430.1A General Design Criteria

This DOE Order provides General Design Criteria (GDC) for variousengineering disciplines. This GDC is mandatory for all DOE related workand provides minimal acceptable design requirements for DOE Facilities.Although DOE facilities are not mandated to follow state, county, and otherrequirements, it is recommended to interface with the non-DOE authoritiesto accommodate their intent as much as possible. The GDC contains 16numerical divisions devoted to major building systems or design specialities.According to DOE instructions, GDC must be used in the planning, design,and development of specifications for facilities, including the developmentof site and equipment-specific designs. Provided the GDC is not adequate,

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supplemental standards may be used. The ASME B31.3 Chemical Plant andPetroleum Refinery Piping standard and the Industrial Vacuum Practices areconsidered to be supplemental standards that will be used for the HVCEdesign.

The following sections of the GDC are considered applicable for the HotVacuum Conditioning Equipment Design. The criteria evaluation documentdeveloped for the Hot Vacuum Conditioning Equipment goes into theapplicability of the GDC in more extensive detail.

Division 1. General Requirements

Section 0111-99.0.1, Non-Reactor Nuclear FacilitiesParagraphs 1,4, 5, and 6 on Page 1-97,Paragraphs 2 and 3 on Page 1-98.

Section 0111-99.0.2, Tornado of Extreme WindPortions of this section are applicable.

Section 0111-99.0.4, EarthquakesThe entire section is applicable.

Section 0111-99.0.7, Explosion, Internal Pressurization, Criticality, andOther DBA Causes.

Section 0140 on Quality Assurance.

Division 13. Special Facilities

Section 1300-1, Coverage and ObjectivesMany sub-sections are applicable.

Section 1300-2, Safety AnalysisSection 1300-3.2, Safety Class Items

Most of this section's contents are applicable. This section alsoproposes the use of ASME Boiler and Pressure Vessel Codeswherever they are applicable.

Section 1300-3.3, Single Failure Criterion and RedundancySection 1300-3.4, Equipment Environment Considerations

Most of the requirements specified in the three subsections areapplicable.

Section 1300-3.5, MaintenanceSecond paragraph of this section is especially applicable.

Section 1300-3.6, TestingPortions of first and second paragraphs are applicable.

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Section 1300-4, Nuclear Criticality SafetyThis section describes the procedures to assess as early as possibleif the potential for nuclear criticality exists. Several portions of thissection may be applicable.

Section 1320 Irradiated Fissile Material Storage FacilitiesThis section describes irradiated fissile material storage facilities(ISMSF). Portion of subsections 1320-1, -2, and -3 are applicable.

C. WHC-CM-4-2 Quality Assurance Manual

This manual describes the requirements that apply to WHC Divisions andDepartments which prescribe, perform, or verify activities affecting qualityincluding operations, decommissioning and decontamination, andenvironmental activities. This manual emphasizes that quality assurancecontrols must be applied to any items and activities performed under WHCManagement. The manual consists of 19 sections with each sectiondedicated to a certain aspect of quality control.

This is a compulsory requirement for each operation involved in the SNFtransfer from K-Basins. Requirements of this manual in conjunction with 10CFR Part 830.120 should provide more than adequate quality control.

D. WHC-CM-6-1 Standard Engineering Practices

This manual establishes the engineering practices which ensure that uniformmethods are in place for performing all tasks under WHC Control. Theseprocedures provide methodologies for tasks such as design review,configuration management, change control, specification preparation, andreview and approval requirements. The use of this document is stronglyrecommended on all engineering, development, and project tasks whichculminate in a document design and/or deliverable hardware end items.

Of several sections in this manual, Section 4 on Design VerificationRequirements is the most applicable for Hot Vacuum ConditioningEquipment Design. This section provides methods and proceduresgoverning design verification measures to verify the design adequacy. Thisrequirement and DOE Order 6430.1 A provide comprehensive guidelines forthe design task.

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APPENDIX E • PERFORMANCE SPECIFICATIONS REPORT

E. NRC Regulations

The DOE established in the K-Basin Spent Nuclear Fuel Project - RegulatoryPolicy, dated August 4, 1995, the requirement for the SNFP facilities toachieve "nuclear safety equivalency* comparable to NRC licensed facilities.An evaluation was performed to identify any additional requirements thatwere needed to supplement the existing and applicable DOE requirementsto establish nuclear safety equivalency with the NRC licensed facilities. Theadditional requirements were consolidated into 29 items. All items are to beimplemented per the NRC regulations with the exception of the designearthquake which will be implemented in a manner that establishedequivalence in safety, as opposed to direct equivalence to the regulation.

6.0 DESCRIPTION OF REFERENCE REQUIREMENTS

The requirements listed in Appendix C will be used as reference documents. Theserequirements have no direct impact on the design, but may affect the designmethodologies.

10 CFR 20 and 10 CFR 71 are promulgated by the Nuclear Regulatory Commission(NRC). It should be noted that DOE nuclear facilities are not required to complywith NRC regulations. DOE, however, use the NRC requirements as a source ofguidance and good practice for the SNF transfer program.

10 CFR 20, Standards for Protection Against Radiation, establishes standards forindividual protection from ionizing radiation resulting from activities conductedunder licenses issued by NRC. These regulations quantify the permissibleradiation doses to various body parts of an individual. The prescribed dose limitsdo not apply to doses due to background radiation and radiation received as partof a medical therapy or due to voluntary participation in medical research programs.

This regulation does not have direct impact on the Hot Vacuum ConditioningEquipment Design. However, this regulation will be maintained for reference asdose rates may have to be considered in the design process.

10 CFR 71, Packaging and Transportation of Radioactive Material, is also an NRCRegulation which establishes requirements for packaging, preparation for shipment,and transportation of licensed material. This regulation also describes proceduresand standards for NRC approval of packaging and shipping procedures for fissilematerial. The packaging and shipping aspects are also subject to other NRC

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regulations and requirements of other agencies, such as the Department ofTransportation.

This regulation does not have direct bearing on the Hot Vacuum ConditioningEquipment Design. However, these regulations may have to be consulted to verifythat the Hot Vacuum Conditioning Equipment Design poses no problems forpackaging and transportation.

A. DOE Regulations

10 CFR 835, Occupational Radiation Protection, is a DOE Regulation whichis very similar to 10 CFR 20. 10 CFR 835 promulgates radiation protectionstandards, limits, and program requirements for protecting individuals fromionizing radiation resulting from the conduct of DOE activities. Activitiesconducted under NRC license are not covered by this regulation. Like 10CFR 20, this requirement is also considered as a reference requirement.

B. OSHA Requirements

29 CFR 1910, Occupational Safety and Health Standard, is promulgated bythe Occupational Safety and Health Administration of the Department ofLabor. The intent of this directive is to carry out OSHA requirements whichhave been found to be National Consensus Standards or EstablishedStandards. All routine industrial operations are covered under thisrequirement. From a simple administrative function such as maintainingworker's exposure and medical surveillance records to complex operationssuch as handling hazardous materials are covered by 29 CFR 1910.Minimum environmental controls required for a work area, provisions ofproper personal protective equipment, fire protection requirements, noisecontrol, and providing medical and first aid during emergencies are alsocovered under this requirement. These regulations may be exempt if it isdetermined that these standards do not improve health and safety forspecially designated employees.

These is no direct impact of these regulations on the Hot VacuumConditioning Equipment Design, but the design may have to beaccomplished such that the Hot Vacuum Conditioning Equipment usageadheres to 29 CFR 1910. Hence, this regulation is maintained for reference.

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C. DOE 1300.2A Department of Energy Technical Standards Programs

This DOE Order sets forth policies and responsibilities for development andapplication of technical standards under DOE controlled programs. Thisorder stipulates that any applicable Non-Government Standards (NGSs)must be used and the usage must be properly documented. This Order alsostates that all DOE facilities, programs, and projects will use NGSs in theirdesign, construction, testing, modification, operation, decommissioning,decontamination, and remediation when such standards are adequate. If theexisting Federal Standards is more conservative than NGSs, DOErequirements will be used. Uses of all standards in the design have to beproperly documented.

This DOE Order is a general guideline for using the Technical Standards.This document is kept on the reference list.

D. DOE 1540.2 Hazardous Material Packaging for Transport -Administrative Procedures

This Order establishes administrative procedures for the certification anduse of packaging methods for radioactive and hazardous materials. Theadministrative procedures also summarize the actions associated with thereview and approval of packaging for the transportation of radioactive andhazardous materials. This Order details the review and approval procedurethat provides a basis for DOE to assure DOT, NRC, and other agencies thatregulations are compiled with and the entire process is relevant to that ofNRC.

This DOE Order has no direct impact on the Hot Vacuum ConditioningEquipment Design. As the packaging process has very little effect on theHot Vacuum Conditioning Equipment Design, it is unlikely that this Order willbe used during the design process. However, DOE 1540-2 is retained forreference.

E. DOE 1540.3A Base Technology for Radioactive Material TransportationPackaging Systems

DOE 154OA is a culmination of DOE Orders 1330.1 D, 1540.1 A, 15402, and5480.3; 10 CFR 71 and 49 CFR 171 through 179; Atomic Energy Act; andthe Department of Energy Organization Act of 1977. This Order establishesDOE policies and responsibilities for coordinating and planning base

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technology for radioactive material, transportation packaging systems.Radioactive material is defined as any material having a specific activitygreater than 0.002 microcuries per gram.

This DOE Order is more of an administrative document than a designdocument. Consequently, this Order will have very little impact on either theHot Vacuum Conditioning Equipment Design or the design process.However, this document is maintained for reference purposes.

F. DOE 5480.4 Environmental Protection, Safety, and Health

This DOE Order provides listing of requirements for the application of themandatory Environmental Protection, Safety, and Health (ES&H) Standardsapplicable to all DOE Operations. This Order must be followed duringdesign, construction, modification, and decommissioning. All permanent andtemporary facilities must comply with this Order. The requirements listed inthis DOE Order are divided into the following three categories:

1. Mandatory ES&H Standards (Statutory Requirements): Thosestandards that are mandatory as a result of Non-DOE Federal orState Statutes are addressed in this category. None of thesestandards are applicable to Hot Vacuum Conditioning EquipmentDesign.

2. Mandatory ES&H Standards (Policy Requirements): Standards thatare mandatory because of DOE Policies are listed under thiscategory. Subsection F which addresses Nuclear Safety may beused for guidance for Hot Vacuum Conditioning Equipment Design.However, these standards are mainly oriented for nuclear reactors.

3. Reference ES&H Standards: Those standards that are notmandatory but are useful to refer to as good practice and for generalES&H purposes. None are directly applicable for Hot VacuumConditioning Equipment Design.

This DOE Order does not appear to have any direct impact on the HotVacuum Conditioning Equipment Design. However, this document will beretained as reference.

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G. Fiscal Year 1995, Hanford Mission Plan, Volume 1, Site Guidance,September 1994

The Hanford Mission is to cleanup the site, develop new technologies, andto help the economic diversification of the region. The transfer of K-Basinfuel is a part of the cleanup mission. This document has no impact on eitherHVCE design or the design process. However, this document is the basicreport in which all Hanford cleanup programs are described. This documentis maintained on the reference list.

H. WHC-CM-2-14 Hazardous Material Packaging and Shipping

This WHC Manual describes requirements and procedures for packagingand shipping hazardous wastes both on-site and off-site of Hanford. Thismanual has been prepared by WHC based on several CFRs, DOE Orders,WACs, and other pertinent documents including WHC-CMs. In addition toother requirements, instructions of this requirement have to be followed onlywhen the SNF is categorized as hazardous material.

This requirement has no direct impact on the Hot Vacuum ConditioningEquipment Design. This document is maintained for reference.

I. WHC-CM-3-5 Document Control and Records Management Manual

This manual was developed to provide requirements and procedures formaintaining the information that is produced for any project. The informationcould be as paper, punched cards, magnetic tapes, computer disks, etc.The main objective of this program is to preserve records that may be usefuland of future value in a proper manner.

There is no impact of this requirement on the Hot Vacuum ConditioningEquipment Design. However, all the paper work and computer formatteddata will be transferred to WHC for up keeping the records. This manual isretained for reference purposes only.

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ADDENDUM 1

APPLICABLE REQUIREMENTS FOR THE VACUUM DRYING MODULESUBPROJECT DESIGN

1. 10 CFR Part 830.120, Quality Assurance

2. DOE 6430.1 A, General Design Criteria

3. WHC-CM-4-2, Quality Assurance Manual

4. WHC-CM-6-1, Standard Engineering Practices

5. WHC-SD-SNF-DB-003, Rev 1, Additional NRC Requirements

Addendum 1 to Appendix EE l - 1

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ADDENDUM 2

MISCELLANEOUS APPLICABLE DOCUMENTS

1. DNFSB letter of May 26, 1994, to Secretary O'Leary recommending expeditingthe SNF removal from K-Basins to an interim storage until an option is chosenfor ultimate disposal.

2. J. E. Lytle letter to T. P. Grumbly, Approval of Path Forward for N-Reactor SpentFuel Interim Storage, DOE EM-36, 9 November 1994, regarding the expeditioustransfer of N-Reactor SNF to interim storage, but still within the applicableregulatory requirements.

3. SNF Project K-Basins Path Forward Acquisition Strategy (WHC-SP-1144,December 1994 draft) which describes the following four key interconnectingsubsystems:

Staging and Storage Facility (SSF)Multi-canister Over packs (MCO)Transportation SystemFuel Stabilization Facility (FSF)

4. U.S. Department of Energy (DOE) October 1994, Spent Nuclear Fuel ProgramRequirements Document (SNF-RD-PM-001), Revision 1, describing themanagement approach to integrate, coordinate, and optimize activitiesnecessary for conditioning, handling, and transporting SNF to interim storageand preparing SNF for final disposal.

5. WHC-EP-009, WHC Reference Guide Acronyms and Abbreviations, Vol. 1, part

1.

6. WHC-IP-0117, Procedure Development Specification Manual.

7. WHC-SP-0708, Westinghouse Hanford Company Conduct of Operation.

Addendum 2 to Appendix E l 2

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ADDENDUM 3

REQUIREMENTS FOR REFERENCE

1. 10 CFR 20, Standards for Protection Against Radiation

2. 10 CFR 71, Packaging and Transportation of Radioactive Material

3. 10 CFR 835, Occupational Radiation Protection Standards

4. 20 CFR 1910, Occupational Safety and Health Act of 1976

5. DOE 1300.2A, Department of Energy Technical Standards Program

6. DOE 1540.2, Hazardous Material Packaging for Transportation

7. DOE 1540.3A, Base Technology for Radioactive Material TransportationPackaging Systems

8. DOE 5480.4, Environmental Protection, Safety, and Health Protection

9. Fiscal Year 1995 Hanford Mission Plan, Volume 1, Site Guidance, September1994

10. MRP 5.20, Packaging and Transportation of Hazardous Material

11. DOE 5480.28, Natural Phenomena Hazards Mitigation

12. Spent Nuclear Fuel Project, K-Basins Path Forward Acquisition Strategy,WHC-SP-1144, December 1994 (Draft)

13. WHC-CM-2-14, Hazardous Material Packaging and Shipping

14. WHC-CM-3-5, Document Control and Records Management Manual

Addendum 3 to Appendix E El-3

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APPENDICES

APPENDIX F

COST ESTIMATE BACKUP

F-i

HOTCu ^rtONING SYSTEM EQUIPMENT

CONSTRUCTION SUMMARY

Merrick Engineers and ArchitectsConstruction Cost Estimate


7(25/96Prepared By: C.Ggstafson

DESCRIPTION

CONSTRUCTIONPROCESS MODULEPROCESS PIT COMPONENTSSERVICE MODULEAUXILIARY FACILITIESPROCESS ENCLOSURE

QTY UNIT

55

55

5

EQUIPMENTUNIT TOTAL

$ 97,603$1,260,000$ 69.950$ 59.601$ 490,000

S 585,618$1,260,000$ 69.950$ 59.601$ 490,000

DUCTING/PIPINGUNIT TOTAL

$ 52,890$ 180.000$ 61,650$ 50,593$

$ 317,342$ 180,000$ 61,650$ 50,593$

INSULATIONUNIT TOTAL

$ 14,271$ 12,000$ 5,750$ 9.409$

$ 85,626$ 12,000$ 5,750$ 9.409$

ELECTRICALUNIT TOTAL

$ 10,577$$ 18.120$ 40.799$ 2.500

$ 63.461$$ 16.120$ 40,799$ 2,500

INSTRUMENTUNIT TOTAL

$ 117.883$$ 73,635$ 157.727$ 10,000

$ 707,299$$ 73,635$ 157,727$ 10,000

ASSEMBLYUNIT TOTAL

$ 6,500

$20,000$20,000$50,000

$ 39,000$$ 20.000$ 20,000$ 50.000

INSTALLATIONUNIT TOTAL

$ 12.850

$ 14.110$150,000

$ 77,100$$ 14.110$150,000$

SUB-TOTAL $2,465,169 $ 609.585 $112,785 $124,880 $ 948,660 $129,000 $241,210

CONSTRUCTION SUMMARY SUB-TOTAL

EQUIPMENT SUB-TOTALDUCTING/PIPING SUB-TOTALINSULATION SUB-TOTALELECTRICAL SUB-TOTALINSTRUMENT SUB-TOTALASSEMBLY SUB-TOTALINSTALLATION SUB-TOTAL

$2,465,169$ 609,585$ 112,785$ 124,880$ 948.660$ 129,000S 241.210

CONSTRUCTION SUB-TOTAL

OVERHEAD LESS EQUIPMENTPROFIT (SUB-TOTAL 8. OVERHEAD)

18%10%

$ 389,901$ 502,119

CONSTRUCTION TOTAL $5.523,309

HOT CO .^TONING SYSTEM EQUIPMENT

PROCESS MODULE

Merrick Engineer* and ArchitectsConstruction Cost Estimate


7/28/96Prepared By: C.Gustafaon

DESCRIPTION

PROCESS MODULEBLOWER - SINGLE STAGEBLOWER • SINGLE STAGEHEAT EXCHANGER - PLATEHEAT EXCHANGER - PLATEHEAT EXCHANGER - TRAPTANK - EXPANSIONPUMP - SCROLL VACUUMHEATER - ELECTRICALHEATER-ELECTRICALFILTER - HEPAFILTER • HEPAFILTER - HEPASPECIALTY INSTRUMENTS

PROCESS MODULE SUB-TOTAL

PHS-BLO-1X51VPS-BLO-1X06MCS-CLR-1XS3VPS-CLR-1X03VPS-PFR-1X01PG-ACC-1X31VPS-VAC-1X04PHS-HCL-1X52VPS-HCL-1X05PV-F-1X71VPS-F-1X02VPS-F-1X0T

QTV UNIT

EAEAEAEAEAEAEAEAEAEAEAEA

EQUIPMENTUNIT TOTAL

511,000S 24,068

5,0731.500

10,0001.0008,0008,8002.0001.000

$ 12.581512,581

11.00024,068

5.0731,500

10.0001,0008,0008,8002,0001,000

12,58112,581

$ 97.603

DUCTING/PIPINGFACTOR TOTAL

0700.701.001.000.801200.700.500.500 060.060.06

7,70016,8485,0731,5008,0001.2005,6004.4001,000

60755

S 755

$ 52,890

INSULATIONFACTOR TOTAL

0.150.150.200.200.20

0.250.100.100.100.100.10

1,6503,6101,015

3002,000

2.000880200100

1,2561.258

$ 14.271

ELECTRICALFACTOR TOTAL

0.100.10

0.100.150.15

0 06

1.1002,407

BOO1,320

300

4.650

$ 10.577

INSTRUMENTFACTOR TOTAL

0.130.130250.250 25

0.301501.500.500.500.50

1,4303.129

t 1,2681 3751 2,500

2,400t 13.2001 3.000( 5001 6.291( 6.2911 77,500

$ 117,663

PROCESS MODULE SUB-TOTAL SUMMARY

EQUIPMENT SUB-TOTALDUCTING/PIPING SUB-TOTALINSULATION SUB-TOTALELECTRICAL SUB-TOTALINSTRUMENT SUB-TOTAL

SKID ASSEMBLY COSTSKID INSTALLATION COST

97.60352.89014,27110,577

117,883

6,50012,850

SUB-TOTAL PER PROCESS MODULE $ 312.574MULTIPLIED BY 6 BAYS 6

PROCESS MODULE SUB-TOTAL

OVERHEAD LESS EQUIPMENTPROFIT (SUB-TOTAL 8. OVERHEAD)

PROCESS MODULE TOTAL

18%10%

$ 232,169$ 210,761

HOT CONDITIONING SYSTEM EQUIPMENT

PROCESS PIT COMPONENTS

MerricK Engineers and ArchitectsConstruction Cost Estimate

7/28/96Prepared By: C.Gustafson

DESCRIPTION

PROCESS PIT COMPONENTSOVENPROCESS PIT COVERTRENCH COVER

QTY UNIT

6 EA7 EA7 EA

PROCESS PIT COMPONENTS SUB-TOTAL

WHC-SD-SNF-CDR-007, REV.

EQUIPMENTUNIT TOTAL

$140,000$ 35,000$ 25,000

$ 840,000$ 245,000$ 175,000

$1,260,000

0

DUCTING/PIPINGUNIT TOTAL

$30,000 $180,000

$180,000

INSULATIONUNIT TOTAL

$2,000 $12,000

$ 12,000

ELECTRICALUNIT TOTAL

$

INSTRUMENTUNIT TOTAL

$

PROCESS PIT COMPONENTS SUB-TOTAL SUMMARY


$1,260,000$ 180,000$ 12,000$$

PROCESS PIT COMPONENTS SUB-TOTAL

OVERHEAD LESS EQUIPMENTPROFIT (SUB-TOTAL & OVERHEAD)

PROCESS PIT COMPONENTS TOTAL

18%10%

$1,452,000

$ 34,560$ 148,656

$1,635,216

F-3

HOT CX..JITIONING SYSTEM EQUIPMENT

SERVICE MODULE



7/28/96Prepared By: C.Gustafson

DESCRIPTION

SERVICE MODULEPUMP - TURBO VACUUMPUMP - SCROLL ROUGHERFILTER-HEPA TRAINBLOWER - SINGLE STAGESPECIAL INSTRUMENTS

SERVICE MODULE SUB-TOTAL

VAC-VAC-3041VAC-VAC-3042PV-F-2041,2,4,5PV-BLO-2043,6

QTY UNIT

1 EA1 EA4EA2 EA

EQUIPMENTUNIT TOTAL

$14,350$ 8,100$ 6,875$10,000

$ 14,350$ 8,100$ 27,500$ 20,000

$ 69,950


2.002.000.100.70

$28,700$16,200$ 2,750$14,000

$61,650


0.100.15

$$$ 2,750$3,000

$ 5,750


0.100.100.050.100.25

$ 1,435$ 810$ 1,375$ 2,000$12,500

$18,120


0.300.300.520.13

$ 4,305$ 2,430$14,300$ 2,600$50,000

$73,635

SERVICE MODULE SUB-TOTAL SUMMARY



$ 69,950$ 61,650$ 5,750$ 18,120$ 73,635

$ 20,000$ 14,110

SERVICE MODULE SUB-TOTAL $263,215


18%10%

$ 34,788$ 29,800

SERVICE MODULE TOTAL $327,803

F-4

HOTCi. .HONING SYSTEM EQUIPMENT

AUXILIARY FACILITIES

Merrick Engtn t - . j and ArchitectsConstruction Cost Estimate


Prepared By:7/28/96

C.Gustafson

DESCRIPTION

AUXILIARY FACILITIESCHILLER - SPLIT SYSTEMTANK-EXPANSIONPUMP - CHILLED WATERPUMP - CHILLED WATERTANK - EXPANSIONHEAT EXCHANGER - GLYCOLPUMP - COOLING WATERPUMP - COOLING WATERPROCESS STACKSTACK MONITORING

AUXILIARY FACILITIES SUB-TO

CHW-CH-2026CHW-ACC-2021CHW-P-2022CHW-P-2023CW-ACC-2011CW-HX-2014CW-P-2012CW-P-2013

TAL

QTY UNIT

1 EA1 EA1 EA1 EA1 EA1 EA1 EA1 EA1 EA

EQUIPMENTUNIT TOTAL

$38,5401,629

t 2.0002,000

t 1,6293,103

» 1,6001,6007,500

$ 38,540I 1,623f 2,000

2,0001,6293,103

t 1,6001,600

! 7,500

$ 59,601


1.001200700.701.201.000.700.70

$38,540( 1,955I 1,400f 1,400f 1,9551 3,103( 1,120t 1,120t

$50,593


0.20

0.150.15

0.200.150.15

$ 7,708$

$ 300$ 300$$ 621$ 240$ 240$

$ 9,409


0.10

0.10010

0.100.10

0.25

[ 3,854

i 200! 200g

t 160t 160

$36,225

$40,799


025

050050

0.250.130.13

$ 9,635

$ 1,000$ 1,000$$ 776$ 208$ 208$$144,900

$157,727

AUXILIARY FACILITIES SUB-TOTAL SUMMARY



$ 59,601$ 50,593$ 9,409$ 40,799$ 157,727

$ 20,000$ 150,000

AUXILIARY FACILITIES SUB-TOTAL


AUXILIARY FACILITIES TOTAL

18%10%

$ 77,135$ 56,526

$ 621,789

HOT CONDITIONING SYSTEM EQUIPMENT

PROCESS ENCLOSURE



7/28/96Prepared By: C Gustafson

DESCRIPTION

PROCESS ENCLOSURETITAN VII MANIPULATORHELIUM LEAK DETECTORWELDER WITH SUPPLYDRUM BAG STATIONTOW MOTORENCLOSURECONTROLS

PROCESS ENCLOSURE SUB-TOTAL

EQUIPMENTUNIT

$ 250,000$ 20,000$ 15,000$ 45,000$ 10,000$ 150,000

DUCTING/PIPINGTOTAL

$ 490,000 $

INSULATIONTOTAL

ELECTRICALTOTAL

$ 2,500

$ - $ 2,500

INSTRUMENTTOTAL

$ 10,000

J 10,000

PROCESS ENCLOSURE SUB-TOTAL


ASSEMBLY COST

$ 490,000$$$ 2,500$ 10,000

$ 50,000

PROCESS ENCLOSURE SUB-TOTAL 552,500

OVERHEAD LESS EQUIPMENTPROFIT (SUB-TOTAL S OVERHEAD)

18%10%

$ 11,250$ 56,375

PROCESS ENCLOSURE TOTAL 620,125

F-6

Hot Conditioning System Equipment Merrick Engineers and AichitectsEquipment List WHC-SD-SNF-CDR-007, REV. 0 Prepared by.

AAAAAAAA

CHWCHWCHWCHWCWCWCWCW

MCSMCSMCSMCSMCSMCSPGPGPGPGPGPG

PHSPHSPHSPHSPHSPHSPHSPHSPHSPHSPHSPHSPHS

TAG#

10002000300030004000400150006000ACCCHPP

ACCHXPP

CLRCLRCLRCLRCLRCLRACCACCACCACCACCACCBLOBLOBLOBLOBLOBLO

OVENOVENOVENOVENOVENOVENHCL

202120262022202320112014201220131153125313531453155316531131123113311431153116311151125113511451155116511154125413541454155416541152

ITEM

Beta/Gamma Participate MonitorBeat/Gamma Participate MonitorAlpha/Beta Participate MonitorTritium MonitorAlpha/Beta Participate MonitorTritium, MonitorRecord Air SamplerRecord Air SamplerExpansion TankChillerChilled Water Circ.PumpChilled Water Circ.PumpExpansion TankGlycol/CW ExchrCW PumpCW PumpMCO Chiller ExchangerMCO Chiller ExchangerMCO Chiller ExchangerMCO Chiller ExchangerMCO Chiller ExchangerMCO Chiller ExchangerFitter Blowback ReservoirFilter Blowback ReservoirFilter Blowback ReservoirFilter Blowback ReservoirFilter Blowback ReservoirFilter Blowback ReservoirHeat/Cool BlowerHeat/Cool BlowerHeat/Cool BlowerHeat/Cool BlowerHeat/Cool BlowerHeat/Cool BlowerMCO OvenMCO OvenMCO OvenMCO OvenMCO OvenMCO OvenMCO Heating Element

EQUIPMENT SPECIFICATIONS

72 liter capacity25 ton15gpm@40ftTDH15gpm@40ftTDH72 liter capacity240,000 BTU/hr50gpm@115ftTDH50gpm@ 115ft TDH94,000 BTU/hr94,000 BTU/hr94,000 BTU/hr94,000 BTU/hr94,000 BTU/hr94,000 BTU/hr10 liters10 liters10 liters10 liters10 liters10 liters750 ACFM© 6 in sp - 375 deg. C750 ACFWI® 8 in sp - 375 deg. C750 ACFM@ 8 in sp - 375 deg. C750 ACFM@ 8 in sp - 375 deg. C750 ACFM@ 8 in sp - 375 deg. C750 ACFM@ 8 in sp - 375 deg. C

60 W/inA2

ELECTRICAL LOAD/SERVICE

115 VAC/60 Hz/15 A115 VAC/60 Hz/15 A120/240 VAC/50/60 Hz150/230 VAC/50/60 Hz120/240 VAC/50/60 Hz150/230 VAC/50/60 Hz1/4hp/115V/60Hz/5A1/4hp/115V/60Hz/5ANone30 KW/440V/3 phase1/2hp/20V/1 phase1/2 hp/20 V/1 phaseNoneNone3 hp/230 V/1 phase3 hp/230 V/1 phaseNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNone5 HP/240 V/1 phase5 HP/240 V/1 phase5 HP/240 V/1 phase5 HP/240 V/1 phase5 HP/240 V/1 phase5 HP/240 V/1 phaseNoneNoneNoneNoneNone^one

25 KW/240 V/1 phase

EQUIPMENT COST

$54,700$54,700

$5,000$6,000$5,000$6,000$1,250

. $1,250$1,629

$38,450$2,000$2,000$1,629$3,103$1,562$1,582$5,073$5,073$5,073$5,073$5,073$5,073$1,000$1,000$1,000$1,000$1,000$1,000

$11,000$11,000$11,000$11,000$11,000$11,000

$140,000$140,000$140,000$140,000$140,000$140,000

$8,800

Hot Conuitioning System Equipment Merrick Engineers and ArchitectsEquipment List WHC-SD-SNF-CDR-007, R E V . 0

7/29/96Prepared by: C. Gustafson

PHSPHSPHSPHSPHSPVPVPVPVPVPVPVPVPVPVPVPV

VACVACVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPS

T A B *

HCLHCLHCLHCLHCL

FFfFFF

BLOBLO

FFFF

VACVACBLOBLOBLOBLOBLOBLOCLRCLRCLRCLRCLRCLR

FFFFFFFFFF

12521352145215521652117112711371147115711671204320462041204220442045304130421106120613061406150616061103120313031403150316031102120213021402150216021107120713071407

ITEM

MCO Heating ElementMCO Heating ElementMCO Heating ElementMCO Heating ElementMCO Heating ElementMCO Vault FinerMCO Vault FilterMCO Vault FilterMCO Vault FilterMCO Vault FilterMCO Vault FilterVent BlowerVent BlowerMain Vent HEPAMain Vent HEPAMain Vent HEPAMain Vent HEPAMain Dewar Vac PumpMain Dewar Boost PumpHe Redrculation BlowerHe Redrculation BlowerHe Recirculation BlowerHe Recirculation BlowerHe Recirculation BlowerHe Redrculation BlowerMCO Vent CoolerMCO Vent CoolerMCO Vent CoolerMCO Vent CoolerMCO Vent CoolerMCO Vent CoolerMCO Vent HEPAMCO Vent HEPAMCO Vent HEPAMCO Vent H6PAMCO Vent HEPAMCO Vent HEPAMCO Vent HEPAMCO Vent HEPAMCO Vent HEPAMCO Vent HEPA


60W/in»260W/inA260W/in"260W/inA260VWinA2150ACFM150ACFM150ACFM150ACFM150ACFM150ACFM1000 CFM @ 9 In sp1000 CFM @ 9 in sp1000 CFM1000CFM1000 CFM1O00CFMBase pressure < 1x10* -10 ton-Ultimate total pressure <: 10" -2 torr20ACFM20ACFM20ACFM20ACFM20ACFM20AOFM560 BTU/hr560 BTU/hr560 BTU/hr560 BTU/hr560 BTU(hr560 BTU/hr20ACFM20ACFM20ACFM20ACFM20ACFM20ACFM20ACFM20ACFM20ACFM20ACFM


25 KW/240 V/1 phase25 KW/240 V/1 phase25 KW/240 V/1 phase25 KW/240 V/1 phase25 KW/240 V/1 phaseNoneNoneNoneNoneNoneNone3 HP/440W3 phase3 HP/440v/3 phaseNoneNoneNoneNone600W/240V/1 phase1 HP/230 V/1 phase1/4 hp/115 V/1 phase1/4 hp/115 V/1 phase1/4 hp/115 V/1 phase1/4 hp/115 V/1 phase1/4 hp/115 V/1 phase1/4 hpM 15 V/1 phaseNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNoneNone

EQUIPMENT COST

$8,800$8,800$8,600$8,800$8,800$1,000$1,000$1,000$1,000$1,000$1,000

$10,000$10,000

$6,875$6,875$6,875$6,875

$14,350$8,100

$24,000$24,000$24,000$24,000$24,000$24,000

$1,500$1,500$1,500$1,500$1,500$1,500

$12,581$12,581$12,581$12,581$12,581$12,581$12,581$12,581$12,581$12,581

F-8

Hot Conu.uoning System Equipment Menick Enginetis and ArchitectsEquipment List


7/29/96Prepared by: C. Gustafson

VPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPSVPS

TAG*

FF

HCLHCLHCLHCLHCLHCLPFRPFRPFRPFRPFRPFRVACVACVACVACVACVAC

15071607110512051305140515051605110112011301140115011601110412041304140415041604

ITEM

MCO Vent HEPAMCO Vent HEPAMCO Vent HeaterMCO Vent HeaterMCO Vent HeaterMCO Vent HeaterMCO Vent HeaterMCO Vent HeaterMCO Vent PurifierMCO Vent PurifierMCO Vent PurifierMCO Vent PurifierMCO Vent PurifierMCO Vent PurifierMCO Vent Vac/Circ PumpMCO Vent Vac/Circ PumpMCO Vent Vac/Circ PumpMCO Vent Vac/Circ PumpMCO Vent Vac/Circ PumpMCO Vent Vac/Circ PumpSkid I/O InterfaceSkid I/O InterfaceSkid I/O InterfaceSkid I/O InterfaceSkid I/O InterfaceSkid I/O InterfaceMisc Instrument & Control Central System


20ACFM20ACFM50W/ln"25OW/ln*250W/inA250W/in»250W/ln"250W/inA21500 BTU/hr/copper gauze/active C1500 BTU/hr/copper gauze/active C1500 BTU/hr/copper gauze/active C1500 BTU/hr/copper gauze/active C1500 BTU/hr/copper gauze/active C1500 BTU/hr/copper gauze/active CUltimate total pressure < 10* -2 torrUltimate total pressure < 10" -2 torrUltimate total pressure < 10" -2 ton-Ultimate total pressure < 10* -2 ton*Ultimate total pressure < 10* -2 torrUltimate total pressure < 10* -2 torr

PLC; Operator Console, Panel


NoneNone1 KW/120 V/1 phase1 KW/120 V/1 phase1 KW/120 V/1 phase1 KW/120 V/1 phase1 KW/120V/1 phase1 KW/120 V/1 phaseNoneNoneNoneNoneNoneNone1 HP/230 V/1 phase1 HP/230 V/1 phase1 HP/230 V/1 phase1 HP/230 V/1 phase1 HP/230 V/1 phase1 HP/230 V/1 phase

15 KVA to 1 phase lighting pane

EQUIPMENT COST

$12,581$12,581

$2,000$2,000$2,000$2,000$2,000$2,000

$10,000$10,000$10,000$10,000$10,000$10,000

$8,000$8,000$8,000$8,000$8,000$8,000

$10,000$10,000$10,000$10,000$10,000$10,000$50,000

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Systxn Equipment Advancad Tachnology SactorContract #MW6-SWV-31CM16, Talk *17 Project No 30012318


APPENDICES

APPENDIX G

CALCULATIONS

G-i


Appendix GCALCULATIONS

CALCULATION LOG

CalcNo.

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

Rev.No.

InitialInitialInitialInitialInitialInitialInitialInitial

Description

General CommentsMCO Heat Transfer CoefficientsMCO Heating Temperature ProfileMCO Cooling Temperature ProfileMaterial Balance CalculationsTemperature Diff. on MCO during Cool-DownHeat Exchanger Duty - All UnitsWITNESS Model Run

Date

5/20/965/7/96

5/13/965/13/966/12/966/25/966/24/967/25/96

Page

G-1G-2G-8G-16G-24G-40G-47G-51

G-ii

MERRCK. ***•*


w >w / « f

RMWOTT

oD M

General Comments Relating to theHeating of Nuclear Fuel in the MCO

L&A-

1112It14IS

n20

w3SM

It is piopoted that the nuclear foci contained in the MCO be bated by faced coovectioa on bothtbeoumdeofthcMCOtndontbcinfideoftheMCO. Tte foDowing calculations will show theWiipuiHuro profilq mocated with both hesfcig tad cooBag by tins method. Tbcse profileswen developed tinoajh^uje of ni to«ive»pre»dJhBetbe»lb«linoe. Steady M e heating is

g " ntteofhettwnsfefU - oveadleoeffieitntcfhBtttaniftr

A T - If taperJlme difSaecce between sonroe of h e t rod the recepmr of heat

4rougt4e MCO to die fed is at*. Heady sate, m integral faun of ftisHut fbvn divides the heat Uwifu ptoceB into 6 iiiimMf iuuetiients aod

•manes Ready »t»tt of eichincnnjent By nmmmf all iacremeaa a heat ttms&r profile msybe obtained. This profile icflects fheonaieady state satme of the heat trmiler prooess winch

* liVCE

Kern, D. Q../Vi>ee» Scot Tramfkr. New Yo*- McGnw Hill, 1950.

Handbook of Chemistry and Phytict. 37th ed. Oeveland: Chemidl Rubber PaoBshiag Co1935.

Peny, R.H. OunttalEngineer* Handbook. fthed.NewYcsk: MeGnwHBll, 19M.

MeCabe and Smith. JAnr Optmtions cf ChemicalEngimertng. New Yotk. MoOiaw » n ,19S6:

MCO toterftnt Characurfstics. Rev of Jan II, 1996.

C n w TtdmHal Paper 410- Flow qffhilds. Chicago: Crane Co, 1965.

G,-'


Rti.UMn

efate

577/S*.

HvC5/11 ft*

Calculation of Heat Transfer Coefficientsfor Heanng and Cooling the MCO with Air

Tie idadonriups shown here test the manlar space fcr different mat of air flow in a cross-flow

The findings show that an exterior MCO heat transfer coefficient ( A.) of 5 Btn/hr ft1 °F may beachieved trifli an amalar «p»cing of 1" and an air-flow rate of 750 ACFM.

WhUe 250 ACFA4 was origiaaUy conadend, it was thown that the ^ bating cycle was extendedtwo faonndne » fte lower external film coefficient and beat capacity of air. Increasing the «iiSow to 750 ACFM provide* a profile more in line with the HVCE performance specifications,albeit Sin 1.2 boun longer an beat up thro desired.

It should be noted that the air-Sow rats ha; an effect on both betting and oooliqg tunes.

The key lemaissfae fatte sfe efficient Any result in increasing that parameter willhive a. detr effect on reducing the healing cycle time. A t intorior heal transfer coefficient (*j) of1.77 Btu/hrft2^Fwas calculated using a relabonship rbr laminar flow in innuli Beeause of thecomplex interior geometiy and its efiect upon cocveotiirt heat tnmstr, this-valne was rrduca) to1.0.

The interior heat tnosfcr coefficient remains as the controlling, racier in foil heating and coolingoperations. Furfiw detailed calculation of this value is recommended.

Calculated by.Checked by:

Lauren Ames 5/7/96David Munger 5/29/96

G-2-

WHC-SD-SNF-CDR-007, REV. 0 2/^

Calculation of Interior Heat Transfer Coefficientfor MCO to Fuel Heating

The relationships used here are taken from Perry, pages 10-13 and 10-14, as well as the sectionsdealing with convection appearing in the other referenced texts on heat transfer. Because the areaof the fuel is so much greater than the area of the interior surface of the MCO, the rate of transferfrom the MCO to the helium controls, not the rate of heat transfer from the helium to the fuel.

Try forced convection with 10 SCFM purge rate:

MCO Volume Empty = 272 galMCO Volume Loaded = 134 galVoid Volume = 138 gal

For heat transfer calcs, assume this is annular volume:

Cross section rods = — ft3 /160/12 ft = 1.34 ft2

7.48 gal

7tr2=1.34ft2 /- = 0.65ft D, = 1.31 ft £1 = 24.5-1

= 23.5/12

= 1.96 ft

D.,JP Dl-D? 1.962 -1.312

N«. = - ^ ~ D,q= 7

D = — =1.62 Ft. (Kern,p. 105)

at 170° C mean temp

(2734-1701F=10SCMx I =16.2ACFM

Natural convection calculations:

300-40Properties at mean temp.: = h40

= 170'C

= 338°F


.0 = 2 ft

g = 32.17x36002 = ft / hr2

p x359 ft3 798

0 = i (ideal gas) = ^ - ^ = 0.0013

Lt^ = 375 - 40 = 335* C = 603" F (max)

A'™, = 375 - 300 = 75' C = 135* F (min)

H 3 3 8 F = 0.025 eN = 2.42x0.25 = 0.0605 lb / f t -hr (McCabe and Smith)

(2)3x 32.17 x 36002x (0.0069)2x 0.0013x603cfl ~ (0.0605)2

NOR =34xlO6

N pr =0.761 (Perry, p. 3 -247)

170'C443- £C

kH,@n0'C= 19.3xl(T2 watts/meter 'K (Perry, p. 3-247)

watt 3.413 Btu 1 meter 'K*».@170 C= 0.193 x x x

meter 'AT watthr 3.281ft i.8"F

= 0.112 Btu /hrft'F

Annular area = 7t (>22 - r 2 )

= 1.67 ft^


16.2 ft3 lmin 1Vel = x x r = 0.16 ft /sec.

min 60 sec 1.67 ft

p =0.0069 #/ft3fftom p. 1)

u =0 0605 #/fthrx — = 1.68x10"5 #/ft./sec.3600 sec.

0.16 ft 0.0069 #1.62 fix x 5—

N. = ^ S =106.4R' 1.68xlO~5 #/ft.-sec.

for heat transfer of laminar flow in annuli (Perry, p. 10-15)

D 1.62 n,^ t = 0.12 — = 1^ t 0 . 1 2

i 160/12 u,

£>, 1.96- L = = 1.50£>, 1.31

^ =1.02 (0.761)5 (lO6.4)a45 (0.12)a4 (l.50)as (34xlO6)°°5

= 10.25

h.LA'M;=-J— /t = 0.112 Btu/hrft'F

L = distance across annulus = D2 - D, = 1.96 -1.31

= 0.65 ft.

^ J A : 10.25x0.112 Btu

' " L "0.65 ft. hr/ft"F

= 1.77 Btu / ft2 ht. gF

Because the interior of the MCO is complex and the helium must travel through fuel holdingbaskets, then through more than one layer of fuel rods, and because the flow (10 SCFM) uponwhich the calculation is based on is on the high side, the calculated coefficient of 1.77 is beingdiscounted to 1.0 Btu/ft2hr °F. This value will be used in all subsequently derived heating andcooling temperature profiles for the MCO.

WHC-SD-SNE-CDR-007, REV. 0

Calculation of Outside Film Coefficientfor Forced Circulation

It will be assumed that heat will be transferred via cross-flow convection in the annulus. Thesesegmented baffles will be used to reverse flow and force cross flow.

The first iteration will calculate the outside film coefficient (ho) at an air flow of 250 ACFM.

Assume spacing between the outer wall of the MCO and the inner wall of the heat-transferplenum of 1 inch

k \k

where

Dc,= 4 x hydraulic radius = — — =

propertiesfor average of inlet and outlet temp.

Cp = forairat300°C(572°F)-.26Btu/#°Fk = 0.0228 Btu - Ft/Ft2 Hr °Fu = 0.028 ep x 2.42 = 0.068 16/Ft.-hr

C R » _ 026 x 0.68 _

k 0.0228

JH =/i°p2°2g3(0.775)-'/3 JH = 15.8 A,, (Kern Fig 28, p. 838)

DJL>

= 1282 #/fT

0.33 x 1282

JH = 4 4 ho = 44/15.8 = 2.8

Suggest trebling the air rate rather than reducing the annular space


G, = 3,846 #/hr ft2 (750 ACFM)

0.33x3846N. = = 19,000

"' .0668JH= 80

fto= 80/15.8 = 5BTU/°Fhrft2

By reducing the annular area a factor of 3@250CFM the same ho may be achieved.

it - lit = 0.55 ft2

4 = 05^/ = 0.18

7tr22 = 0.18 + lit r2 = 1.03 = 0.34

o r / 1 6 " annular space

This is too small. Use 750 ACFM with 1-inch annular spacing.

Note temperature profiles attached showing the effect of each condition.


•88 MERRICKDDD niiw

COMPUTER CALCULATIONCOVER SHEET

PROJECT #30012318

NEW MEXICO OFFICE

CALCULATION TTTLE: frlf-tt r MJA0iA->0ft. »•* M C - 0 MeaViAa. Xt v ^ p V<V>V< I 4—

CALCULATION INDEX NO.: P ^ C- - ^

SUBJECT/PURPOSE OF CALCULATION:.

\ <~

PROGRAM NAME: f :

PROGRAM REVISION:

INPUT DATA SOURCE:

REMARKS:

y- r:

p ' ^ 4 •-,

0

ATTACHED ARE:

PRINTOUT OF INPUT DATA RESULTS

D PRINTOUT OF SPECIFIC PROGRAMMING OPTIONS AND/OR INSTRUCTIONS

D DOCUMENTATION OF SOURCES AND/OR DEVELOPMENT OF FORMULA

ORIGINATOR: (_

INPUT DATACHECKED BY:

'/IDATE

WHC-SD-SNF-CDR-007, REV. 0 w_ .X,

CALCULATION METHODOLOGY FOR DETERMINING MCO HEATING TEMPERATURE PROFILE

Tie heating profile consists of a series of heat balances on six minute increments which are integrated over time to describethe temperature profiles of interest. The calculation allows for heat from the oven and heat from the nuclear activity of thefuel.

At MCO operating pressures near atmospheric the heat input from external heating of circulating helium is minimal and isnot considered in this calculation. As the internal pressure is increased, heat added to the circulating stream can besignificant and this calculation would underestimate the rise in temperature for the following reasons:

1 the internal heat transfer coefficient would increase significantly,2. conduction through the helium would be significant and would add to heat transfer from forced convection, and3. the mass flow of the helium through an external heat source would provide a significant boost to fuel heating.

The calculations forming the temperature profile are made as follows. All English units are converted to metric in a tablewhich is the basis for the graphical information. Spreadsheet formulas are shown in bold.

Hot air in (°F)This value is manually set at each hourly increment.

End time (hours)Time is stepped off in 0.1 hour increments from 0 to 20 hours.

Delta temperature air to MCO CF)This is the difference between the average hot air temperature and the wall temperature of the MCO.(hot air temp in + hot air temp out)/2 - MCO wall temp

Wet heat into MCO (Btu/hr)This is the heat into the MCO from the oven less the heat from the MCO to the fuelexternal heat transfer coefficient x external surface area of MCO x delta temperature air to MCO - heat from MCO

Hot air temperature out (°F)This is the hot air into the oven less the temperature resulting from heat transferred to the MCO/F(air temp in -(net heat into MCO + net heat from MCO - nuclear heat) / heat capacity of air x mass flow rate ofair) < MCO wall temperature THEN MCO wall temperature ELSE (net heat in + heat from MCO - nuclear heat) /heat capacity of air x mass flow rate of air)

MCO wall temperature (°F)net heat in x (end time this period - end time previous period) / (mass MCO x specific heat MCO) + previous walltemperature

Temperature of fuel rods f°F)previous temperature of fuel rods + (heat from MCO x (end time this period - end time previous period) / (mass offuel + specific heat of fuel)

Heat from MCO (Btu/hr)This is the heat from the MCO to the fuel plus the heal generated from the nuclear activity of the fuel(MCO wall temperature - fuel rod temperature) + nuclear energy from rods

calculations by Lauren Ames on HANHEAT3.WQ1 5C/96reviewed by David Munger

0,-H


HANHEAT3.WQ1 of 5/7/96 — FOR CALCULATION OF HEATING TEMP PROFILESanta Fe Engineering, Ltd. - LBA

hi (Btu/lb*ft2*F*hr)to MCO ou

Al (ft2) of5

92

h2 (Btu/lb*ft2*F*hr)thru MCO

A2 (ft2) of

M*C (air inml*cl (MCO im2*c2 (fuel

Tl = air tem

183

397.8471.6

451

AIR TEMP DATA ENTRY TAKES PLACEIN COLUMN N

[assumes 750 ACFM]

programmed as shownT2 = air temp out (F)tl = MCO wall temp at

increment end (F)t2 = fuel rod temp at

increment end (F)

Q = internal rad heatgenerate

Hot airin

(Tl)

266266266266266266266266266266392392392392392392392392392

835

EndTime(hrs)

0.00.10.20.30.40.50.60.70.80.91.01.11.21.31.41.51.61.7

1.8

Deltatemp.

air/MCO

16265

10673867175676662

12399969289868380

Net Heatinto MCO(Btu/hr)

74,52025,83044,28128,19634,11526,58127,78423,79523,31920,88048,86937,03635,30933,21331,28329,48027,797

78 ! 26,227

Hotairout(T2)

104197149188172190186195196201174184192200207213219

225

MCOwall(tl)

104120125135141148

154159164169174184192200207213219

225231

Fuelrods(t2)

104104105106107108110111113114116118119121123126128

130133

Heatfrom MCO(Btu/hr)

4,1614,5395,2355,6356,1326,4876,8567,1497,4287,6598,3788,8759,3339,74610,11710,45010,74711,011

G- 10


Hot airin

(Tl)

392518518518518518518518518518518617617617617617617617617617617

662662662662662662662662662662707707707707707707707707707707707707

EndTime(hrs)

1.92.02.12.22.32.42.5

2.62.72.82.9

3.03.13.23.33.43.53.63.73.83.94.04.1

4.24.34.44.54.64.74.84.95.05.1

5.25.35.45.55.65.75.85.96.06.1

Deltatemp.

air/MCO

75136128123119115

11110710410097

144136132127123119116112109106125120117113110107104

1029996

117112109106103101989694918987


24,76123,39151,09346,56143,91541,36438,98736,76934,69832,76430,95929,27250,46646,37243,79541,32339,02036,86834,85832,98131,22729,58738,40535,78133,89432,10230,42828,86427,40026,03224,75123,55332,78130,53929,00827,54826,18324,90523,71022,59021,54220,55919,639

Hotairout(T2)

231236241252262271

280288296303310317323334344353362370378385392399405413421428435441447453459464469476482488494500505510515520524

MCOwall(tl)

2362412522622712802S8296303310317

323334344353362370378385392399405413421428435441447453459464469476482488494500505510515520524528

Fuelrods(t2)

135138140143146149

152155158161165168172175179183187191195199203207212216220225

229234238243248252257261266271276280

285290295

299304


11,24411,44912,13712,73313,27213,75614,18914,57514,91715,21915,48415,71416,31316,82917,29017,69918,06018,37718,65218,88919,09119,26119,58219,85120,08220,27820,44020,57220,67620,75320,80720,83921,03221,18221,30321,39621,46321,50621,52821,52921,51221,47821,428

WHC-SD-SNF*DR-007, REV. 0

Hot airin

(Tl)

7077077 07707707707707707707707707707707707

707707707707707707707707707707707707707

7077077077077077077077077077077077077077 07707707

EndTime(hrs)

6.26.36.4

6.56.66.76.86.97.07.1

7.27.37.47.5

7.67.77.87.98.08.18.28.38.48.58.68.7

8.88.99.09.1

9.29.39.49.59.69.79.89.9

10.010.110.210.310.4

Deltatemp.

air/MCO

868482807977767473717069686765646362616059595857565554

53535251505049484847464645454443


18,77517,96617,20616,49315,82315,19414,60214,04613,52313,03012,56612,12911,71611,32710,95910,61210,2849,9739,6799,4009,1368,8868,6488,4218,2068,0017,8067,6207,4437,2737,1116,9566,8076,6656,5286,3976,2716,1506,0335,9215,8125,7085,606

Hotairout<T2)

528532536

539543546550553556558561564566569571

574576578580582584586588590592593595597598600602603605606607609610611613614615617

1 618

MCOwall(tl)

532536539

543546550553556558561564566569571

574576578580582584586588590592593595597598600602603605606607609610611613614615617618619

Fuelrods<t2)

309

314318 _|323328332337342346351355360364

369373377382386390394398402406410414418

422426430434437441445448452455459462466469

472476

479


21,36421,28721,19921,09920,98920,87020,74320,60820,46720,32020,16720,00919,84719,68119,51219,34019,16518,98818,80818,62818,44618,26318,07917,89417,70917,52417,33917,15416,96916,78516,60116,41816,23616,05415,87415,69415,51615,33915,16214,98814,81414,64214,471

G-IL

WHC-SD-SNfF-CDR-007, REV. 0

Hot airin

(Tl)

707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707707

EndTime(hrs)

10.510.610.710.810.911.011.111.211.311.411.511.611.711.811.912.012.112.212.312.412.512.612.712.812.913.013.113.213.313.413.513.613.713.813.914.014.114.214.314 .414.514.614.7

Deltatemp.

air/MCO

43

424241414040393938383737363635353434343333323231313130303029292828282727272626262525


5,5095,4145,3235,2345,1485,0654,9834,9054,8284,7544,6814,6104,5414,4744,4084,3444,2824,2204,1604,1024,0443,9883,9333,8793,8263,7743,7233,6733,6243,5753,5283,4813,4353,3903,3463,3023,2603,2173,1763,1353,0943,0553,016

Hotair

out(T2)

619620621622623625626627628629630

631632633634635636636637638639640641642642643644645646646647

648649649650651651652653654654655656

MCOwall(tl)

620621622623625626627628629630631632633634635636636637638639640641642642643644645

646646647

648649649650651651652653654654655656656

Fuelrods(t2)

482485488492495498501504506509512515518521523526529531534536539541544546549551553556558560562565567569571573575577579581583585

587


14,30214,13413,96713,80213,63913,47713,31713,15813,00112,84512,69112,53912,38812,23912,09111,94511,80111,65811,51611,37711,23811,10210,96710,83310,70110,57110,44210,31410,18810,0639,9409,8199,6989,5809,4629,3469,2329, 1189,0068,8968,7878,6798,572


Hot airin

(Tl)

707707572572572572572572572572572572572572572572572572572572572572572572572572572572572

572572572572572572572572572572572572572572

EndTime(hrs)

14.814.915.015.115.215.315.415.515.615.715.815.916.016.116.216.316.416.516.616.716.816.917.017.117.217.317.417.517.617.717.817.918.018.118.218.318.418.518.618.718.818.919.0

Deltatemp.

air/MCO

2524

-43-37-35-33-30-28

-27-25-23-22-20-19-18-17-16-15-14-13-12-12-11-10-10-9-9-8-8

-7-7-6-6-6-5-5-5-5

-4-4-4-4-4


2,9772,9392,902

(28,185)(24,646)(23,043)(21,462)(19,995)(18,629)(17,357)(16,173)(15,071)(14,045)(13,089)(12,199)(11,371)(10,599)(9,881)(9,212)(8,590)(8,010)(7,470)(6,967)(6,499)(6,063)(5,657)(5,279)(4,927)(4,599)(4,294)(4,009)(3,744)(3,498)(3,268)(3,054)(2,854)(2,668)(2,495)(2,334)(2,184)(2,044)(1,913)(1,792)

.Hotairout(T2)

656657657658652647642637

633629626622619616613611608606604

602600598597595594593591590589588587586586585584584583

MCQ

wall(tl)

657657658652647642637633629626622619616613611608606604602600598597595594593591590589588587586586585584584583582

582 ! 582582581581581580

581581581580

580

Fuelrods(t2)

589591593595596598599601602603604605606607608608609609610610611611612612612613613613613613614614614614614614614614614614614614

614


8,4678,3638,2607,6127,0386,5036,0055,5435,1134,7134,3423,9973,6763,3783,1012,8442,6052,3832,1771,9861,8091,6441,4911,3491,2181,096

983878781691607530459393332276224176131915318(14)


Hot airin

(Tl)

572572572572572572572572572572

EndTime(hrs)

19.119.219.319.419.519.619.719.819.920.0

Deltatemp.

air/MCO

-4-3-3-3-3-3-3-3-3-2


(1,678)(1,573)(1,474)(1,382)(1,297)(1,217)(1,143)(1,073)(1,009)

(949)

Hotairout(T2)

580579579579578578578578577577

MCOwall(tl)

579579579578578578578577577577

Fuelrods<t2)

614614614614614614614614614614


(43)(70)(94)

(117)(138)(157)(174)(190)(204)(217)


MERRICK COMPUTER CALCULATIONCOVER SHEET

PROJECT #30012318

NEW MEXICO OFFICE

CALCULATION

CALCULATION INDEX NO:

SUBJECT/PURPOSE OF CALCULATION: ex

to

PROGRAM NAME Qiyoirl-To V^O —» (Lon.\) gr|pj)

PROGRAM REVISION:

INPUT DATA SOURCE:

REMARKS:

VT x . r» \

o

ATTACHED ARE

PRINTOUT OF INPUT DATA RESULTS

D PRINTOUT OF SPECIFIC PROGRAMMING OPTIONS AND/OR INSTRUCTIONS

• DOCUMENTATION OF SOURCES AND/OR DEVELOPMENT OF FORMULA

ORIGINATOR:. DATE:'

INPUT DATACHECKED BY:. D fi n DATE 3

WHC-SD-S.NF-CDR-007, REV. 0 /f3/CALCULATION METHODOLOGY FOR DETERMINING MCO COOLING TEMPERATURE PROFILE

The cooling profile consists of a series of heat balances en six minute increments which are integratedover time to describe the temperature profiles of interest. The calculation allows for heat transfer to theoven from the heat capacity of the MCO and its contents and heat from the nuclear activity of the fuel.The model is the same as for MCO heating except that negative heating rates indicate a reverse directionof heat flow from the MCO system to the cooler air from the oven.

At MCO operating pressures near atmospheric the heat removal from external cooling of circulating heliumis minimal and is not considered in this calculation. As the internal pressure is increased, heat removed bythe circulating stream can be significant and this calculation would underestimate the rise in temperaturefor the following reasons:

1. the internal heat transfer coefficient would increase significantly,2. conduction through the helium would be significant and would add to heat transfer from forced

convection, and3. the mass flow of the helium through an external heat source would provide a significant boost

to fuel cooling.

The calculations forming the temperature profile are made as follows. All English units are converted tometric in a table which is the basis for the graphical information. Spreadsheet formulas are shown in bold.

Cool air in CF)This value is manually set at each hourly increment.

End time (hours)Time is stepped off in 0.1 hour increments from 0 to 20 hours.

Delta temperature air to MCO CF)This is the difference between the average cool air temperature and the wall temperature of the MCO.(cool air temp in + cool air temp out)/2 - MCO wall temp

Net heat to MCO (Btu/hrtThis is the heat to the MCO to the oven less the heat from the MCO from the fuel. It is a negative value,external heat transfer coefficient x external surface area of MCO x delta temperature air to MCO -heat from MCO

Cool air temperature out CF)This is the cool air into the oven less the temperature resulting from heat transferred from the MCOIF{a\r temp in - (net heat to MCO + net heat from MCO - nuclear heat) / heat capacity of air x massflow rate of air) < MCO wall temperature THEN (net heat in + heat from MCO - nuclear heat) / heatcapacity of air x mass flow rate of air) ELSE MCO wall temperature

MCO wall temperature (°F)net heat in x (end time this period - end time previous period) / (mass MCO x specific heat MCO) +previous wall temperature

Temperature of fuel rods (°F)previous temperature of fuel rods + (heat from MCO x (end time this period - end time previousperiod) / (mass of fuel + specific heat of fuel)

Heat from MCO (Btu/hr)This is the heat from the MCO to the fuel plus the heat generated from the nuclear activity of the fuel. It isa negative value.(MCO wall temperature - fuel rod temperature) + nuclear energy from rods

calculations by Lauren Ames on HANHEAT4.WQ1 5J3/96reviewed by David Munger


HANHEAT4.WQ1 of 5/7/96 — FOR CALCULATION OF COOLING TEMP PROFILESanta Fe Engineering, Ltd. - LBA

1hi (Btu/lb*ft2*F*hr)

to MCO oAl (ft2) of

592

h2 (Btu/lb*ft2*F*hr)thru MCO

A2 (ft2) of

Cp air (inml*cl (MCOm2*c2 (fuel

Tl = air te

183

562

471.6451

AIR TEMP DATA ENTRY TAKES PLACEIN COLUMN N

[assumes 750 ACFM]

programmed as shownT2 = air temp out (F)tl = MCO wall temp at

increment end (F)t2 = fuel rod temp at

increment end (F)

Q = internal rad heatgenerat

Cold airin

(Tl)

410410410410410410410410410410284284284284284284284284

284

835

EndTime(hrs)

0.00.10.20.30.40.50.60.70.80.91.01.11.21.31.41.51.61.7

1.8

Deltatemp.

air/MCO

-367-107-94-90-83-78-72-68-64-60

-119-94-91


(49,221)(51,204)(44,077)(41,574)(37,505)(34,595)(31,583)(28,996)(26,566)(24,381)(51,353)(38,855)

-87 1 (36,966)-84 (34,695)-81 i (32,605)-78 1 (30,654)-75 (28,834)-72 i (27,136)

Coldairout(T2)

0499

504493490484480

475472468465494483474467459452446440

MCOwall(tl)

572562551541533525517

511504499494483474467459452446440

434

Fuelrods(t2)

572572572573573573

572572571571570569568567566565563

562

560

Heatfrom Fuel(Btu/hr)

1,9841,046251(485)

(1,137)(1,724)(2,249)(2,718)(3,135)(3,506)(4,346)(4,950)(5,509)(6,018)(6,481)(6,902)(7,282)(7,626)

G-i,


Cold airin

(Tl)

284104104104104104104104104104104104104104104104104104104104104686868686868686868686868686868686868686868

68

EndTime(hrs)

1.92.02.12.22.32.42.52.62.72.82.93.03.13.23.33.43.53.63.73.83.94.04.14.24.34.44.5

4.64.74.84.95.05.15.25.35.45.55.65.7

5.85.96.06.1

Deltatemp.

air/MCO

-70

-157-146-141-135-130-125-121-117-113-109-105-102-99-96-93-90-87-85-83-81-96-93-90-88-85-83-81-79-77-75-73-72-70-69-67-66-64-63

-62-61-59

-58


(25,551)(24,073)(64,094)(58,039)(54,651)(51,374)(48,323)(45,477)(42,821)(40,343)(38,031)(35,872)(33,857)(31,975)(30,218)(28,576)(27,043)(25,610)(24,271)(23,019)(21,848)(20,753)(28,009)(26,097)(24,762)(23,491)(22,304)(21,193)(20,154)(19,181)(18,270)(17,417)(16,618)(15,869)(15,167)(14,509)(13,892)(13,312)(12,768)(12,256)(11,776)(11,324)(10,899)

Coldair

out(T2)

434429423410398386375365355346338330322315308302295290284279274270265259254249244239234230226222218215212208205202199197194192189

MCOwall(tl)

429423410398386375365355346338330322315308302295290284279274270265259254249244239234230226222218215212208205202199197194192189187

Fuelrods(t2)

55955755555355154854654 3540537534531528525521518514511507504500497493489486482478474471467

463459455452448444440436433429425422

418


(7,935)(8,213)(9,190)

(10,042)(10,819)(11,524)(12,162)(12,739)(13,258)(13,724)(14,141)(14,512)(14,841)(15,130)(15,384)(15,604)(15,792)(15,952)(16,086)(16,195)(16,282)(16,347)(16,539)(16,694)(16,823)(16,927)(17,008)(17,068)(17,108)(17,131)(17,137)(17,128)(17,106)(17,070)(17,023)(16,965)(16,897)(16,821)(16,736)(16,643)(16,544)(16,439)(16,329)


Cold airin

(Tl)

686868686868686868686868686868686868

167167167167167167167167167167266266266266266266266266266266266266266266266

EndTime(hrs)

6.26.36.46.56.66.76.86.97.0

7.17.27.37.47.57.67.77.87.98.08.18.28.38.48.58.68.78.88.99.0

9.19.29.39.49.59.69.79.89.9

10.010.110.210.310.4

Deltatemp.

air/MCO

-57-56-55-54-53-52-52

-51-50-49-48-48-4 7-46-45-4 5-44-43

7310

-1

-2-3-4-5-6433835333028262523212019


(10,499)(10,122)(9,767)(9,432)(9,116)(8,818)(8,537)(8,271)(8,019)(7,780)(7,555)(7,341)(7,138)(6,945)(6,762)(6,588)(6,422)(6,264)(6,114)16,80014,31513,24412,18411,20310,2919,4448,6577,9267,247

29,38726,18024,43522,74621,17719,71618,35617,09115,91214,81513,794

17 1 12,84416 ! 11,95915 11,135

Coldair

out(T2)

187185183181179177175173171169168166165163162160159157156155158161164167169171173175111

178185190195200205209213216220223226229231

MCOwall(tl)

185183181179177175173171169168166165163162160159157

156155158161164167169171

173175177

178185190195200205209213

216220223226229231233

Fuelrods(t2)

414411407404400397393390386383380376373370367

364360357

354351348345343340338

335333331328326324322321319318316315314313312311310

309


(16,213)(16,093)(15,968)(15,840)(15,709)(15,575)(15,439)(15,300)(15,160)(15,018)(14,875)(14,730)(14,584)(14,438)(14,292)(14,145)(13,997)(13,850)(13,703)(13,155)(12,661)(12,195)(11,756)(11,342)(10,952)(10,585)(10,237)(9,910)(9,600)(8,906)(8,281)(7,699)(7,157)(6,652)(6,183)(5,746)(5,339)(4,961)(4,609)(4,281)(3,977)(3,693)(3,429)

~ Z.D


Cold airin

(Tl)

266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266266

EndTime(hrs)

10.510.610.710.810.911.011.111.211.311.411.511.611.711.811.912.012.112.212.312.412.512.612.712.812.913.013.113.213.313.413.513.613.713.813.914.014.114.214.314.414.514.614.7

Deltatemp.

air/MCO

14131211111099887

766555444433333

22222222111111111


10,3689,6548,9908,3717,7957,2596,7606,2965,8635,4605,0864,7374,4124, 1093,8283,5653,3213,0942,8832,6862, 5022,3322,1732,0251,8871,7591,6391,5281,4251,3281,2381,1551,0771,004

937874816761710663619578540

Coldairout(T2)

233236238240241243245246247249250251252253254254255256257257258258259259260260260261261261262262262

262263263263263263264264264264

MCOwall(tl)

236238240241243245246247249250251252253254254255256257257258258259259260260260261261261262262262262263263263263263264264264264264

Fuelrods(t2)

308308307306306305305304304304303303303302302302302301301301301301301300300300300

300300300300300300300300299299299299299299299299


(3,183)(2,955)(2,742)(2,545)(2,361)(2,189)(2,030)(1,882)(1,744)(1,616)(1,497)(1,386)(1,283)(1,187)(1,097)(1,015)

(937)(866)(799)(737)(679)(626)(576)(530)(487)(447)(410)(376)(344)(314)(286)(261)(237)(215)(194)(175)(158)(142)(126)(112)(100)(88)(76)

G-U


Cold airin

(Tl)

266266266266266266266266266266

266266266266266266266266266266266266266266266266266266266

266266266266

266266266266266266266266266

1End

Time(hrs)

14.814.915.015.115.215.315.415.515.615.715.815.916.0 j

16.116.216.316.416.516.616.716.816.917.017.117.217.317.417.517.617.717.817.918.018.118.218.318.418.518.618.718.818.9

266 I 19.0

Deltatemp.

air/MCO

11111111

11

1100000000000000000

00J00

0000000000


504471440411385360336

315295276258242227213199187175165155145137129121114107101969085

81767268

65615855535048454341

.Coldair

out(T2)

264264264264264264265265265265265265265265265265265265265265265265265265265265265265265

265265265266

266266266266266

MCOwall(tl)

264264264264264265265265265265265265265265265265265265265265265265265265265265265265265

265265266266266266266266266

266 j 266266 266266 266266 266266 ! 266

Fuelrods(t2)

299299299299299299299299299299299299299299299299299299299299299299299299299299299299

299299299299299299299299299299299299299299299


(66)(57)(48)(40)(32)(25)(19)(13)(8)(3)26

10141720232527

293133353637383940

4141424343

434444444444444444

44

WHC-SD--SNF-CDR-007, REV. 0

Cold airin

(Tl)

266266266266266266266266266266

EndTime(hrs)

19.119.219.319.419.519.619.719.819.920.0

Deltatemp.

air/MCO

0000000

!__ 000


40383635333231292827

Coldlairout(T2)

266266266266266266266266266266

MCOwall(tl)

266266266266266266266266266266

Fuelrods(t2)

299299299299299299300300300300


44444443434343424242


MERRICK COMPUTER CALCULATIONCOVER SHEET

PROJECT #30012318

IffiW MEXICO OFFICE

CALCULATION TITLE:.

CALCULATION INDEX NO.:

SUBJECT/PURPOSE OF CALCULATION:

, ^ t i Wki- U , '^ -\ l u - o c U C' i A U c ' i V C i \ ^

PROGRAM NAME: LCo S f

PROGRAM REVISION: O» O

INPUT DATA SOURCE: C-- A c >- -V • C c l l A g I , A \ \- i o '

REMARKS:

ATTACHEO ARE:

"35 PRINTOUT OF INPUT DATA RESULTS

O PRINTOUT OF SPECIFIC PROGRAMMING OPTIONS AND/OR INSTRUCTIONS

^ DOCUMENTATION OF SOURCES AND/OR DEVELOPMENT OF FORMULA

ORIGINATOR:

INPUT DATACHECKED BY: DATE:


Material Balance Calculations

(I " - -

The following pages contain printout from the MS Excel spreadsheet used to prepare the material balance. Thecell columns and rows are labeled so that they may be referenced to the calculations shown in the following notessection. Some manual calculations on vacuum pumping speed follow the Excel output.

prepared by L.B. Ames 6/12/96

MATBAL2.XLS WHC-SD-SNF-CDR-007, REV. 0

2

34567891011

1213141516171819202122232425262728293031323334353637383940414243

44

4546474849

AOperatinq Cycle


Temp. C IF)

Press Torr {psia)Flow rate std I/sec (scftn)Vac rate l/minH,kg/hr (Ibs/hr)

O,kg/hr (ttis/hr)N?kg/hr (Ibs/hr)Hekg/hr {Ibs/hr)

I"' gram/hr (Ibsfiir)Kr"qram/hr {Ibs/hr)Cs"'qram/hr (Ibs/hr)

Max heat rate kcal/hr [Btu/hr)

Process Duration (Note 4)Approx. Total DurationWater Removed kgHydrogen Removed kg

MCO volume (liter) =External MCO piping (liter) =Cyl. gas fill rate (al/m) =Cyl gas fill pressure (psia) =Gas constant (liter • torr * [K]" •

[gmol]') =System operating pressure(psia)Specific heat of helium (cal/gC)1 atm (100-300C)5atm(100-300C)

V1CO gas Circulation rate (ACFM)

B

MWt

2

32284

13186137

C I D I E I FOngoing utility

Dewar vacuum draw1

20-375

1.00E-04nil

68-707

1.S3E-06nil

ongoingongoing

507.1960.56

28018

62.361

13

0.5190.519

10

MCO area hood vent2

20

76066

68

14.7140

130 hr130 hr

G | H I I I JPreparation for heating cycle

Initial vacuumevacuation

3

40

100.067

3.

6.8015

104

0.1S30.142

)0

mmmm.

Helium filling of MCO4

20

9315.32

3.42

12.9515

68

1811.29

7.55

mm.mm.

Pagei

MATBAL2.XLSWHC-SD-SNF-CDR-007, REV. 0

2

34567ft9

101112131415

16171819202122232425262728293031323334353637383940414243

44

4546474849

AOperating Cycle


Temp. C (F)

Press Torr ipsla)Flow rate std I/sec {scfm\Vac rate l/minH,kg/hr (/fcsflir)O,kg/hr {Ibsmr)N2 kg/hr (Ibs/hr)Heka/hr Ubsrtir)

I1" gram/hr (Ibs/hr)Kr"gram/hr (/bsTir)Cs"'grani/hr {Ibsmr)

Max heat rate kcal/hr (Sfuftr)


vlCO volume (Irter) =external MCO piping (liter) =Cyl. gas fill rate (al/m) =Cyt gas fill pressure (psia) =Gas constant (liter • lorr • [XT' •

Igmoll') =•System operating pressureIpsia)Specific neat of helium (cal/gC)

1 aim (100-300C)5atm(100-300C)

VICO gas Circulation rate (ACFM)

B

MWt

232

284

13186137

K L M I N | O | P | Q | RHeating of MCO (40C to 3

MCO heating air5

375

760149

17,640

13.2 hr14

707

14.7316

70,000

Note 3)hr.

Helium heating(Heater inlet)

6A

102

6881.90

1.22

13.214

216

13.34.037

2.70

hr.hr.

Helium heating(Heater outlet)

68

325

6721.90

1.22

142

13.214

617

134.037

2.70

562

hrhr

j

Periodic heliumpurging to 200 C

7A

200

6880.005

0.003

0.002

88

g moles @ 40C=g moles ©200C=g moles © 300C=

392

M.30.0T)

0.007

0.007

hr.hr.

19.5496712.93667

10.6790

Page 2

MATBAL2.XLSWHC-SD-SNF-CDR-007, REV. 0

2

34567891011

1213141516171819202122232425262728293031323334353637383940414243

44

4546474849

AOperating Cycle


Temp. C (F)

Press Torr (psia)Flow rate std I/sec (scftn)Vac rate l/minH, kg/hr {Ibs/hr)

O,kg/hr (Ibs/hr)N, kg/hr (Ibs/hr)He kg/hr (IbsAir)I"1 aram/hr (IbsAir)Kr"gram/hr {Ibs/hr)Cs"'gram/hr ilbs/hr)

Max heat rate kcal/hr (Btu/hr)

Process Duration (Note 4)Approx. Total DurationWater Removed kghydrogen Removed kg

MCO volume (liter) =External MCO piping (liter|=Cyt. gas rill rate (al/m} =Cyl gas fill pressure (psia) =Gas constant (liter • torr * [K]"1 *

gmoir ' ) -System operating pressurepsia)

Specific heat of helium (cal/gC)1 atm(100-300C)5 atm (100-300C)

MCO gas Circulation rate (ACFM)

B

MWt

2

32284

13186137

S | T | U | V [ W | XJ+C)Helium purging 200 C

to 300 C7B

300

6880.003

0.002

0.001

5.36

572

13.30.006

0.004

0004

hr.hr.

1.8140.165

Helium for purgeduring heat-up

8

20

9310.004

0.003

13.3

68

180.009

0.006

hr.

Purifier Outlet9

100

1.90

212

4.037

Page 3

MATBAL2XLSWHC-SD-SNF-CDR-007, REV. 0

2

3456

78910111213141516171819202122232425262728293031323334353637383940414243

44

4546474849

AOperatinq Cycle


Temp. C (F)

Press Ton- tpsla)Flow rate l td I/sec (scftn)Vac rate l/minH,ko/hr (ttaVnr)O,kgflir (/ostfir)

N, kgmr <M>s/hr)Heka/hr Ilbs/Tir)l'"aranVhr Vbsfor)Kr1* aram/hr VbsAir)Cs"'grammr </6s/Jiri

Max heat rate kcal/hr {Btu/hr)


MCO volume (liter) =External MCO piping (liter) =Cyl. gas fill rate (al/m) =Cyi gas flit pressure (psia) =Gas constant (liter • torr * [K]"' *

Igmoll"1) =System operating pressure(psia)Specific heat of helium (cal/gC)

1 atm(100-300C)5atm(100-300C)


B

MWI

232

284

13186137

Y I 2 AA | ABVacuum condition

Vacuum draw10

300

50.032

3.0 0005

0.135

7.948

57?

0.0970.067

500.001

0.298

minhr.

0.0560003999375

Notes:

Inert gas purge duringvacuum

11

20

9310.030

0.135

4848

68

180.064

0.299

hr.hr.

1. Although hydrogen may be present at concent

I2. Run 23 data assumed to be at MCO operating

3. Heating

A. Massra

5. This is

6. This is

AC | AD AE | AFCooling of

Cooling air12

80NM*C

760256

18.144

1414.6

rations great*

conditions.

176

14.7542

72.000

hr.hr.

Helium added for cool-down

13

20

9315.324

3.423

0.95715

68

n11.288

7.547

mm.mm

r than 5%v. it is inherently safe beca

rate is determined with an internal heat transfer coefficient of 1 8tu / pound degree F sq.

te times process duration equals mass. Approximate total duration is for eye

ws maximum of a programmed temperature schedule

ie minimum of a programmed temperI

ture schedule

B time deter

Page 4

MATBAL2XLS WHC-SD-SNF-CDR-007, REV. 0

1

4SS781

1011

1213141516171819202122232425262728293031323334353637383940414243

44

4546474849

AOperating Cycle


Temp. C (F)

Press Torr ipsla)Flow rate sld I/sec (scftn)

Vac rate l/minH, kqfhr ( jtwhr)O,ka/hr llbsfar)N, kg/hr [Ibs/hr)

Hekq/hr {Ibs/hr)l"'gram/hr (Ibs/hr)Kr16 qram/hr llbs/hr)Cs'"qram/hr Ubs/hr)

Max heat rate kcal/hr (Blu/hr)


MCO volume (liter) =External MCO piping (liter) =Cyl. gas till rate (al/m) =Cyl gas fill pressure (psia) =Gas constant (liter * torr * [K]"1'

|gmoir')=:System operating pressure(psia)Specific heat of helium (cal/gC)

1 atm(100-300C)5atm(100-300C)

MCO qas Circulation rate (ACFM)

B

MW1

232284

13186137

AG | AH | Al AJCoolinq of

Helium cooling14A

100

6723.053

2.006

1313.5

e itsconcer

. hr and exte

inationonly

212

136.473

3.143

hr.hr.

tration when

rnal heat trar

Helium cooling148

102

6883.053

2.006

1313.5

diluted wouli

sfer coefTicie

216

13.36.473

3.143

hr.hr.

dbelesstha

nt of 5 Btu /

AK | AL I AM I ANOxyqen passivatio

Nitrogen added15

20

9313.482

15.668

1212

n1%lS)gr»fk

sound degre<

68

787.382

34.548

hr.hr.

•antly below

F sq. ft. hr.

Oxygen added16

20

9310.071

0.365

1212

tsLEL

68

1B0,151

0.806

hr.hr.

Pages

'30


2

3456

7891011

1213

141516171819202122232425262728293031323334353637383940414243

44

4546474849

AOperating Cycle


Temp. C (FJ

Press Torr {psia)Flow rate std l/sec (scftn)Vac rate l/minH, kg/hr (ibsfor)

O,kg/hr ((os/hr)N, kg/hr (Ibs/hr)

He kg/hr {Ibs/hr)

l"'gram/hr (Ibs/hr)Kr"gram/hr (tos/ftr)Cs"'gram/hr (Ibstor)

Max heat rate kcal/hr {Btu/hr)


MCO volume (liter) =External MCOpipjng (liter) =Cyl. gas Till rate (al/m) =Cyl gas fill pressure (psia) =Gas constant (liter • torr • (K)" "

gmoir1)-System operating pressure(psia)Specific heat of helium (cal/gC)

1 atm (100-300C)5atm(100-300C)


B

MWt

232

284

13166137

AO | AP

Circulating passivationgas17

150

6662.576

1212

302

)3.35.462

hr.hr.

AQ | AR I AS | ATInert Gas Packing

Oxygen Evacuation16

150

50.067

3.

7.9015

302

0.0970.142

50

mm.min.

Helium Fill19

150

11374.667

3.000

195815

302

229.894

6.615

min.min.

Page 6

G-3>\


Cell: C6Note: Range of allowable heating and cooling temperature

Cell: G6Note: Assumes receipt at 40 degrees C.

Cell: 16Note: Assumes ambient temperature at start of rilling.

Cell: K6Note: Set at the maximum permissable temperature for the MCO shell. This temperature is programmed to ramp up to this value. See MCO

Heating Temperature Profile for suggesting temperature vs. time for this stream.

Cell: M6Note: Set based upon blower inlet temperature specifications plus 2 degrees rise for heat of compression.

Cell: W6Note: Set by inlet temperature restriction to circulation blower.

Cell: Y6Note: per specification

Cell: C8Note: Vacuum for effective thermal resistance.

Cell: G6Nole: Set per WHC-S-0460 rev. A of 3/11/96

Cell: 16Note: Fills to this pressure for maximum internal heat transfer.

Cell: M8Note: Filis to this pressure for maximum internal heat transfer.

Cell: P8Note: Assumes 0.5 psi drop across helium heater

Cell: Y8Note: per specification

Cell: E9Note: Equivalent to 150 ACFM.

=150-(4S9.7<-32)/((459.7f68)-60-0.0353)

Cell: G9Note:=G9-(10/760)-(273/{273t40))I(1/60)

Cell: 19Note: Based upon flow set at 280 liters/min at 120 psia.

=JC$41 "(JC J42/14.7)-(273/(15*273))/60

Cell: K9Note: «750-(273/(273*K5)C28.3/60

Cell: M9Note: =O8

Cell: N9

Note: Maximum internal helium flow based upon Performance Specification WHC-S-0460, rev A

Cell: P9

Note: Maximum internal helium flow based upon Performance Specification WHC-S-0460, rev A=$C«48'(O7/760)-(273/(273*O5))

Page 7

G,-SZ


Cell: Q9Note: =($R$41-$R$42)*22.4/(Q20-3600)

Cell: S9Note: =($R*42t$R$43)-22.4/(S20-3600)

Cell: U9Note: =(Q8-Q2O*S8-S20)/U20

Cell: W9Note: =M8

Cell: Y9Note: Set based upon the capacity of the vacuum pump at operating conditions.

Cell: AA9Note: =AA12*1000'(22.4/B12)/3600

Cell: AE9Note: Based upon flow set at 280 liters/mm at 120 psia

Cell: AH9Note: Maximum internal helium flow based upon Performance Specification WHC-S-0460. rev A

=$C$50"(AG7/760)-(273/(273*AG5))

Cell: AI9Note: =AG8

Cell: AJ9Note: Maximum internal helium flow based upon Performance Specification WHC-S-0460, rev A

Cell: AK9Note: Based upon now set at 280 liters/mm at 120 psia

=AM8-(98/2)

Cell: AM9Note: =(AM11/3.6)'22.4/$B$11

Cell: AP9Note:=$CJ50*(AP7/14.7)-(460/(4«HAP5))

Cell: AQ9Note:=AQ9-(10/760n273/(273*40))-(1/60)

Cell: AS9

Note: =22.4'($AS$7'($C$41 •$C$42)/($C$45'($AS$5*273)))/(AS20'60)

Cell:Y11Note: Five volume percent of nitrogen purge per Run 23.

=Y8-0.05'3600/22.4)-2/1000

Cell: AM12Note: Based upon 37 kg of UO2 formed over a 12 hour period

Cell: Y13Note: =(1.8'6O722.4)-$B$12/10O0

Cell:AA13Note:=Y12

Cell: AK13

Note: Based upon being a 98%v diluent for enough oxygen to produce 37 kg UO2 over 12 hour period.

Pages

G-33


Cell: 114Note: =(4/22.4)M8*3600/1000

Cell: S14Note: =S8"3600*0.004/22.4

Cell: U14Note: =(Q13"Q20*S13*S20yU20

Cell: AE14Note: =(AE8*3600V22.4)'O.OOVB13

Cell:AG14Note: =AG8*3.68*(B13/22.4)

Cell: AI14Note:-AG13

Cell:AS14Note: =0.004-($AS$7'($C$41 •SC$42)/($CW5*($AS$5*273)))/<AS20/60)

Cell: L19Note: This Is taken from the temperature profile on spreadsheet HANHEAT3 WQ1

Cell: Q19Note: =013X48

Cell: S19Note: =S13X48

Cell: AC19Note: Taken from Cooling Temperature Profile spreadsheet HANHEAT4.WQ1

Cell: G21Note: computed from pumping speed formula from Perry page 5-34 with calcs enclosed in appendix

Cell: 121Note: =({($C$39+$C$40C{115/14.7)-(273/(15*273))yi8)/60

Cell: Q21Note: Taken from MCO Temperature Profile for heating. Assumes starting heat up at 40C

Cell: S21Note: Taken from MCO Temperature Profile for heat up.

Cell: Y21Note: time for vacuum evacuation only

Cell: AA21Note: per specification

Cell: AE21Note: =((C41 •C42)/(AE8#((273*Y5)/273))'(14.7/C46))«0

Cell: AQ21Note: from pumping speed formula of Perry

Cell: AS21

Note: =22.4-($AS$7-(ICJ41 •$C$42)/($C$45'($AS$5+273)))/$C$43

Page 9

6,-3*/

MATBAL2.XLS \rac-SD-SNF-CDR-007, REV. 0

Cell: S23Note: Assumes all hydrate water crvaigftd with tuel is rernoved during heat up between 200C and300C. The interface listing give no more than 4

lbs of this type of water

Page 10

CU+jt ~ ^C-SD-SNF-CDR-OOT.REV.O

•ftn-/* ~ C.CcCA-

/ . / -

J-^n—-• coo |

iC-OCCl, OObO

. CG<o]

^1 X la

11

'*1

ilii

0 ~ o,

Vc

O •

= \.G1 no'

UJ

-X-o.>S.\F-CDR-007, REV. 0 /(

f(C.icG, I

Q f(iei7- ^ — - F

G-3?


HVC-6LBA

7/26/96

CALCULATIONS TO DEMONSTRATE THE TEMPERATUREDIFFERENCE ON THE MCO DURING COOL-DOWN

Since issuing the 90 percent CDR, we have received calculations from Q-Metrics whichindicate a temperature difference of approximately 150°C across the MCO when takingapproximately 24 hours to heat the fuel to a bulk temperature of 300°C. This calculationwas performed using finite element analysis. It supersedes the calculation submittedwith the 90% CDR.

It should be kept in mind that the MCO can be operated within its 100°C temperaturedifference specification by changing the temperature profile, taking longer to either heator cool. We will constrain the profile with both the 50°C rate spec and the 100°Cgradient spec in the final MCO temperature patterned profile and intend to coordinatethese changes with Q-Matrix through WHC.

FROM : Panasonic FfiX SYSTB1 PHONE NO. :

Q-MetricsWHC-SD-SNF-CDR-007, REV. 0

Q-Metrics, Inc.P.O. Box 3016WoodiflViUc, WA 98072-3016Faone: (206) 915-8590/Fw: (206)481.5953

Date/Time: 7/2/96 No. of Pages (Including cover):

«" Deliver To: Curt Mlska/ WHC

Fax Phone: ( 509 ) 376-3252 _ Voice #: 376-7103

Project: Spent Fuel Thermal Support Project #:E014N-KBasin

Subject: MCO Wall Temperature Transient For Heatua/Cool Down

Message:The attached figure illustrates the estimated wall temperatures along the MCO lengthduring the heat up and cool down cycles of the hot conditioning process. The analysis isbased on the following assumptions:

1) Merrick's proposed approach of using 750 cfm of air in a 1-inch annulus aroundthe MCO. Flow proceeds from bottom to top.

2) Five layers of Mark IV fuel baskets with maximum decay heat. No chemicalreaction heating Is assumed for this analysis.

3) MCO design with the welded head. No special head region heaters employed.

The curves presented on the figure are defined as follows:TPLUG - average temperature of MCO closure plugT3 - inlet air temperatureTA270 - temperature of MCO sidowall at bottomTB70TC70TD70TE70TF70TG70TG74

approximately 17 Inches above the bottom45 "73 "101 "129 "132 "145 "

As teen from the figure, the MCO wall temperature gradient Is expected to be relativelylow except in the head region. Without some sort of supplemental heating or cooling, theclosure plug will lag the average MCO wall temperature by up to 100°C during heat up and75°C during cool down.

Let ma know If you have any questions.

From:Attachment: Transient plot Qregoi .en, P.E.

FROM : Panasonic FHX SYSTEM. PHCNE NO. : ' _— - - Jul. 08 1996 B4:05Pn 92


i

UJ

(3) 3HniVH3dW31

G,-iz

FROM : Panasonic FAX SYSTEM NO. . Jul. 02 1996 02:13=M PI


Q-Metrics, Inc.P.O. Box 3016WoodiBVillc, WA. 98072-3016Phone: (206) 915-8590/Fu: (206) 481-5953

Date/Time: .7/2/96 No. of Pages (Including cover):

w Deliver

Fax Phone

To: Curt

( 509)

Project: .Seeni

Subject: is/ICO

FuelWall

Mlska/ WHC

376-3252

Thermal Support,

Voice #:

Project

Temperature Transient For

376-7103

#:E014N-KBasin

Haatuo/Cool Down

The attached figure illustrates the estimated wall temperatures along tho MCO lengthduring the heat up and cool down cycles of the hot conditioning process. The analysis isbased on the following assumptions:

1) Merricfc's proposed approach of using 750 cfm of air in a 1-inch annulus aroundthe MCO. Flow proceeds from bottom to top.

2! Five layers of Mark IV fuel baskets with maximum decay heat. No chemicalreaction heating Is assumed for this analysis.

3) MCO design with the welded head. No special head region heaters employed.

The curves presented on the figure are defined as follows:TPLUG - average temperature of MCO closure plugT3 - inlet air temperatureTA270 - temperature of MCO aldewall at bottomTB70TC70TD70TE70TF70TQ70TG74

approximately 17 Inches above the bottom45 "73 "101 "129 "132 "145 "

A» teen from the figure, the MCO wall temperature gradient Is expected to be relativelylow except in the head region. Without some sort of supplemental heating or cooling, theclosure plug will lag the average MCO wall temperature by up to 100°C during heat up and75°C during cool down.

Let me know if you have any questions.

From:Attachment: Trensient plot Gregory .en, P.E.

FROM : Panasonic FAX SYSTB1

Q-Metrics

PHONE NO.. : Jul. BE 1996 04:04Pti Pi


Q-Metrics, Tnc.P O. Bo« 301ftWwxtinville, WA 98072-3016Phone: <2W 91J-8590/F*x; (206) 481-5953

Date/Time: 7/8/96 No. Of Pages (including cover):

Deliver To: Curt Miska/ WHC

Fax Phone: ( 509 ) 376-3252 Voice #: 376-7103

Project: Snent Fuel Thermal Support Project #:E014N-KBasin

Subject: Mark IV Fuel Temo. Transient For Heatup/Cool Down

Message-.

The attached figure Illustrates the estimated average (TSNF), maximum (TFMAX). andminimum (TFMIN) fual element temperatures during the heat up and cool down cycles ofthe hot conditioning process. The plot Is a companion to the plot faxed to you on 7/2. Inaddition to the analysis assumptions described in that tax. the following pertinent factsneed to be added:

1) nc credit is taken for heating and cooling via ths feed gases.2) Only "clean" Mark IV fuel Is assumed. A thermal model with sludge coated fuel

and the latest fuel basket design Is being created and checked out.

Let me know if you have any questions.

Attachment: Transient plotFrom:

Gregory J. Bankan, P.E.

RCu bY;Merr;cK r/ c ui-o o e m e r

FROM : Panasonic FflX SYSTEM" PHONE NO. -: " " - " Jul. 32 199£ 02:13PM P2


MCO Heat-up/Coot-down Transient

400

350

GS

29

i6II

TIME (Hours)

WHC-SD-SPJF-CDR-007, REV. 0

838 MERRICKO D D ««•»••«««.

COMPUTER CALCULATIONCOVER SHEET

PROJECT #30012318

NEW MEXICO OFFICE

CALCULATION TITLE: .

CALCULATION INDEX NO.:. /-/ t/C - 1

SUBJECT/PURPOSE OF CALCULATION: K ,-• t « •' **--

c - c L >< - i i $ 3

PROGRAM NAME:

PROGRAM REVISION:

INPUT DATA SOURCE:

REMARKS:

- ! Vi

M 5 U)on-r> VC?-O

ATTACHED ARE

X ^ PRINTOUT OF INPUT DATA RESULTS

D PRINTOUT OF SPECIRC PROGRAMMING OPTIONS AND/OR INSTRUCTIONS

• DOCUMENTATION OF SOURCES AND/OR DEVELOPMENT OF FORMULA

ORIGINATOR: />/•/ DATE:

INPUT DATACHECKED BY:•: LA At* DATE:

JKHCrSD-SNFCDR-OO?, REV. 0

Vacuum Pumping System Coolers

C. Air ®. Ambient Conditions = 0.0181 BTU/Ft3

MCO

20 SCFM Z _135- F ^

H,

sir F

1 Q'—

20SCFM ,90' F ^

20 SCFM70' F

H.

vps-PFR-noi OPSIG212' F

[

a

l/v\l H,

VPS-CLR-1103 0PS1G100' F

20SCFM70 - F

Mass Flow Ht

lOFt3

Min

68 460 0.0103*X r— = 0.0527 #/UmH

572460 Ft

He Heat Load g,

0.0527*/// 60Min 1.25BTU (212-572)* F-X X- =-1423BTU/HrMin Hr #' F

//.Heat Load Q2

0.0527#/H. 60Min 1.25BTU (100-212)° F-X X X- -443BTU/Hr

Min Hr # ° F

20 SCFM each for Air Cool in

0.0181 BTU 20 Ft3 60 Min-X — X . . =21.72 BTU/ Hi 'FFt3 ' F

Load

Min Hr

Hr 2172 BTU^

443 BTU H r ' FQ2 Load — X——-— = 20.4'FTemp. Rise

Hr 2172 BTU

jJVHC-SD-SNF-CDR-007, REV. 0

MCO Cooling System CoolerMCS-CLR-1153

Assume 82,000 Btu/hr max duty which is the rate of heat transfer for an MCO temperaturechange of 50° C per hour.

CASE#1: High Temp Case 572° F Air @ 750 ACFM

750 Ft3 (68 x 460) 0.075 * 60 m

m (572 + 460) Ft3 H 7 ~

82,000 Btu Hr # "F

Hr 1,726 # .241 Btu

= 1726 #/Hr

= 197" F

375 °F

10 GPM Cooling H,0

@66.4° F

750 ACFM Air

572° F

Hr

GPM-X = 16.4° F1BTU 10 GPM 500#/Hr

375 + 460750 ACFM = 606.8 ACFM@375° F

WHCSD-SNF-CDR-007, REV. 0

CASE #2: Low Temp Case 300 FAir@750ACFM

750 Ft3 68 + 460 0.075* 60 m

m 300 + 400 Ft3 Hr

82,000 Btu Hr # "F

= 2.345 #/Hr

Hr 2,345* 0.241 Btu

750 Ft3 155 + 460

= 145° F

300 + 460= 606ACFM@155' F

10GPM

@155° F

lQGPMCool H,0

@66.4° F

750 ACFM Air

300° F

G-so


§5§ COMPUTER CALCULATIONCOVER SHEET

PROJECT (30012318

NEW MEXICO OFFICE

CALCULATION TITLE T r o C - C - ^ S < ~i •

CALCULATION INDEX NO.:

SUBJECT/PURPOSE OF CALCULATION:~Tp CJXS<> U I O L V t HV-C O . p i p r « a X i

veAor- TO tm&ks. ~fl>rgnqk ^Ug. MCS ^

PROGRAM NAME:

"7. QPROGRAM REVISION: "^g-'E.1

INPUT DATA SOURCEbuOfe. SK-2.-300411 6 l o C _ t T

REMARKS:

ATTACHED ARE

X ^ PRINTOUT OF INPUT DATA RESULTS

D PRINTOJT OF SPECIFIC PROGRAMMING OPTIONS ANCHOR INSTRUCTIONS

D DOCUMENTATION OF SOURCES AND/OR DEVELOPMENT OF FORMULA

ORIGINATOR:

INPUT OATACHECKED BY: DATE:


INTRODUCTION:

The following report summarizes results taken from a simulated run of a model createdin WITNESS Release 7.0. WITNESS can simulate real events through random numbergeneration and will create reports documenting inputs into the model as well as resultsfrom the actual run. The following statistics report details the activity of each blockduring the simulated run. The following summary report describes the characteristics ofeach block and thus how they behaved in the model. Any questions regarding reportinterpretation should be directed at Merrick.

PURPOSE:

The purpose of this model is to calculate the approximate process time for 10 casksthrough a hot conditioning process.

ASSUMPTIONS:

1. All information for the model, except for shift times, was supplied by the blockflow diagram, Figure 2.1-1, Hot Conditioning Model Operating Sequence.This included identification of each process, order of processes, processtimes, decision blocks, and percentages on yes/no decisions.

2. Decision blocks that did not indicate a percentage were assigned a 50/50chance yes or no.

3. Only one item could be processed for each cycle.4. Shift times were input to the model. It was assumed seven days on, no days

off. Each day on consisted of three 8 hour shifts.5. No statistical or deterministic breakdowns were included in the model.6. The model had an infinite amount of labor available, i.e. tasks were not

resource constrained.7. Ten (10) complete operations would be modeled.8. An allowance of 24 hours was placed in the model between cycle completion

and restart to allow for any clean up or preparatory activities.

CONCLUSION:

The model determined it would take approximately 115.52 hours to process each caskthrough the entire process. To process ten casks consecutively, approximately1,410.30 hours would be required; this is roughly 59 days, or 8.5 weeks. Of course,these results are largely based on the above assumptions. Consideration should begiven that these assumptions are valid.

WHC-SB-SNF-CDR-O07, REV. 0

STATISTICS REPORT:

HCSE 1 Report Time: 1410.30

PART STATISTICS REPORTED BY ON-SHIFT TIMENumber Number Number Number Number Av. Av.

Name Entered Shipped Scrapped Assembled Rejected W.I.P W.I.P Time

puck 21

BUFFER STATISTICSTotal Total

Name in out Now in

20 0 1 1.44 96.48

REPORTED BY ON-SHIFT TIMEAverage Av. after Delay

Min Size Time No. Time

holdpuck 10 10

MACHINE STATISTICSNumber

Name of Ops. %Idle %Cycle

0 0.00 0.00

REPORTED BY ON-SHIFT TIME

%Stopped ^Waiting

sel oven

con_cell

opn_valt

plac_cvr

att__covr

remv cvr

opn_valv

10

10

10

10

10

10

10

10

10

10

10

10

10

99.94

99.88

99.88

99.88

99.82

99.94

99.88

99.88

99.88

99. B2

99.94

99.88

99.82

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

Busy

BlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDown -BlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

o.oo0.000.000.00

o.oo0.000.00

o.oo0.00

o.oo0.00

o.oo

SetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

o.oo0.000.000.00

- S~3

WHC-SD-SI«=-CDR-007, REV. 0

Numberof Ops. *Idle tcycle (Stopped %Waiting

evac_MCO

fill_MCO

leak_chk

passleak

cls_valv

disc_vlv

cln_port

inst_vlv

insl_cvr

cls_valt

het_cycl

surv_cel

discproc

perftest

accept

add_purg

coolpass

10 99.76 Busy : 0.24

10 99.94 Busy : 0.06

12 99.79 Busy : 0.21

12 99.99 Busy : 0.01

2 99.99 Busy : 0.01

2 99.99 Busy : 0.01

2 99.99 Busy : 0.01

2 99.99 Busy : 0.01

10 99.94 Busy : 0.06

10 99.94 Busy : 0.06

10 91.49 Busy : B.S1

10 99.65 Busy i 0.35

10 99.94 Busy : 0.06

10 99.82 Busy : 0.18

10 65.96 Busy : 34.04

11 96.44 Busy •. 1.56

11 99.99 Busy : 0.01

1 98.30 Busy : 1.70

10 91.49 Busy : B.51

DownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlocked

SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.000.00

RepairSetupCycleRepairSetupCycleRepairSetupcycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupcycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

0.000.000.000.000.000.000.000.000.000.000.00

o.oo0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.00: 0.00: 0.00

WHfrSD-SNF-CDR-007, REV. 0

flame

evacMCO

pass_gas

pass_per

cool down

evacMC02

fill He

move in

conn eel

openvalt

remveovr

clos_MCO

weldcovr

instweld

weldroot

vis_insp

clenweld

accept2

grind

rep_weld

Numberof Ops.

10

10

10

10

10

10

10

10

10

10

10

10

10

10

14

14

14

4

4

%Idle

99.76

99.94

91.49

92.91

99.76

99.94

99.82

99.94

99.88

99.94

99.82

99.SB

99.76

99.65

99.83

99.83

99.98

99.93

99.93

%Cycle

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

0

0

8

7

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

.24

.06

.51

.09

.24

.06

.18

.06

.12

.06

.18

.12

.24

.35

.17

.17

.02

.07

.07

%Scopped

Down :BlockedSetupDownBlockedSetupDownBlocked

SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.000.000.000.000.00

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.000.000.00

: 0.00• 0.00: 0.00: 0.00: 0.00: 0.00

%Waiting

Repair :SetupCycleRepairSetupCycleRepairSetup

CycleRepair :SetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

0.000.000.000.000.000.000.000.00

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.000.000.00

: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00

WHC-SD-SNFrCDR-007, REV. 0

Numberof Ops.

15

15

15

15

15

15

15

15

5

5

10

10

10

10

0

0

11

11

1

%Idle

99.

99.

99.

99.

99.

99.

99.

99.

99.

99

99

99

99

99

100

100

99

99

99

82

S2

73

62

82

91

82

.98

.91

.91

.65

. BB

.99

.65

.00

.00

.87

.99

.98

tCycle

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy

Busy

Busy

Busy

^Stopped

Down :Blocked :Setup :Down :Blocked :Setup :Down :Blocked :SetupDown :Blocked :SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.000.000.000.00

o.ooo.oo0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

o.oo0.00

o.ooo.ooo.oo0.000.000.000.000.000.000.000.00

o.oo0.000.00

: 0.00: 0.00• 0.00

: 0.00: 0.00: 0.00: O.OO: 0.00: 0.00: 0.00: O.OO: 0.00: 0.00: 0.00: 0.00: 0.00

Waiting

Repair :Setup :Cycle :Repair :SetupCycle :Repair :Setup :Cycle :Repair :Setup :CycleRepairSetup :Cycle •

RepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

o.oo0.00

o.ooo.oo0.00

o.oo0.000.000.000.000.00

o.oo0.000.000.000.000.000.000.000.000.000.000.000.00

: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00I 0.00

aply_dev

bleed

inspect

cleen

accept3

grind2

reprweld

makecovr

visinsp2

accept4

covrpass

grind3

repweld

visinsp3

accepts

grind4

WHC-SD-'SNF-CDR-OO?, REV. 0

Name

Numberof Ops. %Idle %Cycle

1 99.98 Busy :

10 99.65 Busy :

10 99.88 Busy :

10 99.99 Busy :

0 100.00 Busy :

0 100.00 Busy :

10 99.65 Busy :

13 99.85 Busy :

13 99.98 Busy :

3 99.95 Busy :

3 99.95 Busy :

10 99.C5 Busy :

%Stopped %Waiting

repaweld

corpass2

visinep4

accepts

grinds

reparwld

cvrpass3

visinsp5

accept7

grindfi

repr_wd

cvrpass4

visinsps

accepts

grind7

repr_wld

apply_di

soke

10

10

0

0

12

12

12

99

99

100

100

99

99

99

.88

.99

.00

.00

.ee

.86

.79

Busy

Busy

Busy

Busy

Busy

Busy

Busy

0.00

0.02

Down :Blocked :SetupDown :Blocked

Setup :3ownBlocked :SetupDown :Blocked .SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlocked

SetupDownBlocked

SetupDownBlocked

SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlocked

SetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.00

o.oo0.000.000.000.000.00

o.oo0.000.000.000.000.00D.000,000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00

Repair :Setup :Cycle .Repair :Setup .Cycle :RepairSetup :CycleRepair :Setup :CycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00

WHCrSD-SNF-CDR-007, BEV. 0

Numberof Ops.

12

12

12

12

12

2

2

10

10

10

10

10

10

10

10

10

10

10

10

\Idle

99.

99.

99.

99.

99.

99.

99.

99.

99.

99,

99

99

99

99

99

99

99

99

99

86

86

93

86

99

96

96

29

.29

.65

.88

.88

.88

.82

.88

.88

.94

.94

.65

VCycle

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy :

Busy

\Stopped

Down :Blocked :Setup :Down :Blocked :Setup :Down :Blocked :Setup :Down :Blocked :Setup :Down :Blocked :Setup :Down :BlockedSetup :Down :BlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetupDownBlockedSetup

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

o.oo0.000.00

o.oo0.00

o.oo0.00

o.oo0.000.000.000.000.000.00

o.oo. 0.00

0.000.000.00

: 0.00: 0.00: 0.00: 0 .00: 0.00: 0.00

%Viaiting

Repair :Setup :Cycle :Repair :Setup :Cycle :Repair :Setup :Cycle :Repair :Setup :Cycle :Repair :Setup :Cycle :Repair :Setup :Cycle :Repair :SetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycle

•

0.000.00

o.oo0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

. 0.00: 0.00: 0.00: 0.00: 0.00: 0.00: 0.00

aplydevl

bleed2

inspect2

cleen2

accepC9

grinds

repr_wel

remvtrap

new_trap

wastdrum

remvshed

hot_trap

topshiel

tie_bag

closdrum

undocovr

rem_covr

closvalt

survcell

. 0

Numberof Ops. %Idle ICycle %Stopped %Waiting

pull_MCO

Down10 99.94 Busy : 0.06 Slocked

SetupDown

10 99.62 Busy : 0.18 BlockedSetupDown





9 S4.68 Busy ; 15.32 BlockedSetupDown

0.000.000.00

o.ooo.oo0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

RepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepairSetupCycleRepair

0.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.00

VARIABLE STATISTICS

Name Indices

counter

SHIFT STATISTICS


< - Value(s) >

10


Name On-Shift Off-Shift Completed Shifts

worktime 100.00 0.00 8

SUMMARY REPORT:

HCSE_1 Report Time: 1410.30

PART SUMMARYMaximum Attribute Output Actions Part Contains

Name arrivals type Group rule C L route fluids Rep

1 Variablepuck

BUFFER SUMMARY

Name Qty Delay Capacity Input

holdpuck 1 None 1000 Rear

1 Push N N No

OutputDim. Rule

No

<-Actions->I 0 Min Max Rep

Front First

, REV. 0

MACHINE SUMMARY

Name

sel_ovenmove_MHM

lowr_MCOremv_MHMmov_cellcon cellopn valtplac cvratt_covrremv cvrinst cvrinst valopn valvevac_MCO£ill~MCOleak_chkpassleakcls_valvdisc_vlvcln_port

insl_cvrcls_valthet_cyclsurv eeldiscprocremvprocpurg vacperftestacceptadd_purgcoolpassevacMCOpass_gaspass_percooldownevacMC02fill_Hemove inconn eelopenvaltremveovrclos_MCOweldcovrinstweldweldrootvis_inspclenweldaccept2grindrep_weldsoakaply_dieremv_dieaply_devbleed

Qty

11111111111111111111

1111111111111111111111111111111l111

Type

SingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingle

SingleProductionSinglesingleSingleSingleAssemblySingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingle

LabR C

N NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN N

N NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN HN NN NN HN NN HN NN NN N

Down

NNNNNNNNNNNNNNNNNNNN

NNNNNNNNNNNNNNNNNNNNNNNNNNNNHNNNNNN

Inputrule

PullWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitwaitWaitWaitWaitWaitWaitWait

WaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWait

Outputrule

PushPushPushPushPushPushPushPushPushPushPushpushPushPushPushPushPercentPushPushPushPushPushSequencePushPushPushPushPushPushPercentPushPushPushPushPushPushPushPushPushPushPushPushPushPushPushPushPushPushPercentPushPushPushPushPushPushPush

ActionsS F B R

N N N NN N K NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N N

N N N NN N N NN N N NN N N NN N N NK N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN H N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N NN N N N

FluidF

NNNNNNNNNNNNNNNNNNNN

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNHNNNNN

rulesE

NNNNNNNN

NNNNKNNNNNNN

NNNNNNNNNNNNNNNNNNNNNNNNHNNHNKNNNNNN

ReF

IIIIIIIIIIIIIIIIIIII

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

G-& o

\*!HG-SD-SNF-CDR-002. REV. 0

LabName

inspectcleenaccept3grind2reprweldmakecovrvisinsp2accept4covrpassgrindsrepweldvisinsp3accept5grind4repaweldcorpass2visinsp4accept6grind5reparwldcvrpass3visinsp5accept?grind6repr wdcvrpass4visinsp6acceptsgrind7repr_wldapply_disokeremov diaplydevlbleed2inspect2cleen2accept9grindsrepr welremvtrapnew_trapwastdrumremvshedhot_traptopshieltie_bagclosdrumundocovrrem covrclosvaltsurvcelldisccellremvcellmovinMHMpull_MCOremovMHM

Input outputQty

11111111111111111111111111111111111111111111111111111l111

Type

SingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleSingleProductionSingleSingleSingleSingleSingleSingleSingleAssemblySingleSingleSingleSingleSingleSingleSingleSingle

R

NNNNNNNNNNNNNNNNNNNNNNNNNNNNKNNNNNNNNNNNNNNNNNNNHHNNNNNNN

Actions M U I O .C

NNNNNNKNNNNNNNNNNNHNNNNNNNNNHHNNNNNNNNNNNNNNNNNNNNNNNNNNN

Down

N

NNN

NNNNNNN

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNHN

rule

WaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWaitWait

rulesrule

PushPushPercentPushPushPushPushPercentPushPushPushPushPercentPushPushPushPushPercentPushPushPushPushPercentPushPushPushPushPercentPushPushPushPushPushPushPushPushPushPercentPUBhPushSequencePushPushPushPushPushPushPushPushPushPushPushPushPushPushPushPush

s

NNNNNNNNNNNN

NNN

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

NNNNNNNNNNNN

F B

N NN NN NN NN NH NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NN HN NN NN NN NN NN ItN NN NN NN NN NN NN NN NN NN NN NN NN NN NN NH NN NN N

R

NNNNNNNHNNN

NN

NNNNNNNNNNNN

NNNNN

NNNNNNNNN

NNNNKN

NNNNNNNHHNNN

F

NNN

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

NNNNNNNNNNHN

E

NNNNNNNNNNNNNNNNNNNNNNNNNN

NN

NN

NNNNNNNNNNNNNHN

NNNNNNNNNNN

N

Rep

IIIIIIIIIII1IIIIIIIIIIIIIIIIIIIIIIIIII

IIIIIIIIIIIIIIIIIII

PushPush

YN

YN

NN

NN

NN

NN

II

. 0

Lab Input Output Actions Fluid rulesName Qty Type E C Down rule rule S F B R F E Rep

next_MCO 1 Single N N N Waitregroup 1 Single K N N Wait

VARIABLE SUMMARY

Name Quantity Type

counter 1 Integer

SHIFT SUMMARY

ActionsName Type Periods Total Work Time Overtime S E Rep

worktime Main 7 168.00 168.00 0.00 N N Yes

WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Sy»t«m Equipment Advanced Technology SectorContract«MW6-SWV-310416,Tnk*17 Project No. 3001231S


APPENDICES

APPENDIX H

VENDOR CUT SHEETS

H-i

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning System Equipment Advanced Technology SectorContract*MW6-SWV-310416,T«tk«17 Project No. 30CM231S


APPENDIX H - VENDOR CUT SHEETS

1.0 STACK MONITORING

2.0

3.0

A-1000A-2000A-3000A-3001A-4000A-4001A-5000A-6000

Beta/Gamma Particulate Monitor (1)Beta/Gamma Particulate Monitor (1)Alpha/Beta Particulate Monitor (1)Tritium Monitor (1)Alpha/Beta Particulate Monitor (1)Tritium Monitor (1)Record Air Sampler (1)Record Air Sampler (1)

CHILLED WATER SYSTEM

CHW-ACC-2021CHW-CH-2026CHW-P-2022CHW-P-2023

Expansion Tank (1)Chiller (1)Chilled Water Circulation Pump (1)Chilled Water Circulation Pump (1)

COOLING WATER SYSTEM

CW-ACC-2011CW-HX-2014CW-P-2012CW-P-2013

Expansion Tank (1)Glycol/Cooling Water Exchanger (1)Cooling Water Pump (1)Cooling Water Pump (1)

4.0 MCO COOLING SYSTEM

MCS-CLR-1X53 MCO Chiller Exchanger (6)

5.0 PROCESS ENCLOSURE

Remote Manipulator (1)Weld Head (1)

6.0 PROCESS HEATING SYSTEM

PHS-BLO-1X51 Heat/Cool Blower (6)PHS-HCL-1X52 MCO Heating Element (6)

H - i i

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning System Equipment Advanced Technology SectorContract #MW6-SWV-310416,T««k #17 Project No. 30012318


APPENDIX H - VENDOR CUT SHEETS

7.0 PROCESS VENT

PV-BLO-2043PV-BLO-2046PV-F-1X71PV-F-2041PV-F-2042PV-F-2044PV-F-2045

8.0 VACUUM SYSTEM

VAC-VAC-3041VAC-VAC-3042

Vent Blower (1)Vent Blower (1)MCO Vault Filter (6)Main Vent HEPA - First Stage (1)Main Vent HEPA - Second Stage (1)Main Vent HEPA - First Stage (1)Main Vent HEPA - Second Stage (1)

Main Dewar Vacuum Pump (1)Main Dewar Boost Pump (1)

9.0 VACUUM PUMPING SYSTEM

VPS-BLO-1X06 He Recirculation Blower (6)VPS-CLR-1X03 MCO Vent Cooler (6)VPS-F-1X02 MCO Vent HEPA (6)VPS-F-1X07 MCO Vent HEPA (6)VPS-HCL-1X05 MCO Vent Heater (6)VPS-VAC-1X04 MCO Vent Vacuum/Circulation Pump (6)

H - iii

Particulate,Iodine andNoble Gas

Monitor

WHC-S">S.Y~-c:.> •.-.>: /

Model PING-3B

SELF-CONTAINED MICROCOMPUTER-BASEDUNIT FOR MONITORING STACK EFFLUENTSAND WORK AREAS

FEATURES INCLUDE: DIGITAL DISPLAYS,BACKGROUND SUBTRACTION, HIGH AC-CURACY AND SENSITIVITY, SIMPLE TOOPERATE AND MAINTAIN

A D I V I S I O N OF

_. .. I P ThermoEberline M E Electron PING--

CORPORATION

H-i

WHC-SD-SNF-CDR-007, REV. C

Model PING-3BPaniculate, Iodine and Noble Gas Air Monitoring System

GENERAL DESCRIPTIONThe Model PINQ-3B Is a microcomputer-based, cart-mounted monitor designed tomeasure the airborne concentration or stackemission rates of radioactive particulates,iodine, and noble gas. The PING-3B is simpleto operate and maintain, containing all of thenecessary hardware and programming (soft-ware) to be a complete, stand-alone system. Asimple, easy-to-understand keyboard allowsthe operator to input operating parametersand request current or historical data for hard-

copy output. The microcomputer monitors theoperation of the detectors and Dumpingsystem, does all of the calculations, and com-municates with the keyboard, printer, digitaldisplays and alarm system. Eberline's dataacquisition methods and background subtrac-tion features yield the lowest possibleminimum detectable concentration from agiven detector configuration. The PING-3B isideal for backfltting at existing nuclear powerplants that have analog systems.

SPECIFICATIONS

MICROCOMPUTERThe microcomputer handles eight channels:one each for paniculate and iodine, two fornoble gas, and four for background subtrac-tion.It accumulates count data from each detec-tor, then computes count rates and subtractsuser specified background factors.

It determines, annunciates and logs statuschanges to the printer for each channel andcontrols the alarm lights and check sources.The microcomputer computes and retains theaverage net count rate in history files for eachchannel. The PING-3B automatically prints(logs) the one-hour history files for any or allchannels at a user-specified time each dayand can optionally log the ten-minute filesevery four hours. Files are maintained for thepast 24 one-minute, ten-minute, one-hour andone-day averages.

History file information can be averaged, in-tegrated or differentiated. In addition, themicrocomputer can calculate the averagerelease rate for a history file based ondischarge rate when the PING-3B is used as astack or duct monitor.

Battery-backed random access memoryenables the PING-3B to retain channelparameter files in the event of a completeloss of power to the system.

Continuous flow and pressure Inputs from anew solid-state flow sensor combined withnew programming enables the PING-3B toperform derived concentration calculations onfixed filter channels resulting in readouts inunits of dCI/cm'. Absolute pressure

12-84

measurements made by the flow sensor allowthe microcomputer to correct the noble gasreadings for variations In chamber pressures.

SECURITYTwo key-locked switches provide securityagainst unauthorized operation or modifica-tion of channel parameter files. The first keyis necessary to allow operator commandssuch as "pump on" and "check source". Thesecond, and highest priority key, is necessaryto alter data base parameters such as alarmsetpoints.

DISPLAYThe Eberline Display III is a LED (light emit-ting diode) display module used to displaycurrent channel readings. The format of thedata display is three significant mantissadigits with a 1 V«-dlglt exponent (10 ± " max-imum). An array of six lights display the cur-rent status of the selected channel. The chan-nel to be displayed Is selected by a thumb-wheel switch located on the display panel.

PRINTERThe printer assembly consists of a new andhighly reliable 40 column, 7 x 7 dot matrixprinter. This printer has been used worldwidein retail, financial and industrial terminals,and has a mean printhead life expectancy of1.5 x 10* characters. The new printer is one ofthe most significant improvements incor-porated into the PING-3B. As part ofEberline's continuing effort to support currentPING-3 users, the new printer is now availablein a PING-3 printer upgrade kit.

WHC-SD-SNF-CBR-007, REV. 0

KEYBOARDThe keyboard is the communication pointfrom man to machine and has two subgroups.One group is the instruction pad, and the se-cond group is the data pad. All commandsbegin with a single entry via the instructionpad, followed by an entry or entries via thedata pad, and are terminated with the ENTERkey. Numerical data (calibration constants,etc.) are entered in fixed decimal point scien-tific notation. The instruction and data padsare color-keyed according to function.

SAMPLER AND DETECTOR SUBSYSTEMAn Eberline Model SA-13 sampler assemblycontains sample chambers for paniculate,iodine, and noble gas in one compact, 4 Tlead-shielded assembly (3 inches of leadshielding with 1 inch of lead between detec-tors).

PARTICULATEFixed Filter 47-mm-diameter, Millipore SM isrecommended. (Part No. FIFP1/9)

Detector Eberline Model RDA-3A, beta scin-tillation detector with the Model RDS-1 solid-state alpha detector for radon backgroundsubtraction.

Nominal Sensitivity (at flow rates of 60 Umin):'"Cs = 5 cpm/h for 1 x 10" " MCI/cm\~ S r - " Y = 8.8 cpm/h for 1 x 10" " jiCI/cm',T c = 3.B cpm/h for 1 x 10-"MCI/cm'.

Range: Approximately 10 - " to 10~* pCI/cm'.

Background: Approximately 25 cpm (depen-ding on geographic location) plus 10 cpm permR/h of external " 'Cs field. Both fixed and"live" background sources may be specifiedfor background subtraction. A solid-statealpha detector provides a means of subtrac-ting out the build-up of radon daughters onthe filter, and the area monitor provides ameans of subtracting gamma background.The noble gas effect can be subtracted via aportion of the low-range gas channel data.

IODINECartridge: 2-inch-diameter x '/i-inch-thickmetal-cased cartridge containing TEDA im-pregnated charcoal (Part No. FIFC1/4). Silverzeolite cartridges are available upon request.

Detector Eberline Model RDA-2A 2-inch-diameter x 2-inch-thick Nal(TI) crystal with a" 'Am seed embedded for automatic gainstabilization for drift-free pulse-heightanalysis.

Nominal Sensitivity: " ' I = 3.5 cpm/h for 1 xlO-'VCi/cm* at a flow rate of 60 Umin.

Range: Approximately 10 - " to 10- ' pCi/cm1.

Background: Approximately 45 cpm (depen-ding on geographic location) plus 15 cpm permR/h of external " 'Cs gamma which is sub-tracted via the adjacent energy window.

NOBLE GAS (LOW RANGE)Volume: 2.65 inches in diameter x 3 inchesdeep (270 cm' volume). Approximately 35 cm'of the volume is taken up by the noble gasdetector.

Detector. Eberline Model RDA-3A beta scin-tillation detector, 2-inch-diameter x 0.010-inch-thick plastic with 1.6 mg/cm' aluminizedMylar* window.

Nominal Sensitivity:'"Xe = 28 cpm for 1 x 10- ' ^Cl/cm'

at 14.7 psia;»Kr = 41 cpm for1 x 10->Ci /cm'

at 14.7 psia.Range: Approximately 10- ' to 10- ' pCi/cm*<uXe equivalent.

Background: Approximately 25 cpm (depen-ding on geographic location) plus 10 cpm permR/h of external '"Cs field. An empiricallydetermined fraction of the background chan-nel is subtracted to correct for gammabackground.

NOBLE GAS (INTERMEDIATE RANGE)Volume: 2.65 inches in diameter x 3 inchesdeep (270 cm1 volume). This is the samevolume viewed by the low range noble gasdetector. (Approximately 35 cm' of the volumeis taken up by the noble gas detector.)

Detector Eberline energy-compensatedGeiger-Mueller (G-M) tube.

Nominal Sensitivity:1MXe = 0.41 cpm for 1 7Bq MeV/cm»

(5.99 x 10-4 (.Cl/cm1) at 14.7 psia,"Kr = 0.61 cpm for 1 yBq MeV/cm>

(0.01 MCi/cma) at 14.7 psia.

Range: Approximately 10- ' to 10* pCi/cm*"•Xe equivalent (1 to 10' -pBq MeV/cm").

Background: Approximately 0.5 cpm (depen-ding on geographic location) plus 1 cpm permR/h of external "Co field. An empiricallydetermined fraction of the background chan-nel (identical detector in the lead shield) issubtracted for background compensation.

tf'3

AREA MONITORA gamma-detecting area radiation monitorwhich has a range of 0.01 to 100 mR/h isincluded.

MISCELLANEOUS SPECIFICATIONSElectronics: Eberline Interface Boxes, ModelsIB-2, IB-3C and IB-4A, which contain thedetector high voltage, signal amplifier andline driver, and provide the function of inter-facing the detectors to the microcomputer.Battery Backup: The PING-3B contains a bat-tery which powers the electronics for 8 hoursin the event of a loss of external power. Thisinsures against information being lost fromthe microcomputer's memory.

Check Source: There is a motor-driven checksource assembly for each of the monitoringchannels, except the intermediate range no-ble gas. Installed sources include a 30 pCi'"Cs for paniculate and low range noble gas,a 0.5 iiCi '"Ba for iodine, and a 0.3 /iCi"Sr -^Y for area monitor (NRC license re-quired). The check source is completelyshielded from the detector in a retracted posi-tion, and it is actuated either individually oras a group by keyboard request.

Analog Signal Input The acquisition of ananalog signal may be desirable in the eventthe PING-3B is used as a stack monitor. Asignal can be acquired which is represen-tative of the stack flow rate and used in com-putations of radioactive effluent release rates.Six channels of analog input are standardwith the PING-3B. Two of the channels are us-ed for input of absolute and differentialpressure from the installed transducers withfour channels of input available for othersignals.

PUMP AND FLOW INDICATION SYSTEMPump: Eberline Model RAP-3 with adjustable,regulated flow to a maximum flow of110 Umin. Recommended sample flow rate is60 Umin.

Flow Indicator The flow measurement systemconsists of absolute and differential pressuretransducers which pass information to themicrocomputer. This information is then usedto calculate the mass flow rate of themonitored air stream. The current sample flowrate in liters per minute may be viewed at anytime by selecting Channel 15 on the digitaldisplay. Channel 14 displays the samplepressure. This solid-state flow transducersystem is used to correct problems definedby NRC Notice 82-49.

MECHANICAL SPECIFICATIONSSize: 36.4 Inches wide (44.5 inches withhandles) x 31.75 inches deep x 50.1 incheshigh {0.92 m x 0.81 m x 1.27 m) with casters.

Weight: Approximately 1500 pounds (682 kg).

Operating Temperature: 32 °F to 122 "F (0 *Cto 50 *C).

Power Requirements: 115 Vac, 60 Hz at 15 Amaximum (typically 7 A running). (220 Vac,50 Hz optional.)

Inlet and Outlet Connections: 1-inch-o.d.(2.54 cm) tube-compression fittings.

OPTIONSHigh Range Noble Gas DetectorAn Eberline Model SA-9 detector assemblyproviding 3 Inches (7.6 cm) of lead shieldingIn a 4 T configuration.

Detector. Energy-compensated G-M tube with0.7 iiCl "Sr - * * / check source which views aportion of a 1-inch stainless-steel pipe run-ning through the SA-9.

Nominal Sensitivity: 0.01 cpm per ?BqMeV/cm1 at 14.7 psia

Range: 1 to 10* pCI/cm' <"Xe equivalent.

Background: Background compensation is ac-complished by automatically subtracting aportion of the signal from the G-M detectorimbedded In the SA-13 lead block.

Analog Signal Output OptionOccasionally it is desirable to output a signalwhich is representative of the radiation levelsensed by a particular detector in thePING-3B. This is made possible by the analogoutput option which is a 4 to 20 mA currentloop. Any or all of the measurement channelsmay have this option except Channel 2 (alphapaniculate).

Manual Purge/Qrab Sample OptionThis option provides the necessary valves andplumbing to allow purging the PINQ-3B and toallow grab sampling. All valves included inthis option are manually-operated, stainless-steel valves.

A DIVISION OF

Eberline I c ElectronC O R P O R A T I O N

P.O. Box 2108Sinta Ft, New Mexico 87904-2108(505) 471 -3232 TWX: 910-98M676

- WHC-SD-SNF-tDtt-OOV, REV. 0

Model PING-3Participate, Iodine, and Noble Gas Air Monitoring System

02-03 NORIIAL01 IODINE02 CPfi03 CAL.CONSTANT0« BKS*1 CH*05 BKW1 FACTOR06 BKG*2 CH*07 BKGS2 FACTOR08 m.BKG.SUB.09 HI AUt SET10 ALT ALK SET11 TN ALfl <Z/II)14 L0G6ED? HO19 SMt.FLO.CH.20 FLOW (CC/H)21 REL.FLO.CH.22 REL.FLO.FAC.

+1.00E+000

•0.00E+000

+0.OOE+W•O.OOE+Oo•l.OOE+Oi•l.OOE+Ot•l.OOE+Oe

00+0.00E+0.300•O.OOE+OC

02-03 NORHAL01 IODINE02 UCI03 CAL.CONSTANT<U BK«1 CH405 BKGtl FACTOR06 BKG«2 CH*07 BKGS2 FACTOROS FIX.BKG.SUB.09 HI ALII SET10 ALT ALT SET11 TH ALII <Z/n>16 LOGGED' HO19 SAO.FLO.CH.20 SAH.FLO.FAC.21 REL.FLO.CH.22 Ra.FLO.FAC.

+2.00E-05

•O.OOE+000

•O.OOE+00•O.OOE*Ofi

00 E 0•l.OOE+0*

1

15•1.ODE+0000•o.ooE-oe

iodina Channa/ Paramatar Ffia(shown baton tdlt)

lodina Channal Paramatar Fiia(thown aftar adit)

A I M ACKCHECKSOURCE

CHANNELSELECT

DISPLAY m - B f

Visual Display

.WHC-SD-SNF-CDR-007; Rljy. 0

fURGf /G" * • SAMf Lf OPTION

PING-3B Functional Diagram

PMG-3S Printer and Keyboard

AlphaParticulate

SamplerAssembly

A-3000

Model SA-4A

COLLECTS AND MEASURES AIRBORNE ALPHAPARTICULATE

SOLID-STATE DETECTOR

MAY BE USED TO MEASURE SPECIFIC ALPHA EMITTERS(for example "oPu, 2MTh, z^U, or »«U) WITH RADONDAUGHTER BACKGROUND SUBTRACTIONMAY BE USED TO MEASURE RADON DAUGHTERSINDIVIDUALLY OR AS A GROSS MEASUREMENT

DESIGNED TO INTERFACE WITH DIGITAL OR ANALOGSYSTEMS

MB • • A subs id ia ry of

cberline **—*•*•—•Systems Inc.

i3,000 e<>

SA-4A

H-7

- WHC-SD-SNF-CDR-007, REV. 0

Model SA-4A, Alpha Particulate Sampler Assembly

GENERAL DESCRIPTIONThe Model SA-4A Sampler Assembly utilizes a par-ticulate filter for sample collection and a solid-statealpha detector for determination of the alpha activityon that filter. The detector is followed by an ampli-fier an'd up to three pulse-height-analyzer (PHA)modules. The PHA modules provide the SA-4A withthe capability of monitoring for specific alpha-emitting isotopes as well as performing the func-

tions of signal processing and line driving for inter-facing the SA-4A to a digital or analog system.

The filter is 47 mm in diameter and is easily acces-sible through the front door of the unit. A flowmeter(10 to 100 L/min) is provided. The SA-4A is alsoavailable with a wall-mounting bracket.

SPECIFICATIONSDetector: Silicon-diffused junction type (cleanable)with 490 mm2 area.Filter: 47-mm-diameter; Millipore SM or equivalentrecommended.Counting Efficiency: Approximately 20 percent of2ir from a plated 47-mm-diameter a»Pu source inthe filter holder.Amplifier: Charge-sensitive input allowing veryhigh input sensitivity with excellent noise rejectionfollowed by a dc-coupled amplifier fed back forstability and control. Overall sensitivity is adjustableby an internal gain control.Pulse-Height Analysis (PHA): Normally suppliedwith two, but will accept three pulse-height analyzermodules. Each pulse-height analyzer contains ad-justable threshold and window levels. A windowswitch may be selected "out" for gross counting.Output process line signal drivers are capable ofdriving 2000 feet of twisted-pair cable.

Power Requirement: 12 Vdc at 150 mA (add 50 mAfor each additional PHA card); mating power con-nector is Amphenol No. 165-14.Temperature: Operational from +20°Fto +130°F(-7°C to +55°C); total change in system gain isless than ±5 percent.Size: 6.2 inches wide x 10 inches deep x 8.1 incheshigh (15.6 cm x 25.4 cm x 20.6 cm).Weight: 06 pounds (4 kg).The intake has a screen-protected cap with fourports for approximately 1 in2 total open area. Thecap is easily removed for attachment of a 5-inch-i.d. hose for remote sampling. The outlet has ahose barb for 5/16-inch-i.d. hose.

3-87

EberlineA subsidiary of Thermo Insixumen t Systems Inc.

P.O. Box 2108Santa Fe, New Mexico 87504-2108(505) 471-3232 TLX: 66-0438 EIC SFE

H-S*

r WflC-SD-£NF-CDR-007, REV.-O

r

Alpha AirMonitor ALPHA6 Product Family

ALPHA6A-1

ALPHA6-1

CONTINUOUS AIRBORNE ALPHA MONITOR

USER CONFIGURABLE FOR SPECIFIC ISOTOPE IDENTIFICATION

256 CHANNEL ANALYZER FOR RADON-THORON DISCRIMINATION

TWO RS-232C COMMUNICATION PORTS FOR HARDCOPY PRINTOUT AND COMMUNICATIONWITH PERIPHERAL DEVICES

A VARIETY OF CONFIGURATIONS INCLUDING STANDALONE, REMOTE DETECTOR HEAD,INLINE DETECTOR HEAD, AND NETWORKED SYSTEMS.

A subsidiary of

Systems Inc.ALPHA6

2-6

ALPHA6 Product Family~ WHfcSD-SNF-CDR-007, REV. 0

GENERAL DESCRIPTION

The ALPHA6 product family utilizes a solid-statedetector and a 256 channel analyzer to measurealpha particles of specific energies while minimiz-ing interference from radon-thoron alpha emitters.This increases the sensitivity over conventional oneor two channel pulse height analyzer techniques sothat 4 DAC hours of 2 M Pu may be detected in a typi-cal radon-thoron background.

The instrument incorporates micro-computer tech-nology which greatly enhances the measurementand data storage capabilities. Multiple historicalfiles are maintained so that the most informationpossible may be obtained from the data.

terminal or other computer. Information and setupparameters may be transferred bi-directionally.

A local keypad is included so that calibrationparameters and alarm settings may be input at theunit.

Both visual and audible alarms are actuated whenthe user adjustable alarm setpoints are exceeded.Alarm relay contacts are located on the back panelof the instrument and the alarm status is transmit-ted over communication lines if a printer or otherperipheral is connected.

A mass air flow measuring system provides flowand flowrate information which is used in comput-ing the concentration level. The combination of themass flow system and the 256 channel analyzerensures that the best measurement at the highestpossible sensitivity can be made.

Two RS-232C communication ports are provided sothat data and information may be output to a printerfor hardcopy data retention or so that a communica-tion link may be made between the ALPHA6 and a

A failure warning is given if a major fault isdetected, such as loss of the detector signal, loss ofthe air flow or failure of the real time clock. A localvisual and audible alarm is activated and a nor-mally activated relay drops out to provide an exter-nal alarm. In addition the alarm condition is trans-mitted over the communication lines to a printer orother peripheral.

The instrument is designed to be used with eitheran external air pump, such as the Eberline ModelRAP-1, or with a house vacuum system.

CONFIGURATIONS

The ALPHA6 family of alpha air monitors include avariety of configurations to help meet user specificsystem requirements. The ALPHA6 family includes:

ALPHA6-1 Alpha air monitor utilizing the tradi-tional top entry air intake stack iden-tical to the ALPHA-5A and AMS-3A.

ALPHA6A-1 Alpha air monitor utilizing theradial entry head. The radial entryhead is designed to maximize par-ticulate collection efficiency, meet-ing the requirements of DOE Order5480.11.

ACS-1 Alpha cam system features a central-ized electronics mounted in 19" instru-ment racks and utilizing remote detec-tor heads located in the work place. Acentral computer is used for all displayand control functions. Each rack unitwill hold up to six alpha cam channels.

ALPHA6A OPT1 Remote detector using theradial entry head.

ALPHA6A OPT4 Remote detector using aninline configuration for stack and ductmonitoring applications.

f-Ho

JVHC-SD-SNF-CBR-007, REV. 0

III

i

1

SPECIFICATIONSDetector: Diffused junction, solid state, 490 sq. mm(25 mm dia) active area. The gross efficiency isapproximately 25% (4T). The efficiency to 2MPu isapproximately 17% (4T).

Filter: 47 mm Millipore SM or Fluoropore FS. Depo-sition area is restricted to center one inch diameter.

Readout: The readout is a dot matrix liquid crystaldisplay system. Various forms of information are pre-sented, including time and date, air flow rate, energyspectra, and the measured values (cpm. concentra-tion, etc.) and the alarm points. A strip chart recordertype of presentation is also available with selecta-ble time units of seconds, minutes, hours and days.The display provides prompts to guide the userthrough the menus and historical data files.

Equation Specification: Five user definable varia-bles are available for configuration of the ALPHA6to a specific application. Default equations aredefined for measurement of 8MPu but may bechanged by the user to configure the instrument forthe measurement of different isotopes.

Alarm Determination: Up to six comparisons onthe user variables may be made to determinealarms and/or failures. Default settings determine23«pu alarms but these settings may be changed toreflect changes in equation definitions.

Clock: A real time clock is provided so that allalarms and data can be time stamped.

High Alarm: The computer in the ALPHA6 pro-vides optimum high alarm determinations. Slow,possibly statistical, count rate increases are exam-ined at length while faster increases give animmediate alarm.

Alarm Outputs: High alarm and failure alarm out-puts are available. Relay contacts rated for 1A, 115Vac are supplied. The failure alarm is normallyenergized. Locally, a strobe light and bell areprovided.

Air Flow Alarm: Provides an alert if the flow ratedeviates from the nominal range.

Computer Output: Dual RS-232C communicationports are provided so that the information may betransferred to a printer and so that communicationsmay be established with other peripherals. ALPHA6OPT2 provides an RS-232/RS-485 converter fornetworking a group of alpha air monitors to a cen-tral computer.

Historical Files: Included are files on energyregions, air flow volume, computed values of countsper minute, total computed counts, concentration,etc. Each file kept includes the most recent 64seconds, 64 minutes, 64 hours and 64 days.

Battery Backup: Used to maintain the real timeclock, operational configuration, and historical filesin case of a power failure.

Local Keyboard: For local entry of calibration andalarm parameters and for the selection of informa-tion to be displayed. A security code entry isrequired before operational parameters can bechanged.

Subtraction Function: Provides automatic back-ground subtraction. The amount of subtraction isdetermined by the percentage of the RaA and ThCpeaks which scatters into the region of the isotopeof interest. This percentage varies due to thechanging amount of dust loading on the filtermedium. The equation automatically corrects forthis changing percentage of scatter.

Air Flow System: The air flow system incorporatesa mass flow measurement. Flow data is incorpo-rated in the concentration calculations.

Sensitivity: 4 DAC-hours of 23»Pu can be detectedwith an average radon-thoron background.

Max. Count Rate: Approximately 500,000 cpm

Max. Channel Counts: Greater than 4,000,000counts per channel

Temperature: Operation from 32°F to 104°F (0°C to40°C)

Power: 120 or 240 Vac, 50/60 Hz, at OS A. RFI filterincorporated tor line noise rejection.

Size: AL.PHA6-1

ALPHA6A-1

Weight:ALPHA6-1

ALPHA6A-1

Approximately 13.75 incheshigh x 125 inches deep x 15inches wide (35 cm x 32 cmx 38 cm)

105 inches high x 15 incheswide x 125 inches deep (27cm x 38 cm x 32 cm)

15.4 pounds (7 kg)

14.6 pounds (6.6 kg)

Software Options: Alternate programs are avail-able which default to measure uranium isotopes,thorium and radon daughter products. Contact thefactory for current list of alternate programsavailable.

w tlL-au-aj> r -

CENTRAL COMPUTER SOFTWARECentral computer software is available for systemsusing either individual alpha cams such as theALPHA6A-1 or the ACS-1 Alpha Cam System. Thissoftware provides the operator with centralized dataacquisition and control over all alpha cams con-nected to the central PC. The central computer soft-ware utilizes a pull down menu system and pro-vides the following functions:

Edit Allows the user to display and modify theconfiguration of all alpha cams in the sys-tem. The operator may modify alarm set-points, variable equations and regions ofinterest.

Readings Provides floor plans and group dis-plays which are configured by the

Data This menu item allows the operator todisplay historical and current data.History files are displayed in eithertabular or graphical modes. A graph ofthe current alpha spectrum can alsobe displayed.

Utilities Counter control provides stop, startand reset commands. A clock setfunction is also provided.

TYPICAL SYSTEM CONFIGURATIONS

Individual Alpha Air Monitors

PC BasedCentral

Computer

Printer

RS-232/RS-485:r. Converter

RS-485 Network

r—

r

ALPi-vw'i

'"•' Monitor 'V• •

SJAlphaAifsI; - Monitor . "

ALPHA6A-1:; AlphaAir: .r Monitor'^ -

• Remote.. .'. D e t e c t o r : r

Head* '

PC Based

Computer

InP

serjetrinter

ACS-1 Alpha Cam

RS-232/RS-485.. .Converter

"Dot Matrix*' Printer,;;

Alarm and

Inf

Graphics Printerfor History File Graphsand Alpha Spectrums

itusormation

ACS-1 :Alpha Cam

'-'•Systeniv--

Mil

; Remote.-.-'.Detector

- X ' H e a d V r - -

Typical of 6

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Alpha Cam%':: System '.".

•

=

:~ Remote" ':;:: Detector •'.•

•• Head'o >•

Typical of 6

'Either Remote Detector Head Style May Be Used.

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REMOTE DETECTORS

ALPHA6A OPT1Remote Radial Entry Detector Head

rirrr

rf

Head: Radial Entry Style

Application: Workplace monitoring

Temperature: Operational from 32°F to 122°F (0°Cto 50°C)

Humidity: 0-100% relative humidity

Size: 83 inches high x 7.9 inches deep x 5.5inches wide (21 cm x 20 cm x 14 cm)

Weight: 63 lbs. (29 kg)

Distance from Electronics: Up to 500 cable feet(152.4 m)

Seal: Dust tight

ALPHA6A OPT4Remote Inline Detector Head

Head: Inline Entry Style

Application: Duct and Stack Monitoring

Temperature: Operational from 32°F to 122°F (0°Cto 50°C)

Humidity: 0-100% relative humidity

Size: 7.5 inches high x 4.4 inches deep x 10.25inches wide

Weight: 11.25 lbs. (5.1 kg)

Distance from Electronics: Up to 500 cable feet(152.4 m)

Seal: Dust tight

• WHC-SD-SNF-CDR-007, REV. 0

FIXED MONITORS300 AND 400 SERIES

-.FEATURESI

OVERHOFFTECHr\JOl_OGl

CORPORaTIC

FIXED, RACKMOUNT AND BENCHTOP MONITORS

These are line powered, and continuously operating monitors. They can be built with a large numberof combinations of FEATURES and OPTIONS, to suit the end user's particular needs. They areDesigned around three primary product FEATURES:

• RANGE OF MEASUREMENT• IONIZATDN CHAMBERS. PANEL METERS.

Each feature is designated by an alpha/numerical code.

Fixed monitors are classilied into four basic groups.

31X series — single range, with single ionization chamber- 32Xseries — single range, with dual icmization chamber %i,O00 e.ac^ V i ? i T l ( W M01V1TC/?"

41X series — multi range, with single ionization chamber•42X series — multi range, with dual ionization chamber

1160US K3UTE5OMtFC«D.OHOii1SM705(513)24M400

F E A T U R E S WHC-SD-SNF-CDR-OO7, REV. O

RANGE OF MEASUREMENT

Instruments are available in both single and multi range versions.

The single range instruments are tower in cost, and are recommended when a very wide range ofmeasurement is not required.

Single Range (3XX)Applications which require a limited range of measurement can be met by a single range instrument.designated as "three hundred" series. Range of measurement can extend from tnree decades to liveor even six decades.Mulli Range (4XX)Multi range instruments are used tor applications where a much wider range ol measurement isrequired. These instruments are designated as "four hundred" series, either automatically (AR) ormanually (MR) ranged versions. The most common are instruments with five ranges, however anyrange from three to seven can be supplied For example, to obtain a measurement span ol eightdecades, a four hundred series tritium monitor equipped with a three digit panel meter has 10 beprovided with five automatically switched ranges.

PANEL METERS

Instruments can be supplied with either digital or analog displays. Either linear or logarithmic scalescan be supplied for analog meter laces.Digital Panel Meters (DP)These meters are available in 3Vi and 4V4 digit versions. Single range monitors (300 series) can beequipped with either type of meter, depending upon the measurement range required. Mullirangingmonitors (400 series) are normally equipped with 3'/2 digit panel meters, since the overallmeasurement range is determined equally by the number of automatically switched ranges as by thedigit range of the panel meter itself.Analog Panel Meters (AP)Analog panel meters are available with either logarithmic (LOG) or linear (LIN) scales. A logarithmicscale can cover up to six decades for a 300 series instrument, or up lo nine or even ten decades lorthe 400 series instruments.

ION1ZATION CHAMBERS

Monitors are available with eitnei single or dual chambers. The chambers can be mounted inside theelectronics cabinet (ICI), or they can be located remotely (CR).

lonization chambers are available in a large number of sizes and configurations, each specificallydesigned lor a paticular purpose. A more general desaiption ol the nature and design of lonizationchambers is found on a separate sheet.Single lomzation Chamber (X1X)Dual lonization Chamber (X2X)The middle number in the alpha/numeric code designation for the description of the basic features ofan instrument refer lo the number of the ioneation chambers to form part of the tritium monitor.

Monitors are generally supplied with either single chambers, or with dual chambers, although there areoccasional applications where clusters of three or more chambers can be used.Mounting of lonization ChambersInternal lonization Chambers (ICI)Remote lonization Chambers (ICR)Mounting of the lonization chamber assembly can be internal to the main electronics cabinet Thisionization chamber assembly can also be mounted remotely at distances up to several hundred feetfrom the main electronics cabinet.Chamber mounting must be selected at the time of specifying the instrument.

- • - WHC-SD-SNF-CDR-007, REV. 0

TECHNICAL SPECIFICATIONS

ration provided here is of a general nature, and serves to provide an overview of some of the keyjrmance characteristics to be found in OVERHOFF TECHNOLOGY CORPORATION tritium

monitors.

MEASUREMENTTritium monitors with ionization chambers are capable ol an extremely wide range of measurement.Some OTC tritium monitors are capable of measuring activities as low as 0.01 uQJrri> other versionsof the instruments are designed tor high level measurements, approaching pure streams of tritium.

RADON (ALPHA) PULSE SUPPRESSION (APS)OTC tritium monitors can be supplied with proprietary circuitry which suppresses response to naturallyoccurring spurious background, thereby extending'low level tritium measurement well belowenvironmental radon or cosmic ray background.

STABILITY AND NOISEThe zero stability of an instrument is guaranteed to be equal or better than the smaliesf requiredincrement of measurement. For those instruments which are furnished with a digital panel meter, theshort term drift or noise is equal to, or less than, the least significant digit of the meter.

DBIFT. ENVIRONMENTAL (AZ)

Longterm drift can be caused by tritium plate-out, as well as by changes in the electronics. Auto zeroingcircuitry can be incorporated in order to eliminate all longterm electronic drift. Special chamberconfiguration such as heated or gridded chambers are recommended for prevention of effects fromlritium plate-out.

BESPONSE RATE

measurement signal level and the rate (time constant) are inherently interrelated. Highfeurement levels demand fast response, whereas low measurement levels demand long time

wCiistants, in order to smooth out noise and to provide a stable display To accommodate thiscontradictory requirement, three distinct time constants have been incorporated into the instruments.2 second for measurement above 1000 u.Q/m35 to 10 second lime constant for measurement of 80-1000 /jCi/m320 seconds or more for measurement below 80 jjQ/m3

Time constants usually switch automatically, although manual switching as well as different breakpoints are available.

ALARM SYSTEM. SIGNAL

Dual independent alarms are standard. Smgie. tripie and quadruple independent alarm systems canbe provided

SET POINT

Setting the level at which the alarm is activated is accomplished with the use of front panel mountedpotentiometers. Multi-ranging models also include tront panel mounted rotary RANGE selectorswitches, thereby permitting set point adjustment over the entire range of operation of the instrument.

MODE SELECT CONFIGURATIONSFront panel switch for operator selection ol several alarm modesNon- latchingAlarm active above set point; ceases below set pointLatchingAlarm triggered above set point; remains active until reset Can only be reset after the measurement

• receded below the set point value.

~n alarm which continues active once tripped, bui whicn can be deactivated by means of a pushbutton at anytime, regardless of set point level status

- WHC-SD-SNF-CDR-007, REV. 0

INDICATORS AND ACTUATORSIncandescent or solid state lamps lor alarm status and ac power status. Piezoelectric acousncsignallers with steady or pulsating tones.

INTERFACE24 pin receptacle, located on the rear of the caanet for interface conneaions for remote display,control and alarms, process controls or tor interconnection to digital connputer systems

ENVIRONMENTAL

Temperatureoperating 0°clo+50°cstorage -40°cto*70°cHumidity0-95% RHShock5 G. all directions

PHYSICAL

Power115/230 Vac. 50/60 HzEnclosure19' rack mounting131 deepheights from 5.25' to 10.50"other cabinets available

Weightscabinets—under 10 kgionzation chambers 10 to 50 kg, depending on number, size and shielding.

W-n

W-X-S.D-SNF-CDR-007, REV. 0

EnvironmentalAir Sampler Model RAS-2

WEATHERPROOF HOUSING

OPTIONAL IODINE CARTRIDGE HOLDER

FLOWMETER AND VACUUM GAUGE

47-mm FILTER HOLDER

A OlVlSI ON

ThermoEberline MSS,CORPORATION

$1,250 eg

RAS-2

• WHC-SD-S£(F-CDR;0O7rREV. 0

Model RAS-2, Environmental Air Sampler

GENERAL DESCRIPTIONThe Model RAS-2 is a weatherproof air par-ticulate sampler containing an oil-freevacuum pump, motor, airflow regulator,flowmeter, vacuum gauge, and filter holder.The system is mounted in a weatherproofenclosure (WPH-1) permitting exterior use.The pump and motor provide enough heat toprevent winter freeze-up, and an exhaust fanprovides summer cooling.

The Eberline airflow regulator is designed tomaintain a constant pressure drop across anin-line orifice by controlling a variable bypassvalve into the pump. The orifice is adjustable,permitting flow rate adjustment from nearzero up to the maximum pump flow capacity.

SPECIFICATIONSPump Type: Oil-free, carbon vane

Motor V* HP, 115 V, 60 Hz, 5 A(220 V, 50 Hz optional)

Vacuum: 26 inches Hg at sea level

Flow Rates: See figure

Filter Holder Model FH-1, 47-mm

Flowmeter: 0 to 100 Urn in (0 to 3.5 ft'/min)

Vacuum Gauge: 0 to 30 inches Hg(0 to 760 mm Hg)

Size: 23 inches long x 9.25 inches wide x 13inches high (58 cm x 23.5 cm x 33 cm).

Weight: 60 pounds (27 kg)

FLOW(ft'/min)

S 10 IS ZO 29VACUUM AT INTAKE (INCHES OF H«)

This flow control system permits the pump tooperate at a minimum pressure drop at alltimes, which provides cooler pump operationto extend the lifetime.

It should be noted that when pressure varies,the flow through an orifice with a constantpressure drop will vary as the square root ofthe ratio of the absolute pressure. Therefore,if filter loading creates a pressure drop o150 percent of the original pressure, the flowreferenced to atmosphere will decrease by30 percent.

AVAILABLE ACCESSORIES

Iodine Cartridge Holder Model ICH-1

Iodine Cartridge: Part No. IC-1

Calibration Adapter Model ZP10758009(Mates FH-1 to 1-inch NPT)

Filter Paper Part No. FIFP8, 47-mm

CalibrationThe unit is supplied with a three-point flowcalibration using a mass flowmeter.

CALIBRATION ADAPTER (Shown with masstlowmeter attached) mass flowmeters are notsold by Eberline.

12-84

A DIVISION O*

_. .. s s ThermoEberline I K BeamP.O. Box 2108 « " " " " » > ~Suit* F«, New Mexico 87504-2108(505) 471-3232 TWX: 810-9854678

ACS-1 ALPHA CAM SYSTEM . o

ACS-1 Alpha Cam System

The Alpha Cam System (ACS-1) is based on theEberline Model Alpha6 Alpha Air Monitor, withappropriate design changes to create the most effi-cient system configuration. The most significantdifference is the use of rack mounted electronicsmodules. Up to six Alpha6 electronics modules canbe placed in one 19" rack. The electronics moduleis the heart of the Alpha6 monitor and includes thepulse processing electronics, MCA (multi channelanalyzer) and the microprocessor based computersystem used to analyze the spectral data and con-trol the monitor. In order to conserve valuable floorspace, improve the man-machine interface and cutthe costs of multiple individual displays, a PCbased system controller for readout and control ofthe monitoring system is used. The individual dis-plays, typical on the individual Alpha6 cams, havebeen removed and the PC will provide this functionfor the whole system. The PC also provides dataarchiving/report generation capability. The elec-tronics modules perform the monitoring and alarmfunctions independent of the central computer.Therefore, a loss of the central computer does notcompromise the safety function of the ACS-1.

The ACS-1 is comprised of two modules: the elec-tronics module and the remote detector headassembly. These modules are connected by a sin-gle multi-conductor cable. The detector headassembly may be located up to 500 ft away from theelectronics module. Either the radial entry or inlineversions of the remote detector head can be used.

Electronics Module

The electronics modules are contained within the19" rack mount enclosure which is capable of hold-ing up to six electronics modules. The electronicsmodule is the standard computer board used in theAlpha6 Alpha Air Monitor. In this configuration theliquid crystal display and keypad typical to eachmonitor are removed in favor of a single PC baseddisplay/control system for all monitors. The displayand keypad is not necessary on each monitor whenall the monitors and the display/control computersystem are all located together. The display/controlcomputer system provides an enhanced operatorinterface by displaying the current status and read-ing of all monitors in the system on one display.

Contained within the electronics modules are thepower supply, the multi-channel analyzer and elec-tronic subsystems to support the flowmeter, com-munications and various alarms. Each electronicsmodule has an RS-232/RS-485 converter for com-munications to the system display/control com-puter. Two relay outputs are provided for each mod-ule. One relay is provided for alarm and a secondrelay for failure conditions. Each relay has a set ofDPDT contacts.

The rack unit has indicating LEDs for each chan-nel. The LEDs provide indication of normal, alarmand failure status for each channel. Each channelalso includes a connector for a portable terminalaccessible just behind the hinged front of the panel.The portable terminal allows the operator to take agiven channel out of the system tor periodic main-tenance and calibration.

2-92

EberlineA subsidiary ai Thermo Instrument Systems lac.

P.O. Box 2108Santa Fe. New Mexico 87554-2108(505)471-3232 FAX: (505) 473-9221

W-ZJO

WHC-SD-SNF-CDR-007, Rev. 0"

Pages H-Zl through H-28 have been removed from the document due tocopyright and/or trademark restrictions. The information on these pages canbe obtained from the project manager.

H-21 through H-28

S I::>-SNI ;-C['R-OC,RE:V. O

9 m Si *>-May 11989

Split SystemAir Conditioners

20 through 120 Ton

-2026 6/22./%

I PerformanceData


_ Condensing Unit With Evapontor Chiller

42.744.146-2• 33

45.04S.446.046.6"7°52.653.053.754.555.0

ida Ambient Temperature Entering Conoem

15315316.617.4'7-9

_ ! < * _105

15316.417.218.018.6

19.419319320.020.2

14.414315.716.4

19.519.720.020320.4

15.015316317.017.5

21.621.822.022322-521322.022722-522.7

23.724525.726927.7

29.129.429330330.5

22.521224.425.5

32/)32.6

32331334.936537.7

40.140.4

33.1343

37.5.38.7

30431432334.535.6

43.644.144.745.0

39L340.642.544.545.9

3M32233.83i536.6

44.445.0

50.65 U51.6

37.238.440342243.5

55.05555&256B573

43.946.047.4

50351.051.7 43.5

44.946.848350652.954.6

5&S59.059.760.561.0

44345.848.050251B

56.6573578

66367J67J

Tons13.514.014.715.4

16.016.5

21J21.923.024.1

28-529430332.533.529230231.833334.43HS36.137.839.740336.037.239.0403

41.743.145.247.4483

21224.524325024324.524.725.1253

20:020.621.622.623320.621.222323324.0

24.624825.125525.724325.025.425.7263

119• 193 i

20.4 '! 21.4

22.1 .'

20.121.122.1223

27427.627328328-527.627328.128.52a7

17.7ia319320.220.818^18319320.821.4

30330.731.031.431.630.730331331.631335336J2

37.137.448-248.6

493503

49.550.150-561.261.762.4

61.762.1623

72.172.773374.575.1

553583611631

54.054.555356.156.6

51.052355.458.160.0

59360.5613623623

48349.852.455.0563

66.467.068.068369.6

45.146.749351.753.4

73.6743753763763

r

Data .WHC-SP-SNF-CDR-007, REY. 0

Rfluni 29-1 — Ajr-Coolod Condensing Unit £ R A U C 2S Ton

«7/T 00 KOT CAl tV*ASS COHN

U l / T l l W VOLTAK

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29

WHC-SD-SNF-CDR-Q07, REV. 0

DimensionalData

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NOTES:

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ENGINEERING SPECIFICATIONSAND DIMENSIONS

C-SMf-CDR-007, W.X 0

I i 3 1 0

r32

15

I

The contractor shall furnish (andinstall in location as snown on theplan) an Aurora Type (321 horizon-tal) (323 flange mounted) (324Ahorizontal) Centrifugal Pump size

(bronze fitted) lal! bronze)(ail iron! construction Each pumpshall have a capacity ofG.P.M. at ft total head and

specific gravity The pumpis to be furnished with case wearingring and a mechanical seal, vwth ailmetal parts to be 31 6 stainless steel."Buna-N" bellows. Ni-resisi seat,and carbon washer.FLEXIBLE COUPLEDPUMPS — MODEL 324AThe pump shaft is to be stainlesssteel with (grease lubricated) (oil lu-bricated) ball bearings. The pump isto be flexible coupled to a standardhorizontal NEMA motor ofH.P phase Hertz.

voltage R.P.M. (dripproof) (totally enclosed) (explosionproof) enclosure. The pump shall bemounted on a (fabricated steel driprim) (steel) base plate. Pump andmotor alignment must be checkedaccording to the Standards of Hy-draulic Institute after the pump hasbeen installed.

?CLOSE-COUPLED PUMPS -MODEL 321-323The pump is to be close-coupled to aNEMA motor of . . / * T . HP., Sl«c.i-£phase,. W. . Hertz.. 1^0 . voltage.. .l.?i~o R.P.M., (drip proof) (totallyenclosed) enclosure, with stainlesssteet motor shaft. The motor shall bedesigned to Aurora Pump speci-fications as to vibration limits.

bVftignt 3'9 C ODtn Of io oroof motors on**

Dimensions i re "oi speatitO as iney vrtiotor manufacturer5 Aad OLHT>D. oast ana motor w«iqm -o> :6 Not 'or construction DufDOtes unless :•

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WHC-SD-SNF-CDR-007, REV. O

MATERIAL OF CONST.

281

II

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en

Pl.!e

act.!

3ian

DESCRIPTION

;onnections —•1 N.P.S.F

iion —Facing Suction

-eter at Impeller

Diarneier at Seal

Dianlater Between Bearings

lerer at Coupling End

Couonng Keyway

Max

Bear

Bear

Bear

Bear

Deflection at Seal Face

ing (InDoard Radial)

mg lOutooard Tnrust)

ing Centers

ing Type

DIM.

Var.

CCW

19/32

3/4

1-3/8

7/8

1-3/8 Lg.x3/32Da

.002

206K

206 KG.

5-11/16

Ball

t*LLU0NZ!

SteNnet.

LIMITATIONS

MAX. BASED ON STO. MATL'S S WATER

Casmg

Case Weiringflmg

Impeller

MotorSricner

Snail

Powerframe 32*A

CasnroiASTM A48

BronieASTM 962

9'onzeASTM B5S4

CasiironASTM A«J|

Stam. SieelAISI 416

Cast ironASTM A4«

Cist 'ranASTM A4S

Cast ironASTM A48

Cast IronASTMA48

Cast ironASTM A4S

Sum StealAI51416

Cast ironASTM A4S

BronzeASTMB62

BronzeASTM 962

BronzeASTM 8504

BronteASTMflQ

Stain StttiAISI 316

Cast ironASTM A48

Speed — rpm 3500

Horsepower 7-1/2

Temperature

Close 22SCoupled

Frame 225Mounted

Hydrostatic Test — P.S.I. 220

Mm. 3,0 Bearing LifeUnder Max. flee. Load

Stainless site I metal oirts "Buna-N"elastomer oarts. Ni-mist wai and car-Don watner tAll eronze has Viton t«s-totner parts and ceramic M » I

Case Working Press — P.S.I. 175

Suction Press — P.S.I.175

...--1

4

WHC-SD-SNF-CDR-007, Rev. 0"

Pages H-35 through H-42 have been removed from the document due tocopyright and/or trademark restrictions. The information on these pages canbe obtained from the project manager.

H-35 through H-42

" WHC-SD-SNF-CDR-007, REV.

PENTAD ASSOCIATES, INC. '

FAX TEAHSHITXAL

DATE: June 14, 1996

TO: Santa Fa Engineering

ATTH: Dave Hunger

FAX »: 505-983-5608

FROH: Paa Standley

RES Heat Exchanger S»-HX=35l3Plate & Frame / MaxChanger Sizinge

Total pages (ineluding oov«r)I 6

MESSAGE:

Dava, please find the following sizings, per our conversation.

7 9 » S . Linoon Suite 102Uteton, CO 80122-271S

3CS 794-4802303 794-2345 FAX


MJOIOQK.*t r a n t s f SMBOMNQUQUOTATION

ISAVE KBHGCR MTfc 16 /12 /96

YOU* I

Mfll 1

1£C 013343-18A M f HK*

or F » lagain. » i)>«iln tM •Wliuilo tt mum Ow

Unit Fries $ 2443.0t

WHC-SD-SNF-CDR-007, REV _0

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WHC-SD-SNF-CDR-007," REV. U „

TMHTEft. IMC.KAXCBMKiSlt SPECirlCATZCW SHOT

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your Tranter Kepraaentativa i*:

PSRAS Asaoeiaeaa. Inc.7*50 S. Lincoln. Suit* 102Llcelatan, Co 80122

(301) 794-4102

•«i» KAXCHMMBft perforaasea suaraataa ia baaad ac tua accuracy of tha datapraaantad akova, and tha euatoaera ability to supply product and oparatiaaeandltlaaa in oonforaanea with eaa above.

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UFX-18-1 THREADED (4) REV. «-!-««

• T O M LOCATION

WHERE THIS

•MOTE

OMOHUTED

QUOTATION FROM - - C,\N - P - 2-0) 2

PUMP & SUPPLY

D BOX 3180

D BOX 1317

E 1424 WEST CEOAK

O BOX 1351

PHONE X7-265-1207

701-572-8012

TO:

CASPER. WYOMING 82602

ROCK SPRINGS. WYOMING S29O2

OENVER, COLORADO 80223

WILUSTON. NORTH DAKOTA 5S801

°»*: 2-26-96Merrlck

tMOUWYNO:

• MOUECTEDBY

Quotation No. 411796Tony Goveas

Ml M M eontracta nuda By ua ora maoa Mikioct lo ma Wloi ant: (1) Falcon Pump A Supply ahall not ba liaMa lor any aaiay in ma eomptalionot anyoamiael cainaC by alrilia or any omar laoor dmmillwa. or by lira, Nooo. a c t « Qod. or act of ma public anamy, or oy any cauaa alulaoaoorbayonom control; 12)kabiuiy, il any, ol Falcon Pump * luppur lor any datoa in •rorunanahip or matanal ia UnwaP atrictty» ma anammalMwrnatonaiwillbouppuadloranypan•roMn o*loelt«o, bul no claim for labor will ba alia wad far oamapoa roaultinQ horn Ooloet in workmanship or malarial.

QUANTITY DESCRIPTION PRICE

Goulds ICS lxUi-5. 3 T*S»e, 3450 RFK, single phase, TEFC close

coupled centrifugal pump

Total Unit Price

Goulds ICS lxlk-5, 3 HP, 3450 RPM, 3 phase, TEFC close

coupled centrifugal pump

$1582.00i

Conditions: 50 GPM ? 115' T0H

Pumpage: De-mineralized water

Total Unit Price

Slnc

$1646.00

T«m. Net 30

K U K M Factory

n.B^. 3-4 Weeks _ARO (Alttr Haenpi e ( OrOoO

14-

WHC-SD-SNF-CDR-0Q.7, REV. 0 .;• _

" GarSTAINLESS STETL

MODEL

ICSFEATURES

Superior Materials ofConstruction: Precision invest-ment casting for liquid-end compo-nents are all type 316 stainlesssteel.

Compact Design: Close-coupled.save space and simplifiesmaintenance and installation.High Efficiency Impeller: 316 caststainless impeller of open designfor efficient operation and fastclean-up.

Casing Features: Stainless steelconstruction with NPT threadedconnections, optional drain andvent with stainless steel plugs.Mechanical Seal: Standard JohnCrane Type 21 with carbon versusceramic faces, Viton elastomers.and 316 S.S. metal pans.Optional high temperature andmild abrasives seals available.Motor: NEMA standard opendnp-prool or totally enclosed fancooled enclosures. Rugged ballbearing design for continuous duty.

APPLICATIONS

Designed for ultra pure water,chemical and general services.Specific uses are for:•Washer Equipment• Ultra pure water systems• Scrubbers• Chemical Transfer• Water reclamation and treatment• Beverage processing• Pharmaceutical service• Machine tool coolant

SPECIFICATIONS

Capacities to:56 GPM (13rrrVh) at 1750 RPM103 GPM (24rrrVh) at 3500 RPMHeads to:33feet(10m)at1750RPM129 feet (40m) at 3500 RPMWorking Pressures to:i75PSIG(12bars)

Maximum Temperature to:212°F (10CTC) with standard sealor250"F (121*C) with optional higtemperature version.

Rotation clockwise when viewedfrom motor end.

M O T O R S

NEMA standard design:1750 RPM V4 HP or 3500 RPMV4 through 3 HP ratings. 56J frame.Open drip-proof or totally enclosedfan-cooled enclosures. Ball bearingdesign stainless steel shaft.

• Single phase voltage 115/230 ODPand TEFC. (3HP model 230 voltonly) Built in overload with autoreseprovided.

• Three phase voltage 208-230/460ODP and TEFC. Starter andheaters must be ordered separately

IG&LWHC-SD-SNF-CDR-007, REV. 0

Stainless SteelClose-Coupled Centrifugal Pumps1750 RPWI

Dimension Print

SECTION 1MODEL ICSEffective May. 1991

ENGINEERING DATA

Clockwise Rotation Viewed from Drive End

InsUltalionDrawing No.

119-64

Certified for comttuaien purposesDForApprowl D For Record

-IT

WEIGHTS & DIMENSIONS -DETERMINED BY PUMP

Pump

1 > 1V.-5

1/.«tK-5

Suet.NPT

1%

IK

Distil.HPT

1

tx

I

3.7S

3 «

ft

.841.06

W

3.01

2M

X

ASi

• w i .Mai.

17

t7

NOTES:1 Pumps will Oe shippad with top vertical discharge as standard, far other oriantalions, ramovv casing botls.

rauue to desired position, and tqruen W bolls » 24 IBs.-*..2 Dimensions in inches, weight m pounds.3 Not to be used lor construction purposes unless cenlied4 Motor dimensions may vary «"»> motor manutacturers

• Weight i> liquid and only. For complete pump. Mid wetghl ol applicable motor shown below.

AVAILABLE MOTOR WEIGHTS

w

'A

OOP

19

MMorWeiiMtfciPeWBis

1Fhneme20

IftweUP19

TEFC

20

SKCmCATWtS A M SU»J«CT TO CMANOC WflHOUT NOTICC. PBlNrtOlNU.SDOI.I7S

it. «r 83J

•84 5-3 370 383 371 I *!MATERIALSOF CONSTRUCTION

torn Hi.

100

Iflt

126

114

330*

370

370H'

371

383

401

412A

513

Dtmutnn

Ca»o

Motor Adapter

snanswve

SealHousinc

SnimPack

H.H. Scnw. Adapter to Casing

H.H. Screw. Adapter to Seal Hsg

N.H. Screw. Adaour io Motor

Mechanical Seal

Dram Plug. Casing (Optional)

O-fUno. ImoMer

O-Amg. Cumg

Ualenals

AISI3USS

Cast iron

AISI 316 S.S

Piasre

AISI 304 S.S

"see chart

AISI 316 S.S

Viton

Partita.

10K38

10K39

10K40

Slnitt

Mild Chemical

Hoi Water up to 250* F

Moo Abrasives

"Medwricil SeaU-ltui 3>3

R»U1Y SatMMrt

Ceramic

Carbon Ni-fitsot

Tnngslen-Carblde

Etntmn

Won

Effl

Won

»1UIP«U

316S.S.

CimTytt

21

PUMP DIMENSIONS & WEIGHTS

HP

<h

V.1

i

675 tS

Mater Wti«Miiidu°tl<i

RPM

1790

3S00

3500

3900

3900

3900

3SO0

1

4.12

M N w

OOP19

19

22

29

31

36

40

750 III

TEK

20

—

24

26

36

39

49

mu

Sffkan

OOP

19

20

2224

27

39

42

3.79

RFC

20—

23it

33

37

H

.41

cNo.

S.5

1034

10J4

10.77

11J111.78

13.34

- WL

17

121_l?__ie_Hoka ~17~

A GOULDS »UMFS C

Close-CoupledWHC-SD-SNF-CDR-007, REV. 0

- Performance CurveMode l lCS ix i V4

SECTION5

METERS FEET I

; Model/Size ICS1x1Vi-5I IMP. DWG No. 119-56

RPM3500Curve No. CN284R01 jOpuonjI Impel.

! Coo.

I *B

I C

I 0

E

F

G

H

J

t

M

N

K m

5 H -

5 V

5'

« V

4V--

4 1-"

4 'l'

3 ' W

3>;-

3 'A*

3 V

3 W

T

METERS FEET!

a

30

; Model/Size ICS1x1'/4-5i IMP. DWG No. 119-56

RPM1750 iCurve No. CN287R01 !

Option** impellerOrdevng

Code

A

8

C

D

E

F

G

H

J

K

I

M

N

s li-

sa-

s'*'*•

4Vi*

4 W

4 V

3 .4"

3 V.-

3V»"

3 V

3V»-

r

45 US. OPM

V

urn rang Sit put*pno*

Pt»O

CAPAOTY

rustnmiirPump Item

Condition nf Scnnrj Imo DiaRPM TDH Fff%

Certified (or AoprovalQBy nal» Rernnt H

NODIBJ uom

WHC-SD-SNF-CDR-007, REV.OMAHLO COL P.O. BOX 171 w > n o i s M a n n (530-13

I Date:

Attn: _Firm: _

Fax#:

FAXT» FROMName: Chris L»hmannPhone: (314) 677-7731 ext. 38

FAX: (314)677-1203

•a i MMmaaen aw « privlBgad, oonfdamal andjam ia»xji»Ma Iw daiharna »w m«aao« t> ih»

•Mlaii.aroaeMolMeeinnur*«ianiaiMca)ri>ioha>ad. « you u a rwrtvadflnriratunVwoWiutf fiHBSMt Wut by rrna TtiwiK vou.

• • C»// back Immediately Ifymu Mm not receive all pages • •

REFERENCE:

MESSAGE:

Chris LohmannCoil Sales

MhlC \<\

WHC-SD-SNF-CDR-007, REV. 0 ^ „ : .

MARLOCOL F.QBOX171 HOMWGE. MOBOUnaaCHe PHONE31«-B"-eBOO

June 14, 1996

Subject: Santa Fe EngineeringMario Q* 96230370

Dear Mr. Hunger,

Mario is pleased to provide budget pricing per your request:

Met ExtendedQty. Description Bach Mot

(1) Airtight Housing w/ Transitions and

Cl)8W8-12-5£>llF-l-H-.5-R-W *5,073 ?5,073

All pricing is F.o.B. High Kidge, MO, freight collect.

Materials of construction:

rins; .010" thk. 304 stainless steelTubes: .049" wall, .625" O.D. 304 stainless steelHeaders: SchlQ 304 stainless steel pipeConnections: 1" Class ISO 304 stainless steel pipe flangesCasing: nia. 16 ga. 304 stainless steelInsulation: TBD

Asawbly consists of as airtight coil assembly with upstream anddownstream transitions from square coil face to round pipe flanges-Intire assembly will be covered with insulation.

Coil connections will be sane end.

If you have any questions, please call ne at (314)677-7731 ezt.38.

Thank you for the opportunity.

Best Regards,

Chris Lohmann

WHC-SD:SNF-CDR-OO7, REV. o

MARLO (R), P.O. BOX 1T1, HIGH RIDQE, MO. BS049-0171

^PRESENTED BYAriO (3t4) 677-6600P.O. Box 171High Ridge, Missouri 83049-0171

ENTRY DATE = 08-14-1996CUSTOMER ID = SANTA FE ENGINERINGTAG NUMBER =PROGRAM ID ~ WATER COIL RATING / VERSION 3.8APPLICATION = COOLING

DESCRIPTION

Air flow (ACFM)Ent. air DB / WB (F)LVB. air DB / WB (F)Total capacity (BTUH)Surra, capacity <BTUHJEnt / Lvg water (F)Water flow (QAL/MIN)water ve1ocity(FT/S£C)Water pres. aroo (FT)Face velocity(FT/MIN)Stct. air P.D. (IN.WQ)Altitude (FEET)

RATING

750• 302.0 / 0.0

134.9 / 0.093,838

as,ess90.0 / 73.4

6.02.74.2

727.30.61440

COIL DESCRIPTION

FIN HEIGHT =FINNED LENGTH =FACE AREA =TUBE MATERIAL =TUBE THICKNESS «FIN MATERIAL =FIN THICKNESS -TURBULATORS =INSIDE FOULING =OUTSIDE FOULING =

12.37512.0001.0

SS304.049SS.01N00

FLUID TYPE = WATERGLV CONCENTRATION 0 X

IARLO MODEL*: 8W 8- 12.0-6611F- 1.O-H/V-0.SO-R/L B/W

COIL RATED IN ACCORDANCE WITH CURRENT EDITION OF ARI STANDARD 410.• DENOTES VARIABLE(S) OUTSIDE THE CERTIFICATION RANGE.

WHC-SD-Slfr-CDR-007, REV. 0

MARLO (R), P.O. BOX 171. HIQH RIDQE, MO. 63049-0171

••EPRESENTED BYjtarlo (314) 677-6600P.O. Box 171High Ridge, Missouri 63049-017i

ENTRY DATE = 00-14-1996CUSTOMER ID = SANTA FE ENQINERINGTAG NUMBER =PROGRAM ID = WATER COIL RATING / VERSION 3.8APPLICATION = COOLING

DESCRIPTION

Air flow (ACFM)Ent. a i r DB / m (F)Lvg. a i r DB / WB fF)Total capacity (BTUH)sens, capacity (BTUH)Ent / Lvg watar (F)Water flow (GAL/MIN)Water VBlodty(FT/SEC)Water pres. drop (FT)Face vs>ocity(FT/MIN)Std. a-tr P.D. (IN.WG)AltitudB (FEET)

RATING

750572.0 / 0.0182.B / 0.0

101.312161,318

50.0 / 90.36.02.74.2

727.30.37440

COIL DESCRIPTION

FIN HEIGHT = 12.375FINNED LENGTH = 12 OOOFACE AREA = 1.0TUBE MATERIAL = SS304TUBE THICKNESS - .049FIN MATERIAL = SSFIN THICKNESS = .01TURBULATORS = NINSIDE FOULING = 0OUTSIDE FOULIMQ = OFLUID TYPE * WATERQLY CONCENTRATION 0 %

4ARL0 MODEL*: 8W 8- 12.0-S611F- 1.0-H/V-0.50-R/L B/W

COIL RATED IN ACCORDANCE WITH CURRENT EDITION OF ARI STANDARD 410.• DENOTES VARIABLE(S) OUTSIDE THE CERTIFICATION RANGE.

Titan III WHC-SD-SNF-CDR-007, REV. 0

The TITAN III is a dexterousand powerful teleroboticmanipulator system that isavailable in a variety ofconfigurations for use inextreme environments.

• TITAN III SIdeally suited for applications

using remotely operated

vehicles and manned

submersibles at depths to

21,000fsw (6,500 m).

T TITAN III TDesigned for nuclear

inspection and maintenance,

environmental restoration,

sorting and characterization,

disassembly and

dismantlement, and explosive

ordnance disposal.

• TITAN III VME

For customers developing

applications in the VME

environment, this system

provides a shared memory

interface to the user's VME

control system,

G E C A L S T H O M

SCHILLING ROBOTIC SYSTEMS

To meet the critical demands of remote manipulation in hostileenvironments. Schilling Robotic Systems, Inc. (SRS) offers theTITAN III, a dexterous, servo-hydraulic, telerobotic manipulatorsystem with six degrees-of freedom. The TITAN, now in its thirdgeneration, has a proven track record of reliability and unequaledperformance in some of the most demanding environments in theworld. SRS's six-degree-of-frcedom miniature replica master armensures comfortable and intuitive manipulator operation.Constructed primarily of 6-4 titanium, the TITAN III is capable oflifting 250 Ib (Il3.4kg)at its full reach of 75.4 inches (191.5 cm).

The variety of possible remote work tasks requires ihe manipulatorto be highly reliable, field maintainable, and adaptable. SRS'sexperience in designing and manufacturing teleroboticmanipulators for extreme environments has resulted in a range ofstandard configurations and options to meet a variety ofrequirements.

SRS offers the Titan III S for manipulative tasks that require highdexterity and a large payload capacity, and that must be performedin hostile subsea environments of up to 21,000 fsw (6,500 m). TheTITAN III S is ideally suited for use on remotely operated vehicles(ROVs) and manned submersibles. It comes equipped witheverything nece^.iry for installation on hydraulically poweredvehicles, including a slave arm. compact master controller with

Titan 111WHC-SD-SNF-CDR-007, REV. o"

Top View Side View

TITAN III slave arm dimensions (Inches)

TITAN III compact master controller wHhreplica master arm

replica master arm, control electronics, slave controller withsubmersible enclosure, electrical interface cables, and hydrauliccompensator. Available options include software for roboticcontrol and Cartesian control.

The TITAN III T offers the same performance and dexterity as theTITAN III S, but is designed for land-based applications orshallow water applications up to a depth of 100 feet (30.5 m).Typical applications include commercial nuclear inspection andmaintenance, environmental restoration, hazardous materialsorting and characterization, disassembly and dismantlement, andexplosive ordnance disposal. With the addition of a user-suppliedhydraulic power unit, the TITAN III T is shipped ready foroperation, with a slave arm, compact master controller with replicamaster arm, control electronics, slave controller with enclosure,and electrical interface cables. Available options include radiationhardening (for applications exceeding 1x10 ! rad gammacumulative dosage), tool interchange, Cartesian control, androbotic control.

For customers developing applications in the VME environment,SRS offers the TITAN III VME, which provides a VME interfaceto the user's host control system. This configuration provides ashared memory interface to the user's VME control environment.The system includes a slave arm, electrical interface cables, slavearm data acquisition electronics, and a VME interface card.Options include a force/torque sensor, tool interchange, andMagellan (a 3-D, graphics-based, integrated telerobotic controllerthat simplifies remote operation in both structured andunstructured environments).

GENERAL DESCRIPTION

Mode of operation Closed-loop position controlInput device Six-degree-of-freedom replica master armDegrees of freedom Six plus grip

SLAVE ARM SPECIFICATIONS

Maximum reach 75.4 in. (191.5 cm)Weight in air 223 Ib (101.2kg)Weight in sea water 168 Ib (76.2 kg)Maximum lift capacity at full reach 250 Ib (113.4 kg)Maximum grip opening (standard gripper) 3.9 in. (10 cm)Maximum grip force 1,000 Ib (4,448 N)Maximum wrist torque 1,200 in-lb (135.5 N-m)Wrist rotate, slaved 360 degreesWrist rotate, continuous 0-35 rpm

MASTER CONTROLLER DIMENSIONSLength 19.1 in. (4B.5 cm)Width -. 6.0 in. (15.25 cm)Height 2.7 in, (6.9 cm)Weight g,s ib (4.3 kg)


SLAVE ARM FUNCTIONS

Function

Azimuth

ActuatorType

Torque or Force® 3000 ps!

MechanicalRange

Rotary 18,000 in-lb (2,032 N-m) 270'

Shoulder pitch

Elbow pitch

Wrist pitch

Wrist yaw

Wrist rotate

Jaw

Linear

Rotary

Rotary

Rotary

Gerotor

Linear

21,400 in-lb (2,416 N-m)

9,200 in-lb (1,038 N-m)

4,000 in-lb (451.6 N-m)

4.000 in-lb (451.6 N-m)

1,200 in-lb (135.5 N-m)

1,0001b (4,448 N)

120"

270'

180*

180'

360"

3.9 in.(10 cm)

HYDRAULIC REQUIREMENTS

Fluid type: Petroleum-based or water/glycol-based hydraulic fluid(non-corrosive)

Viscosity 10-200 cStFlow 1.5-5,0 gpm (5.7-19.0 l/min)Pressure 3,000 psi (200 bar)

ELECTRICAL AND TELEMETRY REQUIREMENTS

100-240 VAC 50/60 Hz standard. Consult SRS for other poweroptions.

Standard with RS-422/485 half-duplex, optional RS-422/485 full-duplex or RS-232 communication protocol.Consult SRS for other telemetry options.

OPTIONS

Robotic software

Radiation hardening(up to 1x107rad gamma)

Tool interchange

Magellan

Force/torque sensor

Extended depth rating to21,000 fsw (6,500 m)

Titan illsT

• "

Titan IIIT

T

T•

Titan IIIVME

• •

•TTT

• The TITAN III VME -ses Magellan robotic software." The TITAN III S standard ciepih ra'.ing ,s up 10 5,000 Isw (1,524 rr)

Magellan is a 3-D, graphics-based, integrated telerobotic controller.Magellan simplifies complex tasks by providing computer-aidedteleoperation through modeling, motion planning, and manipulatorcontrol. With features such as simple and efficient trajectoryspecification, real-time graphical display, and collision-free pathplanning, Magellan provides a cost-effective solution to complexremote manipulation problems.

TITAN III T shown with interchangeablerotary power tool, 90' drill head

TITAN III tool interchange coupling

Examples of interchangeable electricand hydraulic tools

WHC-SD-SNF-CDR-007, REV, 0

Titan» • "

E'evation View (1 square = 4 inches)

m

Plan View (1 square = 4 inches)

TITAN III range of motion (inches)

TITAN III FEATURES

• Corrosion-resistant titaniumconstruction

• Miniature replica master arm

• Wide range of motion

• High payload-to-weight ratio

• Rugged and reliable

G E C A L S T H O M

SCHILLING ROBOTIC SYSTEMS1632 Da Vinci Court

•avis. California 95616, USAPhone.- (916) 753-6718

Fax: (916) 753-8092

ACCESSORIES

• Hydraulic power unit (TiTAN III T/VME only)

• Interchangeable locls (consult SRS for specifications)

• Hydraulic nose kits

• Spares kits

• Mounting pedestal

FOR MORE INFORMATIONContact SRS tor configuration detail sheets ana technicalapplication guides for the TITAN III S, T, and VME.

Descriptions and specifications are subject to change without notice.' Comner Schilling Robotic Systems. Inc. for the latest information.

© 1995 Schilling Robotic Systems. Inc.

Developed by Bcrttelle, the Remote Ordnance NeutralizationSystem (RONS) is a stair-climbing, off-road vehicle with robotic

control, fiber optic communication system, remote operatorcontrol system, and a TITAN telerobotic manipulator system

tf-SBB

WHC-SD-SNF-CDIWJ07, REV. 0DIMETRICS,

Model 'F' GTAW Weld HeadP/N 282-1100-103

Features• Precision electromechanical servos for

Travel, AVC, Wire Feed and Oscillator.

• Patented, zero backlash traction drivetravel carriage. No expensive gear drivetravel mechanisms.

• Fast mounting to all Dimetrics circular andflat track without latch roller change-out.

• Weld head mounted jog and sequencecontrols.

• Optional front-end/wire manipulatorconfigurations for most any application.- 'A' single wire, one direction- 'C dual wire, bi-directional- 'D' deep groove, bi-directional

• Optional remote video viewing front-endswith mechanized torch tilt and wiremanipulation.

Specifications

Travel Speed:

Jog Speed:

Oscillation Travel:

Arc Voltage Control Stroke:

Wire Size:

Wire Spool Weight/Size:

Wire Feed Rate:

Wire Positioning:

Welding Torch Rating:

Axial Clearance:

Radial Clearance:

Head Weight:

Cable Length/Weight:

oSu

40 1PM2.00" •1.50" ••.030" to .063" diameter2 lbs., 4" diameter std.0 - 99 IPMUp/Down +/- 3/8"In/Out +/- 15"300 AMPS, 100% duty cycle17.75" (minimum)4.75" (minimum)20 lbs. Hess cable)35'. 40 lbs.

1 1.00' CroK-Seam with 1.00' Oscillation Stroke plus 1.00' Slid* Travel

' 2.25' Vertical Slide Adjustment

Model 'F' Weld Head pictured with 'C Front-End

August 1993


P.O. BOX 100

Zellenopte. PA 16063-0100

Phone: (412)452-8121

Fax: (412) 452-0388

QUO #: H80346-1

Customer:

Attention:

Fan Application:

Quantity 1 , S i s*

Customer Inquiry:

I BjHHI yjj-fr 'COMPAHY*.*.195 BAST ROAD" ~LOS ALAMOS SA B7B44

CARLA ODSTAFASOH (EBX:S0S-662-3B51) (F

I. C. FAB

33 X i/a- , Typ* BBIBOG-5 , An. #8. Claaa rv , Inlet SHSI

VBRBAL 5-29-96 31*MKT-1996

8:505-662-0606 BXT.3143)

i;780 750 8.000- 0.03340 „ 710^

Uote: Bvase required to meet performance.

:jrice complete with

#905 m 1800KPM 3 / 6 0 / 4 6 0 TEFC STD.MOTOR

liOTB :TBE ABOVE REVISED QOOTB I S BASSD OR THE VBRBAL XXFORNATIOH• - •-- I F TOD RBQOIRE MDITIOHAL IBFORMKRON, PLSASB

3.701.60

910,551 Ba. Pan

$498 Ba. FanS232 Ba. Fan

OF 5/29/96.ASVX8S.

Flanged inlecFlanged Outletinspection DoorCasing DrainSplit HousingShaft SealHeat FlingerInlet Screen "Coupling QuardShaft Guardv-belt Dr. Ord.Ituulacion diptEvase by OthersSTD.PRIMER

Hsg.meelShaft1 PR.

Weight

STBBLSTBKL MATBRXRL

ALLOY MATBRIAL>y/16«ePHER.HIJl.BRO

1,462 l b s .

•^ --

««C0 M/TC/SO

INS.

DRIVE SIDECLOCKWISE ROTATION FAN TYPE: 33" RBI 806

PROPOSAL DRAWING00 NOT USE FOR

CONSTRUCTION PURPOSES

ROBINSON INDUSTRIES INCZELIENOPLE PA.

MAY 31,1996 B0346C

OUTLET EVASE REQUIREDAS PART OF FAN DESIGN

SUPPLIED BY OTHERS33 X V j S-HSX-

ROBINSON INDUSTRIES INCQUOTE NUMBER: HB0346-I

ZELIENOPLE PA.MAY 31.1996

ROBINSON INDUSTRIES INC.FAN: 33 X 0.5 HB1806-5 SWSIFOR: MERRICK S COMPANY

10

SPEED: 17B0 RPMTEMP: 710 DEG. FDENSITY: 0.0334 #/FT3

DATE: 5-30-199'QUOTE #: HB0346-1

FANSTATIC

PRESSURE(IN-H20)

SP—— — 1 —-—

1 .E BHP

\7

IN-H20

- \

50 CFM

- \

\\

\

BHP

NOTE: INLET400 BOO

VOLUME (CFM)

1200 1600

EF- 1se- iTF- 1

WHC-SD-SNF-CDR-007, REV._O

ROBINSON INDUSTRIES, INC. " - T3ATE i 05731/1996

SOUND PROGRAM OUTPUT

QUOTE # :H80346-l DATE: FHI MAY 31 1996CUSTOMER :MERKICK & CO.DESIGN :RB1806-5 DIAMETER: 33.00000 INCH RPM: 1780.00 WIDTH: SWSICPM : 750.00 PS-INCHES H20: 8,00000 BLADES: 18

NEAR FIELD APPROXIMATELY 3 FEET

SOUND POWER LEVEL RATINGS SHOWN ARE DECIBELS REFERRED TO 10-12 WATT ANDOBTAINED IN ACCORDANCE WITH AMCA STANDARD 300.RELATED AIR PERFORMANCE RATINGS PfiR AMCA STANDARD 210.PWL FOR EACH BAND AND DBA ARE CALCULATED PER AMCA STANDARD 301.LEVELS SHOWN DO NOT INCLUDE MOTOR OR OTHER AUXILIARY EQUIPMENT.

OPERATING CONDITIONS OTHER THAN THE ABOVE STATED VALUES CAN RESULTIN SIGNIFICANTLY DIFFERENT SOUND LEVELS.

DATA IS FOR USE BY A SYSTEM ACOUSTICAL DESIGN ENGINEER FOREVALUATION OF THE FAN SINGULARLY AND WITHIN A SYSTEM.BECAUSE OF THE INFINITE VARIATIONS IN SYSTEM ARRANGEMENTSAND THE MANY FACTORS WHICH AFFECT SOUND PRESSURE LEVELS,IT IS THE DESIGNERS RESPONSIBILITY TO PROPERLY APPLY THIS DATA BASEDON HIS KNOWLEDGE OF THE SYSTEM. SOME GUIDELINES FOR USE OF THIS DATA ARE:FOR "NEAR FIELD" COMPUTER DATA TO APPLY TO DUCTED INLET AND OUTLETINSTALLATIONS, ANY OPENING IN THE DUCT,MUST BE A MINIMUM OF 100 FEET REMOTE OF THE FAN.OPENINGS WITHIN THIS RANGE ARE ASSUMED TO EMIT A SOUND PRESSURE EQUALTO THE SOUND POWER LEVEL. THIS ALSO APPLIES TO UNTREATED INLET & OUTLETEXPANSION JOINTS. NOTE THAT FOR DUCTED INLET/OUTLET THE DUCTWORK THICKNESS ANDDENSITY MUST EQUAL THAT OF THE FAN HOUSING TO ACHIEVE THE SOUND LEVELS NOTED.

NEAR FIELD—A HEMISPHERICAL SPACE WHERE SOUND PRESSURE WAVES FROM ONERADIATING SURFACE TEND TO INTERFERE WITH WAVES GENERATED BY OTHER SURFACES.NEAR FIELD BOUNDARY, DISTANCE FROM RADIATING SURFACE, IS RELATEDTO TH2 WAVELENGTH OF THE LOWEST FREQUENCY AND OVERALL SIZE OF SOURCE.

FREE FIELD--AREA BEYOND NEAR FIELD, WITH NO OBSTRUCTIONS, WHERE SOUNDPRESSURE LEVELS DECAY 6 DB FOR EACH DOUBLING OF DISTANCE FROM NEAR FIELD.

LEVELS SHOWN DO NOT INCLUDE MOTOR OR OTHER AUX EQUIPMENT

OCTAVE BAND LEVELSBAND NO. 1 2 3 4 5 6 7 8 DBAMID FREQ 63 125 250 SOO 1000 2000 4000 8000

SOUND POWER LEVELS AT ACOUSTIC CENTER OF FANPWL+/-2dB 83 86 B9 80 79 76 71 68 85

FOR DUCTED INLET AND OUTLET INSTALLATIONESTIMATED SOUND PRESSURE LEVEL FOR NEAR FIELD WITH 0.2BOOO INCH CASING LOSSSPL+/-2dB 70 68 68 57 52 47 38 32 61

ESTIMATED SOUND PRESSURE LEVEL AT 0.00000 FEET BEYOND NEAR FIELD OF CASINGSPL+/-2dB 70 68 SB 57 52 47 38 32 61

o "Asy 'zoo-aao-jws-as-3HM/S'001?l

•axi XOSXIHOH 8 8 C 0 j s r , T f J D L „ . „ „„ __

Tubular andProcess Assemblies

Circulation Heaters6" Flange

Fig. I A Dimension I BDimension CQhnenston"• ' "• ' (mm) f- "- • ' •- •

6.16.2

6.36.4

39 X.49 S.

70 X.

91X.

(991)

(1259)

(1792)

(2326)

2 0 *31

52

73

(521)(787)

(1321)

(1854)

: 17

2 7 ',.•

48 V

I 69'*

1432-

I699

(1232;

(1765:

6" 150 Ib ANSI Flange—WATROD Element

Application:60W/in2

StMlTank12-Coppar

(9.3 W/cm2)

60 W/ln*StnlTank

15-Copper(9.3 W/cin!)

Sean Water2436

46

60

72100

120

30

45

60

75

90

125

150

6.1

6.1

6.26.2

6.3

6.364

6.1

6.1

6.2

6.2

6.3

6.3

6.4

CFPC715G10

CFPC721G10

CFPC715G10XCFPC721G10X

2

3

35

CFPC715G3

CFPC721G3CFPC725R3

CFPC732G3

CFPC737B3

CFPC715G3X

CFPC721G3X

CFPC726R3X

CFPC732G3X

CFPC737R3X

224

4

4

5

5

5

5

5

CFPC715G11

CFPC721G11

CFPG72SR11

CFPC732G11

CFPC71SG11X

CFPC721G11X

CFPC72SR11X

CFPC732G11X

1

2

22

3

3

3

5

CFPCMSlfr""CFPC721G5CFPC726RSCFPC732G5

CFPC737R5

CFPC7SOR5

CFPC760G5

CFPC715GSX

CFPC721G5X

CFPC726R5X

CFPC732G5X

CFPC737R5X

CFPC7S0R5X

CFPC7BOO5X*

1

1

22

22

4

1

5

5

5

55

5

212 (97)

217 (99)

222 (101)

226 (103)

290 (132)

298 (136)

360 (164)

215 (96)

223 (102)

226 (103)

268 (131)

296 (134)

306 (139)

370 (168)

Application:60W/in2

316 SS Tank

12-316 SS

(9.3 W/cntf)

Paaalvatad

60WAn»

316 SS Tank

15-316 SS(9.3 W/cmJ)

Paaalvalad

Deionized Water, Oemineraiized Water24

36

48

60

72

100

120

3045

60

75

90

125150

6.1

6.1

6.2

6.2

6.36.36.4

6.1

6.1

6.2

6.2

6.36.364

CFPR715N10

CFPR721N10

CFPRT15N10XCFPR721N10X

3

3

3

5

CFPR715N3

CFPR7Z1N3

CFPR727E3

CFPR732N3

CFPR73a£3

CFPR715N3X

CFPR721N3X

CFPR727E3XCFPR732N3X

CFPR73>E3X

22

4

4

4

5

5

5

5

5

CFPR715N11

CFPR721N11

CFPR727E11

CFPR732N11

CFPR715N11X

CFPR721N11X

CFPR7Z7E11X

CFPR732N11X

2

3

3

3

3

33

5

CFPR715N5

CFPR721N5

CFPR7276S

CFPR73JNS

CFPR7ME5

CFPR751E5

CFPR7S0N5

CFPR71SN5X

CFPR721N5X

CFPR727E5XCFPR732NSX

CFPR73IESXCFPR751E5XCFPR76ONSX

1

1

22

224

1

5

6

6

555

212 (97)

217 (99)

222 (101)226 (103)

290 (132)

298 (136)360 (164)

215 (98)

223 (102)226 (103)

288 (131)

296 (135)306 (139)370 (168)

Alt circulation heaters are Assembly Stockunless otherwise noted.AvailabilityAssembly Stock: 5-7 working days.Standard: 10 working days.

338

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6136.48

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•T 70= F ind 29.32" bitomtttr.II ncluda driif l o i j t iinci itiown I I tot itiMard MW. AW ind OW tins with inlft tnd outlet due High speed ratings may require special comtiuction. Contact Buffalo Forge Company.

\T ^ ^ BUrrMC FORGE CCMPAVY / BUFFALO .•VfW YORK 2 9

Jjji j i i j .AiAjj •-JMJJ.AI;I)J. inNGLE INLET

:>FECIAL REMOVABLESCFCLLCOUSTRUCTION

S" ANDARC SCROLL;ONS"RIJC""ION

ARR. NO. 10

FAN PARTS LIST

12282C3467

101111A

- Housing- Backplate and Flange Wheel- Open Wheel- Paddle (Blast) Wheel- Inlet Cone- Inlet Stand- Shaft- Pillow Block Bearing• Bearing Base- Arr. 9 Motor Slide Rails- Arr. 10 Motor Slide Rails

12 -13 -14 -

15 -15A-15B-16 -17 -17B-

Standard or Raised Access DoorMotorCombination AH-Weather Cover andBelt GuardV-BeltsMotor Sheaveran SheaveBelt GuardArr. 4 Motor BaseArr. 8 Motor and Bearing Base

18 -19 -20 -21 -2 1 A -22 -25 -25A-27A-28A-28B-

Shaft SealHeat SlingerOutlet Damoer -—.Standard Drain. Vi Tapped Pipe CouplingFlanged Type DrainInlet ScreenCouplingCoupling GuardRail Type Vibration IsolatorsInlet FlangeOutlet Flange

BUFFALO FORGE COMPANY I BUFFALO. NEW YORK 6 3

W"

Bulletin No. 936

Rectangular, Round,and Nipple-Connected

Type B RIters Constructedand Tested in Accordance with

• MIL-STD-282

• IES-RP-CC-001.3


Filter Design and ConstructionFitter MediaThe filter media in Flanders' Nuclear Grade filter ele-ments is all glass (boron silicate microfiber) and containsa waterproofing binder which adds strength under bothwet and dry conditions. Flanders manufactures its ownfilter media to meet or exceed the requirements ofMIL-F-51079 (latest issue). Flanders '007' media iscurrently listed on the U.S. Army Qualified Products ListQPL 51079. QPL-approved media which have beentreated for resistance to airborne acids are also avail-able; consult the factory.

SealantsFire-retardant urethanes are used to bond the filter elementto its integral frame. PUREFORM™ filters are made usingsolid urethane whereas separator-type filters aremade with either polyurethane foam or solid urethane.

Frame MaterialPlywood— Fire-retardant plywood frames are ideal formany applications, and are easier to incinerate orbreakdown for disposal than are metal frame filters.However, they are not recommended for use in systemshaving high-moisture content, since they may warp orsupport biological growth. Stainless steel frame materi-als should be used in moisture-laden applications.

Stainless Steel—Type 409 and Type 304 stainlesssteel frames are also available. The 14-gauge Type 409stainless steel is used in place of the cadmium-platedand chromized steel that was used in the past. However,since the Type 409 material has a low resistance tocaustic atmospheres, the Type 304 stainless steel isrecommended for those applications.

Flandars PUREFORM™ filters use • formed,corrugated element that i t salt-supporting.

Separator-type filters us* paper oraluminum toil to saparste the foldsof th* filter element

WHC-SD-SNF-CDR-007, :.•..-v. C

Frame StyleThe technique that will be used to seal the filter inservice determines the selection of the filter frame style.(See illustrations below.)

Fluid Seal — Metal frame fluid seal filters have afabricated channel (*/«" wide x 'It" deep) located on oneface. Wood frame filters have a routed channel{'It" wide x 'I*" deep) on one face.

Gasket Seal— Metal frame gasketed filters are providedwith one or two flanges for the placement of the gasketas specificed by the customer. On wooden frames, thegasket is simply applied to the edge of the frame.

Fluid or Gasket SealFluid Seal — BLU-JEL* Seal was developed byFlanders' and is the standard fluid seal material.Service temperatures are to 392°F. For completeinformation on BLU-JEL* Seal, see Data Sheet 06019.

Gasket Seal— Gasketed filters for normal service aresupplied with either closed cell sponge neoprene or^ohrlastic silicone sponge gaskets (V4* x V«"). High-

temperature fitters require the special sealants describedon page 8. Specify upstream, downstream, or both tor thelocation of the gasket or fluid seal in the model number.

FaceguardsThe standard faceguard is 4 x 4 mesh, 23-gauge,welded and galvanized dipped steel. Type 304 stainlesssteel faceguards (4x4 mesh, 17-gauge woven wire perASTM A276) are also available for highly-corrosiveatmospheres. Faceguards protect the media, but are nota guarantee against damage due to mishandling. Specifyfaceguard location as upstream, downstream or both.

Underwriters Laboratory, UL 586To be listed under UL 586, filters must be submitted toUnderwriters Laboratories for extensive testing includingspot name, and environmental exposure to heated air. AUL 586 listing is accepted by the DOE as meeting theHeated Air requirement for Nuclear Grade filters.

UL labels are optional. Some high-temperature filters, andfilters larger than 24' x 30' x 11W, are not eligible for UL 586.

The Fluid Seal The Gasket Seal

Filter Knife

FluidSealChannel

FitterGasket

Seal

filled channel provided on the filter. Flandersinvented the fluid seal in response to requirementsfor an absolute seal in the most critial appl ications.In most cases, fluid seal filters are also easier andquicker to change out than gasketed filters.

A filter clamping mechanism is typically used tomaintain sealing pressure on gasketed filters.Gasket seals have a tendency to develop bypassleaks, primarily because of compression set.


Nipple-Connected FiltersNipple-Connected Nuclear Grade filters are availablewith one (N1) or two (N2) pipe connections, and withseparatorless PUHEFORM1" or separator-type filterelements. Frame materials are Type 304 or Type 409stainless steel and 3/4" fire-retardant plywood Onlygasket seals are available. High temperature models arealso available (see page 8 for information on sealants).Nipple-Connected filters are made of the same materialsspecified in M1L-F-51068 but are not tested for roughhandling, wet over-pressure, or heated air as called outby that specification. Flanders performs acceptancetesting of penetration and resistance only.

N1 FiltersTYPICAL METAL FRAME FILTER IXUSTRATED

N2 FiltersTYPICAL WOOO WAVE W.TCT ILLUSTRATED

- W Z K -

FitterPack

^ -WZK-

r i ""* i 1

N1 or N2 Filters with PUREFORM™FiKer Elements

SIZE~>IGNATOR H

BB-0 S*

CC-D 12"

CC-F 12"

GG-D 24"

GG-F 24"

W

V12"

i r24"

24"

DIMEND

vr12"

16"

12"

16"

SIONSX

4*

4"

8"

4"

8"

Y

3"

4"

4"

12"

12*

zI V

1 V

I V

4"

4"

NOMINALRATED

CAPACny

35

100

160

500

1000

MAXIMUMINITIAL

RESISTANCE

1.0" W.Q.

N1 or N2 Filters with Separator-Type Filter Elements

SIZEDESIGNATOR

BB-A

BB-0

CC-0

CC-F

GG-D

GG-F

H

er8"

i r12"

24"

24"

W

er8"

12"

12"

24"

24"

DIMENSD

V

10"

i r16"

12"

16"

IONSX

3'A."5 ' V

5.W1 W

5'A"

1 1 V

y

z3"

4"

4"

12"

12"

z

1'A"

1 V

1 V

I V

4"

4"

RATlCAPAt

20

35

100

160

500

1000

NOMINAL MAXIMUMRATED INITIAL

1.0" w.g.

NOTE:

N1 Filter, frte

specify the locationot the nipple (i.e.upstream ordownstream).

When oroerinQN1NZnHcustomer shouldspecify the size ofmempptg

Flanders'standardsizes (see the Vdimensions) arenot appropriate.

Vi-72-

WHC-SttSNE-CDR-007, REV. 0

Roughing Prefilters frames of N1 filters may be extended 2 ' in depth

.u accomodate a roughing prefilter. Intimate the v prefixin me model number to specify this option. Also requires aspecial size designator. Contact the factory for details.

Prefiltsr Pmfilter

Gasket Seal (N1 Filters Only)Gaskets are made from 1/4" x 3/4" closed cellneoprene material. Specify location of the gasket as up-stream, downstream, or both, in the filter model number.

IWoodFmm* Mvtsl FWTM

Drilled Flanges (N1 Filters Only)•standard flanges may be located on the fitter face or onjie nipple connection. These flanges may be drilled in astandard pattern or according to customer specifications.Flanders' standard patterns arm as follows: 5/16" diameterholes equally spaced and centered on the filter face flange;or 5/16" diameter holes equally spaced and centered onthe nipple-connected flange.

Slip-On FlangesOptional 150 pound slip-on flanges for pipe-nippleconnections shall be available in carbon steel or Type304 stainless steel, and in any standard IPS size.Other sizes and types of flanges are available per customerspecifications.

Faceguards(N1 and N2 Filters)Standard taceguardmaterial is 4x4 mesh,23-gauge, weldedand galvanized dippedsteel. Type 304 stainless steel faceguards (4x4 mesh,17-gauge woven wire per ASTM-A276) are also avail-able for highly corrosive atmospheres. Specify taceguardlocation as upstream, downstream, or both.

UL 586 (N1 and N2 Filters)To be listed under UL586, filters must be submitted toUnderwriters Laboratories for extensive testing includingspot flame and exposure to heated air. A UL586 listing isaccepted by the DOE as meeting the Heated Air Re-quirement for Nuclear Grade fitters. UL labels are optionaland are applied only it specified by the buyer.

NOTE: High-temp. • w» not eligible lor UL5M.

Nippt#-Conntct#d

Filter Face Flang*

c r5/5- '

Rang*

i iI i

ii !

I;

I i; i

|||

[I

Model Numbers andSpecification

To write a specification for Nipple-

Connected Filters, use the Designating

Chart on Page 15 to determine the model

number. Fill in the numbered locations in

the Suggested Specification Text on Page

16 with the model number and other

appropriate selections from the listing at

the bottom of the page.

13

- F- ^ - 2 0 " ' T WHC-5D-SNF-CDR-OO7, REV. 0

Containment HousingsWith In-Place Test

In-place testing of hepa filters and adsorbers is requiredfor nuclear systems and should be considered for anyHVAC system where toxic participates or gases arepresent in the effluent airstream. The testing ot adsor-bers usually presents no problem since the freon thatis used to challenge the system passes through particu-late filters. Hepa filter banks require distance both upand downstream of the bank to successfully introduceand disperse challenge aerosol on the upstream side

and to mix potential leakage into the airstream (i.e. foran efficiency test) on the downstream side. This is notalways a practical solution in complex filter trains. Flan-ders offers a complete built-in test system that can beinstalled between successive filter banks. Regardlessof the number of filters in parallel or in series, themaximum distance between successive banks utiliizedby test apparatus is 28". (See below) (Refer to FlandersBulletin No. 381C for further information.)

r

Fig. 6 — E-6 Filter Housings with In-Place Test Sections TJC fnnc, (3

©FLANDERS FILTERS, INC., 1988 FOREMOST PRODUCERS OF HEPA FILTERS AND SYSTEMS FOR SCIENCE AND INDUSTRY-SINCE - i»o

WHC-SD-S.NF-C.DK-UU/,

E-6 (Hepa Filter) HousingComponent and Designating Codec

HouMo

•ingdelfiber

—-

E «

How to

HousingSize

Designator

R u n High sWida

1 x 1

1 x 2

1 x 3

2 x 1

2 x 2

2 x 3

3 x 1

3 x 2

3 x 3

4 x 1

4 x 2

4 x 3

1

Order

HeightA

30"

60"

90-

120"

WidthB

27-'A-

51-'V

75-'A"

27-'/4-

51-'/V75-'/4-

27-'/4-

51 -VS

75-V41

27-'/4*

51 -V.-

75-'/4*

Depth C

StandardFiltersOnly

(SizeGG-F)

24"SpecifyQO-F

SundardRrtereWith2-.4",or6-

Prefilters

36-'/i"SpecifyQO-F2,OO-F4

HousingMaterial

Standard

orType304L

Stainless Steel(Type 316 orType 316L

Stainless SteelOptional

I '

1

Right-HindAccess

Typeof

Housing

T y p . 1

Typ«3

Example: E-6 2x2 GG-F2 (304) L Type 1

Type of DoorArrangement

Type 1 Housing: The standardE-6 Housing has an access dooron one side and a flanged plateon the other. The owner mustspecify left or right-hand access.

Type 3 Housing: This housingconsists of two side-by-side hous-ings in parallel. Access to the fil-ters and operation of the filterremoval rod is from both sides ofthe parallel housings (see page8.)

Special E-6 Housings are avail-able upon special request.

©FLANDERS FILTERS, INC., 1988 FOREMOST PRODUCERS OF HEPA FILTERS AND SYSTEMS FOR SCIENCE AND INDUSTRY SINCE - 195c

C Additional E-6 Information ^Housing

SizeDesignator

HtenHigli«W!d<

1x11x21x32x12x22x33x13x23x34x14x2

^ 4x3

Nominal Capacity ICFM)

1000 CFMPer Filter

10002000300020004000600030006000900040008000

12000

1200 CFMPer Filter

12002400360024004800720036007200

1080048009600

14400

1500 CFMPer Rlter

15003000450030006OO0900045009000

135006000

1200018000

Approximate Weight (in lbs.)

GG-FHousing

180270335360540670540810

1005720

10801340

GG-F2Housing

300375480600750960900

11251400120015001920 J

12

- WHC-SD-SNF-CDR-007..KEV. 0 ^_

SAIC ACCEPTANCE TEST PROCEDURE

Project No.: 9277-01 f486.ll Cust/P.O.: LESAT7950460

Item Description: Bubbletighl Damper OEM: RuskinMndel/PartNo.: BTR-92 and BTO-92 nwy/Spec.: 50-00U62-0ID thru -13D

EGS-TR-927701-104Revision PrigAttachment: 1 Part:Page 1 of 1

Safety Function: Maintain structural integrity and operabilitv before, during andaftrr a seismic event .

Prep. Date: hi -i

1. Product Identification

a) ManufacturerVerify the manufacturer to be Ruskin. Record tag information and attach to the data sheet.

b) Model NumberVerify the model number to be as specified on Figures 1-1 through 1-13.

2. Physical Attributes

a) DimensionsVerify dimensions are per the customer-approved drawing (Reference Figures 1-1 through 1-13) by review of theRuskin Final Inspection Reports.

b) ConfigurationVerify the damper is free from damage and is of the configuration depicted in Figures 1-1 through 1-13 or thecustomer-approved drawings. Record the customer-approved drawing number, induding revision, on the data sheet.

3. Mechanical Attributes

a) MaterialVerify the material used for construction of the dampers has been independently tested and accepted by SAIC/EGS.The following materials shall be verified:

FrameFlangeBlade

Blade SoftenersActuator BracketWeld Wire

Verify all welders performing welding on the damper are certified to ASME Section DC

Electrical Attributes

Verified per Paragraph 5.

Opcrabilily

a) Proper OperationVerify each damper operates as required by Ruskin Procedures Nos. 092395 and 092295.

LOC 980

Hi

3!

03

5: ^

5 5

«O -WHC-SD-SNF-CDR-007, REV. 0 . ^ 2 . . "', - ^ ^

,0

•AV

t0.

5k

<|

r" U

LS^V

Figure 1-5

H-77LOC 980


PRICE LIST

How to order your Turbo Mini or Turbo Cart Pumping Station

vmiurinfia Varian Turbo Mini Pumping Station or TurN« * i.-irtPumping Station is quick and easy. Please use the eiicl< >scdOrder Form rind this Price List to configure ami pnee yourturbo pumping system.

1 -or product inionn:ition aK ui a sysun: component, ruleriu ihe accompanying suppi<--incuts tor Tiirl*> Pumps anilControllers, Vacuum liaunc- and (Controls. Mechanical Pumps,and Vah es Part numbers :;"id prices tor all basic system con-tiyurations and eustomer-se ice table options and accessories arelocated in this Price List. Ir what you want is not here, pleasecall us at 1-SUU-NN2-742O [i> discuss how we can build it tor vou.

Turbo Cart Pumping Station Turbo Mini Pumping Station

Turbo l'limpsPITMf SIZE

VTnTiirlxil ' imip'

V70l)Turl» I'ump"

VTOU'TurWj I'imip °

V25(lTurl*i Pump "

Y.IIKHIT Turl»i I'ump "

55H Turin, I 'ump"

VTIMIHT Turin) I'limp °

VHIOUA Tuilxi I'ump °

DESCRIPTION

iM )-(0 Inlet

4 " Cl'K Inlet

1SO-6.1 Inlet

4 -" CFF Inlet

1S( 1-6.1 Inlet

4 CFF Inlet

ISO-HHI Inlet

'." CFF Inlet

1SO-1M) Inlet

•• CFF Inlet

1SO-1MI Inlet

v" CFF Inlet

1SO-2IMI Inlet

I " " CFF Inlet

[SO-2II0 Inlet

in" CFF Inlet

I2OV/M»IZ

.V44.MSI'-'O57

.1.144-MSP-'l.1S(i

,\144-MSI'-'AV>1

.\144-MSn-'>.l(,2

.1.144-MSI'-<».Vi5

.WJ-MSI'-'l.VX.

.1344.MS]'-Sf>07

.!A44-MSI'->s<rf)S

.1.144-MSP-<IO.1'I

.\144-MSI'-'tlM(l

,1.144-MS1'-')O4'>

.\144-MSI'-(l05<)

.1.144-MSI'-t«)57

.1.144-MSI'-'»I)5S

.\144-M.SP-9II5.1

,l."l44-MSIi-(«l54

ORHEK NO. | LIST22mysonz i I'KICK.

3344-MSC-S.157 \ S5.7*i')O(i

.WH-M.SP-S.15S 5 ^ 5 c H I

.1344-MSP-S.10I

.W44-MSP-S.VO

3.144-MS]'-N.l(i5

3.144-MS]'-S.V,(,

(i.niiii tHI

<">.IS5 fM>

h..V)5iKi

( I .?J IPI«J

.1.144-MSI'-S5(I7 s.4'>?i«i

.1.144-MSIl-.s5us 1 v 1,-15 l»l

M44-.\ISP-'M.V1

.VVI4-MSP-1H4ll

M44-MSP-'J14'1

.\%44-MSI'-'M5u

.1.144-M.SI"-'I157

,1.144-MS1'-'H5S

,\144-MSI'-V15.1

.1.144-MSI'-(n54

IJ.W'ill

14.525IMI

I ' I .7MII . (HI

Ih.'XHI 1111

22.5511 (HI

I2«\ MHIZ

,1.*44 :-- -7. 57

. U 4 4 - ' - : -7.15S

.1.144 •••~l'-7.1iil

.1.144- • •> 1 - ; .VL '

.1.14; ~-5A(i5

.1.144- ^-5.1(,(,

.1.144- -:p-25dl

.1.14^ •-'-2511"

ORDER NO.22»V/.«>HZ

.1.144-MSP-I..157

.U44-MSP-H.15S

.VH4-MSI'-(i.l(il

.1.144-MSI'.<,.U,2

.1.144-MSI'-4.1(.5

.1.144-MSI'-4.1(>1

.1.144-MSP 2502

N/A

NVA

N/A

N/A

N/A

N/A

N/A

N/A

••KICK

S4...7UUI

4.')75l«>

5.1 Kl

5.45UCHI

7.(,lJ5tMI

7.N45IH1

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A• n™. .,-,.,„„ ,.,.„ mdv.l..,url..m1,to imip inlii v.-nxii. piini,. , „ • ! , •„. ,- , . , , . | , t , ,«,- • i v „.,. ;- „ „ .,,«k-,..,nl, .,»,:,„,.„

Options and Accessories for Turbo Cart and I'urho Mini Pumping Stations

IMNCKiniON1 1 -1 uim lH:iphr:iani I'ump ] t

1 2 S •-•iin l)i;i|)lir;iuii] l'ump °° T

1 2) elm Dn StTnll I'ump

1 SIMn.\kvh:imciit l ^un ip""

1 SD-'nt VkvlMiiK-jiM^ump"0'

1 SD-Jdfi Mi..L-li:mit;:)i 1'iimp "*

1 M^' t - 'NUvhimic- i lKimp"1"

1 M'-.|-t'.\Wli:mif:iM'ump1"1-

1 Mi-7i«i\l lvn:init-:iM1uiTip1'

,V144-MSl'-()2lMi | SJ..»S

.l.U4-MSP-tl2iU ! . ' O ' H H H

.1.M4-\ISP-U2(O ( 7 i ini i i i i i

.V'44-\|S|MOil.l i I \>.

,I,*44-MSI'-M2(M • ].^"

,vM4-MSl'-(i2n5 : ) ..sn I« I

334 4-\ISI'-D2<"> •• l.'iuuuu

.*.W4-.MSI'-n2n7 | 2 . ^7 'MH.

; . ;_ i . \ |s |MO^ ••.'!

URIIKKM).• -_.\|S|'-IMI'»M

• -..\|s|>.(||(MI

- -^.\|M>.IIII«>7

--.\|M'-lni l)S

\. . \

\ ' . \

\ A

LIST PRICKS2..1SD1M)

.V2lW)iM)

N/A

l.lfrft.on

l.NHUMI

N/A

N/A

N/A

" • • \ ' \ / . \

3nan®vacuum products\ uriiin \ nciiiini I121 llunncll Avenue1.1'Miigion. MA O217.V.AI.W I SA

U 7 8J j U - l : I - M M I S X \ I ( I A \ II-.H

| .N<MI-M».1-2727 ft -.ui

I : l \ : (< .17I MHI .S4 .17

7) S6I-72(MI

hoc >LJJ

1LLJ^ ^

i—~^ ^^ >

<rCOLJLJOQ


(iniiyc Controller Options

IH-NCKIITION

U\']iH• Diaphragm Manometer Control °

l>V|i)<>-2 Diaphragm Manometer Control ijswipomisi °

ft Transducer. SST. %" NTT

1' Transducer. Silicon. X" NTT

K Transducer. KF-lu Flange

P so l Thermocouple Gauge Control "°

t. Hid Thermocouple Gauge Control "

* Slo-2 Thermocouple Gauge Control *"

i; 5.11 Thermocouple Gauge. X\V-10 Flange

k- 5.11 Thermocouple Gauge. NW-16 Flange

fc 5.11 Thermocouple (iauge. NW-25 Flange

i 5.11 Thermocouple (iauge. VW-10 Flange

t. 5.1! Thermocouple Gauge. I'/' CF Flange

K 5.11 Thermocouple Gauge. 2Y<" CF Flange

•-- O.nveeTorrGaune Control aD°

ComccTorr Gauge Control (2 set points) ' "

W'\']iM)-2Gau«e Control (2 set points) "

Transducer. Silicon, A" NTT

Transducer. Silicon. KK-16 Flange-

Transducer. SST. IT NTT

Transducer. SST. KF-ln Flange

]|YloOJ'ir:i]ii(iaii&L-Control '

M\'HMi-2 I'iram Gauge Control (2 set points) "

Transducer. A" Tuhulat.on

Transducer, KF-ld Flange

S(>0 Cold Cathode Gauge Control *

•S/iO-2 Cold Cathode Gauge Control (2 set points) =

524-2 Cold Cathode Gauge. ] " Tubulation

524 2 Cold Cathode Gauge. NV-25 Flange

524-2 Cold Cathode Gauge. 2'/" CF Flange

525 (:old i ;ath-Kle (iaugc. 1" Tuhulation

525 (:<ild (latitude (Jaime. N'W-25 Flange

525 Cold Cathode Gauye. MV-40 Flange

MtiliM.nime (hasic mil l . i;aut;mg card ret].)

T/CCard '

I'HVCard '-

(7C Card -

IVA Card

Set I'uiiit Card

ComecinHiCant '

ClU.Card '

KS-2.^2 Cimpii ier huenncc

UV4s5'422CompiiK.| interlace

^•M l.irr li:iMc 1 "mi. \2\ T/C and 11 I \M.\ 1

s t.tiI..rrUaNiel nit. i 2 I T/( :'> and ( I I CVC "

s.-]l |..M IS.ivk' I'llit I I I IV.\ T

vniTori hasic r m l . - ] H ;/i

. , n l o f i Si-i I'IIIM!

. n i l . , , , UV4SVJ22

= 7 1 Gai i^ I n k I Ivvni ' luhiibn.m; : i ' . . I I I ^ I . I I ^ . J ' . i i

" . •-ii i i.- I I I I V \ \ \ . 2= 1 lan^e

- --.,•:• ;.:*,, \ U . 4 ' i | i : 1 1 , . ,

•" • • . ..- !• '•• G i i " h i ' - n h i . o n

• • ' - -•• • - I . ! W ' . . i i N i i » . p i i c i l i y . - u a t b l ' l - ' :.

Turbo Cart

OKDFK NO.

,1.14-1-MSI'KJ2IW

.1.144-MSP-D21O

."U44-MSP-0211

.W44-MSI'-0212

.\144-MSP-I)21.1

.V144-MSP-O214

.1.T44-MSP-0215

3.144-MSP-0216

3344-MSP5311

.V144-MSP-5312

.V144-MSP-5.11.1

.1.144-MSP-5314

J.144-.MSP-5315

3.144-MSP-5.1H.

.V144-MSP-O217

,1.144-MSP-(I21S

.1144-MSP-U21')

.U44-MSP-O22O

.W44-M.SP-II221

.(344-MSP-0222

3.M4-MSPJ 122.1

.1.M4-MSP-O224

.V144MSP-1I225

.1.144-MSP-()22(.

.1.144-MSI'-O227

.1.144-MSI'-()22,1-

.V144-MSP-II22')

.1.144-MSP-02.1II

.V144-MSP-II2.1]

.1.144-MSP-D2.12

,1.144-MSP O 2 M

.V144-MS!'-5252

.1.144-MSP-525.1

.VM4-MSI'-! 12.1.1

.1.144-\ISI'-ll2.M

.V14-I-MSIMI2.15

.1.M4-MSP-I12.1-,

.1.144-MSP-I12.17

.1.144-M.SP-H2.1S

.1.H4-MS]'JI2.V

.1.144-MS]'-(.4'I]

.Vl44-MSP-i.4.<'i

;..144-MM'-vMI(

.I.-44-.MSC I.'-I2

.>.M4-MSr-l.'H2

.'• •44AISI' L'MJ

.^•44-MSr-I 'M 1

. U4-MSI I.'M.-

. . j4 - \ ;>> ' i . ' i u

,;.'44 MSI' I.-.4-

V-1---M-.,':r.

' •4J MSI' 2-J7!

v l - i MM I'4T !

."".'-i-l-M-!' 217 1

• • • — M ^ l : I , 1

• • ; - J . M > r j j - i

Pumping Station

LIST PRICE

; S.157 ou

557.110

.157 mi

227 Oil

2M.IKI

2l5.m,•415 (Ml

M5.IHI

S6.IKI

87.(HI

S9.IHI

93 (M)

93.IKI

96(HI

475(1(1

<>H5 (H)

7.1S (HI

512.IKI

55S(H)

M().(HI

( S7.(HI

5S.1.IHI

7.1S (HI

'«.(«)

1.14.IKI

(,75(Hi

<)75 (HI

,1H5(HI

415.IHI

-125 (Ml

.125 (HI

.155 (HI

•155.IKI

77oil(t

47IKHI

7snoo(,2(11111

l l)5 (Ml

M5IIH

1,2111111

I5UIKI

I25.KI

1.1 <,.=,.IIII

1.1',5 mi1 ' 71 5 I n 1

l,S?lll l

, „ ,<„ ,

1 - ... . . L i .. .

I l l " MM

1 I 5 1 HI

1 -i S MM

1 ' > MM

] • > > ( , . ,

rr - 1 /

- Turbo Mini

ORDKK MK

.V.44-MSIMI1II1

.1.144-MSP-lll(l2

1.144-M.SP-(ll().l

.V.44-MSIMIHM

.-..-.44-MSP-(ll()5

.':,44-MSP-(ll(H,

i.'44-MSP-(ll()7

l.144-MSIMII((S

.1144-MSP-5.il 1

1.144-MSP-5312

.V44-MSP-5.11.1

-vl44-MSl'-5.114

••144-MSP-5315

1.M4-MSP-5.11O

.••.'•44-MSl'-l)l(W

.V'44-MSP-II11(>

••44-MSI'- l l l l l

/• •44\1SI'-II112

-•44-MSP-lll l. l

•"'44-MSP-l)114

-••44-MSP-II115

.- -4-1-MSI--II111,

--••44.MSIMII17

V-44-USI'-O] IS

.'•.••44-MSP-IH l ' l

.•'•44-MSI'-(H2(l

•'•44MSP-(I121;;44-.\!SP-O122

;.;.44-MSl'-(ll2.1

'•;44-MSl'-(II24

"•'•44MS1>-5251

;. .44-MSP-5252

.•••44-MSP-525.1: •44-MSI1-(H25

•••44-MSIMI12(,

'- -44-\ISr-()127

- ;44-MSri l l2S

••44-MSI'-lll2')

-•.44-MSI'-lll.lll

• •44-MSl'-ll1.11

•44-\lSl'-(,4lJl

.44-MSI'-(,4.W

•44MSr-S<l4(l

• '41.\lSr-l. l>12'

•14-MSP-I.')121

•4 J MM- l.'M22

•||-MSP-I.'||I2

- i -MM' I.'U.12

• 1 H N ' - I . ' I N . I

.1 > W . | , M J I

- i M'*i' '1711

• M M ' 24712

-i.MM-.217 1.1

4 1 MM' 21717

: : '.I-.I- 24714

• 1 MM- 217 1*

Pumping Station

| LIST PKICt

S . I " MM

5 5 7 MM

.157 IMI

227 MM

2MM<>

215 MO

415 OO

545 (Mi

KM 10

S7 00

N'XH)

'J.I 00

<>3<NI

<>!,(*>

-175- (Mi

(<S5 (HI

7.VS itn

5I2.OM

55s (Mi

M M I M )

f).S~ (HI

5 M (HI

7.VS.IHI

'>») (Ml

l.*4(MI

f.75.(Ki

'175 0(1

.VS5 00

415(MI

425 OO

.125.00

.155.(HI

J55 oo

77M IKI

47MIKI

7.N0.O0

(»2(HIO

u l)n (Hi

1 ')5 (K1

515IHI

' ) 2 M I N I

1 5M OI I

125<Mi

l . !h5(Ni

l. l io.MO

715 mi

r,.s^ IKI

Ml

I^URI

! 5

1H5IHI

1 1 > IKI

II5KI

l ^ m .

i I2>i>n

•>5«K.

varian®vacuum products

WHC-SD-SNF-CDR4X)?, REV. 0

PurnDTiQ soeed ,,s

ri-of *<isioft ratio

-j ) . - s'-"3sur<-

t!-.t*: ttange

fo"!iin^ tlanqe

Rotational speed

Sc^rtup time

N, 550 ^ 600 H : MO

N-, . U 10-J H~ 1 x 10" ri. • >

With recommend mecnamcai ourni< 1 x iO' l cmba''< 1 > 10'u:TorrWith recommenced diaohraqm PUTSQ

2x 10 s mbar (1 * 10"9Torri

DN 160 ISO DM60 CFF f8" ODiDN 100ISO OM00CFF(6'OD)

NW25 KF

42.000 RPM

5 mm

Recommended

torepump

Operating position

Cooling requirements

Bakeout temperature

Vibration level(displacement)

Operating ambienttemperature

Weight lbs (kg}

T'lvo-sraqe rorarv1 DU^D 50 30

Diapnragrn pump f.'C 5C

Any

Forced an

Water optional

120'C a; inlet flange iCFF version

< 0.01 )j.m ai inlet flange

ISO: 30.8 (14); CFF 43 (19.51

Description Part

NumberPrice Shipping

Weight ibs i*.

Pumps

Turbo-V550 Pump with ISO 160 inlet flange

TurDo-V550 Pump with 8" CF inlet flange

Turtx)-V550 Pump with IS0100 inlet flange

Turbo-V550 Pump with 6" CF inlet flange

969-9049

969-9050

969-9047

969-9048

$11,285 • «

$11 "285"

SI 0.265

$10,265

35 (16.0)

48(21.5)

35 (16.0)

48(21.5)

Controllers

Turt»-V550 standard controller, 220 V

Tur6o-V550 standard controller, 120 V

Accessories

969-9444

969-9544

$2,590

J2.590

35(15.7)

35 (15.7)

Inlet screen, DN 100

Inlel screen. DN 160

Healer band, 120 V

Heater band. 220 V

Water cooling kit

Air cooling kit

Vibration isolator, ISO 100

V^ration isolator. CF 6"

Vibration isolator. ISO 160

Vibration isolator. CF 8"

Vent flange, NW 10 KF

Vent device with adiustable delay time

Vent valve with fixed delay time

969-9302

969-9304

969-9808

969-9807

969-9318

969-9314

969-9342

969-9332

969-9343

969-9333

969-9109

969-9831

969-9833

$85

$113

$295

$295

$75

$330

$1,375

$1,640

$1,985

$2,290

$30

$1,150

$605

(0.5)

(0.5)

(1.0)

(1.0)

(0.5)

(3.0)

(3.0)

(3.0)

9 (4.0)

(4.0)

(0.5)

(2.2)

(2.0)

To order, call 1-800-882-7426 Turbo Pum

Controllers for V300HT, V550, and V7C0IHTPiimpWHC-ED-SNF-CDR-007, REV. 0

'- * «=-_ _

These Turbo-V controllers are microprocessor-controlted fre-quency converters with self diagnostic and protection featuresIhat ensure the highest degree of reliability. The compact, 'A rackunit, has a multifunction alphanumeric display for pump status anderror code diagnostics. The front panel display is a two-line dotmatrix LCD display with back lighting. It displays rotational speedas the pump starts up and indicates when full speed is reached.At any time during the operation of the pump, the speed, current,

power, and bearing temperature can be displayed. Additionally,the microprocessor acts as a pump cycle log. and can displaythe number of vacuum cycles, the cycle time for the current cycle,and the total operating hours on the pump. Remote operation canbe accomplished with logic level contact closures, and withoptional computer interfaces.

PCB controllers are available on request.

Technical Specifications

input

Maximum input powerOutput voltageOutput frequencyMaximum output powerStartup powerOperating temperatureStorage temperature

Ordering InformationDescription

Controllers

V300HT /100/120/220/240/V1 ph, 50/60 H z /350 VA j _90 VAC, 3 ph/

933 Hz I250 W170 W0°Cto+40°C!-20'Cto+70°C

V550 \ | V700HT100/120/220/240 V1 ph, 50/60 Hz600 VA56 VAC, 3 ph700 Hz325 W420 W I0°Cto+40°C /-20'C to +70°C /

100/120/220/240 V1 ph, 50/60 Hz600 VA56 VAC, 3 ph700 Hz350 W420 W0°C to +40°C

-20°C to +70°C

\ /Part \

NumberPrice x ? Shipping

Weight ib. ikgl

Standard controller for TurboV300HT pump, 120 VStandard controller for Turbo-V300HT pump, 220 VStandard controller for Turbo-V550 pump, 120 VStandard controller for Turbo-V550 pump, 220 VStandard controller for Turbo-V700HT pump, 120 VStandard controller tor Turbo-V700HT pump, 220 V

969-9524969-9424969-9544969-9444969-9545969-9445

$2,260$2,260$2,590$2,590$2,860$2,860

35 (15.7)35 (15.7)35 (15.7)35 (15.7)35 (15.7)35 (15.7)

AccessoriesOutput mating connector (input included with controller) 969-9852 $30RS-232 computer communication kit 969-9850 $130RS-422 computer communication kit 969-9849 $130^S-485 computer communication kit 969-9848 $130extension cable (controller to pump) for V300HT 969-9950LOOOO $245Extension cable (controller to pump) for V550 and V700HT 969-9951LOOOO $275

(0.5)(0.5)(0.5)(0.5)(3.0)(3.0)

O O O O Insert the tenglh m centimeters (enampie: cable 1.5 m long s 969-9950L0150). If the two connectors only are required, onaer 969-9950L0O00 or 969-9951L0000.

To order, call 1-800-882-7426 Turbo Pumps

Instruments-GaugHigh-Vacuiiin Pi rani Gauge

J*[ ' U H H

The Varian HV100 and HV100-2 High-Vacuum Pirani Gauge;:measure pressure from 0.01 mTorr to 100 mTorr (105 mbarto0.1 mbar) and offer precision and high resolution digital electron-ics. These compact instruments use a newly-developed Piranisensor which incorporates an upscale trim to improve trackingability The extremely rugged sensor is constructed with a solid,inert, noble metal that maintains its calibration over long penods.

Lower operating temperatures in the Pirani-type gauge tube (halfthat of thermopile gauges! enhances stability as does a uniquetemperature compensation network. The gauge tubes arematched so they can be replaced without recalibration

WH<:-SD-SN]:-CDFt-007. Rf V

The Varian HV100-2 dual set point controller operates two inde-pendently-set control relays. Set point values are easily adjustedIrom the front panel and displayed on the meter Push-to-setswitches simplify display of the set point pressures, without inter-rupting the pressure measurement circuit. Relays have 3-ampere.Form C contacts. Screw tern- -als tor the relay outputs areprovided on the rear panel.

Both the indicator and me co~:'cl!er instruments feature simple,single-hole installation The ne.v panel mounting system makespanel mounting as easy as t u - ng a screw. Gauge tubes have}< inch O.D. tubulation that fits sandard quick connects.

Linear analog output 0 to 1.0 VDC

Optional dual set points

~TJ5~ VAc750/60~Hz: 230VAC

Line regulation

Temperature compensation

Digital LED display

Ideal for analytical as well as industrial usesProcess control with ± 002 -^Torr (± 2 x 105 mbar)set point reliability

Meets all power requireme-s at no additional cost

Change in line voltage proc-:es less than 1% changein reading

Changes in ambient tempe-jture between 0°C and 50°Cchange the reading less tha- 0.004 mTorr (5 x lO* mbar)per °C at hard vacuum

Crisp, clear, and sharp pressjre reading

To order, call 1-800-882-7426

^ :f -CD •<:<(? R.1

i 0 0 i m"Torr(± 10"5 mban resolutio

AccuracyEerter than 5°° of value or ± 0.03 m

»hJCliever is larger

Set Point Range

Adjustable over 100% of range

Set Point Repeatability

i 0.02 mTorr

{t2x10-6mbar)

Recorder Output

Cto 1.000 VDC

For accurate and easy calibration, an optional vacuum gauge

calibrator is available. See Ordenng Iniormation tor part numbers.

Li •: ~

3 •

M n m !

P IV 1

P' lWC-

A;.pj;;x',

A[iDic«ir

Net We

Indicates

Control-

Relays

1 SPOT

i

i i:b n>- > 'TM ina :t)Pi

i ling tiarawaie inciucii j

Consumption

lil ' j ly 1 waft tor mQi(23to

•.a'ely 2 watts tor controller

1 9 M

1 :b,2oz(0.5kg):' 1 Ib. 6 02 (0 75 kg)

relay for each set point;

3 ampe-es at 115 VAC, non-inductive

Transducer Dimensions inches limn)

p 3.50 (89)-

75(19) 1

I

—11.25 (32)

IP (•P.1)

Orderiira Information

Description

HV100

HV 100-2

HV100

HV 100-2

HV100

HV 100-2

HV100

HV 100-2

Calibrator

Calibrator

Transducer

Transducer

Transducer

Transducer

Transducer

Transducer

PartNumber

6522-08-415

6522-08-420

6522-08-440

6522-08-445

6522-08-515

6522-08-505

6522-08-520

6522-08-510

6528-30-010

6526-30-030

6543-25-025

6543-25-026

6543-25-027

6543-25-028

6543-25-030

6543-25-029

Price

$563

( • « ,'$718 ' « * „

"$563

$718

$202

$718

$563

$718

$202

$202

$99

$130

$140

$140

$134

$130

Model

No set points (Torr)

^ Two set points (Torr)

No set points (Torr|

Two set points (Torr)

No set points (mbar)

Two set points (mbar)

No set points (mbar)

Two set points (mbar)

(Torr)

(mbar)

V Tubulation

SST. Mini-CF, non-rotatabte

SST, Cajon 8 VCR (female)

SST, Caion 8 VCO (female)

KF16 Flange

SST, KF25 Flange

Voltage

(115 V)

(115V)

(230 V)

(230 V)

(115 V)

(115 V)

(230 V)

(230 V)-

-

-

-

-

-

-

-

ShippingWeight n» l»g|

1.0(0.5)

1.5(0.8)

1.0 (0.5)

1.5(0.8)

1.0(0.5)

1.0(0.8)

1.0(0.5)

1.5(0.8)

1.0(1.5)

1.0(1.5)

1.0(1.5)

1.0(1.5)

1.0 (1.5)

1.0(1.5)

1.0(1.5)

1.0(1.5)

NOTE • Special-length cable quotations are available upon request.

To order, call 1-800-882-7426 Instruments - Gauge Controllers 227

amWHC-SD-SNF-CDR 007, REV. 0 Turbo Pump .Mini Station

Turbo Cart Pumping Station

i

WHC-SD-SNF- :DR-007, REV. 0

Warian'i New 600DS Dry Scroll Pump incorporate atechnolog} that produces clean, cost, effective, and re i-able vacuum pumping performance

Unlike many other types of dry pumps, the 600DS KEI ;both a low ultimate pressure and high pumping speei .With a base pressure in the 10"3 Torr range and supe iorpumping efficiency, it is suitable for applications wbe e

. oil-sealed mechanical pumps have typical]}" been usec .

In the oil-free scroll pump, crescent-shap€:d pockets a-eformed and bounded by the meshed scrolls. As theorbiting scroll moves within the fixed scroll, these pork-ets progressively decrease in volume as they move thepumped gases in the spiral path from inlet to discharge.Sealing is accomplished with PTFE seals againstanodized aluminum walls eliminating the need for oilsealing.

Because the scroll pump is intrinsically clean, there isno risk of contaminating your vacuum system. Conven-tional oil sealed mechanical pumps require costly acces-sories (traps and baffles) to achieve only marginal levelsof cleanliness. Since no oils are required, the costs ofpurchasing and disposal of them are eliminated. Fewmoving parts and carefully chosen materials of con-struction minimize pump failures, with typical mainte-nance intervals of twelve to eighteen months. All thesefactors contribute to low cost of ownership and maxi-mum uptime.

Varian's 600DS Dry Scroll pump is the preferred choicefor your clean high vacuum requirements.

Turbo. Ion, or Cryo Pumped SystemsLoad Lock ChambersLeak Detection SystemsOpticsResearchAny application where the presence of hydrocarbonsis detrimental to your process

Scroll Design

ILow ultimate pressureHigh speedCompact sizeQuiet, low vibration operationTwo moving partsLong service life

Oil Free No risk of oil contaminationNo expensive traps or filtersNo costs of buying and disposing of oil

Carefully chosen construction materials Long life operationLow maintenanceLow cost of ownership

• Free Air DisplacementMHz 600//ml21cfm)SO Hz 500 i/m (17.5 cfrni• Pumping Speed60 Hz 500 llm (17.5 eta)50 Hz 420i/m(15cftn>• Ultimate Total Pressure<10-2Torr(mbar)• Inlet ConnectionNW-40• Outlet ConnectionNW-25• Motor Rating0.8 hp (0.6 kW)• Electrical Supply1 Phase/60 Hz/120V3 Phase/60 Hz/208V• Noise Level at 1 meter60dBA• Operating Range40°F to 105°F (5°C to 40°C)• Weight88.2 lb (40.0 kg)

WHC-SD-SNF-CDR-007, REV. 0 Varian Part No.- Description600DS-16120 Model 600DS with base, hour meter.

and direct drive motor (1 ph/60 Hz.'120V600DS-36208 Model 600DS with base, hour meter,

and direct dnve motor (3 ph/60 Hz.'208V'

Minor Maintenance KitMajor Maintenance Kit

I1000

cE

"^ 100

"D

[/I

Pum

/

_ . .- • '

:: ± j—--—

H;

S >1

10-' 10"2 10"' 10° 10' 10* 10'

Inlet Pressure, Torr_ 1 _ = „


MD 101Magnetic-Drive Regenerative BlowerFEATURES• Hermetically designed seal-less blower• Continuous operation• Manufactured in the USA• Maximum flow: 29 SCFM• Maximum pressure: 25" WG• Maximum vacuum: 23" WG• 0.25 HP TEFC motor standard• Disconnect motor without disassembling from piping• Blower construction — cast aluminum housing,

impeller and flanges; permanently sealed ballbearings in housing

• Motor construction — permanently sealed ball bearings• Quiet operation within OSHA standards

OPTIONS• Explosion-proof motors• 50 Hz motor• International voltages• Corrosion resistant surface treatments

ACCESSORIES• Moisture separators• Explosion-proof motor starters• Inline & inlet filters• Vacuum & pressure gauges• Relief valves• External mufflers

BLOWER PERFORMANCEAIR FLOW RATE (M'/MIN) AIR FLOW RATE (M>/MIN)

0.25 0.5 0.75 0.25 0.5 0.75-30-r

r

lli

lii

sa • 0.50

PRESSURE

\

V .

• 1.0

\

\

1fe 1.0 -

-25

S - 2 0

SO : 0.56

SUCTION

SG M

\

.0

\

AIR FLOW RATE (ACFM)

~ —

—•=

' '™ —

•

—

4540Iff

500

300

100

30

10

•— —

— •

AIR FLOW RATE (ACFM)

— • i

•••

" —— —

— " —

« =

--—r

EG&G ROTRON, SAUGERTIES, NY. 12477 • 914/246-3401 • FAX 914/246-3802

WHC-SD-S\F-C3."iW»7,;

A t f E i G ROTRON

MD 101Magnetic-Drive Regenerative Blower

: 11-1/2 NPT(2 PLACES)

MOUNTING HOLES

. INDIMENSIONS:

TOLERANCES:

(UNLESS OTHERWISE NOTED)

MM" ft(l

TOLERANCES: .XX ± ~

L*> OS7 DUM ON TEFC MOTOR, 075" HPT ON XP MOTOR

SPECIFICATIONS

MODELPart No.Motor Enclosure TypeHorsepowerPhase — FrequencyVollaqeMotor Nameplate AmpsMaximum Blower AmpsInrush AmpsStarter SizeService FactorThermal ProtectionBearing TypeShipping Weight lbs (kg)

MD101CB4038014TEFC0.25

Single - 60 Hz1152.02.27.2001.0

Automatic, Manual ResetSealed. Ball

40 (18)

MD101CC4038271

XP0.25

Single - 60 Hz1152.62.27.2001.0

AutomaticSealed. Ball

40 (18)

Specifications subject to Changs without notlca. PlaSM contact factory lor specification updates.

EG&G ROTRON, SAUGERTIES, NY. 12477 • 914/246-3401 • FAX 914/246-3802

V/HC-SD-SJV^JDR-COT, REV. o

TRAHTSK. a r t .sficiTi:jLiicai

0*t»cuati

PHJTAD ASSOCIATES, SBC. Iten tt\atmi; ABOO

Kim 3363HX-03-0412-HP-012 / 0.0(0

Total Unita ; iOoita l a F t r t l l a l =»/*OBita In Sarias :K/A

Technician i IXSPass Arranasnaat: l x l

Flow B i n Countsr FlowTotal K«at Triuitfer Ar««: 2.8 SQ FT

Fluid circulatedTotal Flow DataUnit Flow Hat*SpauiClw lt«al•pac i f ic OravltyTnsraal ConductivityViacosityInlae Tanparature

Jjutlac Taavaratura(T^jaasttra nrop-parating Frasaura

Maae Btohanfsa

* C0HSSRUCT10Bcoda atamp

Bee Sidauua42.S000 OFB43.50001.14000.00010.0*000.0223212.000066.00000.0O4?14.7000

• ID.l

aml T U / t U DCS PIBTO/(«R FT SM P)CP AT AVO TWPDBO t

on rSSI TotalFSX6

Cold SidatMTEK1.00001.00001.00060.JM70.33SS1.2»70SO. 0000SI.13660.052460.0000

BPKDTU/CLD DOO r)

FV oaa p)CP AT AVG TSMPOtO tDBS FPSI TotalMIO

BTU/nt TOTAL

TsakG trcasurs iOasign «aas)ensuracULlL M4t r * '

aeliO32$3C013. P

•otai Chia ia a hot gas run

EBB Iuno

mathUuagthlUlht

a.oo-13.00"1.70*0.7k>

Flata* and Flceinga : 3161. SS

Your Trantar u ^ c w a n u u n i s :

S e t r ?Lictlaten. CO 80122

(303) 19«-4iO2partecaaaea guaranta* ia baasd on tha aoewrmoy o< eha data

praaantad abova. and tha costoaan ability to auroly product and operatingoonditiona is cottfornana* wieh tha abova.

QOSIR XJTfT

-r~_'WHCSSl>SNF-CDR-007, REV. 0

P R O P O S A L

July 25,1996

Santa Pe Engineering2204 Burthen RoadSant»F«,NM 87505

Attention: DaveMunger

Reference: Pall Proposal Number BP7ACDR96-129PD1

DearMr. MuDger

Thank you for your continued interest in FlaB Advanced StparattomSjutOM Mini ourproducts. I am pleased to oflo you n^bodgetoy quotation for an Ulti«Met™clean»blc,Metal HEPA rated filter.

The filter is designed tot the following eondnia

Fluid:Flow:Temperature:Pressure:

Nitrogen or Helium20ACFM0-57ST5TOR-* 10FSIO

Tie Pall UlnMct™ Air Fflter Aatemhly conaisb of one (1) 8" diameter, 304 SST filler6"l

The filter anemhlyi» a completely doaedcaniiter that ii welded permanently shut. Thecanister is * cylindrical filter vessel wrth weld cap end* and 1" ISM ANSI flanged inletand outlet connection! located on the center line of the veaael.

3200 Nmnhtn Btulntrd • BMU Hilb, NT US4» • USA • Hn-u }I6-4»4~}4OO • /far S16-4U-522»

, REV. 0

P R O P O S A L

PIH Propom Ninbor BP7ACDM6-12WDC

Prices for the Pall UtemMet™ Air Filter Assembly ss described herein air.

Price for one (1) assembly:

Price each for three (3) assemblies:

Estimated delivery time is 12-16 weeks after receipt ofa purchase order.

The UhraMet™ Air Assembly offers Santa Pe Engineering advantages:

HJghStnnfta:

All stainless itoel, M y welded construction.

CleMUtble!

The filters can be cleaned using a variety of mechanical methods.

High Temperature Capability:

Sustained operation at 750°F with intermittent temperatureexcursion to HOOT.

Safety:

The strength and durability of UltnMet™ Air filters providemaximum protection to people and the environment

3200 Nmkm MrmlmnJ • &ut Uilk. NY 11341 • USA • Mra# $16-494-5400 ' Ax 516-434-333)6S:ET 966T-S2-i0

-— ^tJC-SD-SNF-eDR-007, REV. 0

P R 0 P 0 S A

rations MPrap<ailNuabirBr7ACDR96-129PDI

Pall Corporation is a900+ million dote, muW-n«tionil company and the world's largestproducer of fine poroui media fitters. In order Co lucoeed, it iiettandaltiittVK providebetter value to oar customers. We are dedicated to tbii policy, which is why Pall's filtergales ire four to five timesmat of our nearest competitor. We took formed to toeopportunity of wotting with you to provide a deanabie, high effioianoy metal filtersystem. Ifyon have any questions, or requite further assistance, please do not hesitate tocontact me directly at (607) 753-6041 Bet. 1680 or Teree Rush of Kyser Company, Inc.

Very truly yours,

PallAitwtetiStpantioiu SytUms

Paul DittmanSenior Applications Engineer

CC: Kytet Company, Inc.5821 Midway Park Blvd. Ne/Suite KAlbnquerque.NM 87109Comact: Teree RushPhone: (505) 343-9355Fax: (505) 345-0885

1200 Nmitn ttuU—rd ' Bjut HIUi, NY 11S4B • USA ' Pktn, 516-494-H00 • Ft* 516-484-1229d

J U L - 2 2 - 9 6 IB.^01 FROM-RUST GEOXKCH J. NC/ " if _LI

3»iHC-SD-SNF-CDR-OO7, REV. 0

ULTRAMET AIR FILTER GRADES ANDTHEIR CHARACTERISTICS

SPECIFICATIONS

F i l t e r M e d i u m

W« Temile Strength: 25 lb./m. width,minimum, after IS'tmnure soak in *"ater.

Tensile Strength After Radiation: 25Lb./itv. width, minimum, aftei exposure toan integrated gamma radiation dose of6.4x10''RAD.

Water Repellency: Zero penetrationunder 30 inches of water pei M1L-STD-282.

Water Repellency After Radiation: Zeiwpenetration under 6 inches of vmtcr afterexposure to 6.4 x 10' RAD.

F i l t e r E l e m e n t s

Resistance to Heated AIR Reiiscanttoail at 75CF for 48 hours or at 1000°F fot 5uiinutts per UL-58(i and MIL-F5106S:

Spot Flame Rcxi.stance: No sustainedflttme on dowmtream side and nocransmicol of flame to outside surfaces perANSI8132.1.

Resurancc to Moisture and Overpressure:No permanent damage aftet 10 psi waterdiiferennal for 1 liour.

Resistance to Rough Handling: Nodamap! perMIL-STD-282, method 105.9.

Quality Assurance: ToASME-NQA-1-1989 and in accordance with M1L-F-51079. Certified to ISO9001.

Dust Capacity: 29 yn/ft.! per ASHRAE52-76.

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C/36 Circulation heaters Chromalbxi

Small capacity/low flow gas heaters 3Stainless steel0.5 to 3 kW120 and 240V, 1 phaseIncoloy81 sheath (50 W7in*)Type GCHIS-C

ApplicationFor heating gases, especially efficientfor low flow rate/high temperature appli-cations. (Outlet temperatures to 600°F)

FeaturesCompact, nigged design permitseasy installation.Overtemperature protection. Type Kthermocouple located inside heatingelement sheath.

Accurate process control by meansof Type J thermocouple installed in theheater outlet.Controls — ordered separately. Con-sult Controls Section of this catalog.

High temperature insulation and in-sulation jacket.

304 Stainless steel construction ofall wetted parts except Incoloy* sheath.Special voltage and wattage ratingsavailable. Contact your local Chroma-lox representative.

3/4"-14 NPTOutlet (IntThreads)

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arian's New 600DS Dry Scroll Pump incorporates atechnology that produces clean, cost effective, and reli-able vacuum pumping performance.Unlike many other types of dry pumps, the 600DS hasboth a low ultimate pressure and high pumping speed.With a base pressure in the 10'^ Torr range and superiorpumping efficiency, it is suitable for applications whereoil-sealed mechanical pumps have typically been used.I ie oil-free scroll pump, crescent-shaped pockets are(• ;d and bounded by the meshed scrolls. As theorDu:ng scroll moves within the fixed scroll, these pock-ets progressively decrease in volume as they move thepumped gases in the spiral path from inlet to discharge.Sealing is accomplished with PTFE seals againstanodized aluminum walls eliminating the need for oilsealing.

Because the scroll pump is intrinsically clean, there isno nsk of contaminating your vacuum system. Conven-tional oil sealed mechanical pumps require costly acces-sories (traps and baffles) to achieve only marginal levelsof cleanliness. Since no oils are required, the costs ofpurchasing and disposal of them are eliminated. Fewmoving parts and carefully chosen materials of con-struction minimize pump failures, with typical mainte-nance intervals of twelve to eighteen months. All thesefactors contribute to low cost of ownership and maxi-mum uptime.

Varian's 600DS Dry Scroll pump is the preferred choicefor your clean high vacuum requirements.

Turbo. Ion. or Cryo Pumped SystemsLoad Lock ChambersLeak Detection SystemsOpticsResearchAny application where the pr ; - : ice of hydrocarbonsis detrimental to your process

Scroll Design Low ultimate pressureHigh speedCompact size

it, low vibration operation• - *-vo moving parts• Long service life

Oil Free No risk of oil contaminationNo expensive traps or nitersNo costs of buying and disposing of oil

Carefully chosen construction materials Long life operationLow maintenanceLow cost of ownership

WHC-SD-SNF-CDR-007, REV. 0• Free Air Displacement '60 Hz 600 i/m (21 cftn)50 Hz 500 Urn (17.5 cftn)• Pumping Speed60 Hz 500 Urn (17.5 cftn)50 Hz 420 Urn (15 cftn)• Ultimate Total Pressure<10-2Torr(mbar)• Inlet ConnectionNW-40• Outlet ConnectionKW-25• Motor Rating0.8 hp (0.6 kW)• Electrical Supply1 Phase, 50/60 Hz, 100/115/200/230 V3 Phase, 50/60 Hz, 200/208/230/380/415/460 V• Noise Level at 1 meter60dBA• Operating Range40°F to 105°F (5°C to 40°C)• Weight88.2 lb (40.0 kg) 1 Phase100 lb (45.0 kg) 3 Phase

Varuui Part No. Description

600DS-1UNIV Model 600DS with base, hour meter,and direct drive, 1 phase motor

600DS-3UNTV Model 600DS with base, hour meter,and direct drive, 3 phase motor

600DS-KMI Minor Maintenance Kit600DS-KMA Factory Rebuild Service

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APPENDICES

APPENDIX I

CRITERIA EVALUATION

I-i

WESTINGHOUSE HANFORD COMPANY MERNCK & COMPANYHot CondKlonino, Sy«tom Equipment Project Advmctd Technology SactorContTKt«MWS-SWV-31(M(6,TMk#17 Projact No. 30012318


APPENDIX I - CRITERIA EVALUATION

CRITERIA EVALUATIONfor the



1.0 INTRODUCTION

Spent Nuclear Fuel (SNF) is to be conditioned by heating it in an inert (helium)environment, by holding the heated SNF under vacuum until the outgassing ratediminishes, and by controlled oxidation of exposed uranium surfaces. Theprocess will be accomplished by placing a container full of SNF, called theMultiple Canister Overpack (MCO), into an oven where it will be connected to aprocess system that can circulate gas through the MCO and that can draw avacuum within the MCO while the oven heats the MCO. The hot conditioningprocess development and the hot conditioning process equipment design,fabrication, and installation are the scope of the Hot Conditioning SystemEquipment (HCSE) project.

The HCSE is to be housed in an addition to the Canister Storage Building (CSB)called the Hot Conditioning System Annex (HCSA). The HCSA is to be coupledto the CSB such that it is completely open to the storage area of the CSB. Thisarrangement allows the MCO Handling Machine (MHM) to perform transactionsof MCOs between storage tubes that are below the CSB floor and the HCSEovens that must also be in tubes below the floor for proper MHM interfacing. TheHCSA is a separate project from the HCSE being performed through an additionof scope to the CSB project.

The interface of the HCSE/HCSA/CSB projects determines many of the criteriafor the HCSE. The CSB utilizes work performed previously as part of the HanfordWaste Vitrification Project (HWVP). The building foundation was completedpreviously and the final design of the CSB building has been issued for review inpreparation of an immediate construction start. Therefore, the structural andnuclear material release confinement criteria have been selected andimplemented for the CSB. Since there will be no wall between the HCSA and theCSB, the same criteria must also apply to the HCSA.

The CSB facility design is based on the fact that the MCO will always besecondarily contained within very rigid/protected structures (below groundstorage holes with thick concrete plug caps or within the MHM) that will be

1-1

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WHC-SD-SNF-CDR-007 , Revision 0

APPENDIX I • CRITERIA EVALUATION

qualified to perform the confinement functions required during and after credibleDesign Basis Accidents (DBAs). Therefore, the CSB design does not include abuilding shell and ventilation system designed to perform nuclear materialconfinement. It follows that the HCSA will not have a building shell or ventilationsystem designed to perform nuclear material confinement.

Given that the HCSE does have the potential of accidentally releasingradioactive material through a variety of scenarios caused by a variety ofinitiators, the responsibility of providing nuclear material confinement systems toadequately protect site workers and the off-site public lies with the HCSE project.This fact is fundamental to the selection and interpretation of appropriate criteriagiven below.

2.0 FACILITY CLASSIFICATION CRITERIA

2.1 DOE STD -1027 "Hazard Categorization"

The design of a nuclear facility necessarily requires iteration between designconcept development, hazards analysis, and criteria definition in order to arriveat a consistent package of criteria and designs. This is because the hazardclassification (HC), which is key to the criteria selection and designcharacteristics of the facility can be controlled to some extent by controlling theamount and form of the radioactive materials that will be present in the processsystems and facility. The performance categorization (PC) of structures,systems, and components (SSCs) that are subjected to postulated Design BasisAccidents (DBAs) is dependent on the HC. And, the determination of whetheran SSC is "safety class* or "safety significant" is determined by the off-siteconsequences (safety class) or on-site consequences (safety significant) ofreleases that might occur as a result of DBAs. However, calculation ofconsequences requires some model of the facility and the processes that itcontains. PC and safety class determinations imply certain structural loads andanalysis, as well as special design features to assure that there are no singlepoint failure modes for an SSC.

DOE Order 5480.23, "Nuclear Safety Analysis Reports", requires that a HazardCategorization (HC) be performed for planned nuclear facilities for the purposeof establishing a graded approach to safety analysis. Ratings range from HC-1for the most hazardous rating to HC-4 for non-nuclear facilities. Themethodology for assessing the Hazard Category is given in DOE STD-1027-92,"Hazard Categorization and Accident Analysis Techniques for Compliance withDOE Order 5480.23, Nuclear Safety Analysis Reports".

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In a general sense DOE STD -1027 defines HC's as follows:

• HC-3: Hazard analysis shows potential for only significant localizedconsequences. Facilities with quantities of radioactive materials in excess ofthe Table A-1 values which would yield a does of 10 Rem in 24 hrs at 30 musing the calculation method given in Attachment 1.

• HC-2: Hazard analysis shows potential for significant on-site consequences.The facility has potential for nuclear criticality events or has quantities ofmaterial at risk and energy sources to effect a release that would exceed 1Rem exposure at a distance of 100 m. using the calculation method given inAttachment 1, or would require on-site emergency planning activities.

• HC-1: Hazard analysis shows the potential for significant off-siteconsequences. Category A reactors ( > 20 MW) and facilities designated byPSO.

The STD -1027 methodology is based on comparing the radiological inventoryof a facility to HC Threshold Quantities (TQ) provided in Attachment 1. TheStandard recognizes that large quantities of radioactive materials may bepresent in a facility, but in a containment vessel, distribution, or a form thatprecludes release, and which need not be counted in the inventory when makingthe HC determination.

• "The concept of independent facility segments should be applied wherefacility features preclude bringing material together or causing harmfulinteraction among from a common severe phenomena It is not desirableto estimate the potential consequences from an inventory of hazardousmaterials when facility features would preclude bringing this materialtogether. Therefore, the standard permits the concept of facility segmentationprovided the hazardous material in one segment could not interact withhazardous materials in other segments.*

• "Additionally, material contained in DOT Type B shipping containers (with orwithout overpack) may also be excluded from summation of a facilitiesradioactive inventory."

• "Alternatively, for facilities initially classified as Hazard Category 2, if releasefractions can be shown to be significantly different than these values basedon physical and chemical form and available dispersive energy sources, thethreshold inventory values for Category 2 in Table A-1 may be divided by theratio of the maximum potential release fraction to that found on Page A-9. All

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assumptions which are used to reduce the inventory at risk should besupported in the Hazards Analysis."

Facilities that have radioactive material inventories in excess of the HC-2 maybe derated to HC-3 by demonstrating that hazardous material is not part of theat-risk inventory and by scaling the threshold values according to the ratio ofrealistic facility specific release fractions to the release fractions that wereassumed when the thresholds were established. A discussion of the TQassumptions and calculations is given in Attachment 1 of the standard.

At this time, the Hazards Analysis for the HCSE/HCSA is being performed.Preliminary results suggest that the MCO package will limit the postulatedreleases to levels that will not exceed the site boundary (public exposure)limitation. The hazard category rating for the HCSE/HCSA facility and processsupport systems that confine releases will be HC-2 (the same as the CSB) .TheHCSA and HCSE will not have any safety class SSCs. The consequences foronsite workers are expected to exceed the limits that are allowed withoutmitigating SSCs. Therefore, the HCSA/HCSE projects will provide safetysignificant SSCs to confine releases.

Given that the CSB/HCSA structures are not designed to confine releases andthe CSB/HCSA facilities do not include HEPA filtered exhaust, the HCSE mustprovide the safety significant SSCs.

2.2 DOE STD -1021 "Performance Categorization"

DOE Order 5480.28, "Natural Phenomena Hazards Mitigation" establishes agraded approach for determining the Performance Categorization PC of aStructure, System, and Component (SSC) when subjected to NaturalPhenomena Hazards based on the probability that SSC response will exceed asafety limitation. Guidance for PC determination is given in DOE STD 1021-93,"Natural Phenomena Hazards Performance Categorization Criteria forStructures, Systems, and Components". Figure 1-1 of STD 1021 summarizesthe guidance. It can be seen from the table that SSCs that perform a safetysignificant function in an HC-2 facility will be rated PC-2.

PC-2 rating does not require dynamic finite element analysis. The critical facilitystatic analysis methodology given in-UBC may be applied to HCSE safetysignificant SSCs such as the process piping, HEPA filters, and so forth.

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2.3 DOE 6430.1A "Facility Type Categorization"

The HCSA will be a "Nuclear Facility" as defined in the glossary of terms (page21). Therefore, it will be a "Special Facility" as defined by paragraph 1300-1.1.The criteria given in Division 13 "Special Facilities" are the basic guidance forthe design of the HCSA and HCSE. Application of Division 13 requirementsinvolves the general requirements given in Section 1300 as well as therequirements given in the applicable facility type section. In addition, the specialfacilities specific paragraphs labeled - 99.0 in the Discipline Divisions apply.

The HCSA will be classified as an Irradiated Fissile Material Storage Facility(IFMSF) because it is an extension of the CSB. As discussed above, the HCSEis an active process that could have accidental releases with a higher frequencythan a passive SNF storage facility and some amount of radioactivity may bewithdrawn from the MCO as a normal process practice. The inclusion of thisHCSE process within the IFMSF does not alter the CSB criteria so long as theHCSE includes its own confinement SSCs.

2.4 10 CFR Part 72 "Licensing Requirements for the IndependentStorage of Spent Nuclear Fuel And High Level Radioactive Waste"

The DOE has stated that it generally desires to comply with the requirements ofthe CFRs except for the licensing requirements, except for those instances andfacility types that are not specifically addressed by the CFRs, and except forthose instances where the DOE policies are more conservative than therequirements of the CFRs.

The CSB will comply with the requirements of 10 CFR Part 72 because it is anSNF Storage Facility. The HCSA, as an extension of the CSB will also beconsidered to be an Independent Spent Fuel Storage Installation. Thisclassification is dependent upon designing the HCSE so that it confines nuclearreleases without reliance on the facility structure and systems.

3.0 DESIGN CRITERIA

3.1 DOE Orders & Standards

Table 3.1 contains a list of DOE Orders and DOE Technical Standards thatcontain provisions that will effect features of the design of the HCSE/HCSA orthat may effect the contents of the engineering/design documentation of theHCSE/HCSA.

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W H C - S D - S N F - C D R - O O 7 , Revision 0


A brief description of each of the entries is as follows:

5400.1 General Environmental Protection Program -This order states thatenvironmental notification and reporting requirements are to be determinedon a facility case by case basis. It requires an annual environmental reportwhich is essentially an emissions summary. It requires that anenvironmental protection plan and an environmental monitoring plan bedeveloped and approved. These should be approved before authorizationto initiate operations is given. The HCSE design will have to includeappropriate monitoring capability.

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DOE ORDERS SUMMARY

ORDER/STANDARD

5400.1

5400.3

5400.4

5400.5

5440.1 E

5480.1 B

5480.4

N5480.6

5480.7A

5480.9

5480.19

5480.21

5480.22

5480.23

5480.28

5481.31

5483.1A

5700.6C

5820.2A

6430.1A

STD-0101

STD-1020

STD-1021

STD-1022

TITLE

General Environmental Protection Program

Hazardous and Radioactive Mixed Waste Program

Comprehensive Environmental Response, Compensation, and Liability ActRequirements

Radiation Protection of the Public and the Environment

National Environmental Policy Act Compliance Program

Environment, Safety, and Hearth Program

Environmental Protection, Safety and Health Protection Standards

DOE RadCon Manual

Fire Protection

Construction Safety and Health Program

Conduct of Operations Requirements for DOE Facilities

Unreviewed Safety Questions

Technical Safety Requirements

Nuclear Safety Analysis Reports

Natural Phenomena Hazards Mitigation

Start-Up and Restart of Nuclear Facilities

Occupational Safety and Health Program for OOE Contractor Employees atGovernment-Owned Contractor-Operated Facilities

Quality Assurance

Radioactive Waste Management

General Design Criteria

Compilation of Nuclear Safety Criteria for Potential Application to DOE Non-ReactorNuclear Facilities

Natural Phenomena Hazards Design and Evaluation Criteria for DOE Facilities

Natural Phenomena Hazards Performance Categorization Guidelines for Structures,Systems, and Components

Natural Phenomena Hazards Site Characterization

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DOE ORDERS SUMMARY(Continued)

ORDER/STANDARD

STD-1024

10CFR835

STD-1027

STD-1044

STD-3003

STD-3006

STD-3009

STD-3011

40CFR61

TITLE

Guidelines for Use of Probabilistic Seismic Hazard Curves at DOE Sites

Radiation Exposure

Guidance For Preliminary Hazard Classification and Accident Analysis Techniques forCompliance With DOE Order 548023, Safety Analysis Reports

Guide To Good Practices for Equipment and Piping Labeling

Backup Power Sources for DOE Facilities

Planning and Conduct of Operations Readiness Reviews

Preparation Guide for U.S. DOE Nonreactor Nuclear Facility Safety Analysis Reports

Guidance for Preparation of DOE 5480.22 fTSR) and DOE 548023 (SAR)Implementation Plans

National Standards for Hazardous Air Pollutants

5400.3 Hazardous and Radioactive Mixed Waste Program - This orderimplements RCRA in the DOE. The HCSE will generate radioactive waste that isregulated by RCRA.

5400.4 CERCLA Requirements -This order implements CERCLA in the DOE.

5400.5 Radiation Protection of the Public and the Environment -Sets limits on publicdoses from normal operations. Defines Derived Air Concentrations and implementsICRP recommendations.

5440.1 E NEPA Compliance Program - This order implements the NationalEnvironmental Protection Act in the DOE.

5480.1B Environment, Safety, and Health Program - This document is the masterdocument for the 5480 series of orders.

5480.4 Environmental Protection, Safety, and Health Protection Standards - Thisorder implements a list of regulations that apply to private organizations but whichare not automatically applied to the DOE. The order is a useful reference list.

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N5480.6 DOE RadCon Manual - This notice sets policy regarding radiationexposure limits, radiation area practices, and ALARA considerations. A designprogram is required to achieve the ALARA goal. The guideline also contains criteriagoverning the design of change rooms and other radiation/radioactive materialcontrol procedures. One key criteria is the ALARA design guideline of 500 mR peryear for an individual radiation exposure.

5480.7A Fire Protection - This order relates to nuclear facility safety issues suchas fire protection of safety class equipment, fire hazards analysis for the designbasis fire to be included in the SAR, seismic criteria for the fire protection system,and life safety codes. It sets forth provisions that address loss limitation forgovernment owned facilities.

5480.9 Construction Safety and Health Program -This order implementsrequirements found in the OSHA regulations regarding construction safety.Construction specifications should reference appropriate requirements.

10CFR835 Radiation Protection for Occupational Workers - This document sets therequirements for radiation exposure protection and As Low As ReasonablyAchievable (ALARA) policy.

5480.19 Conduct of Operations Requirements for DOE Facilities - Safety of workersand protection of the public requires that nuclear facilities be formally managed byoperations program that meets high standards of discipline. In the nuclear power,NRC, arena the conduct of operations requirements are specified by the ICRP. Thisorder implements similar requirements for facilities regulated by the DOE. Itaddresses operations procedures, shift changes, operator training, and so forth.The design team will write a draft Conduct of Operations Plan.

5480.21 Unresolved Safety Questions - Is analogous to 10CFR50.59. Establishesa process for changing the operating basis of the facility. Allows the operator thefreedom to perform experiments and investigate safety issues that may arise whileconducting day-to-day operations.

5480.22 Technical Safety Requirements - This order requires that safety limits forthe operating parameters of the facility be established, that procedures for assuringthat these limits are not exceeded be established, that these parameters bemonitored, and that response actions for conditions outside the safety limits bedetermined.

5480.23 Nuclear Safety Analysis Reports - This order applies in its entiretybecause it is the document that defines the requirements for safety analysis andSARs, which are the means of demonstrating that the public/environment andworkers are adequately protected. The major impacts on the project are:

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Syittm Equipment Project Advmctd Ttehnotogy SoetorCortJBet*MW6-SWV-310416,T«sk#17 Project No. 30012318



• A preliminary hazards analysis is to be performed and published. Guidance isgiven by DOE STD-1027.

• A Preliminary Safety Analysis Report (PSAR) is to be developed. The PSARis developed simultaneously with design. There is iteration between safetyanalysis and design. The PSAR analysis demonstrates that the designadequately mitigates the consequences of the hazards presented in thehazards analysis.

• A Final Safety Analysis Report is to be developed. This report updates thePSAR to reflect the as-built facilities and incorporates the operating proceduresfor the facilities.

5480.28 Natural Phenomena Hazards Mitigation - Establishes requirements forresponse of facilities to natural phenomena such as earthquakes and high winds.

5480.31 Start-up and Restart of Nuclear Facilities - Sets out requirements forauthorization to initiate operations utilizing nuclear materials. Essentially thisdocument establishes the DOE "licensing" criteria. The Operating Readiness Planshould be written by the design team. Th plan should follow the guidance of DOE-STD-3006.

5483.1A Occupational Safety and Health Program for DOE Contractor Employeesat Government Owned Contractor Operated Facilities - This order implementsOSHA within the DOE.

5700.6C Quality Assurance - The document is analogous to ASME NQA-1 whichis a nuclear facilities quality assurance guideline required by DOE 6430.1 A.

5820.2A Radioactive Waste Management - This order requires a wastemanagement plan, has D&D requirements, and sets waste characterizationstandards, as well as establishing numerous other requirements that affect both thedesign and operations of the CVDS.

6430.1A General Design Criteria - This order sets forth design criteria for allengineering disciplines as well as special facility and special equipment criteria.Facility type classification and safety class SSC requirements are discussed inSection 2..3 above.

Key confinement system ventilation requirements are referred to ERDA 76-21and to the 1550-99 paragraphs of the order. The key statement comes from1550-99.0.1 "General Ventilation and Off-Gas Criteria", "These criteria coverventilation and off-gas systems, or portions of them, that are identified as safetyclass items in accordance with Section 1300-3.2, Safety Class Items". Strictly

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speaking, this means that the HCSE will not be governed by these requirements.None-the-less the principles stated in 1550-99.0.2 "Confinement VentilationSystems" should be followed as a matter of good engineering practice (exceptwhere specific references to the safety class characteristics of the system aremade). The basic design concepts for exhaust filtration performance and stackdesign should be derived from safety analysis that analyzes the consequencesof credible release scenarios.

Section 1300-12 "Human Factors Engineering" requires that a human factorsprogram plan be written. The level of detail of the plan is to be determined by thecomplexity or safety issues associated with human activities. The subsectionsalso set out extensive human factors requirements for human factorsengineering. The HCSE should write and implement a plan given that theradiation exposure during operations can severely restrict the staff planning.

STD-0101 Compilation of Nuclear Safety Criteria For Potential Application toDOE Non-Reactor Nuclear Facilities - This STD contains a listing of references.

STD-1020 Natural Phenomena Hazards Design and Evaluation Criteria for DOEFacilities - This standard gives guidance regarding the selection of designcriteria to be applied to nuclear facilities structural design.

STD-1021 Natural Phenomena Hazards Performance Categorization GuidelinesFor Structures, Systems and Components - See discussion in Section 2.2.

STD -1022 Natural Phenomena Hazards Site Characterization - The site NPHshave been characterized by the CSB project.

STD -1024 Guidelines For Use of Probabilistic Seismic Hazard Curves at DOESites - Seismic hazards risks have been established for the HCSA/HCSE by theCSB project.

STD-1027 Guidance tor Preliminary Hazard Classification and Accident AnalysisTechniques for Compliance With DOE Order 5480.23, Safety Analysis Reports -See discussion in Section 2.1.

STD -1044 Guide To Good Practices For Equipment and Pipe Labeling - Setsforth guidelines for labeling equipment and piping.

1-11

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHatCond)ionlngSyrtMnEqui|imnlProjKt Advwo«l Ttchnotogy SwlorConlract«MW6-SVW-310416,Tnk*17 Project No. 30012316

WHC-SD-SNF-CDR-OO7, Revision 0


STD -3003 Backup Power Sources For DOE Facilities - There is no safetyrequirement for backup power in the CVDS. The guidance in the is guideline willbe followed if backup power is included for other reasons.

STD-3006 Planning and Conduct of Operations Readiness Reviews - ORRplanning will be addressed by the design team in order to assure that thenecessary engineering documentation is ready for the ORR.

STD-3009 Preparation Guide for U. S. DOE Nonreactor Nuclear Facility SafetyAnalysis Reports - See discussion in Section 2.1.

STD-3011 Guidance for Preparation of DOE 5480.22 (TSR) and DOE 5480.23(SAR) Implementation Plans - These plans will be drafted as part of the designprocess.

40CFR61 National Standards for Hazardous Air Pollutants - This sets forthrestrictions on the release amount of those materials considered by thisstandard to be hazardous air pollutants.

3.2 NRC Equivalency

Report WHC-SD-SNF-DB-003 Rev.1, December, 1995, "Spent Nuclear FuelProject Path Forward Additional NRC Requirements" addresses implementationof the U.S. DOE K Basin Spent Nuclear Fuel Regulatory Policy (August 4,1995)to achieve "nuclear safety equivalency" to comparable U.S. Nuclear RegulatoryCommission (NRC) licensed facilities. This report addresses the project as awhole. Each of the components of the project is required to look at applicationfor the specific features of the components. This section addresses applicationof each of the 29 items in WHC-SD-SNF-DB-003 to the HCSE as follows:

1. Fire Protection - Assure that DOE 5480.7A and DOE 6480.1A areequivalent to 10 CFR50, Appendix R. There are significant hazardsassociated with the event that a hot MCO undergoing conditioning mightbe suddenly flooded with fire water. A Fire Hazards Analysis will beperformed to determine appropriate fire protection system features.

2. Response to Natural Phenomena Hazards. The key difference is thatNRC includes a Design Basis Tornado and missile analysis. The CSBand HCSA will not be designed to perform nuclear release confinement inthe event that they are struck by a tornado. The HCSE will containappropriate tornado resistant features (such as oven installation in

1-12

WESTINGHOUSE HANFORD COMPANY MERRICK 4 COMPANYHot Conditioning System Equipment Project Advanced Technology SectorContract #MW6-SWV-310416, Ta«k#17 Project No. 30012318



covered pits) and will also rely on probabilistic arguments for specifictargets.

3. In the event that safety class 1 electrical equipment may be required andmay be exposed to harsh environments The HCSE will not have anysafety class 1 SSCs requiring power to function.

4. SAR should include a loss of power accident analysis. The HCSE will bedesigned to shut down safely to a passive condition in the event of a(Loss Of operating Power) LOOP incident. LOOP analysis is standardpractice in DOE 5480.23 safety analysis as prepared according to DOE-STD-3009.

5. Incorporate the requirements of IEEE Std 484-1987 into the design andinstallation of safety class 1 batteries. The HCSE will not have safetyclass 1 batteries.

6. Incorporate the requirements of IEEE Std 535-1986 into the design andinstallation of safety class 1 batteries. The HCSE will not have safetyclass 1 batteries

7. Incorporate the requirements of IEEE Std 603-1991 into the design ofsafety class 1 instrumentation and control systems. The HCSE will nothave any safety class 1 instrumentation and control systems.

8. Incorporate the requirements of ANSI/ANS 8.3 1986 for criticality alarmsystems. The HCSE will not have a criticality alarm system becausecriticality cannot occur in the process.

9. Human factors planning and engineering. See discussion about the DOE6430.1 A human factors engineering requirements in Section 3.1 above.

10. Use Regulatory Guide 1.26 to assist in assigning appropriate code classto ASME Section III systems and components. The HCSE will not containany ASME Section III systems or components.

11. Regulatory Guides 1.84 and 1.85 regarding application of ASME SectionIII requirements to safety class 1 systems. The HCSE will not have anysafety class 1 systems.

1-13

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot ComttnringSytitmEquipmrt Project Admnced Technology SectorContract #MW6-SWV-310416, Task »17 Project No. 30012318



12. Ensure that the requirements of ANSI/ANS 509 and ANSI/ANS 510 areincorporated into HEPA filter design. The NRC and DOE 6430.1 Arequirements are the same. HEPA filter systems will be designed andspecified according to these standards.

13. Incorporate the requirements of ANSI/ANS 57.1 and 57.2. Does not applyto the HCSE since there will be no cranes.

14. Incorporate the applicable design requirements of Generic Letters 88-14,89-10, and 89-13 into safety class 1 The HCSE will not have safetyclass 1 SSCs.

15. 10 CFR Part 21 requires that manufacturers of procured items reportdefects in items or services for safety class 1 SSC procurement. Standardclause in WHC procurement terms and conditions. The HCSE will nothave any safety class 1 SSCs.

16. 10 CFR 830.120 Quality Assurance program requirements. The normalDOE requirements for compliance with DOE 5700.6c exceeds thisrequirement. The HCSE will follow the DOE requirements.

17. 10 CFR 50.55 requires reporting of unusual occurrences duringconstruction. This is covered by WHC-CM-1-5. The HCSE will observethis requirement.

18. 10 CFR 50, Appendix B Quality Assurance Criteria for Nuclear PowerPlants and Fuel Reprocessing Plants. The normal DOE requirements forcompliance with DOE 5700.6c exceeds this requirement. The HCSE willfollow the DOE requirements.

19. Institute a process to identify safety class 1 equipment that has beenidentified in the commercial nuclear power industry via IE Bulletins andNotices as being potentially defective. The HCSE will not have safetyclass 1 SSCs.

20. 10 CFR Part 20 - incorporate control devices for access to high radiationareas that conform to the requirements of Section 20.161. Therequirement will be met by means of installing shielding and by use of aprocess enclosure that prevents access to the high radiation area abovean oven when the top is open.

1-14

WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conallionina,Sy«tem Equipment Project Advanced Technology SectorContract #MWa-SWV-310416. T w * #17 Project No. 30012318



21. Apply the radiological exposure criteria of Section 72.104 .... The criteriawill be met.

22. Use a deterministic value of 5 Rem in safety analyses for the onsiteworker at the boundary of the controlled area (100 m from the CVDSrelease point) for design basis accidents to assist in determining safetyclass 2 and 3 SSCs (refs. 10 CFR 72.106, .100, .126). 10 CFR Part 72requirements do not apply to the CVDS. The DOE orders and STDs donot address safety class 2 and 3 specifically. Equivalents they discussSSCs that are safety significant to encompass those systems that protecton site workers and plant workers. The DOE criteria is 1 Rem at 100 m.,which is more restrictive than the referenced NRC requirement.

23. Implementation of RG 8.8, Information Relative to Ensuring ThatOccupational Radiation exposures at Nuclear Power Stations Will Be AsLow As Reasonably Achievable, Rev. 3, DOE requirements from DOE N5480.6 are more restrictive than RG 8.8. The design process will includea thorough ALARA analysis that estimates exposure considering sourcetrems, work sequences, and anticipated repair requirements.

24. Implementation of RG 3.26, Standard Format and Content of SafetyAnalysis Reports for Fuel Reprocessing Plants or RG 3.48 StandardFormat and Content of Safety Analysis Reports for an Independent SpentFuel Storage Installation (Dry Storage). The safety analysis methodologyestablished for the CSB will be implemented. The HCSE project willassume that the CSB project has complied with this requirement.

25. Review the monitoring requirements of 10 CFR 20,10 CFR 70.59,10CFR50, Appendix A. These are analogous to DOE 6430.1A 1589-99.0.1.which is a project requirement stated above in DOE 6430.1 A review inSection 3.1.

26. The 10 CFR 50, Appendix 50 general design criteria are adequatelycovered by the application of the criteria in this report.

27. Incorporate a criticality safety value of keff = 0.95. The CVDS cannotachieve a critical condition. Criticality analysis for the configuration of theSNF inside the MCO will be the responsibility of the MCO design team.No criticality analysis will performed as part of the HCSE project.

28. Review ANSI/ANS 57.9 and RG 3.60 which set forth ISFSI design criteria.These criteria affect the CSB and HCSA projects but do not effect theHCSE project.

1-15

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Project Adwnc»d Technology SactorContnKt»MW6-SWV-3A04l6,TMk#17 Project No. 30012318


APPENDIX I • CRITERIA EVALUATION

29. Identify items that are "important to safety" in accordance with 10 CFR72.3 and impose safety class 1 requirements. Items that are important tosafety will be identified and treated as safety significant items.

4.0 NUCLEAR SAFETY PROGRAM CRITERIA

Key nuclear facility safety documents that define public safety aspects of theHCSE/HCSA criteria are discussed in Sections 2.1 through 2.4 above. The keyDOE Orders are the DOE 5480 series and the DOE 5400 and 5500 series.

Worker radiation exposure safety within the plant is defined by 10 CFR 835 andDOE N5480.6. Of these the DOE N5480.6 is the most comprehensive andrestrictive document. A program to achieve radiation exposure As Low AsReasonably Achievable with an administrative control limitation of 500 mrem peryear per person is the stated whole body exposure criteria in DOE N 5480.6.10CFR 835 defines the DOE ALARA design target as 1.0 Rem per year. TheHCSE design criteria will the DOE N 5480.6 value (500 mrem) unless featuresrequired to achieve this value prove to be unreasonable ( in which case the 10CFR 835 of 1.0 rem will be observed).

5.0 OPERATIONS PREPARATIONS CRITERIA

The transition from the end of the HCSE construction project to operations willbe an Operations Readiness Review. This review will be conducted according tothe requirements of DOE 5480. 31. The ORR will determine that the facility iscomplete, that the safety analysis is complete, that TSRs (DOE 5480.22 andDOE STD -3011, 1082) are complete, that appropriate design criteria have beenestablished and met, that systems operations tests are complete, that personneltraining has been completed (DOE STD 1005,1007,1008,1009,1011,1056,1060, 1070,1074, 1078) that safety programs are operational (DOE STD -1082), that an appropriate conduct of operations program (DOE 5480.19 andDOE STD -1032, 1033, 1034, 1035, 1036, 1037, 1038, 1039, 1040, 1041, 1042,1043, 1045,1051, 1054,1055) is in place, that emergency preparednessprograms are appropriate. In order to activate the transition and ORR plan isrequired per DOE STD-3006. This plan should be developed in parallel with thedetailed design.

I-16

WESTINGHOUSE HANFORD COMPANY MERRICK * COMPANYHot Conditioning Syitem Equipment Project Advanced Technology SectorContract«MvV6-SWV-310416,Tnk*17 Praject No. 30012318



Addendum 1 - Listing of Reference Criteria Documents

1-17

SNF DOCUMENT REFERENCES WHC--SD-SNF-CDR-007REV. 0

REFERENCED DOCUMENT

DOE1300.2ATechnical Standards Program

DOE1324.5BRecords Management

DOE 1332.1 AUniform Reporting System

DOE 1360.2BRecords Management Program

DOE 1540.1 AMaterials Transport & Traffic Management

DOE 1540.2Hazardous Material Packaging

DOE 1540.3ARM Transportation Packaging

DOE 4330.4BMaintenance Management

DOE 4700.1Project Management

DOE N 4700.5Project Control Guidelines

RLID 4900.1DOE 5000.3B

Occurrence ReportingRLID 5000.3B

Occurrence ReportingRUD 5000.12DOE 5300.1C

TelecommunicationsDOE 5400.1

Environmental ProtectionDOE 5400.2A

Environmental Compliance Issue CoordDOE 5400.3

Hazardous and Mixed Waste ProgramDOE 5400.4

CERCLA RequirementsDOE 5400.5

Radiation ProtectionDOE 5440.1E

NEPA ComplianceDOE 5480.1B

ES&H ProgramDOE 5480.3

Safety for HAZMAT TransportationDOE 5480.4

ES&H Protection StandardsDOE 5480.6

Safety of Nuclear ReactorsDOE 5480.7A

Fire Protection

IS

IN

SOW

DOEO

X

X

X

IS

H

0435

B

nSEMP

RECTIVES

X

X

X

X

X

X

IS

w

020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

No Design Impact

No Design Impact

WACs also applyNo Design ImpactNo Design Impact

No Design Impact

WACs also applyNo Design ImpactNo Design Impact

No Design Impact

No Design Impact

Expired a/21/94

Has been cancelled

Use DOE 5000.3B

Has been cancelledMo Design Impact

WACs also apply

WACs also apply

Use HSRCM-1 also

WACs also apply

WACs also applyNo Design ImpactWACs also apply

No Design Impact

Addendum 1 to Appendix I11-1

SNF DOCUMENT REFERENCES WHC-SD-SNF-CDR-007 REV. 0

REFERENCED DOCUMENT

DOE 54S0.8AContractor Medical Program

DOE 5480.9AConstruction Safety & Health

DOE 5480.10Contractor Hygiene Program

DOES480.11Radiation Protection for Workers

DOE 5480.18BTraining Accreditation Program

DOE 5480.19Conduct of Operations

DOE 5480.20APersonnel Selection, Qualification, Training

DOE 5480.21Unreviewed Safety Questions

DOE 5480.22Tech. Safety Requirements

DOE 5480.23Nuclear SARs

DOE 5480.24Criticality Safety

DOE 5480.26Trending

DOE 5480.28Natural Phenomena

DOE 5480.29Employee Concerns Management

DOE 5480.31Readiness Review

DOE 5481.1BSafety Analysis and Review System

DOE 5482.IBES&H Appriasal Program

DOE 5483.1 AOSHA for Contractors

DOE 5484.1ES&H Reporting.

DOE5500.1BEmergency Management System

DOE 5500.2BEmergency Categories

DOE 5500.3APlanning for Emergencies

DOE 5500.7BEmergency Records Protection

DOE5500.10Emergency Readiness Assurance

DOE 5630.1 IBSafeguards and Security

DOE 5630.12AS&S Inspection

Addendum

IS

H

SOW

fS

w0435

X

X

X

1 to Appendix 1

«

M

SBMP

ts

IN

O20

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

WACs also applyNo Design ImpactWACs also apply

WACs also applyNo Design ImpactUse HSRCM-1

No Design Impact

No Design Impact

No Design Impact

Mo Design Impact

WACs also applyNo Design ImpactWACs also applyto Design Impact

WACs also applyNo Design ImpactUse DOE action only.See 10CFR840also

WACs also applyNo Design Impactto Design Impact

to Design Impact

No Design Impact

11-2


REFERENCED DOCUMENT

DOE 5630.15S&S Training

DOE 5632.1CProtection and Control S&S Interests

DOE 5633.3BControl and Accountability of Nuc Mat

DOE S700.6CQuality Assurance

DOE 5700.7CWork Authorization

DOE 5820.2ARadioactive Waste Management

DOE 6430.1 ADesian Criteria

DOE-STD-0101 - Compilation of Nuclear SafetyCriteria for Potential Application to DOE NRNF

DOE-STD-1020-94Nat Phen Haz Design & Eval Crit

DOE-STD-1021-94Nat Phen Haz Perf Cat Guidelines

DOE-STD-1022-94Nat Phenomena Haz Site Char Crit

DOE-STD-1023-95Natural Phenomena Hazards Assessment Crit

DOE-STD-1024 - Guidelines for Use ofProbabilistic Seismic Hazard Curves at DOE Sites

DOE-STD-1027 - Guidelines for Prelim Haz Class& Accident Analysis to complv with DOE 5480.23

DOE-STD-1044 - Guide to Good Practices forEquipment and Piping Labeling

DOE-STD-3003Backup Power Sources for DOE Facilities

DOE-STD-3006Planning and Conduct of ORRs

DOE-STD-3009-94Prep Guide for DOE Non-Reactor Nuc SARs

DOE-STD-3011 - Guidance for Preparation of TSRand SAR Implementation Plans

DOE-M-5632.1C-1Protection and Control of S&S

DOE/EH-0173TEffluent Monitoring

DOE/EP-0108Fire Protection for Elec Comp/Data Proc

DOE/EV-0043Fire Protection for Portable Structures

DOE/EV-1830-TSGuide to Reducing Rad Exposure to ALARA

DOE MemorandumRevised Policy for Acceptance for ER

RLID 1360.2BUnclassified Computer Security

IS

IN

SOW

IS

IN

0435

X

IS

W

SEMP

IS

IN

020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

No Design Impact

No Design Impact

No Design Impact

Use project QA plan.

For DOE action only.

No Design Impact

WACs also apply

No Design Impact

No Design Impact


SNF DOCUMENT REFERENCES WHC-SD-SNF-CDR-O07 REV. 0

REFERENCED DOCUMENT

RUD 5480.7Fire Protection

RLID 5480.29RL Employee Concerns Program

RLID 5480.31Startup and Restart of Nuclear Facilities

RUD 5484.1 AEPS&H Report™ Requirements

DOE/RL 92-36Hoisting & Rigging

DOE/RL 93-102Fv 95 Mission Plan

DOE/RL-XXSystems Engineering Criteria

DOE-STD-1073-93Guide for Configuration Management

SEN 15-90NEPA

SEN 35-91Nuclear Safety Policy

HPS-SDC-4.1,Rev 12Facility Design Loads

HPS-SDC-5.1HVAC

SNF-RD-PM-O01SNF Program Requirements

IS

»

SOW

IS

w0435

X

X

»

H

SEMP

X

X

IS

IN

O20

X

X

X

X

X

X

X

X

X

X

X

COMMENT

No Design Impact

No Design Impact

No Design Impact

Document not approvedbyRL.For guidance only.

WACs also apply

Use HSRCM-1

Applicable SeismicCriteria

WASHINGTON ADMINISTRATIVE CODES51-13

Energy Code173-160

Construction and Maint of Wells173-201A

Water Quality Standards173-200

Water Quality for Ground Water173-216

Waste Discharge Permit Program173-218

Underground Iniection173-224

Water Discharge Permit Fees173-240

Sub of Plans for Waste Water Fac173-303

Dangerous Waste Regulations173-304

Min Stds for Solid Waste Handling173-307

Plans173-340

Model Toxic Control Regs

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Addendum 1 to Appendix I

11-4


REFERENCED DOCUMENT

173-360UST Regulations

173-400General Regulations for Air Poll Sources

173-401Operating Permit Regulations

173-460Controls for Toxic Air

173-480Air Quality for Radionuclides

197-11SEPA Rules

246-247Radioactive Air Emmissions

246-247-050Registration

246-247-060Air Emissions Permit

246-249Rad Waste, Use of Commercial Site

246-272On Site Sewage Systems

246-290Public Water Supplies

402-40Wash Std for Prot Against Radiation

446-50Transportation of Hazardous Wastes

Tri Party Agreement

IS

IN

SOW

IS

IN

0435

IS

H

SEMP

REVISED CODE OF WASHINGTON36.58

Washington Solid Waste Disposal36.94

Sewage, Water and Drainage Systems43.21C

State Environmental Policy43.200

Washington Radioactive Waste Act46.37

Vehicle Lighting and Other Equipment46.44

Size, Weight, Load49.17

Wash Industrial Safety and Health Act70.94

Washington Clean Air Act70.95

Solid Waste Management Reduction & Recycle70.96

Washington Underground Storage Tanks70.105

Hazardous Waste Management

IS

m

020

X

X

X

X

X

X

X

X

X

X

X

X

X

XX

COMMENT

X

X

X

X

X

X

X

X

X

X

X

Implemented by WAC

Implemented by WAC

Implemented by WAC



REFERENCED DOCUMENT

70.105DToxic Control Act

90.03Water Code

90.42Washinaton Water Resource Management

90.44Regulation of Public Groundwaters

90.48Water Pollution Control

90.52Pollution Disclosure Act

90.76Underground Storage Tank

ICRP

37Rad. Protect Cost

NUCLEARNRC Reg Guide 1.36

Thermal InsulationNUREG 0700

Control Room DesignNUREG CR-3264

ALARA MaintenanceCOMMERCIAL

American Water Works61

ICBOUniform Building Code

NFPA-70National Electric Code

ORNLTM-10864Remotely Maintained Equipment Des Guide

PAL-1988Health Physics Manual

MIL-STD-1472DHuman Engineering

ASMEB31.1Refinery Piping

ASME 14.5Dimensioning and Tolerancing

NQA-1

Quality AssuranceCODE OF

10CFR20Radiation Protection Standards

10CFR50Domestic Licensing of Production & Util

10CFR51Regulations for Licensing

B

M

SOW

PUBLIC

REGUU

&MILIT

ANSI/A

FEDERA

IS

n0435

ATIONS

XTORYC

X

X

XARYSTA

X

X

X

X

X

X5ME

X

X

XL REGUL

X

IS

H

SEMP

DMMISS

NDARD

ATIONS

IS

M

O20

X

X

X

X

X

X

X

COMMENT

Implemented by WAC

Implemented by WAC

Implemented by WAC

Implemented by WAC

Implemented by WAC

Implemented by WAC

XION

S/GUID

X

X

X

Use HSRCM-1

Use HSRCM-1

S

Use HSRCM-1DOE 5480.11Section 50.48 and App Rfor NRC equivalencyNot applicable to SNFP



REFERENCED DOCUMENT

10CFR71Radioactive Pkg & Trans

10CFR72Licensing of Spent Fuel Storage

10CFR73Protection of Plants and Materials

1OCFR436Life Cycle Cost Methods & Procedures

10 CFR 830.120Quality Assurance

10 CFR 835Radiation Protection

10 CFR 840Extraordinary Nuclear Occurances

10 CFR 961Std Contact for Disposal of SNF & HLRW

10 CFR 1021NEPA

29 CFR 1910OSHA Act

29 CFR 1926Construction OSHA

40 CFR 6.302gFish & Wildlife

40 CFR 52Ambient Air Quality

40 CFR 58Ambient Air Quality Surveillance

40 CFR 60Stds of Perf for New Stationary Sources

40 CFR 61Haz Air Emissions Stds

40 CFR 122Permitting. Regmnts for Land Disp Fac

40 CFR 124Procedures for Decision Making

40 CFR 125Criteria and Stds for NPDES

40 CFR 191Management & Disposal of SNF & TRW

40 CFR 240Guidelines for Thermal Processing

40 CFR 241Guidelines for Land Disp of Solid Waste

40 CFR 260Haz Waste Management System

40 CFR 261Identification and Licensing

40 CFR 262Stds Applicable to Generators

40 CFR 264Stds for Owners & Operators

IS

H

SOW

X

IS

w

0435

X

X

X

X

is

H

SEMP

IS

IN

020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

Use 49 CFRs

Not Applicable

UseRLID 5632.1B

Not Applicable

Use WAC

Use WAC

Use WAC

Use WAC

WACs also apply



REFERENCED DOCUMENT

40 CFR 26SInterim Status Standards

40 CFR 268Land Disposal Restrictions

40 CFR 271Rea for Auth of State Haz Waste Prog

40 CFR 300Nat Oil & Haz Sub Poll Cont Plan

40 CFR 1500Purpose. Policy and Mandate

40 CFR 1501NEPA & Agencv Planing

40 CFR 1502Environmental Impact Statement

40 CFR 1503Commenting

40 CFR 1504Predecision Referrals

40 CFR 150SNEPA & Agencv Decision Making

40 CFR 1506Other Requirements of NEPA

40 CFR 1507Agencv Compliance

40 CFR 1508Terminology & Index

41 CFR 109DOE Property Management

43 CFR 11Nat Resources Damage Assessments

49 CFR 172Dims for Placard Holder

49 CFR 173Requirements for Pack & Ship

49 CFR 393Parts & Accessories Nee for Safe Op

49 CFR 566Manufacturer Identification

49 CFR 567Certification

49 CFR 571Federal Motor Vehicle Safety Stds

IS

IN

SOW

IS

m0435

IS

N

SEMP

IS

M

020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

Use WAC

For DOE action only

US CODE15 USC 2601

Toxic Substance Act16UCS661

Protection and Conservation of Wildlife16 USC 1531

Endangered Species Act16 USC 2901

Fish and Wildlife Conservation

X

X

X

X

Use RCW


11-8


REFERENCED DOCUMENT

25 USC 3001Native American Graves Protection

29 USC 651Occuoational Safety & Health

33 USC 1251Clean Water Act

42 USC 1996American Indian Religious Freedom

42 USC 2011Atomic Enerav Act

42 USC 4321NEPA of 1969

42 USC 5801Energy Reorganization Act of 1974

42 USC 6901Solid Waste Disposal

42 USC 7101DOE Organization Act

42 USC 7401Clean Air Act

42 USC 9601Compensation and Liability

42 USC 10101Nuclear Waste Policy Act

49 USC 1802Haz Materials Transportation Act

46 FR 42237Responses to Environmental Stds

EO-12316Responses to Environmental Stds

PL 92-500Clean Water Act

PL 101-189Defense Authorization Act

IS

nsow

X

IS

w0435

ts»

SEMP

IS

w020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

Use RCW

Use RCW

Use RCW

mplemented by CFRs

•WHO" DOCUMENTSHSRCM-1

Hanford Rad Control ManualCM 1

Company Policies and ChartersCM 1-3

Requirements & ProceduresCM 1-5

Std Operating ProceduresCM 1-8

Work ManagementCM 2-2

Material Management ManualCM 2-3

Property Management ManualCM 2-5

Management Control System

X

X

X

X

X

X

X

X

X

X



REFERENCED DOCUMENT

CM 2-6Data Administration Standards

CM 2-10Cost Accounting Manual

CM 2-14Haz Material Packaging & Shipping

CM 2-15Trainino Administration

CM 3-5Document Control

CM 3-10Software Practices

CM 4-2Quality Assurance

CM 4-3Industrial Safety

CM 4-5QA Qual & Instructions

CM 4-6Compliance Assurance

CM 4-7Unclassified Computer Security

CM 4-11ALARA Program Manual

CM 4-14Radiological Controls

CM 4-16Dosimetry/Medical Services

CM 4-29Criticalitv Safety

CM 4-33Security Manual

CM 4-35Safeguards Material Control

CM 4-38NDE Process

CM 4-40Industrial Hygiene

CM 4-41Fire Protection

CM 4-43Emergency Management

CM 4-44Emergency Preparedness

CM 4-46Safety Analysis

CM 4-50Safeguards Accounting

CM 5-4Laboratories Administration

CM 5-8Pu Finishing Plant Administration

Addendum

IS

nsow

fS

M

0435

X

X

X

X

1 to Appendix 1

«

SEMP

ts

IN

O20

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

11-10


REFERENCED DOCUMENT

CM 5-9PUREX/UO3 Plant Administration

CM 5-13K Basins Policy Manual

CM 5-16Solid Waste Management

CM 5-34SWD Operations Administration

CM 6-1Standard Engineering Practices

CM 6-2Project Management

CM 6-3Drafting Standards

CM 6-10Welding Manual

CM 6-12Project Procedures

CM 7-4Environmental Monitoring

CM 7-5Environmental Compliance

CM 8-7Operations Support Systems

CM 8-9Workmanship Standards

EP-0009Acronyms and Abbreviations

EP-0063-4Solid Waste Acceptance

EP-0231-5Surplus Facilities Program Plan

EP-0496Pollution Prevention Implementation

EP-0722Systems Engineering F&Rs

EP-0779Architecture Systhesis Basis

EP-0830SNF Path Forward

GG-DWG-01Preperation & Control of Drawings

GG-DWG-02Layering Conventions

GG-DWG-03Drawing Index

GG-DWG-04Parts List/BOM

GH-CLIM-01Hanford Site Climate Data

IP-0117Procedure Development

Addendum

ts

w

sow

X

X

ts

m0436

X

X

X

X

X

1 to Appendix I

nSBHP

X

X

IS

w020

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

1 1 - 1 1


REFERENCED DOCUMENT

IP-0240Operating Procedures Format

IP-0263Bldg Emeraencv Plan East Patrol Bldfl

IP-0382Nuclear Materials Safeguards Users

IP-0565Safeguards Disk Procedures

IP-0821Plutonium Operation Admin

IP-O836Order Compliance Admin

IP-1026Engineering Practice Guidelines

IP-1043Occupational ALARA Program

IP-1117Systems Engineering Manual

IP-1140Procedure Development & Control Services

S-0436Performance Specifications

SD-GN-DGS-30011Radiological Design Guide

SD-GN-ER-1006K-Basin Floor Loads

SD-GN-ES-30006Criteria for Uniform Bolting Preloads

SD-MA-SPP-001Welding Procedure Supporting Document

SD-NR-SA-O24Structural Feasibility of Consolidation

SD-SNF-CM-001SNF Configuration Management

SD-SNF-CM-003SNF Interface Control

SD-SNF-DB-004SNF Project Seismic Design Criteria, NRC Equiv.

SD-SNF-OGS-001K-Basin Design Guidelines

SD-SNF-SD-O02SNF Technical Baseline

SD-SNF-SD-003SNF Technical Baseline

SD-SNF-SEMP-001SNF Engr Management Plan

SD-SNF-TI-O09Design Basis Feed Preparation

SD-SNF-TI-012Underwater Fuel Survey

SD-WM-OSR-006OSRs for KE & KW Basins

IS

M

SOW

X

X

IS

w0435

X

IS

H

SEMP

X

X

X

X

X

IS

M

O20

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

COMMENT

Not applicable to SNFP

Not applicable to SNFP

Use HSRCM-1



REFERENCED DOCUMENT

SD-WM-SAR-062SAR for N-Reactor Fuel

SN-SNF-SP-005Integrated Process Survey

SNFP-SE-OO6Managing SNF

SNF-RD-PM-001Program Requirements Document

SP-078Conduct of Operations Manual

SP-0843FMEF Maintenance Inspection Plan

SP-0866Conduct of Maintenance

SP-1144Path Forward Acauisition Strategy

SP-1148SNF Proiect Management Plan

OTHERImp Plan for DNFSB 92-3 & 92-7DOE-RL 95-AHW-003

Approval of Path ForwardDOE-RL 95-SFD-132

Approval of Path ForwardDOE-RL 9S-SFD-135

Additional IPS CommentsMemo of Agreement on Path ForwardRevised Policy of Acceptance for ERHanford Site Systems Engr ManualSite Sys engr config Mnamt PlanSitewide Sys Engr Management PlanDNFSB 92-3-HB

Operational Readiness ReviewDNFSB 92-7

Training and QualificationsDNFSB 94-1

DNFSB Safety Board RecommendationMemorandum, 3/1/95

SNF Vulnerability Action PlanRecord of Decision

Prog SNF Management & INEL ER&WMFuture Site WGFY1995 Hanford Mission Plan

Vol 1, Site Guidance, Sept 1994MRP 1.1

Managing DOE DirectivesMRP 2.16

Processing Control Manual Svs ProcMRP 4.16

Administering Progressive DisciplineMRP 4.19

Overtime and Shift Diff for Nox-Exempt EmpAddendum

fS

msow

DOCUK

S

M

0435

ENTS

1 to Appendix I

$»

H

SEMP

X

X

X

XXXX

IS

w

020

X

X

X

X

X

X

X

X

X

XX

X

X

X

X

XX

X

X

X

X

X

COMMENT

Use WHC-SP-0835

Has been replaced

Has been replaced.

Has been replaced.

Not specific to SNFPNot specific to SNFPNot specific to SNFP

1 1 - 1 3


REFERENCED DOCUMENT

MRP 5.44Waste Minimization Program

MRP 6.15Facilitv Shutdown. Standby & Transfer

WHC 9553866-LetterRec Inoegrated Process Strateav

DOE EM-36, 9 Nov 94Lytle Ltr to Grumblyr App of Path Forward

IS

IN

SOW

IS

IN

0435

ADDITIONAL NRC REQUIREMEWHC-SD-SNF-DB-002, Table 5.b

As relates to fire protection10 CFR Part 50.48 & Appendix R

As relates to fire protection10 CFR Part 72.122(c)

As relates to fire protectionRegulatory Guide 1.76

As relates to tornado criteriaSECY-93-087

As relates to tornado criteriaNUREG/CR-4461

As relates to tornado criteriaPotential Revisions to SRP-3.5.1.4, Rev 2

As relates to tornado criteriaWHC-SD-SNF-DB-002, Table 5.c

As relates to tornado criteria10 CFR Part 72.24

As relates to tornado criteria10 CFR Part 72.122

As relates to tornado criteriaReg Guide 1.97, Section 50.49(el (51

As relates to Safetv Class 1 electrical equipmentReg Guide 1.89. Section 50.49 (f) (1-4)

As relates to Safetv Class 1 electrical equipment10 CFR Section 50.63,

Loss of all alternating current powerIEEE Std 484-1987

As relates to safetv class 1 batteriesIEEE Std 535-1986

As relates to safetv class 1 batteriesIEEE Std 603-1991

As relates to safetv class 1 I&C systemsANSI/ANS-8.3-1986

As relates to criticalitv alarm systemsNUREG - 0700

Review against DOE6430.1ASRP18.1

Review against DOE6430.1AReg Guide 1.26 - As relates to assigning appropriate

ASME Section III code classesReg Guide 1.84 and 1.85 - As relates to assigning

ASME Section III for Safetv Class 1 cases

«

H

SEMP

MTS

IS

IN

020

X

X

X

X

COMMENT

Not specific to SNFP

Confirm Safety ClassFire Protection not req.Confirm Safety ClassFire Protection not req.Confirm Safety ClassFire Protection not req.Not applicable, NoSafetv Class equipmentNot applicable. NoSafetv Class equipmentNot applicable. NoSafetv Class equipmentNot applicable. NoSafetv Class equipmentNot applicable. NoSafety Class equipmentNot applicable. NoSafetv Class equipmentNot applicable, NoSafetv Class equipmentNot applicable, NoSafetv Class equipmentNot applicable. NoSafety Class equipmentEvaluate loss of ac power

Not applicable, NoSafetv Class equipmentConfirm that criticalityis not possibleReview

Review

Use to assist

Not applicable. NoSafetv Class equipment


11-14

SNF DOCUMENT REFERENCES WHC-SD-SNF-CDR-OO7 REV. 0

REFERENCED DOCUMENT

ANSI/ANS N5O9-1989, ANSI/ANS N510-1989As relates to Safety Class 2 & 3 HVAC systems

Reg Guide 1.140As relates to Safety Class 2 & 3 HVAC systems

ANSI/ANS-S7.1 and ANSI/ANS-57.2As apDlies to lifting MCOs and Casks

Generic Letters 88-14, 89-10 and 89-13 - Asapplicable to Safety Class 1 mechanical systems

WHC-CM-4-2 App. A, El 3, Rev 1 - As applicable tosafety class 1 procurement specifications

10 CFR 830.120 - Applys to changes in WHC QAPlan WHC-SP-1131

10 CFR 5O.BB(e). DOE 5000.3B, WHC-CM-1-5, Section 7Conditions of Construction Permits

10 CFR Part 50, Appendix B and 10 CFR 72 Subpart GApply WHC duality requirements to SNFP

IEN 96-29 As applies to potentially defective Safety Classequipment.

10 CFR Section 20.1601, Section 20.1003, Section 20.1As applies to high radiation areas

10 CFR Section 72.104 - Criteria for radioactive materialseffluents and direct radiation from an ISFSI or MRS

10 CFR Section 72.106Controlled areas of an ISFSI or MRS

Reg Guide 8.8 - As applies to piping design considerationsfor systems that carry radioactive material.

10 CFR Section 72.24 and Reg Guide 3.48 - As applies tonot in DOE 5480.23 and DOE-STD-3009-94

10 CFR 20, 10 CFR 70.59, and 10 CFR 835 - As applicabeffluent monitoring.

10 CFR 50, Appendix A, General Design Criteria - As applito nuclear safety equivalency.

SRP 9.1.2, Rev 3, and NUREG-0612

ANSI/ANS-57.9-1992Design Criteria for an Independent SNF Storage Installa

10 CFR Section 72.3 - As applies to Important to Safety Sand consider them as Safety Class 1.

IS

IN

SOW

1, Rev

1

301

n

requiren

e to

;able

tionCCs

IS

n0435

ents

M

SEMP

IS

IN

020

COMMENT

Applicable

Applicable

Not Applicable, MCOs& casks not liftedNot applicable. NoSafety Class equipmentNot applicable, NoSafety Class equipmentDOE ROO to review &approve changesImplement WHC OccurReporting SystemEnsure WHC quality reqsremain in effectReview bulletins

Not applicable, no highradiation areas as defined

5 rem for onsite workerfrom DBAApplicable

Applicable to SARs

Applicable

Review during definitivedesignncorporate a criticality

values of 0.95 for Keff.Applicable only to CSB

No applicable SCCs


WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Advanced Technology SectorContrect#MW6-SVW-3104l6,Te*k#n Project No. 30012318


APPENDICES

APPENDIX J

OPERABILITY AND MAINTAINABILITY ASSESSMENT

J- i

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning Sytttm Equipment Adwneed Technology SectorContraet#MW6-SWV-310416,TMlc#17 Project No. 30012318


APPENDIX J - OPERABILITY AND MAINTAINABILITY ASSESSMENT

OPERABILITY AND MAINTAINABILITY ASSESSMENTfor the



1.0 INTRODUCTION

The purpose of this report is to assess the operability and maintainability of theHot Conditioning System Equipment Of The K-Basin Spent Nuclear Fuel StorageProject as described in the Conceptual Design Report.

Beyond ensuring that the process system will perform its intended function, akey design criteria is ensuring that the mechanical and electrical systems canoperate reliably under expected conditions with acceptable maintenancerequirements while simplifying operation and maintenance by site operationspersonnel. Operability and maintainability are important to the efficientperformance of process functions within predetermined schedules, determiningmanpower requirements, controlling maintenance costs, and keeping workerradiation exposure ALARA.

The level of development of the design in progress affects the type ofassessment that can be performed and the format of its results. A design in aconceptual phase necessarily lacks details to permit a detailed assessment.Instead, the most important potential findings of a conceptual design reviewwould be conclusions that particular design concepts are flawed to the point thatdetailed design could not be expected to be satisfactory. This would require achange to the design concept.

The next most important findings of an operability and maintainability review of aconceptual design are identification of the most significant challenges facing thedetailed designer in achieving a satisfactory final product. Next, any otherobservations made while looking for the above two types of findings should bementioned. Finally, specific recommendations are offered.

This report will follow the format described above.

J - 1

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2.0 SUMMARY OF RESULTS

There are no apparent conceptual design flaws which would threaten thebeginning of detailed design. Overall design, layout, and equipment selectionpresent no major operability or maintainability concerns. Three areas ofsignificant challenge for detailed design are identified and two recommendationsoffered as well as a number of specific observations. Subsequently, the findingsof this group were independently reviewed by others with similar background inthe nuclear power industry.

3.0 DISCUSSION

3.1 Methodology

The review was conducted in several steps. Copies of the ConceptualDesign Report were distributed for familiarization to four reviewers withoperations and maintenance experience. An initial meeting was held forpreliminary discussions, question and direction. Next, the expertsreviewed the material individually and accumulated comments. A finalgroup discussion developed consensus and provided the material for thereport.

3.2 Conceptual Flaws

The most important conclusion reached was that there are no apparentconceptual design flaws which would threaten the beginning of detaileddesign. Overall design, layout, and equipment selection present no majorconcerns. Despite the design challenges discussed below, we believethat the correct concepts are being employed and a satisfactory detaileddesign can be completed.

3.3 Challenges for Detailed Design

3.3.1 The detail design of the process enclosure will be a challenge.This tool will be critical. It will have many moving parts e.g.welding support and remote, leak-tight connections exposed tothermal cycling. There are similar design requirements (and evenmore challenging) at the Defense Waste Processing Facility(DWPF) at Savannah River which should provide valuable insightduring the detailed design.

J - 2

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A Failure Modes and Effects Analysis should be done in parallelwith the design process as a design tool to determine critical parts,potential failures/maintenance, spares etc. See Section 3.5.1

3.3.2 Welding the top hat will be time consuming. The weldingequipment will need to be specially designed, and will be complex.Considerable attention must be paid to reliable operation whileallowing for variations to be expected over the population of MCOsto be processed. The complexity will provide a great deal ofopportunity for maintenance problems. See Section 3.5.2

3.3.3 The detailed designer must look carefully at radiation monitoringequipment for potential impact on operation and maintenance.Scheduled preventative maintenance should be performed on thisequipment to assure that they continue to function as they areintended.

3.4 Other Observations

In searching for flaws in design concept and major design challenges, wehave made the following observations.

3.4.1 The detailed designer needs to look carefully at the placement ofcritical valves and at the detailed maintenance that may need tobe performed to make sure that they function correctly (e.g.pressure actuated relief valves), facilitate testing requirementsand don't leak under any potential operating conditions.

3.4.2 Make sure that the process enclosure can handle inspection andcleaning fluid waste such as dye penetrant if used.

3.4.3 Consider the potential impact on maintenance requirements of offnormal operations e.g. over temperature, over pressurization.This could result from a control system failure or a failure of acomponent such as chilled water pump.

3.4.4 Consider the implications of failures of support systems such aschilled water, service air, electrical, HVAC.

3.4.5 Section 2.2.1.2.1 of the Conceptual Design notes that sinceReport VPS VAC 1104 will operate at low capacity this will likely

J - 3

WEST1NGHOUSE HANFORD COMPANYHot ConoStfenino. System EquipmentContract #MW6-SWV-310416. TMk #17





ensure that design life will be achieved. Operation at low capacitycan actually shorten the life of some equipment (e.g. diesels,some centrifugal pumps etc.)

3.4.6 Make sure that maintenance of control system components suchas sensors, detectors, and transmitters is addressed in thedetailed design including replacement, adjustment, andcalibration.

3.4.7 Consider cooler failure and potential impact on other systemequipment.

3.4.8 Consider the life expectancy and potential for maintenance ofelectric heaters to be specified.

3.4.9 Ensure that the detailed design properly addresses processmonitoring instrumentation such as O2 from the standpoint ofreplacement, maintenance and calibration. Ensure that theirpotential impact on production and safety in the event of failure oroff normal operation is addressed.

3.4.10 Make sure that equipment critical to production and safety isidentified so that it will be appropriately maintained to ensurefunction e.g. purge valves, purge supplies, blower seal system,over pressure protections, detectors etc.

3.4.11 Consider the implications of bellows failure in the oven.

3.4.12 What is the reliability history for turbomolecular pumps. What isimpact of failure? What are failure modes and mitigatingmaintenance requirements?

3.4.13 Is the service air system critical to safety and production? If so,performance monitoring may be needed. To preclude equipmentdamage or personnel injury, ensure the system fails safe on lossof electrical power or pneumatics.

3.4.14 Make sure that the trench covers can be removed easily e.g.crane or lifting device located to support removal.

3.4.15 Make sure that equipment in trench is arranged to facilitatemaintenance including valves, piping, instrumentation etc.

J - 4

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHoi Conditioning Syitom Equipment Advanced Technology S«etorConlmct#MW6-SWV-310416,TMk#17 Project No. 30012318



3.4.16 Make sure that the remote maintenance tooling in the processenclosure addresses the potential for fastener or "pop up" springfailure.

3.4.17 Remote maintenance tooling in the process enclosure shouldaddress over torque potential where applicable.

3.4.18 Make sure that lifting devices, lighting, power and service airrequired to easily conduct maintenance is addressed in thedetailed design.

3.4.19 Avoid the possibility of water in the trench. If this cannot bedone, provide means to keep it out of the oven pit

3.4.20 Make provisions for cleaning the weld surfaces following eachgrinding step.

3.4.21 Although it is outside of the scope of this review, the designconstraints on the MCO filter may be difficult to meet. Thisinterface could affect the detailed design if it is changed.

3.5 Recommendations

3.5.1 Prepare and maintain a Failure Modes and Effects Analysis duringthe detailed design. This would provide:

• means to identify systems critical to safety• means to identify systems critical to production• upset conditions which might impact equipment operations or

maintenance• identification of scheduled and preventative maintenance which

would be required• identification emergency procedures required• means to estimate maintenance staffing• means to estimate dose resulting from maintenance• identify critical spares needed• identify additional process monitoring which would

facilitate/delete maintenance

There are a number of software tools available that can be used toguide the above work. These tools provide a structured, consistent

J - 5

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot CondWonlno Sy««n Equipment Advanced Technology SectorContract #MW5-SWV-310416, Taak #17 Project No. 30012318



methodology for conducting a maintenance and operability review.They also provide documentation of the maintenance andoperability program basis.

3.5.2 Consider welding plugs in the MCO ports to seal them rather thanusing a "top hat" cover.

Advantages:

Speed: Steam generator tube plug welding experiencesuggests a single pass tig weld, which could be autogenous(no filler) if designed properly. Production rates of one tubeper hour including plug installation, weld and inspection aretypical in steam generators.

Tooling already developed: Steam generator tooling couldbe adapted to support this application.

Inspection: Steam generators tube plugging operations useonly visual inspection with good results.

Repair is straight forward: Tooling already exists to removea plug weld and re-install. In steam generators this can bedone repeatedly.

Potential cost impact.

Disadvantage:

Would need to address stacking and future drying ifrequired i.e. how to make new connections after weldingin/removing plug.

J - 6

WESTINGHOUSE HANFORD COMPANY MERRICK&COMPANYHot Conditioning Syitem Equipment Advmced T«ehne4ogy SwtorContraet#MW6-SWV-310416, TMk#17 Project No. 30012318



REFERENCES

1) Hot Conditioning System Equipment, K-Basin Spent Nuclear Fuel StorageProject, 90% Submittal, Conceptual Design Report

J - 7

WEST1NGH0USEHANFORD COMPANY MERRICK & COMPANYHot Conditioning Syttem Equipment Advancad Technology SectorContract #MW6-SWV-310416, Task *17 Project No. 30012318


APPENDICES

APPENDIX K

COMMENT DATABASE

K-i

MERRICK ENGINEERS /ARCHITECTS LOS ALAMOS, NEW MEXICO

Project 2318: Hot Conditioning CDR CommentsPART 1: COMMENTS / DISPOSITION

WHC-SD-SNF-CDR-007 Rev 0

REVIEWER COMMENT *

APPENDIX K: HOT CONDITIONING COMMENT DATABASE

HOLD POINT DISPOSITION

Alaconis, W.C.

90% CDR

All comments from the 60% CDR Review must beanswered. To date no response has been given.

All responses to the 60% design comments will be included in thefinal CDR.

Alaconis, W.C.

90% CDR

The concept of manipulator assisted operation Isacceptable, however the ability of the manipulator topreform all of the required functions within the processenclosure needs to be demonstrated with in the timeestimates of the CDR

The time estimates in the CDR are based upon experience. A timeand motion study for the process enclosure will be an element ofthe definitive design

Alaconis, W C .

90% CDR

The dose estimate assumed a solid 1" steel processenclosure to develop the calculations (no viewingwindow). The process enclosure must have a shieldedwindow to allow the operator 100% visual observation ofthe manipulator movement and function. The videoviewing will not provide the 3D reference required.

The process enclosure design will incorporate a shielded window.

Alaconis, W.C.

90% CDR

If the HCSE does not plan on using the helium andnitrogen banks that are being Installed by Fluor Daniel Inthe CSB design, then section 4 (interfaces) lacks theappropriate requirements for siting HCS gas trucks aroundthe facility. Civil and structural interfaces will be requiredwith FD

The HCSE design team will provide any civil/structural designrequired for these tanks. The tanks will be provided after the CSBconstruction Is complete.

Alaconis, W.C.

90% CDR

The current dose estimates of 5 mRem/hr while manningthe manipulator operating station is not acceptable. Thisexceeds 10 CFR 835 requirements of 20% of 835 202.Based on available data there will be approximately 2300operating hours per year on the process enclosure sharedby two operators per shift. At 384 hours (2300/6) peroperator per year a dose rate of less than 2.6 mRem/hr atthe operating station will result in 1R per operator. As aresult of this data a final design estimate of less than 2.5mRem/hr would be expected.

Agree. Will incorporate during definitive design. See Curt Mlskacomments 12-15 and resolution.

DCM 7/29/96 I:\AUTOCAD\2318\DATABASE\COMMENTS.MDB Page K-1


REVIEWER COMMENT * COMMENT

APPENDIXK: HOT CONDITIONING COMMENT DATABASE

HOLD POINT DISPOSITION STATUS

Alaconis, W C

90% CDR

There appears to be a disconnect between the ProjectManagement Plan and the CDR with regard to dellverablesin the M&O Manual area. Clarify what the actualdeliverables will be in this area and the anticipated content.

no The M&O manuals are not currently in Merricks scope.

Alaconis, W.C.

90% CDR

The general area dose estimate of 2 mRem/hr is high. Thecurrent CSB operating deck area dose rate estimate is0 25 mRem/hr. Use of the 0.25 mRem estimate would bemore accurate.

Agree. The definitive design will reflect the 0.25 mrem/hr criteria. DD

Burns. B.M.

90% CDR

2.0 Process, p 12 of 57, pgph 3: "Exposed uranium reactswith oxygen and continues to do so until the surface ispassivated." According to 'Technology of Uranium"(Galkin et at, PNNL library # TN 799.U7 G3) p 15. "theoxide film does not protect the metal against furtheroxidation." Provide a source that shows passivation Ispossible.

Text will be revised to eliminate passivation and to give the reason closedfor the oxidation step.

Burns, B.M.

90% CDR

Figures 2.2-1, 2 2-2. and 2.2-3 not provided. Figures were inadvertently left out. They will be included in thefinal CDR.

closed

Burns, B.M.

90% CDR

Bums, B.M.

90% CDR

2.2.1.2.1, page 16, pgph 2: Blower configured for "basecase pressure of 13 psia". Will it ve able to accomodatethe requirement (in 2 2 12, p 11) to handle 115 psiahelium?

The requirement has been changed to 25 psia to meet other MCO closedrestrictions. A new blower that operates In this pressure range has ,been selected. Previous blower was suitable for operation at 115psia.

2 2.1 2.3, p 17: Cold trap and HEPA is rated for 100 psi.2.2.1.2 allows up to 115 psia for optional operation. Evenif 100 psig, this is slightly less than 115 psia.

As noted in previous comment, operating pressure will now berestricted to 25 psia.

closed

Bums, B.M

90% CDR

Item 8, p 25 (Section 2 2.4), last sentence:"... when H2and H2 ..." Would this be H2 and H2O?

Yes, correction will be made.

Burns, B.M.

90% CDR

2.2.5, pgph 2: You need to ensure any power cutout due toa security system activation will not cut power to essential(safety class? others?) systems.

Essential operations will have a dedicated UPS. These systems closedwill be Identified during definitive design.

Burns, B.M.

90% CDR

2.2.5, item 6, p 28: Need to ensure process gas whichgoes to MCO will be only inert gas, and that O2 will be shutoff. This came to mind assuming we're in the ixidationphase, and power was lost, we don't want to add 0 2uncontrolled.

The systems will be designed to safety shutdown by providing closedcontrol system with UPS and by slightly pressurizing the MCO withinert gas before closing all valves.

DCM 7/29/96 I:\AUTOCAD\2318\DATABASE\COMMENTSMDB Page K-2


REVIEWER COMMENT #



Cowan, R.G.

90%CDR

Several interfaces with the MCO are very simitar to thoseat CSB such as receiving venting and should havecommon solutions The design should attempt to use thesame approach where possible during detailed design.

The interfaces with the MCO are similar for the CSB, CVDS andHCSE. The interfaces are being coordinated with these teams andwith the MCO design team.

Cowan, R.G.

90%CDR

Port covers should be removed at CSB receiving andshould not be handled at HVC

Handling will be required if it is determined that closure of the MCOwill be accomplished by seal welding the port covers at thecompletion of the hot conditioning process.

Cowan, R.G.

90%CDR

Single pass air flow directly around the MCO should beused in place of water cooled circulating air. Although thismay indrease the stack flow, it would be a much easiersystem to maintain and get through safety.

A water study will be included in the CDR to address this issue.Final resolution will be during definitive design.

Cowan, R.G.

90% CDR

Design for premixed oxygen/argon from cylinders outside. We will be using premixed oxygen as you suggest. The presentdesign will accommodate that mode.

Cowan, R.G.

90% CDR

The HEPA filter on the outside will likely trap all Cs andshould include shielding.

A Cs trap will be located in the trench where shielding will beprovided by the trench walls and cover. The trap will be changedusing the manipulator in the process enclosure. This trap will becooled to trap the Cs

Cowan, R.G.

90% CDR

Welding in the oven is not a good idea as this will ask eachstation to do too many functions. One pit designed forwelding will work better even with the extra transfer. Witha good design on shielding, it should be possible to do amanual setup and automatic wakJ for closure.

Welding will be done with a welding machine operated from theprocess enclosure. The process enclosure will service all sixprocess pits with one welder. Welding at the pit does not alter theoven design. If welding were to be moved to the seventh pit with adedicated welder, the process enclosure would still be needed forweld inspection and repair so it would still have multiple functionsto perform.

1

Cowan, R.G.

90% CDR

The proposed vacuum bottle with air heating seems agood concept but if the MCO group will comment to thestepped design for the MCO, It should be possible tosupport both the MCO and vacuum bottle from a topflange This has a lot of advantages for process (the MCOtop would not move during heating) and shielding. (I didnot see how the shielding would work as shown.)

The new design from the MCO contractor accommodates topsupport of the MCO.



REVIEWER COMMENT # COMMENT



Goldman, L.

90% CDR

Using refrigerants containing halogens around the MCOduring HCS operations makes me nervous. They couldget inside and react or break down at temperature to anacid forming gas such as HC1, a diatomic halogen, orpoison gasses. If we had an unexplained loss ofrefrigerant, freon or suva for example, who could say it didnot end up inside the MCO and reacted inside the heatedMCO. Then that MCO would be put up as a "suspect", aspotentially damaged from the halogens.

The cooling for the MCO vacuum system is with ambient air which(eaves no possibility for halogen entry. As currently conceived, theair would be cooled by a closed water loop and the water would becooled by a refrkjerent loop.

Goldman, L.

90% CDR

I wasn't close enough to see the PFD. Was the residualgas analyser going to be used to measure the input andoutput streams of the MCO to determine take up of oxygenby the inside of the MCO? Was the output gas streamcontaining water and H2 going to be measured as it comesout of the MCO? Or how was 0 2 take up inside the MCOgoing to be determined?

The oxygen analyzer is on the MCO gas circulation line. We candetermine the 0 2 uptake within the MCO by knowing thecirculation rate and taking interval samples.

•g

IKurtz, J

90% CDR

Not much in detail about rad monitoring equipment for theworkplace. Just a small section In the ALARA section. Wewill require the use of CAMS and other monitoring thatrequires power, etc. Request you expand on this or saythey will leave it up to us.

Specific details of the radiation monitoring system will bedeveloped during detail design of the HCSA In accordance with thecriteria for the CSB.

Kurtz, J.

90% CDR

Looking over the exhaust instrumentation, I get the feelingthat it may be excessive. I thing you need to have theenvironmental folks look this over. When the CSB wasreviewed, some of that was bound to be excessive andexpensive.

For the conceptual design effort a conservative stack monitoringsystem was selected. The system may be simplified duringdefinitive design.

,1Kurtz, J.

90% CDR

If we want to use the PING-3B Particulate/lodine andNoble gas monitors in the exhaust, I have two brand new,never been used PING-1A units that were purchased forencapsulation. These are equivalent to the 3B's except forthe dual range noble gas. We spent about 30K on each ofthese.

Use of the new PING-1 A units will be evaluated during definitivedesign. This cost reduction opportunity is appreciated.

Kurtz, J.

90% CDR

Looking at these PINGs and our requirements, I'm not surethat these will do the job. The Iodine channels on theseunits are designed to measure 1-131 activity. The 1-129 weare going to try to measure only emits a 40 KeV gamma.Theoretically, the unit can be adjusted to see this butwould be at the extreme low end and would be subject tonoise problems. The current best technology formonitoring 1-129 involves sampling with cartridge filter andlaboratory analysis with low energy gamma detector.

The application of these units will be investigated during definitivedesign. The Iodine trap will use the same cartridge filter so Iodinerelease is not anticipated to be a problem.



REVIEWER COMMENT * COMMENT HOLD POINT DISPOSITION


STATUS

Lucas, C.

90% CDR

Section 2.9:1) Waste items described in the earliersections include; dye penatrant, cleaning fluid, developer,buffer pads, etc. Non of these items are described in thesolid waste section.2) Other disposal requirements need tobe listed besides WAC 173-303 such as WHC EP 0063Solid Waste Acceptance Criteria.3) All of the potentialstreams appear to be workable, I am assuming that theproject will develop an approved disposal path andsummary as a part of the design so we don't design awaste stream that is cost prohibitive to operate (cartridgefilters). For example, having units to be disposed actuallysized to fit In an existing approved container (getpackaging folks on board), and handling methods that donot require high dose expenditure.4) I would recommendgetting Acceptance Services representation in on this earlyto make the road smoother.

We will comply with your suggesstion with the details to be workedout during definitive design.

Merkling, T.

60% CDR

Overhead/Drawing of Cell. This drawing shows a CAM(Continuous Air Monitor) located in the center of the cell.Comment: 1) Ensure that the CAM is of proper sensitivityto detect the nuclides of interest, 2) Ensure that thelocation of the detector/sample hose is such that thenuclides of interest are correctly monitored, 3) Ensure thatcalibration/maintenance of the CAM can be performed withexposure to radiation ALARA.

CAM will be specified during definitive design in accordance withthese recommendations. It is anticipated that maintenance can beperformed while process enclosure is in cold status, I.e. notservicing any of the process pits.

Merkling, T.

60% CDR

Hot Treatment Process Operations Cell FunctionalDescription. Steps that Involve manned entry for survey ofthe cell (steps 24, 58). Comment: From a logisticsstandpoint of making an entry into a confined/contaminatedspace from a radiologically clean space, recommend thatsurveys for radiological contamination be performed usingthe remote manipulator with sample smears being passedout through the pass-through box for analysis. Try toeliminate manned entry until all safety conditions aredetermined remotely.

Recommendations will be incorporated in the definitive design ofprocess enclosure.

Merkling, T.

60% CDR

Shielding and Radiation Exposure Analysis. Comment:Consider an ALARA analysis for maintenance/calibrationactivities in addition to the ALARA analysis alreadyperformed for normal HVC work tasks.

There is no maintenance/calibration activity anticipated when theMCO is present. Traps and HEPA filters are installed in the trenchto assure that process equipment is not contaminated.Maintenance on equipment should be cold.






Merkling, T.

60% CDR

Shielding and Radiation Exposure Analysis. Comment:Section 2.0, To avoid the pitfall of using a single exposurenumber (single numbers give the impression that they areexact), recommend using a range for estimating the totalexposure. This range would be based on the task timesspent in the radiation field. Suggest getting wild SNFOperations and fine-tuning the duration times for theactivities and calculating a range of times (say for"Undoing Top Fasteners, Instead of exactly 10 minutes,give a range of 6 to 12 minutes or whatever is agreed byyourself and operations).

Yes. We are working on a PERT analysis of the productionschedule. This will be delivered during detailed design.

Merkling, T.

60% CDR

Shielding and Radiation Exposure Analysis. Comment:Section 3.1. The sentence T h e workforce and timerequired to perform each exposure activity was estimated"needs to be changed to reflect a combined effort betweenthe ALARA analysis engineer and SNF Operations arrivingat an accurate time determination (see above comment).

Operations input has been requested. The final analysis thatincorporated the maintenance estimates will be completed duringdefinitive design.

Merkling, T.

60% CDR

ALARA Implementation Plan. Comment: Referencecurrent/correct documents. 1) Third paragraph, delete firstsentence (10 CFR 635 Is the design authority). 2) Thirdparagraph, third sentence. Add "design objective forbetween "...federal law governing" and "radiationexposure,,," 3) same sentence, delete "in." 4) Delete"DOE Order 5480.11. Radiation Protection forOccupational Workers," and replace with "DOE Notice441.1, Radiological Protection for DOE Activities." 5)Section 2.0. a) Replace DOE Order 5480.11 with DOENotice 441.1, b) Replace WHC-CM-4-11 with "WHC-IP-1043, WHC Occupational ALARA Program, c) Replace"DOE N5460 6" with "DOE/EH-0256T,"

Comments Incorporated into the 90% Conceptual ALARAImplementation Plan.

Merkling, T.

60% CDR

ALARA Implementation Plan. Comment: Section 3.0 A 3.When the hole cover is pulled, is there a possibility foradditional radiation exposure from gamma scatter or"ceiling shine"? If an analysis shows that this is possible,then it needs to be included in the exposure estimate.

no Sky shine analysis will be incorporated in detailed design.

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STATUS

Merkling, T.

60% CDR

ALARA Implementation Plan. Comment: Section 4 D,3.This section states ttiat "the design will Include ContinuousAir Monitors (CAMs) capable of detecting,.," To meet 10CFR 83S and HSRCM requirements, an analysis wouldneed to be performed that shows the potential of airborneactivity during normal activities. Also, an engineeringstudy (smoke test) should be performed to ensure correctlocatlon(s) of the sampler/monitor.

Will incorporate in detailed design and in startup testing (smoketests, etc)

DD

Merkling, T.

60% CDR

Operations and Maintenance Philosophy. Comment:Administrative limit. 1) Section 1. OB. Change thesentence to allow the facility to manage the administrativelevels accordingly. Suggest "The radiation doses of agiven worker will be administratively controlled per HSRCM-1*2) Section 4.0, first paragraph, first sentence. Changethis sentence to read T h e administrative radiationexposure limitation for the HVCE will be per the HSRCM-1 ."

Comments incorporated into the 90% Conceptual O/M Philosophy closedsection.

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REVIEWER COMMENT • COMMENT HOLD POINT DISPOSITION


STATUS

Merkling, T.

60% CDR

Operations Maintenance Philosophy. Sections 4.1, 4.2,4.3 and 4.5. Background: 10 CFR 635.403(a)(1) statesthai "air sampling shall be performed In occupied areaswhere, under typical conditions, an individual is likely toreceive an annual intake of 2 percent or more of thespecified ALI values. §835.403(a)(2) states that -Real-timeair monitoring,...shall be performed in normally occupiedareas where an individual is likely to be exposed to aconcentration of airborne radioactivity exceeding 1 DAC asspecified in Appendix A of this part or where there is aneed to alert potentially exposed Individuals to unexpectedincreases in airborne radioactivity levels." HSRCM-1,Article 553.1 states that".,. area radiation monitors,,,should be Installed in frequently occupied locations withthe potential for unexpected increases in dose rates,,".Article 553.3 states "The need and placement of arearadiation monitors should be documented,,,,,." Comment:Reading these four sections (Respiratory Protection,Respiratory Protection Program, Respirator Use, andRadiological Alarm System) and seeing words such as"evaluate actual intakes" looks like we are designing afacility where we expect airborne radioactivity andunexpected increases in dose rates from "typicalconditions." I do not believe that this should be the case.Suggest rewording or deleting these sections unless ananalysts indicating that airborne radioactivity (andunexpected increases in dose rates) Is In fact, going to benormal conditions. The Section 4.4, EmergencyRespiratory Protection should cover all off-normal airborneactivities

Comments incorporated into the 90% Conceptual O/M Philosophy closedsection.

97

Merkling, T.

60% CDR

Section 4.0 Radiation Safety and Exposure Control.General Comment: Replace all references to 10 CFR 20and 10 CFR 72 with appropriate DOE references 10 CFR635 and DOE Order 5400.5. Quote these appropriaterules and requirements as needed.

Suggested revisions will be incorporated into the Final Conceptualdesign report.





STATUS

Merkling, T.

90%CDR

Definitions. Cold Trap; 2.1 Sequence Description, ID 25.0;Comment: 1129 is a concern because like tritium it Is anInternal exposure problem and a low energy beta emitter(0.15 Mev) which cannot be detected using normally usedportable RC survey instruments. Since it cannot be easilydetected and it is most likely present, a characterizationstudy needs to be performed to ratio Cs 137 and 1129.Once this ratio is Known, any detected Cs 137 can becoupled with the known 1129/Cs 137 ratio andaccountability can be taken for all radionuclldes ofconcern.

The ratio of Cs-137 to 1-129 is known for the design basis fuel andis documented In the WHC design basis feed document. Draftenvironmental permitting documentation Indicates that mitigation (I-129 removal) is not required. The design of the Cold Trap willcontinue in detailed design, and the need for 1-129 removal will bereassessed at that time.

Merkling, T.

90%CDR

2.1, Sequence Description, ID 5.0,2.8. Comment. Howdoes the enclosure seal to the floor? If there Is no seal, orthe seal depends on the ventilation system to provide acontinuous positive air flow, then this design Idea needs tomatch the expectations of the Safety Analysis and possibleaccident scenarios to prevent potential radiologicalreleases under all possible accident scenarios.

It is anticipated that an Inflatable seal will be provided.

hinC

Merkling, T

90KCDR

Merkling. T.

90%CDR

2.1, Sequence Description, Section 2 1 ID 6.0, ID 105, ID106; Section 2 8 ID 8.0, 9.0; and Drawing SK2-2-300420Comment; Per the Definitions on page v, this annularspace cover has been eliminated. If this Is true, referenceto the cover here and throughout the document needs toalso be eliminated.

The baseline design still requires the annular space cover but it isanticipated that it will be eliminated during detailed design. Thedefinition will be revised.

2.1, Sequence Description, ID 52 - 89: Comment: Is avisual/dye penetrant inspection sufficient for a Safety Classapplication?

The new weld test proposal from the MCO designers specifiesultrasonic testing. This will be Incorporated In the detail design ofthe HCSE.

closed

Merkling, T.

90% COR

Section 2.2.1.2.1, Gas Pumps: Comment: Delete "high-lever from last sentence of first paragraph. The vacuumpump should be radiologically surveyed first and thendisposed of as needed based on the survey. This is inkeeping with the statement on page 57 of 57 of the samesection, "failed equipment will be disposed of appropriatelybased on a radiation survey."

Text changed as recommended. closed

Merkling, T.

90%CDR

Section 2.2.4.9: Comment: Change 1-131 to 1-129, and Kr-86 to Kr-85. This is in keeping with decay patterns andwhat is noted in drawing 300413. If spontaneous fission isa problem, then 1-131 could be present. As noted incomment 1, a characterization study needs to beperformed to calculate the amounts of each of theseisotopes.

Text changed as recommended. closed

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APPENDIX K HOT CONDITIONING COMMENT DATABASE


Merkling, T.

90% CDR

Section 2.3.1, Reference Standards; Comment: Add 40CFR 61 . (NESHAPs for radiological discharge points)

Suggested addition will be made. closed

Merkling, T.

90% CDR

Section 2.3.4 Equipment Description and 3 2.81 & Cinterface T h e HCSE will provide the stack monitoringsystem." Comment: Effluent monitoring and controls shallcomply with the requirements of 40 CFR 61 and the DOE5400 series. Before the type of monitoring equipment Isdecided/designed, the project needs to analyze for what itis monitoring (isotope(s) and amount discharged fromnormal operations as well as releases from DBAs). Theseevaluations are usually a part of the SAR. Thischaracterization study estimates/calculates the totalamount of radionuclides/isotopes transportable toupstream and downstream of the MCO filters and processfilters (normal operations and DBA with Safety Class SSCs[i.e. MCO|). This Information can then be used to calculateif a monitoring or only a sampling system Is needed, anddepending on what is needed, what type and sensitivity ofinstrumentation/sampler will be needed. Without thisinformation, it is hard to design a stackmonitoring/sampling system.

no A conservative stack monitoring system is shown In the CDR. The closeddesign will be revisited during definitive design with theseconsiderations in mind.

Merkling, T.

90% CDR

Section 2.6.2.1, page 39 of 57, second paragraph. T h ewetted surfaces reach the pump." Comment: Delete"and gasses" as the gasses will pass through the systemand up the stack. Delete "Kr* as this Is a gas, and delete"Xe" as this isotope is not present. Consider adding "Co"as this isotope was mentioned earlier in the report.

Suggested changes will be made.

I

i dosed (Merkling, T.

90% CDR

Section 2.8.2 Comment: Delete "high." 10 CFR 835 has aspecific definition for high radiation area with rigid accesscontrols.

Suggested changes will be made.

Merkling, T.

90% CDR

Section 2.8, Process step F12; Comment: Is the locationof the TV camera and equipment considered for ease ofmaintenance for ALARA considerations?

ALARA will be considered in the selection of the camera location closedduring definitive design.

Merkling, T.

90% CDR

Section 2 9 11 Comment: On what is this "1 per MCO"replacement frequency based? The radiation dose will bebased on Cs 137. The MCO filter is designed to filter themajority of all articulates thus the cold trap should remainreasonably Cs free.

The estimate of 1 per MCO is intended to be conservativeExperience will dictate the actual change our rale.

closed

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REVIEWER COMMENT»



Merkling. T.

90% CDR

Appendix B, 1.0 Introduction, second paragraph;Comment: Add narrative to address the minimization ofradiation exposure. See narrative in Section 3B, page 5 of8 of this same section for example.

no Comment incorporated.

Merkling, T.

90% CDR

Appendix B, 4.0, B; Comment: What is the source of this"shall" statement of not exceeding 5.0 mrem/hr?

Document revised to reflect 2.5 mrem/hr criteria. This is per 10 closedCFR 835.202.

Merkling, T.

90% CDR

Appendix C, Section 3.3, page 3 of 9; Comment: Thisexposure result should include exposure from maintenanceactivities as mentioned in Appendix B, section 2 C, T h edetermination should Include normal operations andmaintenance/repair exposure.

Agree. An estimate of maintenance related exposure will be added DDto this analysis during definitive design.

Merkling, T.

90% CDR

The information listed In the vendor section for the stackiso-kinetic sampling head is incorrect. The EberiineALPHA6 is an In-line sampler head which draws a samplefrom an iso-kinetlc sampling array or a shrouded probe (itis not the probe itself) The project still needs a samplingprobe (iso-kinetic or shrouded).

no Probe will be specified in definitive design stage.

ir,

fS

Merkling, T.

90% CDR

Drawing SK-300413; Comment: Delete "Xe-127" from thedrawing, this isotope Is not available.

no We will delete Xe-127 from SK-300413

.BMerkling, T.

90% CDR

Drawing SK-300413; Comment: The Eberiine PING-3B Islisted as the Instrument offered to detect Iodine 129. I donot believe that this PING-3B instrument is sensitiveenough to delect the low levels of this low energy betaemitter. It was designed to detect the higher energy 1-131in higher concentrations than 1-129.

no We will review the Eberllne PING-3B capability regarding 1-129 and closed '<•make any changes necessary during definitive design.

Merkling, T.

90% CDR

Drawing SK-2-300417; Comment: The drawing gives thelook of concrete over the trench [31.72 Inches to the leftand 81.63 Inches to the right of the 3 Inch steel plate overthe center of the MCO). The narrative In appendix B, page4 of 8 states that the trench will be covered with steel toprovide shielding. Which Is correct? Change the drawingto reflect the steel over the trench. Also, there is possiblescatter through the 10 inch push-through HEPA filters asthe filters are configured in the drawing.

no The trench cover will be fabricated of steel. Drawing will beclarified

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REVIEWER COMMENT # HOLD POINT DISPOSITION


STATUS

Miska, C.R.

60% CDR

Please provide clear descriptive names for major pieces ofequipment to eliminate confusion. Also consider providinga numbering scheme that would cooidinate the block flowdiagram with the process sequence etc.

A section that defines names for major pieces of equipment hasbeen added to the CDR and these names are used throughout.Coordination of block flow diagrams with process sequence will bedone during definitive design.

Miska, C.R.

60% CDR

The process sequence appears to be founded on theassumption that the MCO will have some TBD valvesrather than the existing MCO design with quick disconnectfittings. While I do not like the MCO "quick" disconnectfitting the HCS 90% conceptual design will need to bebaselined to the MCO design. Unless "we" can decide ona specific alternative and convince the MCO team andothers to design, test, and implement this concept, then wemust baseline to the existing MCO design.

Agree.Will reissue the sequence to allow for remote connection of quickdisconnects.

dosed

Miska, C.R.

60% CDR

The HCS design needs to provide HEPA filtration on thesupply lines to the MCO. Note the Lab has recentlyexperienced a contamination spread (Cs ?) while theywere working on a furnace gas supply line outside of thehot cell

no Has been Incorporated in 90% conceptual design. Added VPS-F- closed1107 on the dip-tube side of the MCO.

Miska, C.R.

60% CDR

The RGA instrument should be able to sample the offgasprior to the gas cooler/cold trap. I suggest that the RGA beset up to sample the gas from several locations, (supplygas, offgas prior to cooler, after cooler, and just prior toreturn to the MCO). It Is suggested that this instrument befor process control purposes, and that a reliable simple tocalibrate flammable gas analyzer etc be use to determinethat H2 concentration limits are met. This simple reliableinstrument could then ensure compliance with safety limits.

no Issue will be subject of study during definitive design.

Miska, C.R.

60% CDR

The Shield Plug will likely need to be held in place in theMCO vault cover prior to lifting the vault cover. This detailshould be developed In such a way as to essentiallypreclude damage to the MHM / Vault Cover / ProcessEnclosure from improper operation of the restraint. A likelysolution would be to design this restraint as part of the pickpoint for tipping the MCO vault cover. If this was donethen the cover would be constrained when lifted and therestraint would always be removed prior to processenclosure removal.

no Agree. Will Include in definitive design of process pit cover.


WHC-SD-SNF-CDFUX>7 Rev 0




Miska, C.R.

60% CDR

Why are we bolting down the MCO Vault Cover? Note ifthe Intent Is to leave the MCO rupture disk active duringprocessing and to bolt down the cover to mitigate thepotential rupture disk actuation then the following shouldbe considered: 1) The current rupture disk design is tefloncoated (will not work well at processing temperatures) 2) Arecent change is in the works to change the rupture diskpressure to 25 PSI to preclude the consequences of a highpressure blowdown event which was adversely driving theCSB (they would have needed more SC 1 systems).

no Cover not bolted. Sequence of operations corrected in 90% closedconceptual report.

Miska,C.R.

60% CDR

The Process Enclosure sketch shows the wheels locatedon the wrong side of the enclosure.

Two alternates for process pit layout were included in 60% CDR. closed ,Ther wheels were right for one of these. The other has beedselected so the sheels will be rotated.

Miska, C.R

60% COR

Moving the Process Enclosure with a cable winch wouldlikely present a tripping hazard etc. Would it be practical toprovide movement capability to the process enclosure.

Enclosure will be moved with electric tow motor. Incorporated In closed90% conceptual design.

Miska, C.R.

60% CDR

Miska, C R

60% CDR

With the current sketch of the oven the Process Enclosurewould not provide adequate shielding for the worker. Thebest design solution would likely be to reduce the gapbetween the oven wall and the shielding to much less thanthe - 1 foot shown in the sketch to keep the shielding onthe Process Enclosure to a minimum.

Shielding added in 90% conceptual design. Sholder on MCO will closedhelp reduce exposure.

A "rubber seal" on the bottom of the process enclosuremay be necessary to allow this enclosure to meet safetyclass confinement requirements with imposing arequirement for 1E power.

Rubber seal included in 90% conceptual design.

Miska, C.R

60% CDR

The process enclosure needs to provide space for storing6 insulating covers and 6 annular space covers unlessspace for these Hems is provided in the area below eachMCO vault cover. Note surveying and removal of theseHems to a regulated staging are is a much less desirablealternative.

The proposed MCO with a shoulder eliminates the need for theannular space cover. It Is possible that the Insulating covers canbe stored In the trench. This will be finalized during definitivedesign.

DD

Miska. C.R.

60% CDR

The design of the Annular Space Cover should be suchthat it precludes engagement of the MHM grapple to theMCO with the cover in place. If this is not done somepositive means must be provided to preclude damage tothe MCO, MHM, and furnace by lifting the MCO atinappropriate times with furnace pieces in the way.

no MHM interlock discussed in 90% conceptual design.

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Miska, C R

60% CDR

Miska, C.R.

60% CDR

Step #24 survey cell should be revised.Rouline mannedentry Into the process enclosure should be avoidedwhenever possible, especially when surface contaminationstatus is unknown. A manipulator survey of key locationsis suggested instead, possibly with pass through of surveyswipes for counting.

Revised In 90% conceptual report.

Step # 28 and 29 may need to be switched to determine ifthe dryness criteria is met at the end of the 300 degreehold step Note I do not think that this type of test wouldbe meaningful.

Revised in 90% conceptual report.

Miska, C.R.

60% CDR

Step # 25The Process Enclosure needs to be raisedbefore the power rs disconnected.

Agree. Changed in 90% conceptual report.

Miska, C.R

60% CDR

Consider attaching the Process Enclosure to the ProcessModule with an umbilical cord to allow its activities to besurveiled by the PLC control system

Agree. Will be Incorporated in definitive design

Miska. C.R.

60% CDR

Miska, C.R.

60% CDR

Consider locating a furnace PLC Tdiot'Vslatus light where itcan be observed by the operator moving and operating theProcess Enclosure. These "idiof/stalus lights would showwhat part of the process each Individual station was in, andwould help preclude an operator from Inadvertentlyperforming actions on the wrong MCO (station 2 instead ofstation 3 for example). Also it would likely be helpful forthe DCS to have a similar "status board" screen with thestatus of each of the 6 process stations shown pictorially atthe same time.

WW be incorporated in detailed designAgree this and several other visual aids will be provided to theoperators. As these are developed they will be added to theappropriate P&IDs during definitive design.The technology exists to mount a system monitor on the ProcessEnclosure with communications being either a cable or infrared.The Process Enclosure operator should have access to the samedata as the control room operators.

Step 34 Why is the MCO backfilled to a slight negativepressure, this is not consistent with the performancespecification.

Wilt be corrected to agree with the performance spec.

>

! «

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Miska, C.R.

60%CDR

Water should not be used as a coolant for the processoffgas unless it is demonstrated that it Is impractical to useother design solutions such as an air to air heatexchanger. Note this also applies to a lesser degree to theprocess heating/cooling system. Use of water as a coolantin an offgas system located directly above a 300 degree CMCO filled with damaged reactive fuel would raise safetyquestions that would likely have adverse cost andschedule Impacts. Water cooling of the offgashydraulicalfy above the MCO provides the potential for"steam explosions", fuel ignition, and resultant loss ofMCO boundary scenario's that would be very difficult toaddress.

A study is being developed to be included In the final CDR. Thestudy will address the issue of water use In the HCSE. The watercoolers, for the heating/cooling system, with features to preventwater entering the process equipment will be retained for the 90%CDR.

closed

Miska. C.R.

60% CDR

I would like to see heal transfer calculations that show thatthe cookJown of the MCO head occurs In a reasonabletime while complying with the 100 degree C maximumMCO temperature difference limit called out in theperformance specification.

The calculation in the 60% CDR has been replaced by acalculation from Q-Matrix that addresses this Issue. The heatingand cooling profile must be optimized during definitive design tomeet this restriction.

Miska. C R

60% CDR

The Vacuum pump down calculation needs to be redone.Pumping down the MCO to 10 torr will take longer than thetime indicated to transfer the free space gas volume of theMCO.

This calculation is incorrect and has been redone using the methoddescribed in Perry's Chemical Engineers Handbook. 2E With thiscalculation, the evacuation time has been increased by a factor of6 to 7.

Miska. C.R.

60% CDR

Review of the Heat transfer calculations by WHC indicatesthat the calculated Inside heat transfer coefficient HI - 1,and the calculated outside heat transfer coefficient Ho • 5are likely conservative.However a concern was expressedthat the spiral flow envisioned to enhance the outsidecoefficient likely could not be maintained over the full MCOheight with only a 1" gap.

Recent information from Q-Matrix indicates that the heat transfercalculations are not conservative as they show heat up In 20 hoursv rather than 12 and the 100 degree temperature difference acrossthe MCO Is exceeded. Additional calculations are required duringdefinitive design.

Miska, C.R.

90% CDR

Page iii AcronymsThe acronym list Is a good idea, but itdoes not contain very many of the acronyms usedthroughout the document (like PLC, P M C . ) It would bemore beneficial if someone would take the time to look forall the acronyms in the document.

Acronym list will be revised to capture all acronyms used in thedocument.

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REVIEWER COMMENT« COMMENT



Miska. C.R.

90%CDR

Sec 1.0 page 1, Appendix E page 1, and throughoutdocumentPlease use the issued revision 0 of HCSperformance specification, not the old draft revision A.Please discuss with WHC if specific information in rev A isrequired that is not in rev 0. (search doc for rev A)Noterevision 1 of this document will be issued in the near futureand direction will likely be given to use revision 1 for thedetailed design phase-

Document will be revised to reference Rev 0.

Miska, C.R.

90% CDR

Miska, C.R

90% CDR

Sec 1.0 Page 3Statement thai "the proposed HCSEconceptual design should be able to achieve whateverdegassing specification is established by simply heatingand pumping longer" is not totally valid. Some of theresidual moisture (contributor to pressure In sealed interimstorage) after hot conditioning is expected to be tightlyassociated with fuel oxides and sludge, thus holding at thedesign temp can not remove all residual moisture fromoxides. However if oxide inventory is low enough thenmaximum residual moisture criteria can be met. Suggestdeletion of sentence from report.

Section 2 0 pages 6, 7, S, 9, 47, 49, 49, 50, 53, 54 ...Please revise document to show weld inspection techniquemore suitable for remote implementation (radiograph or X-ray for example). Alternately for CDR indicate in text thatmore appropriate weld inspection techniques would greatlyimprove the probability that the process enclosure willmeet duty cycle requirements (will not adversely constrainthroughput). Note I believe DP inspection was chosen atCVD because that weld design would not allow fullpenetration inspection-

no Sentence will be deleted as suggested.

The new weld test proposal from the MCO designers specifiesultrasonic testing. This will be Incorporated in the detail design ofthe HCSE.

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DISPOSITION STATUS

Miska, C.R.

90%CDR

Section 2.0, page 11, 2.2.1.2 (Pressurized Operation), also4.0 page 3 interface MCO7The process can should not bedesigned to support operation at 115 PSIA. The MCOperformance specification/ interface agreements etcrequire it to be maintained below 75 PSID when thetemperature is above 200 deg C. Note also that thispressure is above the current rupture disk design pressure{25 PSI) and thus would require covering or replacing therupture disk. Note the heating and cooling durations in theperformance specification are not hard and fast designcriteria but targets. We should have sufficient excessdesign capacity that pressurized heatup and cool downshould not be required (especially after eliminating the cooldown durations for that would have been required forhands on access to the MCO. Note also if the lobe rotorpump is a high capacity pump this raises difficulty Indealing with particuiate entrainment, and tine breakaccident analysis.Note if gas circulation pump is requiredto guarantee vacuum pump life a more appropriate gascirculation device should be chosen (regenerative blowerfor example). A lobe rotor would not be dependable in thisservice, (it would fail catastrophically the first time flow wasinadvertently isolated or restricted).

The process will be designed to support operation at 25 psia ratherthan 115 psia. A magnetically coupled regenerative blower asrecommended is now shown In the CDR. A pumping study will beperformed during definitive design to select the most appropriatepump for (his service.

Miska. C.R.

90% COR

2.0, Page 12, Third full paragraphSecond sentence isincorrect "Exposed uranium reacts with oxygen andcontinues to do so until the surface Is passivaled." This isincorrect because the uranium will continue to oxidize aslong as oxldant is present. This is true in part becauseuranium does not form a true "passive" surface uponoxidation (the oxidation products begin to spall afterreaching a certain thickness).

Replace first two sentences with the following:During the lower temperature partial oxidation phase of the hotconditioning process, low concentrations of oxygen are introducedinto the MCO in an inert carrier gas stream. This low concentrationof oxygen consumes highly readttve sites on the fuel inside theMCO, reducing the chemical reactivity of the damaged fuel matrixthat may be present in the MCO. Not the reactive sites consumedby this partial oxidation may include small fuel fragments, highsurface area uranium hydride particles, and high surface areauranium metal particles created by the thermal decomposition ofuranium hydride.

Miska, C.R.

90% CDR

2.0, Page 32. 2.4.2 and 2 4 5,Why is it advantageous touse a radio modem to communicate between the PMC andthe PLC (why is mobility required) Also what is the PMC(I did not see rt defined In the control section). Note thesafety analyst are already complaining about not likingreliance on PLC to respond appropriately. The potential forradio interference just adds fuel to that potentialdisagreement (NOTE PUREX had big problems withportable 2 way radio's disrupting sensitive equipment likecentral fire alarm dispatch panels).

During the oral presentation it was incorrectly stated that a radiomodem would be used for data communication between theprocess module and the control room. This circuit Is hard wiredand signals are multiplexed over 2 conductors. A radio modem isonly used between the mobile process enclosure and the controlroom and only to monitor Inputs such as temperature and otherparameters which are not used in closed loop control circuits. Ifcommunication via radio modem Is erratic, this would not impactany of the control circuits.






Mlska, C.R.

90%CDR

2.0, page 43, Instrument Air SystemWhy are we providinginstrument air, has it been decided that the CSB instrumentair supply will not be used?

The instrument air system in the CSB Is at the opposite end of thebuilding. In order to minimize the impact ol the HCSE on the CSBdesign, it will not be extended to the HCSE

Miska, C.R.

90%CDR

3.0. Page 1 and 2 HCSE layout More detail is needed thanIs provided on the referenced drawing SK-2-3-00421. Forexample the exact size of the shuttle table pit needs to bespecified.Note also that the dimension from the centerllneof the nearest obstruction east-west and north south Is notas shown on SK-2-3-00421 (greater clearance isrequired). Also floor elevations need to be specified unlessthe entire floor is at one elevation Note recessing the skidand waste storage area may be highly desirable to preventwater from process cooling leaks, or tire protectionsystems from reaching the furnace or CSB vault tubes.

Shuttle table no longer required as MHM box beam has beenraised to 9 ft and process enclosure will be less than 9 ft. It hasbeen determined that the floor will not be recessed since leakagefrom process cooling water will be contained by the processmodule and no fire protection water is required.

Miska, C.R.

90%CDR

3.0, page 3, Trench Coverl strongly suggest specifying thedesign of the trench to HCSA designer such that a trenchcover greater than 6" could be supported (design strongenough to support a stepped cover extending below lip fortrench cover). I recommend designing to supportsomething like 8-10 inches of steel. This would allow theHCSE designers more flexibility to go above 6 Inches fortrench covers If required for any reason.

no Trench will be specified as suggested. closed '

n

9

»Miska, C.R.

90%CDR

Appendix (general)Please tab each appendix separately.Also please try to arrange the vendor cut sheets in alogical order if possible (group like equipment I.e. hepafilters)

no Appendices will be tabbed as suggested and cut sheets will be closedorganized alphabetically by equipment number.






Miska, C.R.

90% COR

Appendix, SK-2-300418 (Oven Assembly)As shown thefurnace shielding will likely result In much more than the5mR/Hr operator dose rate discussed in the shieldingsection. As shown in the sketch a "direct view" ofunshielded side of MCO would exist it looks like this wouldresult in effectively less than 2 inches of shielding withprocess pit covers up and enclosure in place. This willgive an totally unacceptable dose rate.Note when Iestimate the potential dose to worker at the enclosureusing a factor of 4 reduction In dose per inch of steel, afactor of 4 reduction to correct the dose from 1 meter to thedose at 2 meters, and the safeguards dose of -65 R/hrfrom the side of an unshielded MCO at 1 meter (foraverage fuel not peek shielding design fuel), I end up witha dose rate to the operator at the process enclosuregreater than 1,000 mR/Hr. This is three orders ofmagnitude greater than what the design dose rate shouldbe. Even if concrete is added to the open space to the leftside of sketch SK-2-300418 a severe dose problem wouldstill exist due to the direct beam from the heating/coolingpiping on the right side of drawing SK 2-300418. It is verylikely that this type of shielding design deficiency could notbe adequately address with the process enclosure, andthus must be addressed via the design of the furnace.Note to ensure the success of the HCS project it isessential to be confidant that the pit dimensions and "floorloadings" given to the HCSA designers will be adequate toprovide for this necessary shielding close to the MCO. It issuggested that the steel top shield shown on the sketch begreatly increased in diameter to eliminate any "direct view"of the unshielded portion of the MCO.

These comments address the shielding analysis and the resultingdose rates above the oven and at the process enclosure. Thedose rates calculated for the currently envisioned oven andprocess enclosure are "ballpark" accurate. I agree that a moredetailed (Monte-Carlo) analysis chould be performed (Comment15) given the complex geometries involved. I also agree that moreshielding can, and chould, be incorporated into the oven/processenclosure design to lower the currenly projected dose rate at theoperator station and the general area dose rate above the oven.This will be incorporated during the definitive design. Variousdesign options will be evaluated and a rough contour dose ratemap (with and without the process enclosure) will be provided todemonstrate the feasibility of the design. The oven and shieldingdesing as currently depicted does leave a small unshielded solidangle to the process enclosure. The will be fixed by addingshielding to either the oven or process enclosure - the closer to thesource, the better. The shielding and dose rate Issures aremanageable and will be addressed and resolved during definitivedesign. Text of Exposure Analysis has been revised to reflectoptions for reducing dose rates.

Miska, C.R.

90%CDR

Appendix B, Alara Implementation Plan, page 6, Item BCriteria "Maximum exposure shall not exceed 5.0 mR/Hron the average." is inappropriate for application as anacceptable design dose for personnel performing routine(extended duration work) at a remote operator console.Note this is especially inappropriate when it is consideredthat the impact of the viewing window was ignored, andthat the dose calculations were likely highly optimistic (atbest).

See response to comment 12.






Miska, C.R.

90%CDR

Appendix C ShleldingSee above comments on non-conservative shielding estimation. Also the durationallowance for work by the process enclosure may be nonconservative (I would not be surprised if the enclosure is inuse nearly all the time that the MHM is not in it's way), thusthe dose rate that the worker receives from this sourcemust be minimized. As discussed above this may best bedone by optimizing the design of the furnace. Noteassuming adding shielding will just be added to theprocess enclosure will greatly increase the floor loading,and will likely require abandoning the viewing window(which I am not willing to give up) Nole the reflected dosewhen the process pit covers are open must also beconsidered. This bounce could greatly increase the"background dose" potentially Invalidating the .25 mr/Hrshielding design criteria for the CSB as well as addingsignificantly to the worker dose-


Miska, C.R

90%CDR

Appendix C ShleldingProvide a rough dose contour maparound the furnace (with or without the shielding of theprocess enclosure), t see view angles that are notconsistent with the 5 mr dose at the process enclosure orthe design maximum of 5 mr. Note WHC Is pursuinggetting this type of dose contour map via Jay Ian but thiswill require - 2 months to complete.


1Io90

Miska, C.R.

90% COR

Appendix D, O&M Philosophy, Page 1: I do not believethat the CSB is designed for workers to routinely wearprotective clothing. I believe that the CSB and thus theAnnex should be designed for access in street clothes,with temporary RCA's being used as necessary.

Agree. Document has been revised. IMiska, C.R.

90% COR

Appendix D, O&M philosophy, Page 1, CThe expectedprocess duration for HCS is 2 years with a 10 year designlife for the equipment and 75 year design life for the annex.Note this was not clear in the equipment performancespecification, but will be clarified in REV 1 of theequipment performance specification.

Comment incorporated.

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REVIEWER COMMENT * HOLD POINT DISPOSITION


STATUS

Miska, C.R.

90% CDR

Appendix D, O&M Philosophy, Page 2, EquipmentSelectionAdd new item, components potentially requiringmaintenance or replacement In the furnace should bedesigned for remote manipulator replacement If at allpossible. Note contact maintenance of this equipmentwould only be possible after removal of the MCO, andshielding or removal of accumulated dose contributors(contaminated process lines, cold traps, and filters).

no Comment incorporated.

Miska, C.R.

90% CDR

Appendix D. O&M Philosophy, Page 3Thls page containsseveral -relics' from CVD that must be eliminated including"Drying Bays", "Internal Washdown", "baged connections","Hood".

no Agree. Document has been revised.

Miska, C.R.

90% CDR

Appendix D, O&M Philosophy, Page 3&4, RadiationSafety, second sentence In sectionChange to read:Preliminary estimates suggest that this can be achievedthrough a combination of shielding near the MCO integralto the furnace assembly, and shielding provided by theprocess pit covers or process enclosure.

no Comment incorporated

Miska, C R.

90% CDR

Appendix D, O&M Philosophy, Page 6, ShiektingSectlonon normally Occupied areas implies a dose rate in theseareas of 1/2 mR/Hr. This Is not consistent with the 2mR/Hr used In appendix C. I believe that the "backgrounddose" through the shielding with the trench covers downshould be <1/2 mR/Hr.

no Agree. Shielding design will relect criteria of 0.25 rem/hr. See closed ?Walt Alaconis comment #7 and resolution. S

Miska, C.R.

90% CDR

Appendix D, O&M Philosophy, Page 8, SecondSentenceThe statement that "the facility will be consideredan HC-3 facility..." is not consistent with the HC-2 Indicatedon page 1 of the Introduction to the 90% CDR. At thispoint in time I tend to agree with assuming HC-2designation.

no Document revised to reflect HC-2 designation.






Miska, C R

90%CDR

Appendix E, Understanding of PerformanceSpecificationThis section needs to provide clear indicationwhere the process design is not consistent with theperformance specification. An example Is page 2 "CoolDown for Connection" rather than repeat the performancespecification this appendix should indicate that thisprocess step is not needed because remote connection willbe utilized. It should also be noted that this change willreduce the heating duration as well and will thusbeneficially affect the process cycle time. Anotherexample of what should have been present in this sectionis the proposed deviation from the firm requirement toeliminate reactive fluids (water) for heating or cooling theMCO process offgas.Thls type of presentation would allowformally accept the proposal to eliminate the cool downstep from the performance specification, and modify futurerevisions of the performance specification accordingly.This type of candid evaluation of compliance with theperformance specification will also encourage thoroughconsideration of the issue, and help clarify where deviationfrom the performance specification is not allowed.Examples of areas where deviation of from theperformance specification are proposed by the equipmentdesigner which will not be allowed include exceeding theMCO design pressure limit of 75 PSIA at temperaturesabove 200 degrees C, and the use of water for cooling theprocess offgas.

Section will be revised to reflect current design in terms of initialcookiown, use of water, etc. A study on the use of water forcooling will be included in the final CDR.

Miska, C.R.

90% CDR

Appendix E, page 2, Receipt, c)Correct TypoThere is nosuch thing as a MHM Process Station.

Typo will be corrected. closed



REVIEWER COMMENT* COMMENT

APPENDIXK: HOT CONDIVONING COMMENT DATABASE

DISPOSITION STATUS

Mlska, C.R.

90%CDR

Appendix E, page 3, Partial Oxidation a)Revise toindicate... The MCO cooling system (MCS) will be requiredto maintain the desired setpolnt temperature during partialoxidation.Nole until detailed analysis are completed il isnot Known if the energy release from fuel oxidation willexceed heat loss, or heat addition will be required to obtainthe desired fuel temperature. For example 10 SCFM ofgas flow with a 2% depletion of oxygen would equalroughly 3,000 watts of power. It would be expected tohave an oxygen depletion of about .5% or less, and the"baseline" temperature may be raised above the initial 150degrees C setpoint (up to a maximum of 250 degrees C)until the single pass oxygen depletion approaches thisamount. Note that 5% oxygen depletion at 10 SCFM thepower output from oxidation would be on the same order ofmagnitude as the decay heat of the fuel, implying goodability to control fuel temperature and thus oxidation rate.

no Suggested clarification will be Included In final CDR. closed

Mlska, C.R.

90% CDR

Appendix E, page 4, Final Cool DownWith the remotemanipulation of the MCO head in the proposed hotconditioning design there is no need to cool down the MCOand fuel to temperatures indicated in the performancespecification. The MCO wall and fuel will however need tobe cooled down sufficiently to ensure that the specifiedmaximum temperature for storage (and presumably forhandling In the MHM) will not be exceeded. The currentspecified maximum MCO wall temperature allowed forstorage is 132 degrees C to prevent the fuel temperaturefrom exceeding 205 degrees C.

no We will incorporate your comments

SIMiska, C.R.

90% CDR

Appendix E, page 16-18 Appendix A, B, and C The use ofappendix A, B, and C to appendix E is confusing especiallywhen the main appendices are not tabbed in the bookplease "restructure" Appendix E to eliminate this confusion.

Appendix E will be restructured such that the appendices will becalled addendums.

Mlska, C.R.

90% CDR

Appendix E, page 16The title for this section"APPLICABLE REQUIREMENTS FOR THE VACUUMDRYING MODULE SUBPROJECT DESIGN" isinappropriate. This is the Hot Conditioning System (HCS),or Hot Conditioning System Equipment (HCSE), pleaserefer to the subproject as such.

Correction will be made.



REVIEWER COMMENT *

APPENDIXK: HOT CONDITIONING COMMENT DATABASE


Miska, C.R.

90%CDR

Appendix GPIease try lo tabulate and organize theinformation In this appendix better (a table of contents andpage numbering for this appendix may be required).Obviously this is a detail Issue that is nice but notmandatory, however breaking the appendix Into logicaltabbed sections as a minimum would help.

no We concur. A calculation log will be generated and added to closedAppendix G.

Miska, C.R.

90%CDR

Appendix G, last two pages (PART l/E-9)lt is not clearwhat the purpose is for these two page, or even if theybelong in this document.

no This was not intended. These pages will be removed.

Mrska. C.R.

90% CDR

Appendix H. Vendor cut sheetslt appears that a divider isneeded prior to vendor cut sheets. My book goes directlyfrom appendix G to the vendor cut sheets (Appendix H).

no Tabbed divider will be added.

oclosed i On

1Miska, C.R.

90%CDR

Appendix H, Vendor cut sheetsPlease try to tabulate andorganize the information in this appendix better (a table ofcontents and page numbering for this appendix may berequired). Obviously this is a detail issue that is nice butnot mandatory, however grouping like information, andbreaking the appendix into logical tabbed sections as aminimum would hetp.

no Information in Appendix H will be organized alphabetically byequipment number.

Miska, C.R.

90% CDR

Appendix H, Vendor cut sheetsPlease Include vendorinformation for the manipulator proposed for the processenclosure. This Is a vital piece of equipment whichrequires additionai Information to allow fair evaluation of itscapabilities (for those of us who are no) familiar with thisparticular manipulator).

no We will Incorporate your comments in the final CDR.

Miska, C.R.

90% CDR

Comments 34.1-34.6 refer to Appendix H, Vendor cutsheets, and PSID SK-2-300413 Flanders G-1 Bag In/BagOut housings.1) Per the P&ID these fillers are located inside the trench(changed remotely with the manipulator). Having beeninvolved with the change out of several of these filters Inthe past I am not sure that they are suitable for remoteoperation without significant modification.

no Filters in trench will be custom design lo facilitate manlpuiatorchange out.

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REVIEWER COMMENT«


DISPOSITION STATUS

Miska, OR.

90%CDR

2) A fluid seal filter Is unacceptable for this applicationunless the equipment designer can provide a bullet proofcase that it is incredible (< 1 EE-6) for significant quantitiesof seal fluid (grease) lo leave the filter system and enterthe MCO. Note < 100 grams of organic would significantlydegrade the capacity of the MCO to contain the hydrogenpressure from radiolysis of retained water In interimstorage. Further more if these seal fluids contain halogensthey could potentially degrade the performance of theMCO (Safety Class 1 boundary).

Seal fluids will be eliminated.

Miska. C.R.

90%CDR

3) Restriction on high temperature: The vendor cut sheetBulletin No. 936 page 3 indicates that maximumtemperature for the fluid seal Is 392 degrees F (200degrees C). It Is questionable if the G-1 gasket sealhousing could be made to work (would pass OOP testing)if the filters are installed remotely, and are thermallycycled. Note that the Flanders cut sheets also Indicatethat for high temperature application special sealants arerequired for gasket sealed units, and refers to page 8which is not included in this appendix.

Metal filters will not have the temperature restrictions.

, in

!

Miska, C.R.

90% COR

4) Restriction on high pressure: The vendor cut sheetsindicate that the G1 housing with a high pressure design Isonly good for 15 PSI positive or 14.7 PSI negative. Thiswould not be compatible with a pressurized circulationsystem, and would could not be taken credit for unless allcredible system pressurization mechanisms are eliminated.

Custom designed metal filters will not have this pressure restriction. closed

Miska, C.R.

90%CDR

5) Room for the filter housings: It Is not clear that there isroom in the process trench or furnace pit as it Is beingdesigned to install these filter housings and filters.

Metal filters will be custom designed for this application to fit in the closed 'available space. , f

Miska, C.R.

90%CDR

6) Suggested approach for this filter: it is suggested thatfurther investigation be performed to identify suitablefilters for this difficult application. One potential worthconsidering is PALL sintered metal filters, for example atone time the Hanford site HVWP project was planning onusing Pall Sintered metal media for testable HEPAfiltration. I know that PALL makes sintered stainless steelHEPA media In various configurations, the question is dothey have a housing configuration that is suitable (testable).

Metal filters will be specified in the final CDR.



REVIEWER COMMENT* COMMENT



Miska.CR. 35 Appendix H, Vendor cut sheets, VPS-BLO-11-61) I suspect90% CDR that the equipment specified on the cut sheet is an

inappropriate application for a highly reliable low pressurehot gas reclrculation blower. Note high pressurecirculation is not required or desirable. Sufficient designcapacity should exists to process the MCO in the allocatedtime without resorting to such drastic measures.2) If thisprocess blower (lobe rotor pump proposed) is a highcapacity device this raises greater difficulty in dealing withpaniculate entrapment, and line break accident analysis.It appears from the vendor cut sheets that the smallestblower that could operate with a 13 PSIG pressure risewould have a capacity of - 7 0 CFM at 2 PSIG pressurerise. 3) If gas circulation pump is required to guaranteevacuum pump life a more appropriate gas circulationdevice should be considered (regenerative blower forexample). A lobe rotor would not be dependable in thisservice, (It would fall catastrophlcally the first time flow wasInadvertently Isolated or restricted). This type of blowerwould be acceptable only If sufficient control interlockswere in place to detect and prevent inappropriateoperation.4) This type of blower has a oil lubricated gearcase. This could be a big problem, equipment thatcontacts process gas should not contain organic or waterunless the equipment designer can establish that loss ofsignificant quantities (<100 grams) of oil, or water to theprocess gas / MCO Is incredible (<1 EE-6 frequency peryear).

A study will be proposed for definitive design to select a moreappropriate blower with a low pressure range. We are using amagnetically coupled regenerative blower in the final CDR.

Miska.CR 36 Appendix H, Vendor cut sheets, VPS-CLR-1103, and VPS90% CDR PFR-1101AS Indicated In the performance specification

water shall not be used to cool the process gases thatcontact the fuel Water shall not be used as a coolant forthe process offgas unless It can be demonstrated by theequipment designers that all other design solutions areimpractical. If no other design solutions are available thesystem designer mush establish a design that has featuresthat make it easy to demonstrate that It would be Incredible(<1EE-6/year) to have significant quantities of water enterthe MCO or create excessive steam pressures uponcontacting hot equipment.

A study of water use for cooling Is being developed based on thiscomment and discussions with the PHA team. The study will beIncluded In the final CDR.

Miska, C.R.

90% CDR

MiscProvlde design concept for shuttle table to move theprocess enclosure out of the way of the MHM.

Design concept will be provided.

DCM 7/29/96 I:V\UTOCAD\2318\DATABASE\COMMENTS.MDB Page K-26


REVIEWER COMMENT *



Miska, C.R.

90% CDR

Misc It Is slrongly suggested that if the offgas pipingassociated with the furnace are intolerant of rotationalmisalignment that a feature be provided by the HCSequipment designer to reestablish proper MCO rotationalposition. This could be done by providing a "turntable" inthe welding pit for occasional "off normal" use. Alternatelya turntable could be incorporated into the furnace.

no A turn-table is being developed for the top of the oven to properly closedorient the MCO.

Miska, C.R.

90% CDR

SK-2-300413 P&IDThe RGA Instrument for gas samplingneeds to measure both the supply and exhaust gasconcentration, potentially even before and after the gascooler and traps if we can get significant mass removal(condensation).

(re RGA sampling points) We will comply with your suggestion.

Miska, C.R.

90% CDR

Miska, C.R.

90% CDR

SK-300413 P&IDThe oxygen supply system needs somemore thought and work in the detailed design phase. Thestory for pre dilution of the oxygen (buy at <20% oxygen ininert gas) add at limited rate (orifice) to recirculaling offgas,with measurement to confirm that oxygen concentrationdoes not exceed maximum allowable concentration).

no The gas supply system will be revised to provide these monitoring DDpoints.

SK-300413 P&IDThe design should reflect a highreliability flammable gas monitor or simitar device toensure that the offgas concentration Is maintained lowenough to preclude combustion (easy to use / maintainsafety significant system).

no Study in detailed design. D D

.n(A

O'Neill, C.

90% CDR

The CDR should Include either a HVAC Zone drawing or adescription of the zones.

The Interior of the MCO and connected process equipment will be closedZone 1. The process pit, trench, and process enclosure will be IZone 2 and everything else will be the same zone as the CSB.The text will be modified to reflect this. '

O'Neill, C.

90% CDR

O'Neill, C.

90% CDR

O'Neill, C.

90% CDR

2

3

4

Section 2 9, Solid Waste. This section identifies "Getterand Charcoal Beds" as being a solid waste. The designdoes not Include any of these Hems.

Section 2 9, Solid Waste. The filters from VPS F-t 102 andVPS-F-1107 are not listed here as waste.

Section 3.3.2.2, stack description. The location of thestack should be coordinated with the CSB sub-project tomake sure there is no conflicts.

no

no

no

Depending upon the final selection of the stack monitoring system,these materials could be In it.

VPS-F-1102 has been eliminated and is part of VPS-PFR-1101.This filter as well as VPS-F-1107 will be listed in the solid wastesection.

The suggested coordination is planned with the HCSA and CSBdesign teams.

closed

closed

closed

DCM 7/29)96 I\AUTOCAD\2M8\DATABASE\COMMENTS.MDB Page K-27





O'Neill, C.

90%CDR

Drawing SK-2-300413, Sh.2 Fillers VPS-F-1102 and VPS-F-1107, this type of filter cannot withstand high pressures.If the high pressure option that is mentioned in the CDR isproposed than a different type of niter (metal) will have tobe used.

These filters, Flanders G-1 can be procured in ASME ratedenclosures capable of withstanding 100 psl according to thesupplier we spoke to. That is one of the chief reasons these unitswere specified. Subsequent changes to the design however haveremoved the requirement for this high pressure and the filters willbe reevaluated for 25 psi service.

O'Neill, C.

90% CDR

Drawing SK-2-300413, sh.2. Filler VPS-F-1102, this typeof filter cannot withstand high temperature. A metal filtershould be used in this location.

Filter VPS-F-1102 is now anticipated to be a metal filter

O'Neill, C.

90% CDR

Drawing SK-2-300421. The equipment shown on thisdrawing does not match the equipment shown on SK-2-300413, sh.3. The layout of the equipment should includethe ductwork to make sure there is space for theInstallation.

Space In the area of the Service Module does not appear to be aproblem so the effort was not expended to show the ductworkduring conceptual design. The ductwork will be designed earVy inthe definitive design effort.

Ruff, E.S.

90% CDR

General Note 1: I would like to compliment Paul Smith,Martin Muller, and Lauren Ames on their presentation. Thedesign review was conducted in a very thorough andprofessional manner. They have generated a goodconceptual design study for the hot conditioning project.

Your compliment is certainly appreciated.

Ruff, E.S.

90% CDR

General Note 2: I don't have a copy of the conceptualdesign document, so, I am unable to give page numberreferences for my comments. Comments in this RCR arebased on the oral presentation given in the design reviewmeeting.

Noted, no action required.

Ruff, E.S.

90% CDR

A significant amount of time Is consumed during heat-up ofthe MCO because internal differential temperatures arelimited to 50 deg. C.Suggestion: It would probably beworth additional analysis time to try and develop a rationalfor increasing the allowable temperature differential.

Agreed, subsequent calculations have Identified the 100 Ctemperature requirements for all components of the MCO to be aneven more restrictive parameter.

Ruff, E.S.

90% CDR

I agree with a comment made during the meeting thatsuggested the following: If possible, use a directrefrigerant coil for cooling, not water heat exchangers.

A water study that addresses this Issue will be Included as anappendix in the CDR.

Ruff. E.S.

90% CDR

Observation: In performing grinding operations to affectweld repairs, you will also need a vacuum-type system todean up the grinding swarf (dust).

Good catch, the required functions fo the process enclosure will beexpanded to Include cleanup of the grinding swarf. Perhaps avacuum tube that follows the grinder.

closed





STATUS

Ruff, E.S.

90%CDR

Regarding MCO orientation for process connectionoperations:! believe that it is wishful thinking to expect allof the MCO vessels to maintain an unchanging rotationalorientation from CSB to K-Basin, to Cold Vacuum DryingFacility, to CSB storage tube, to Hot ConditioningFurnace Hence, some sort of rotational alignmentcapability for the MCO must be present in the HotConditioning Facility. As mentioned in the meeting, thiscould be a turntable with "high temperature bearings" in theconditioning furnace. Alternatively, a "room temperature"turntable could be placed in the spare furnace well.

The oven top is being revised to include a tapered roller bearingplate that will allow rotational orientation of the MCO.

Ruff. E.S.

90%CDR

Comments on Process Enclosure shielding:Observation V.Based on the table of radiation exposures presented in thedesign document, most of the hot conditioning dose istaken by the operator in the Process Enclosuremodule Observation 2: It was stated that the ProcessEnclosure was designed primarily as a "constrainingdevice" to prevent the operator from getting direct radiationshine from the open end of the furnace well. To whit, theProcess Enclosure structure Is conceptually designedusing 1" plate steel, with no built-in shielding.

This issue was also identified by Curt Miska, please refer to CurlMiska comments 12-15 and the proposed resolutions.

Ruff, E.S.

9014CDR

(Continued, No. 7 above )l recommend that the ProcessEnclosure front wall, front window, and floor be designedusing as much operator shielding as weight/load limitsallow In addition, overhead shielding and back-wallshielding for the Process Enclosure should also be addedto protect the operator from reflected radiation shine.

See response to comment 7.1.

Smith, C M .

90%CDR

Sec 1 0, Page t of 3 Add CVDS to acryonym list. CVDS will be added to the acryonym list.

Smith. C M .

90KCDR

Sec 10, Page 1 of 3 How does processing the SNF IntoMCO's fit into the final disposition of this material? What Isthe overall milestone/decision that this processingsupports?

Introduction will be expanded to answer these questions.

Smith, C M .

90%CDR

Sec 2 0, Page 12 of 57 #2.2.1.2.2 To further healtransfer/heat-up, or cool down have you considered pre-heating the Helium purge gas going into the MCO?Why/Why not?

The circulating helium wit! be heated or cooled separately from theMCO when the MCO Is being heated or cooled. Preheating newhelium when it is added at other limes would not provide asignificant difference in overall cycle times as the heat capacity ofone helium charge is small compared to the heat capacity of theother components.






Smith, C M .

90%CDR

Appendix H Need Table of Contents listing the vendorcut sheets for somewhat easier reference. Note: Thescroll pump looks like an excellent choice for a vacuumpump. Varian is reputable.

An index to the vendor cut sheets will be provided and the cutsheets will be organized alphabetically by the equipment piecenumber.

Smith, C M .

90%CDR

Sec 2.0, Page 14, 21,25Supplement supplied?

Where are the figures? The figures were inadvertently left out of the 90% design package.They were transmitted following the meeting and will be Included Inthe final CDR.

Smith, C M .

90% CDR

Sec 2.2.3 Page 20 of 57 Has any energy recovery beenconsidered such as using counterflow heat exchanges topreheat gas going to the heaters from another MCO that isbeing cooled?

Each MCO stands alone. While this idea would certainly conserveenergy it has not been implemented for two reasons: (1) MCOcycle times will be unpredictable so there is no assurance thatanother will be in the proper point of its process sequence to takeadvantage of energy savings and (2) the cost of the complexvaMng and ducting would exceed the savings in energy that wouldresult. Another concern would be cross contamination should oneMCO system have a leakage problem.

Smith, C M .

90% COR

Sec 2.2.4 Page 24 of 57 This sequence of operationdoes not reference any of the SK-2-3O0XXX drawings andshould! The process (written) is very difficult to followwithout reference to the sketches. Add "See SK-2-300413,sheet, Appendix A."

References to the P&IDs will be included In the text.

— • eclosed <Smith, C M .

90% CDR

Sec 2 2 4, Page 26 ol 57 paragraph #13 Another majorprocess after welding is the inspection of the weld.

Weld Inspection will be added.

Smith, C M .

90% CDR

Smith, C M .

90% CDR

Sec 2.3.3 Page 30 of 57 Variable speed fan drivers areused for the varying flow rates needed for processing arange of cells at one time. Good design!

Compliment appreciated, no action required.

Sec 2.5 Page 35 of 57 (last paragraph) A variety ofwelding processes shoud be explored. Perhaps the robotcan do the welding. If this is chosen, extra care inselecting a robot and controller/computer that is compatiblewith the electrical and RF spikes that are produced duringwelding processes is needed. Some robotic systems(ASEA) are designed specifically for welding operations.However, here there is a size constraint.

A welder has been proposed by WHC for this purpose, see SectionH for the vendor cut sheet. The specific design will be selectedduring definitive design after the MCO design has been finalized

Smith, C M .

90% CDR

Sec 2.7. t Page 41 of 57 Chilled water system. Doesthe process actually use a glycole mixture that can bechilled below freezing? Will thai be needed to achieve thefinal cool-down cycle?

An unspecified refrigerant Is proposed for the chilled water system.A closed loop water system is proposed for inside the HCSA. Awater vs air cooling study will be included In the CDR.





STATUS

Smith, C M .

90% CDR

Appendix H (Vendor Cut Sheets) Also SK2-2-30O42OHeat exchanges, pumps, heaters, chillers, filters etc., butnot much for the process enclosure. Information neededon the manipulator, detectors, and other bought-out-parts(BOP), (wheel drivers etc).

Cut sheets for the manipulator and welder have been Included inthe CDR. No wheel drivers are proposed, a motorized hand cartwill be used to push/pull the enclosure Into position.

Smith, C M

90% CDR

Page 52 of 57 (Function F1) I would suggest rails for theX-direction and some small amount of Y-positlonlng withinthe enclosure. Standard train rails and wheels couldhandle the large load and do not require customfabrication. (Advantage for transporting to the facility ontrain rails ???)

One requirement from the MHM subproject Is that there be noprojections above floor level. Sunken rails are not desirable sincethey would have a greater Impact on the HCSA design and couldbe contamination traps.

Smith, C M

90% COR

Page 52, F1 At the end of travel for stowage either aturntable could be used or a platform that supports the railsand moves cross-ways on another set of rails (tow profile).With the amount of utilities required at the processenclosure on overhead utility should probably be supplied.

Subsequent to the 90% design presentation the MHM design teamraised the box beam to 9 feet so It can now pass over the processenclosure which wilt be lowered to less than 9 feet. The need forthe shuttle table Is gone.

closed

1to

i

Smith, C M .

90% CDR

Page 52, F2 The whole enclosure doesn't need to lift,only a skirt Is necessary if at all. Perhaps the seal coulddrag on the floor.

This suggestion will be incorported into the design of the processenclosure during definitive design. Currently an inflatable seal isproposed so contact with the floor during transportation won't benecessary. Absence of contamination on the Interior of theenclosure will be verified before the floor seal is broken.

Smith, C M .

90% CDR

Page 52, F3 It was suggested at the design review thata hydraulic actuator for the pit cover could be installed intothe floor. That would be great. I suggest that you lookcarefully at utilizing a 4-bar mechanism type of hlng for thiscover to minimize the swing spare required inside theprocess enclosure. Note in the figure beside that the lidtop swings from positions 1 - 6 to open. ( a drawing, notincluded here, was attached to this comment).

This concept will be evaluated further in definitive design, itcertainty shows promise.

DD

Smith, C M .

90% CDR

Page 53, FS Having stereo vision on the manipulatornear the tool interchange plate is probably moreadvantageous than a force feedback system. Though theoperator can usually view directly and look at the overviewmonitor, the additional view (especially in stereo) willprovide very meaningful assistance. If a force feedbacksystem is Implemented, it should reflect the world or toolorientation force reflections rather than the Individual jointforces. Joint forces are meaningless to a remote operator!

Your comments are appreciated and will passed on to the definitivedesign team who will be dealing with the details of the manipulatorsystem.

DD



REVIEWER COMMENT *



Smith, C M .

90%CDR

Page S3, F7, F9, F10, F11 All power tools should bepneumatic, they are safer, easier to operate, easier toradiation harden, less maintenance, run cool, high power-to-weight ratio.

Final tool selection will be made during definitive design. Theseare all good reasons to select a pneumatic operator.

Smith, C M .

90% CDR

Page 53, F12 This camera should have all remotefunctions (focus, zoom, macro Iris) and include a lightsource with variable intensity control. There is an excellentsystem that uses a single camera system and produces 3-D viewing that this should incorporate. See Al Pardini,WHC, 376-9464.

Final camera selection will be made during definitive design. DDThese recommendatlns will be considered and Mr. Pardini's namewill be given to the detail design team.

Smith, C M .

90% COR

Page 54, F14, F15 Another inspection method would bemuch nicer in a robot-handled package such as an eddy-current sensor.

Subsequent to the 90% design presentation it was determined thatultrasonic testing would be used.

Smith, C M .

90% CDR

Page 54, F17 Consider in-floor hydraulic actuator. Drums with an Internal shield will be interfaced with the processenclosure so expended Cs traps can be placed In them. Thesedrums will have shielded lids that will require removal. As such anin-floor hydraulic actuator Is not appropriate but a hydraulicactuator mounted on the process enclosure wall should beconsidered.

Smith, C M .

90% CDR

Page 54, F1S The automatic tube welder should be selfcontained and not require the robot to positioning it for finemovement welding operations.

WHC has proposed a welder for this purpose. It appears that thiswelder contains the suggested features.

Smith, C M .

90% CDR

Facilities/Utilities Support: Section 3.0 Page 3 of 11Table: Nothing is included for providing pneumatic utilityservice to the process enclosure from the facility. Aseparate hydraulic supply may even get utilized.

The current concept is that the process enclosure will be movedinto position and then an umbilical will be plugged into the requiredservices. The plug-in point will be in the trench cover so therequired services will run In the trench.

Smith, C M .

90% CDR

SK-2-300417 Consider using double sealing, remotelyoperable (with manipulator) quick disconnects.

Quick disconnets of the type described are considered to be thebaseline design. An alternate connector that Is more compatiblewith the process is being designed. The commercial nuclear powerindustry has experienced considerable difficulties using quickdisconnects for this service.

Smith, C M . 25 DWG 420 Process enclosure: Why Is everything so90% CDR n ' 9 n ° " t n e 9rouna"? The wheels should be recessed into

the walls and the platform level lowered.

The height is driven by the reach of the manipulator is placing aspent cold trap in a shielded drum, and the length of the process pitcover when it is opened (hinge on one end). The height has beenreduced to less than 9 ft to pass under the box beam of the MHM.

DCM 7/29/96 I:\AUTOCAD\2318ADATABASE\COMMENTS.MDB Page K-32


REVIEWER COMMENT # COMMENT HOLD POINT DISPOSITION


STATUS

Smith, D.

90% CDR

Introduction page 1. The last paragraph states that theprocess will be designated as a Hazard Category 2system. Hazard Categories are specified for facilities, notfor systems. DOE-STD-1027 allows for facilitysegmentation in determining Hazard Category but theHCSA does not meet the criteria for being designatedseparately from the CSB. This report should note that theHCSA is part of the CSB and the CSB is HC-2 A finalhazard category for the CSB will need to consider theimpacts of HCS accidents.

The introduction will be revised to reflect this comment.

Smith, D.

90% CDR

Appendix E. The functions and requirements shouldIdentify the acceptance criteria for the SNF Theconfinement function of the HCS should be better defined.For example, the allowable leak rate at the designpressure should be Identified since the design does notprovide active confinement during accident conditions.The ventilation flow needs to be specified based uponroutine and upset conditions during the HCS process. Thedesign pressure and temperature for the confinementneeds to be specified based on potential accidents (to beaddressed in the PSE). The design needs to provide thecapability lo periodically lest the confinement function andreplace seals when required. The HEPA filters need to bedesigned for accident temperatures and pressures.

Appendix E only addresses the performance specification, thefunctions and requirements were not available until too late in theCDR development phase to Include and evaluation of \hem In theCDR. The F&R evaluation report will be written early In thedefinitive design phase and these comments will be IncorporatedInto it

Smith, D.

90% CDR

Appendix E. WHC-CM-4-46 should be specified toidentify the design requirements for safety class andsignificant items. Also It appears strange to haveappendices in an appendix (Appendices A, B, and C toappendix £).

We will revise the final CDR to incorporate your first comment. Forthe second comment, the performance specification report waswritten as a standalone document and then Incorporated Into theCDR thus leading to the appendix In an appendix dilema. TheAppendix E attachments are now referred to as addendums.

dosed

Zaman, A.A.

60% CDR

Section 2.0: "Cool Down Process Connection." There willbe some free water left over from the CVC process.Specify or estimate the amount and list whether this freewater demands consideration for further action(conditioning) in the Hot Conditioning Facility.

It would be expected that only a small amount of free water wouldremain after cold vacuum drying, however, it would not beImprobable that several MCO's would contain a greater total waterInventory after cold vacuum drying than is allowed by the HotConditioning Product criteria (1.67 Kg per WHC-SD-SNF-OCD-001). It should be noted that this question Is really "what is theCold Vacuum Drying product criteria." This question should bedirected to the CVD project. (They are preparing a CVD productcriteria document.)

DCM 7/29/96 I:\AUTOCADV2318\DATABASE\COMMENTS.MDB Page K-33

WHC-SO-SNF-CDR-007 Rev 0




Zaman, A.A.

60%CDR

Section 2 0: Some of the temperatures of the definedconceptual processes are potentially close to the ignitionpoint for pyrophoric materials in fuels (eg U-hydrides).Data on ignition point and process temperature selectionbased on the minimum risk for ignition needs to beestablished and justified.

This is not an equipment conceptual design question, this is aquestion pertaining lo the overall SNF process strategy selection.Please refer to the IPS training strategy document "IntegratedProcess strategy for K Basin Spent Nuclear Fuel", WHC-SDSNF-SP-005. lo obtain this type of background information

Zaman, A.A.

60% CDR

Section 2.0: Options for the use of other gases (N2, etc)need to be explored due to the recent study (TI-021) onHydrogen detonation.

The strategy to preclude Hydrogen burn events provided in the HotConditioning Performance Specification, being Implemented by thedesign Is to provide a system design that will ensure both an inertenvironment in the MCO, and dilute hydrogen concentrations toless than 2% (<1/2 of the lower flammable limit In air.) This Is avery conservative approach and should keep the probability ofhydrogen ignition very low.

Zaman, A.A.

60% CDR

Section 5.0: A - The requirements for participation of theSpend Nuclear Fuels Safety (Independent) need to be laidout. This Is In view of the requirements in DOE 5460.5(contractual obligation). DOE 4700 and SNF SafetyManagement Plan.

This is not a valid comment against the equipment conceptualdesign. This is a Hot Conditioning Project Management documentquestion. If after reviewing this document questions still remain,you should contact Rick Bradshaw for further clarification.

Zaman, A A.

60% CDR

Section 5 0: B - The DOE Order lists ASME/ANSI B3I.3under the "Reference Standard and Guides."

Page 8 of the Performance Specification Report, DOE 6430 IAGeneral Design Criteria, does ktlcate that ASME B31.1 ChemicalPlant and Petroleum Refinery Piping standard and the IndustrialVacuum Practices are considered to be supplemental standardsthat will be used for the HVCE design.

\Zaman, A.A.

60% CDR

Section 5.0: B - There are additional divisions/sections thatare important for design consideration of the HotConditioning Facilities Example, 0110-6.1 FireProtection 0110-99 0,1319, etc Add these sections.Add generic statement regarding other than listedreference.

The criteria evaluaton document developed for the Hot VacuumConditioning equipment goes into the applicability of the generaldesign criteria In more extensive detail. This document will beIncluded In the final CDR.

closed

Zaman, A.A.

60% CDR

The most important manual Is SHC-CM-4-46 It providesguidance on safety analysis (hazards, acident, risk, etc)and safety classification.

Further review of the HCS performance specification will be doneduring the detailed design and this potential reference requirementwill be discussed with the HCS design authority to determinewhether It Is applicable to the HCS equipment design.

Zaman, A.A.

60% CDR

Consider reference to DOE 5480 24, 5480 31, 5480.22, etc See response to comment #7 above.

Zaman, A.A.

60% CDR

Does this facility need to be designed and operated toNRC equivalency?

This is the equipment conceptual design, not the facility design.Please refer facility design questions to the facility designer (Fluor).



REVIEWER COMMENT #



Zaman, A A.

60% CDR

Depending on the Safety Classification of the HotConditioning Facilities, the configuration in drawings maychange (eg SC1 will require redundant and single failureproof power supplies/utilities for safe shut down.)

Comment noted. No reply needed.

Zaman, A.A.

90% CDR

The Preliminary Safety analysis/evaluation needs to beperformed to identify the safety class and safety significantstructure, systems and components per DOE 5480.23(section 9.0) DOE 6430.1A (110-5.2) and WHC-CM-4-46. .The information in the drawing needs to be checkedagainst the accident mitigation function specified In thesafety analysis. This could not be done.

A PSAR is being developed in parallel with the CDR. No safetyclass systems have been identified. The design team will continueto work with the safety team to define mitigation measures.

Zaman, A A.

90% CDR

a) We recommend that the 90% design report should adddiscussion on the NRC equivalency issue and Impact onthe process and facilities design.b) Has the evaluation (by NEC experts) been done to seewhere the identification and application of NFPA Article504 ("Intrinsically Safe" systems) apply?

NRC equivalency is addressed in the criteria evaluation that wil bein the final CDR. NFPA evaluation wiif be conducted duringdefinitive design.

Zaman, A.A.

90% CDR

The discussion in the text/report is based on the normaloperations. Need to cover off-normal, accident and designbasis accident.

These operations are addressed by the PHA which is beingdeveloped by WHC. Results of the hazards analysis qre beingincorporated into the design.

Zaman, A.A.

90% CDR

Introduction, p 1, pgph 2: The conditions of high pH in(borated water) and high temperature may producecorrosion of the stainless steel. What is the potentialgeneration of hydrogen gas by this process? Refer toNRC notice 96-34. (Need a copy? Call me at (509) 376-1692.)

When the MCO reaches the HCSE process only chemically boundwater (no free water) will be present, so corrosion of the SST is notanticipated to be a problem. Hydrogen gas will be generated whenthe uranium and zirconium hydrides decompose. These will beremoved before a flammable concentration Is reached. Theprocess gases will be continuously monitored for hydrogen.

Zaman, A. A.

90% CDR

Introduction, p 3, pgph 1: Hot conditioning facility will needto work with the specified design life of 6 yr for the CSB-MHM. Suggest clarification.

The hot conditioning program Is scheduled to be complete in twoyears.

Zaman, A A

90% CDR

Section 2.1, pgph 4: The CSB MHM Is designed to -27 F to115 F ambient temperature. The interfaces with the hotconditioning oven need to be identified and ensuredcompliance.

Maximum MCO storage tube temperatures are expected to beabout 150 degrees-C, which is the temperature of the MCO's whenthey are removed from the oven, the MHM design conditions arebeing re-evaluated by the MHM design team to assurecompatibility.

DCM 7/29/96 t:\AUTOCAD\2318\DATABASE\COMMENTS.MDB Page K-35





Zaman, A.A.

90% CDR

Section 2 0 Process, ID 47.0: Visual inspection of a weldin a safely class MCO boundary may not be acceptable.ASME sec. Ill and applicable V and IX may need to beresearched to determine the minimum requirements(radiography, ultrasonic, etc.)

no This will be revised to reflect ultrasonic weld testing rather than dye closedpenetrant.

Zaman, A.A.

90% CDR

Section 2 2.1.2. t: The Helium blower VPS-BLO-1106 isidentified as "spark proof. The right terminology fromNEC (NFPA 70. article 504) is 'intrinsically safe" and maygo beyond the blower itself to Us electrical/grounding/pipingsystems. If intent is to prevent hydrogen Ignition("classified hazardous location"), correct the terminology.

no The text has been revised

Zaman. A.A.

90% CDR

Section 2.2.1.2.3: Since the MCO is designed to 150 psig.the pressure rating of the system (specifically componentsclose to the MCO) be safe at that rating The text calls out100 psi ("a" or "g").

Although the MCO is designed for 150 pslg. il Is configured with arupture disc with a 25 psig rating. This rating sets the designpressure of the components within the system. The HCSE systemwill also include rupture discs.

.£Ihaw

Zaman, A A

90% CDR

Section 2.2.1.2.4: a) If the PLC are relied on the automaticshut-down for the design basis accident (Impacting off-sitepublic) then their qualification requirements are going to bestringent (IEEE 323, 344, etc) and costly. This needs to beaddressed clearly here.

The interlocks prevent subsequent actions from taking place if theinterlock logic is not satisfied. This is not automatic shutdown.The Pt-C may require operator intervention if all interlocks orsequences have not been satisfied. The system wilt shut down Ina passively safe configuration.

Zaman, A A

90% COR

Section 2.2.2.3.1: Was the Induction electrical heatingconsidered for the process?

Induction heating was considered but abandoned In favor ofconvectfve heating as the convective heating system can be usedfor both heating and cooling. Induction heating would not be ableto assure thai the MCO would not heat up faster than 50 degrees-C/hr or that all parts of the MCO would be within 100 degrees-C ofthe same temperature.

Zaman, A.A.

90% CDR

SK-2-300412: The pump VPS-VAC-1104 needs to besleeted such that operator or maintenance error does nothelp reverse the flow and pressurize the MCO.Hazards/Accident assessment will need to actress suchaccident and mitigation features.

This particular vacuum pump, of scroll design, will not pump gas ifoperated backwards. It is also connected to a single phase powersource which will not reverse if connected incorrectly.

closed

Zaman, A A

90% CDR

Section 2.2.2.3.2: Missing content? If so, please providewrite-up.

Inclusion of this section was not Intended. Text will be corrected. closed,

Zaman, A.A.

90% CDR

Section 2.2.3.1.3.1: The water cooling system may needdetection device for radioactivity that are potentiallyavailable from accumulation over time from MCOsurface/leakage, etc.

There is an air barrier between the water system and the MCO, closedthus no contamination or buildup over time is expected.

DCM 7/29/96 I:\AUTOCAD\2318\DATABASE\COMMEMTS.MDB Page K-36


REVIEWER COMMENT #



Zaman, A.A.

90KCDR

Zaman, A.A.

9O54CDR

Zaman, A.A.

90%CDR

15

16

17

Section 2.2.4, item 3: Assign identification number to trieblock valve.

Section 2.3.1: The codes need to be identified along withdale/revision, eg ASME AG-1, ASME N509, etc.

Section 2.7.4: The air receiver if supporting a safety classof safety significant function may need to have capacityand classification thereto.

no

no

no

Assignment of valve )D numbers will be done at the definitativedesign stage.

The exact standards that apply will be specified during definitivedesign.

This receiver is a utility and not meant to support a safety classfunction. It wiH be U stamped to assure design and construction inaccordance with ASME Section 8, Division 1.

DD

DD

dosed

Zaman, A A

90%CDR

Section 2 9: The Facility has the responsibility tocharacterize their waste before shipment to storage (ieburial ground, WRAP, etc) This function Is missing fromthe document.

Characterization of the waste will be done in the waste storageroom. The text will be revised to reflect this function.

Zaman, A.A.

90% COR

Section 4.0, Interface #MHM3: Current direction Is to allowa mazimum clearance of about seven feet between thefloor and the MHM superstructure. Thsi won't allow the 11'-9" Process Enclosure (SK2-2-300420) to passunder theMHM. (Contact Gerry Bazinet of CSB for currentinformation.)

The configuration shown In the 90% CDR anticipated that theenclosure would be moved out of the path of the MHM rather thanpass under it. Subsequently It has been determined that the MHMbox beam will be raised to 9 ft and the process enclosure heightwill be reduced to 8 ft 6 in.

Zaman, A A.

90% CDR

SK-2-30O413, sheet 2: To keep the MCO isolated, aHEPA filter may be needed between the block valve andthe device VPS-PFR-1101.

Drawing will be revised to Incorporate the filter as recommended.

OCM 7/29/96 I.\AUTOCAD\231SADATABASE\COMMENTS.MDB Page K-37

MERRICK ENGINEERS / ARCHITECTS LOS ALAMOS. NEW MEXICO

Project 2318: Hot Conditioning CDR CommentsPART 2: INDEX OF REVIEWERS


NAME

Alaconis, W.C.

Burns, BM

Cowan, R.G.

Goldman, L.

Kurtz, J.

Lucas, C.

Merkling, T.

Miska, C.R.

O'Neill, C.

Ruff, E.S.

Smith, CM.

Smith, D.

Zaman, A.A.

PHONE

(509) 376-9390

(509) 373-6371

(509) 373-1006

(509) 373-9412

(509)376-7103

(509) 373-7642

(509) 376-1943

(509) 375-3915

(509) 372-3623

(509) 376-1692

ORG/GROUP

SNF Operations

WHC

WHC335

Process Engineering

OPS Analysis/ Waste Handling

Nuclear Safety

SNF Engineering

ICF Kaiser

Mech Eng ICFKH

PNNL

SAR Engineering

LOCATION

MO-285

WHC 78

MO-285

MO-102

2751E

MO-285

2261 STEVENS

H5-70

2400 STVCN

2751E/C-101

B1-10

s,

DCM 7/26/98 I:\AUTOCAD\2318\DATABASE\COMMENTS.MDB Paga K-38

WEST1NGHO0SE HANFORD COMPANY MERRICK & COMPANYHot CondWoninBSyttam Equipment Advwead Technology S*ctorCoi*lct#MW6-SWV-31O416.TMkt17 Project No. 30012318


APPENDICES

APPENDIX L

USE OF COOLING WATER IN THE HOT CONDITIONING SYSTEM

L-i

WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHct Conditioning System Equipment Project Adwnc«d Technology S«cta

O»*«*«WS««V*0416.T«k«7 WHC-SD-SNF-CDR-O07.REV.0 P«*ct No. 30012318

APPENDIX L - USE OF COOLING WATER IN THE HOT CONDITIONING SYSTEM

USE OF COOLING WATERIN THE HOT CONDITIONING SYSTEM

1.0 STATEMENT OF PROBLEM

The proposed process for removing chemically bound water and hydrides fromthe SNF in the MCOs following the cold vacuum drying process involves heatingthe SNF to temperatures of 300 to 350°C and drawing a vacuum. This heatingis followed by cooling the SNF back to 150°C for oxidation of exposed uraniumsurfaces. The process involves cooling in the following process streams.

A. Helium Recirculating Through MCO

During both the heatup and cool down phases, helium is continuouslyrecirculated through the MCO to: a) enhance the heat transfer rate; b)allow monitoring of the heatup/cool down rate; and c) allow monitoring ofthe released gases. Two cooling steps are proposed for this stream.

1. Cold Trap - The released gases could include cesium so a coldtrap will be provided before the gases exit the trench in order toremove the cesium before it can plate out in the above gradepiping where it would result in unacceptable radiation exposure topersonnel in the HCSA. in this case, cold is a relative term, thegases must be cooled to approximately 100°C.

2. Prior to Vacuum Pump/Recirculation Pump - The vacuum pumpthat has been selected for the HCSE has a temperature limitationof 40°C for the gases entering the pump. The recirculation pumpcan be specified for higher temperatures so it does not present thelimitation that the vacuum pump does.

B. Cooling Air Recirculating Through Oven

It is proposed to cool the MCO from approximately 300"C to 150°C byrecirculating air through the annular space between the MCO and theoven. The heat that is transferred to this air must subsequently beremoved before the air is returned to the oven.

The most straight forward means of cooling the gases is to use a refrigerantsystem to chill water which can then be used to cool the process gases. Thedownside to this approach is threefold: 1) if liquid water is introduced into anMCO that has been heated to 300 °C, a steam explosion could occur; 2) if water

L - 1

WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Project Advanced Technology SectorContnKt#MW6-SWV-310416,T««k#17 WHC-SD-SNF-CDR-007 , R E V . 0 Project No. 30012318


is introduced into an oven that has been heated to 300°C, a steam explosioncould occur; and 3) water in a cool MCO would require that the hot conditioningprocess be repeated.

To preclude water being introduced into an MCO which is in a storage vault,water is not allowed within the CSB storage vaults. The fire hazards analysis forthe CSB has determined that a water-based fire protection system is notrequired in any areas where MCOs are handled.

2.0 PURPOSE

The purpose of this study is to identify and evaluate possible options for coolingthe MCO and the recirculating helium loop in the HCSE process.

3.0 CRITERIA

If water is to be introduced into the HCSE process, then the following criteria forprotection of the MCO must be satisfied. Intrinsically safe mechanisms must bedesigned into the cooling system such that water is excluded from the MCOduring normal operations, abnormal operations, and accident conditions such asbreaching of a process line or vessel. This includes both the MCOs in storagetubes in the CSB and MCOs in the HCSE process pits. Additionally, the watermust be controlled such that it is not allowed to be in contact with hot surfacessuch as the interior of the oven. Any system that violates these criteria is notacceptable if air from the HCSA is used for cooling then, whatever system ischosen should have minimal impact on the HCSA air and heat balance. Theselected system should also conform to the HCSA criteria for constant velocity inthe exhaust stack which has been set in the project's application for an airemissions permit.

4.0 COOLING SYSTEM ALTERNATIVES

The cooling methods/alternatives that have been identified and that areevaluated in this study to provide the required cooling are: a) Draw air fromHCSA; b) use the 150 cfm of ventilation air from the process pit; c) cool with agaseous coolant such as carbon dioxide or helium and d) use a chilled watersystem with intrinsically safe features.

L-2

WEST1NGH0USE HANFORD COMPANY MERRICK & COMPANYHoi Conditioning Sydem Equpmtnt Projact Advanced Tachnology Sector

mMli: WHC-SD-SNF-CDR^OT.REV.O P - * * No. 300,23,8


Alternative A - Draw Air From HCSA

Air drawn from the HCSA through a HEPA filter would be used as required andthen exhausted through HEPA filtration and into the HCSA stack. The MCOoven represents from 90 to 95 percent of the cooling load while the heliumcirculation loop represents the remaining 5 to 10 percent of the load. Thevolumetric intake air rate to the MCO is 750 cfm and the combined rate to both ofthe circulating heat exchangers is 75 cfm.

Prior to its introduction to the MCO oven, the air would be blended withcirculating hot air to achieve the programmed inlet temperature, thus the amountof air required from the HCSA would vary, increasing with time, as theprogrammed inlet temperature dropped through the cooling period. The exhausttemperature would reach a maximum of approximately 260°C at the initial stagesof cooling. This hot air would be combined with the ventilation air from the otherMCO pits and be sent to the stack at a maximum of 100°C if two MCOs werebeing cooled simultaneously.

Air piped to the helium cooling loop would be at the free air temperature of 20°C.Compared to the volumetric requirement for the MCO oven, the amount of airrequired for helium loop cooling would be approximately 5 percent of thatrequired for the MCO oven. Exhaust air from the helium loop cooling would becombined with the exhaust from the MCO oven before being sent through aHEPA and up the HCSA stack.

Alternative B - Use the 150 cfm of Ventilation Air discharging from the ProcessPit Ventilation

A constant 150 cfm of process pit ventilation air would be used for both MCOcooling and helium exchanger cooling. This air, having passed through a HEPAfilter, would be heated to a temperature of approximately 25°C, having picked upapproximately 5 degrees from heat losses around the top of the MCO. As in theprevious alternative, it would be blended with circulating air to achieve theprogrammed inlet temperature for MCO cooling. The cooling air to the MCOoven may have to be operated at a higher temperature than what is called for bythe cooling temperature profile, owing to the 150 cfm restriction. This wouldhave the effect of increasing the time required for cooling. This option should bestudied further.

Approximately 5 percent of the pit ventilation exhaust would be piped to fin tubeexchangers in the helium circulation loop. After picking up heat there theexhaust would then join the exhaust from the MCO oven to be directed throughHEPA filtration and up the stack. The combined exhaust ventilation air from allof the MCO process pits would result in a stack temperature of up to 100°C.

L-3

WEST1NGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Syttam Equipment Project Advanced Technolooy SectorContnKt#MW6-SWV-310416,T«*k#17 WHC-SD-SNF-CDR-007 , R E V . 0 Project No. 3001231B


Alternative C - Cool With a Gaseous Coolant Such as Carbon Dioxide or Helium

Candidate gaseous cooling media includes helium, nitrogen and carbon dioxide.All gasses would be handled under pressure to increase the heat capacity perunit volume. While helium and nitrogen would remain as gas, carbon dioxidecould be used above its critical point as a supercritical fluid. In this state, thedistinction between gas and liquid is lost and the fluid would exhibit theproperties of liquid CO2. The triple points of helium and nitrogen are at too higha pressure for their use as supercritical fluids to be practical.

The cooling media would be chilled using a conventional refrigerant expansionsystem. The cold gas would be then moved to the process heat exchangerswhere it would pick up heat from the circulating load. In the case of the MCOoven, this would be the load of the air circulating at 750 cfm and in the case ofthe helium loop, this load would come from the helium.

Alternative D - Use a Chilled Water System With Intrinsically Safe Features

Intrinsic safety can be achieved for cooling the MCO oven air with chilled water.The chilled water would receive heat from the exhaust MCO oven air. Waterentry to the MCO oven could be prevented by piping the circulating air streamthrough a 125-gallon knockout pot that separates and collects any waterleakage, thereby preventing entry to the MCO oven area. The water would beconfined to the process module, well away from the oven. The cooling waterloop would be contained by double walled piping to preclude water leaks fromreaching the HCSA floor. The process module would be designed to containany leakage from the exchangers as well as to serve as a drain for the outerpipe of the cooling water loop.

Intrinsic safety through indirect heat exchange between the helium circulationloop and chilled water is another matter. No intrinsically safe system for heatexchange in this application can be foreseen. All indirect heat exchangemethods can have safeguards but not intrinsic safety. For this reason, watercannot be considered for helium circulation cooling.

5.0 EVALUATION OF ALTERNATIVES

Alternative A - Draw Air From HCSA

When air is drawn from the HCSA, it must be made up by the building's HVACsystem to maintain proper air balance in the annex. With variable flow of airdrawn from the annex, the amount of which depends upon the cooling

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning Syitam Equipment Project Advmcad TKhnotogy S*dorContract *MWfrSWV-310416,Tntc#17 WHC-SD-SNF-CDR-007, R E V . 0 Project No. 30012318


requirements of the MCO, increased control sophistication and increasedcapacity must be provided. This added complexity to HCSA ventilationrequirements makes this option undesirable. The flow through the HCSA stackwould also be variable.

Alternative B - Use the 150 cfm of Ventilation Air discharging from the ProcessPit Ventilation

The HCSA ventilation system is designed to deliver 150 cfm to each of six MCOvaults, the use of this air for ventilating the vaults does not preclude its use insubsequent cooling applications. While not as effective as chilled water in beingable to achieve patterned temperature control of the MCO, it can be done ifsome extension of the time required for cool down is permitted. For heat transferfrom the helium circulation loop only, no reduction in the time required forcooling would be apparent.

Alternative C - Cool With a Gaseous Coolant Such as Carbon Dioxide or Helium

Chilling through the use of high pressure gasses or supercritical fluids requiresattention to pressure containment of these fluids. While adequate heat transfercan be obtained, the fluid system needed to accommodate this consists of extrapressure rated pumps or blowers, receivers and piping. Careful attention mustbe paid to the installation of this equipment, making sure that all leaks arestopped. The consequences of small leaks is the loss of potentially expensiveheat transfer fluid, while massive leakage of materials such as nitrogen andmore importantly CO2 could result in the displacement of air, thereby creating anatmosphere adjacent to the leakage which cannot be safely occupied.

Alternative D - Use a Chilled Water System With Intrinsically Safe Features

Intrinsic safety, excluding water from the area of the MCO oven can be assuredthrough the installation of a knockout interceptor in the air line. Since intrinsicsafety cannot be obtained for the circulating helium stream, air cooling using theheat capacity of a portion of the MCO pit exhaust is suggested.

6.0 RECOMMENDATIONS

Our conceptual design shows and thereby recommends a combination ofAlternative B and Alternative D. This system combines the practicality ofcontrollable temperature obtainable with mechanical refrigeration with theavailability of ample heat capacity for helium cooling from MCO pit exhaust air.

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WESTINGHOUSE HANFORD COMPANY MERRICK & COMPANYHot Conditioning System Equipment Project Advanced Technology SectorContract #MWMWV-310416.T«ilc #17 W H C - S D - S N F - C D R - 0 0 7 , R E V . 0 Praject No. 30012318


Prior to implementation of this method, a complete heat balance will beconducted using any revised cooling temperature profile which may result as aresult of the recently completed Q-Matrix study and the effect the 100°Ctemperature flux specification has upon the programmed cooling temperatureprofile.

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C. J.G. D.K. H.F. W.B. S.D. H.R. G.R.J. B.G. E.W. P.B. L.D. R.B. R.J. R.J. T.W. D.E. W.T.L. H.J. J.A. T.M. K.R. L.T. D.C. R.C. T.A. L.D. R.G. W.M. A.J. I.J. P.P. A.D. L.E. J.P. K.S. M.D. W.D. W.K. E.J. A.

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Hot Conditioning Equipment Conceptual Design Report

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C. A. ThompsonJ. E. TurnbaughD. A. WallaceJ. C. WiborgM. J. WiemersW. LM. EJ. CT. L

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