release stamp document release and change form · 2020-01-07 · 1 spf-001 (rev.d1) document...

1 SPF-001 (Rev.D1)

DOCUMENT RELEASE AND CHANGE FORMPrepared For the U.S. Department of Energy, Assistant Secretary for Environmental ManagementBy Washington River Protection Solutions, LLC., PO Box 850, Richland, WA 99352Contractor For U.S. Department of Energy, Office of River Protection, under Contract DE-AC27-08RV14800

TRADEMARK DISCLAIMER: Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof or its contractors or subcontractors. Printed in the United States of America.

Release Stamp

1. Doc No: RPP-RPT-61916 Rev. 00

2. Title:Functions and Requirements for Tertiary Leak Detection System Examination Tool

3. Project Number: ☒N/A 4. Design Verification Required:

☐Yes ☒No

5. USQ Number: ☒ N/ARPP-27195

6. PrHA Number Rev. ☒ N/A

Clearance Review Restriction Type:public

7. Approvals

Title Name Signature DateChecker Venetz, Ted J Venetz, Ted J 10/30/2019Clearance Review Raymer, Julia R Raymer, Julia R 11/11/2019Document Control Approval Meinecke, Kathryn R Meinecke, Kathryn R 11/07/2019Originator Soon, Glenn E Soon, Glenn E 10/29/2019Responsible Engineer Gunter, Jason R Gunter, Jason R 10/31/2019Responsible Manager Mendoza, Ruben E Mendoza, Ruben E 11/07/2019

8. Description of Change and Justification

Initial Release

9. TBDs or Holds ☒N/A

10. Related Structures, Systems, and Components

a. Related Building/Facilities ☒N/A b. Related Systems ☒N/A c. Related Equipment ID Nos. (EIN) ☒N/A

11. Impacted Documents – Engineering ☒N/A

Document Number Rev. Title

12. Impacted Documents (Outside SPF):

N/A

13. Related Documents ☒N/A

Document Number Rev. Title

14. Distribution

Name OrganizationCastleberry, Jim L TFP PROJECT MANAGEMENTGunter, Jason R TANK & PIPELINE INTEGRITYMendoza, Ruben E TANK & PIPELINE INTEGRITYMiller, Bryant M TANK FARM PROJECTS PROJ CNTRLSSoon, Glenn E TANK & PIPELINE INTEGRITYVenetz, Ted J TANK & PIPELINE INTEGRITY

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DATE:

Nov 11,2019

RPP-RPT-61916Revision 0

Functions and Requirements for Tertiary Leak Detection System Examination Tool

J. R. GunterG.E. Soon

Washington River Protection Solutions LLC

Date Published

November 2019

Prepared for the U.S. Department of EnergyOffice of River Protection

Contract No. DE-AC27-08RV14800

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Approved for Public Release; Further Dissemination Unlimited

RPP-RPT-61916, Rev 0

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TABLE OF CONTENTS

1.0 Introduction ...................................................................................................................... 1-1

1.1 Background .................................................................................................................. 1-1

1.2 Scope............................................................................................................................ 1-1

2.0 Double-Shell Tank Description........................................................................................ 2-1

3.0 Tertiary Leak Detection System Description ................................................................... 3-1

3.1 Environmental Conditions ........................................................................................... 3-4

4.0 Design Functions and Requirements ................................................................................ 4-1

4.1 Standard Requirements ................................................................................................ 4-1

4.2 Leak Detection Drain Line and Foundation Slot Inspection Tool Requirements ........ 4-1

4.3 Robotic Delivery System Requirements ...................................................................... 4-1

4.4 Motion and Force Requirements .................................................................................. 4-1

4.5 Control and Feedback .................................................................................................. 4-2

5.0 References ........................................................................................................................ 5-1

FIGURES

Figure 2-1. General Double-Shell Tank Components ............................................................ 2-1

Figure 3-1. Tertiary Leak Detection System Configuration (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm ......................................................................... 3-1

Figure 3-2. Tertiary Leak Detection System and Tank Configuration (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm ......................................................... 3-1

Figure 3-3. Leak Detection Pit Configuration and Dimensions (Reference Drawing H-2-70306, H-2-71104, and H-2-71905) .................................................................... 3-2

Figure 3-4. Tertiary Leak Detection Drain Line Dimensions (Reference Drawing H-2-70306, H-2-71104, and H-2-71905) ................................................................................ 3-2

Figure 3-5. Concrete Foundation Leak Detection Drain Slot and Drain Line Interface (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm (Reference Drawing H-2-70305, H-2-71103, and H-2-71904)............................................................. 3-3

Figure 3-6. Concrete Foundation Leak Detection Drain Slot Profile (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm (Reference Drawing H-2-70305, H-2-71103, and H-2-71904)........................................................................................ 3-4

Figure 3-7. Evidence of Tank AY-102 Leak Detection Pit Condition................................... 3-5

TABLES

Table 4-1. Tertiary Leak Detection System Examination Tool Requirements ..................... 4-2

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LIST OF TERMS

Abbreviations and Acronyms

DST Double-Shell TankFY Fiscal YearLDP Leak Detection PitNDE Nondestructive EvaluationNEMA National Electrical Manufacturers AssociationNRTL Nationally Recognized Testing LaboratoryOD Outside DiameterPER Problem Evaluation RequestPNNL Pacific Northwest National LaboratoryRCRA Resource Conservation and Recovery ActTOC Tank Operations ContractorWRPS Washington River Protections Solutions LLCUT Ultrasonic Testing

Units

F Fahrenheitft. Feetin. Inchh Hourlb. PoundR RontgenRem Rontgen Equivalent Man

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1.0 INTRODUCTION

Twenty-eight carbon steel, double-shell, million-gallon waste storage tanks located at the Hanford site in Washington State store both radioactive and hazardous waste (as defined by The Resource Conservation and Recovery Act) which is regulated as dangerous waste under Washington State regulations. To monitor their condition and ensure continued viability, these tanks are inspected periodically through a comprehensive integrity program. This functions and requirements document will outline the key characteristics of a robotic inspection solution to conduct visual inspection within the concrete foundation under these tanks. The tank configuration, tool delivery logistics, and environmental conditions present several access challenges that will need to be overcome to successfully develop and deliver a leak detection pit drain line inspection tool.

1.1 BACKGROUND

Double-shell tanks (DSTs) at the Hanford site are constructed with a tertiary leak detection system designed to collect and drain any liquid beneath the secondary liner. This tertiary leak detection systemconsists of a slotted concrete foundation on which the DST is placed. These slots in the foundation are sloped to a connected collection system known as a leak detection sump or ‘pit’. The foundation environment and leak detection pit (LDP) of many DSTs are believed to be subject to intrusion of moisture from the surrounding soil correlated to tank ventilation flow. A programmatic need has been identified to develop an inspection tool capable of traversing the tertiary containment system and provide data that supports tank integrity evaluation. This tool will provide visual inspection capability at a minimum, allowing for confirmation of the status of the secondary liner exterior surface condition under the DST. The inspection tool must be deployable through the LDP riser and navigate the subsurface drain line to the tank foundation space. Further details of this configuration and requirements to achieve success will be provided in this report.

1.2 SCOPE

A functional tertiary leak detection system examination tool will be developed through multiple project phases for deployment in tertiary leak detection system configurations found in the 241-AN and 241-AW double-shell tank designs at the Hanford site. The completed system will be capable of deploymentthrough a 24-inch OD leak detection well from grade down to a connected 6-inch OD leak detection drain. It will deliver an inspection tool through this drain through a series of 90-degree bends to gain access to the primary drain line slot in the concrete foundation beneath the DST. The tool will be remotely controlled by operators with data recording and control systems, located in a trailer outside the tank farm fence line. The inspection tool will include, at a minimum, visual inspection with recording capability and self-contained lighting. Future provisions for material sampling or additional sensors, such as temperature, humidity, or ultrasonic will be considered as well. The system must be capable of operating in a wet/submerged environment.

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2.0 DOUBLE-SHELL TANK DESCRIPTION

DSTs consist of a 75 ft. diameter primary steel tank inside of an 80 ft. diameter secondary steel liner. Both the primary tank and secondary liner are built of the same specification carbon steel and vary in thickness depending on position along the structure. The secondary steel liner is encased by a reinforced concrete shell. The primary tank rests on a refractory concrete slab used to thermally insulate it from the secondary liner and concrete foundation. This refractory slab also provides air circulation/leak detection channels under the primary tank bottom plate. An annular space of 30 in. exists between the secondary liner and primary tank. This space allows for periodic visual surface and ultrasonic volumetric inspections of the primary tank walls and secondary liners. Beneath the secondary liner is the reinforced concrete foundation, which is the target inspection. Access to this region is only available through the tertiary leak detection system.

Figure 2-1. General Double-Shell Tank Components

All DSTs are buried underground, with the top of the concrete dome being approximately 7 to 8 ft. below the surface of the ground. The amount of ground cover increases to more than 15 ft. out at the edge of the dome.

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3.0 TERTIARY LEAK DETECTION SYSTEM DESCRIPTION

The double-shell tanks on the Hanford site include a tertiary system used to collect any liquid that may drain from a compromised primary and secondary containment. This tertiary system environment has been prone to ground moisture intrusion and many have been submerged or wetted, which poses a risk of external corrosion to the secondary liner.

The designs vary by tank farm, but several tanks have a configuration more favorable for inspection tool deployment. In the AW and AN tank farm designs, the slotted concrete foundation slopes to a central drain slot that is connected to a drain pipe at the foundation perimeter at a saddle penetration. The span of the central drain slot is 44-feet 9-inches, from the saddle to the center of the foundation. The connected 6-inch diameter carbon steel drain line then travels a short distance with two 90-degree bends through the soil to an adjacent leak detection pit, which is monitored. The span of the 6-inch diameter pipe section is 24-feet 11.5-inches in total, shown in Figure 3-4. The leak detection pit consists of a 24” diameter well from grade with a 48” diameter sump at the base. The distance between the surface grade and the drain line penetration into the riser is 56-feet in the AW farms and 57-feet in the AN farms. The configuration of the tertiary leak detection system as it relates to the tank is shown in Figure 3-1 and Figure 3-2.Dimensions of this LDP are shown in Figure 3-3. The inspection tool will need to transition from the vertical 24” LDP riser well to the horizontal 6-inch drain line connection and then again to the drain slot and traverse the slot to the center of the foundation. The drain line and slot dimensions can be seen in Figure 3-4 through Figure 3-6.

Figure 3-1. Tertiary Leak Detection System Configuration (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm

Figure 3-2. Tertiary Leak Detection System and Tank Configuration (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm

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Figure 3-3. Leak Detection Pit Configuration and Dimensions (Reference Drawing H-2-70306, H-2-71104, and H-2-71905)

Figure 3-4. Tertiary Leak Detection Drain Line Dimensions (Reference Drawing H-2-70306, H-2-71104, and H-2-71905)

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Figure 3-5. Concrete Foundation Leak Detection Drain Slot and Drain Line Interface (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm (Reference Drawing H-2-70305, H-2-

71103, and H-2-71904)

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Figure 3-6. Concrete Foundation Leak Detection Drain Slot Profile (A) 241-AW Tank Farm and Tank AN-107 (B) 241-AN Tank Farm (Reference Drawing H-2-70305, H-2-71103, and H-2-

71904)

3.1 ENVIRONMENTAL CONDITIONS

Inspection through the tertiary leak detection system has been attempted once previously at Hanford in a different system configuration at tank AY-102, documented in RPP-RPT-56464, 241-AY-102 Leak Detection Pit Drain Line Inspection Report. This effort deployed a remotely operated pipe crawler through the under tank piping in a very similar manner and the lessons learned will serve to informtooling design and outlook for success of this development effort.

Since constructed, the tertiary leak detection sump, drain line, and foundation have likely been and continue to be exposed to varying degrees of moisture intrusion. Based on prior work, the condition in the drain line can range from submerged to dry. Evidence from AY-102 LDP drain line inspection shows growth of corrosion tubercles. They vary in size and are dispersed throughout the drain line. Areas of other debris such as sand, wet mud, loosely adhered scale and corrosion in varying distribution were also observed. The combination of these obstructions and environmental conditions present some challenge to

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traverse the drain line successfully. The inspection tool must be capable of navigating with potentially low friction, uneven surfaces, and minor obstructions.

Figure 3-7. Evidence of Tank AY-102 Leak Detection Pit Condition

The tertiary leak detection system is beneath and adjacent to the double-shell tank. As such, it is likely impacted to a small degree by that proximity with regard to temperature and radiation exposure. The primary tanks contain nuclear waste that generates high temperature and radiation levels. The temperature safety limit established for waste in the bottom 15 feet of the tanks is 250°F; however, the temperature of waste in the tanks is generally below 200°F and typically near 130°F. Tank 241-AZ-102 has the highest average operating temperature, with a temperature of approximately 185°F measured in waste located four inches from the tank bottom. Little data exists on radiation levels at the bottoms of the tanks; however, estimates have been 50-100 rem/hour based on estimated and known waste compositions and resulting gamma radiation. Given the configuration of two layers of carbon steel and a minimum of 8-inches of insulating refractory between the waste and the tertiary leak detection system, the impact is believed to be lessened considerably.

The outdoor conditions during deployment into and retrieval from the tertiary system environment may expose equipment to wind, dust, snow, rain and other outdoor hazards. The full set of climatological conditions are specified in TFC-ENG-STD-02, REV A-12, Environmental/Seasonal Requirements for TOC Systems, Structures, and Components.

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4.0 DESIGN FUNCTIONS AND REQUIREMENTS

There are generally considered to be two components of a successful tertiary leak detection system examination tool. The first is a device to conduct inspection from the drain line entrance and through the path to the center of the concrete foundation drain slot. This device will likely need to be deployed via another tool positioned in the leak detection well/sump location. This two-stage approach has been common to other inspection operations in Hanford DSTs. The following sections highlight the functionality of various aspects of a successful inspection system and Table 4-1 provides a comprehensive list of requirements.

4.1 STANDARD REQUIREMENTS

Standard requirements are configuration and operations driven requirements that will pertain to and influence the design of all technologies that will enter and operate in the tertiary leak detectionenvironment. In cases where a range of functions or performance requirements could be satisfied, minimum requirements and preferred requirements (goals) are stated.

4.2 LEAK DETECTION DRAIN LINE AND FOUNDATION SLOT INSPECTION TOOLREQUIREMENTS

Leak detection drain line and slot inspection tool requirements are those that influence the design of the inspection technology and ensure that data quality objectives are achieved. The inspection tool must deploy from the leak detection pit riser position and be able to traverse the entirety of the drain line and concrete foundation drain slot radius, navigating the transitions and conditions present in that path. While conducting the inspection, the system must not cause damage to the tertiary leak detection system or create environmental risks. The system will provide visual inspection capability at a minimum with onboard lighting and recording capability.

4.3 ROBOTIC DELIVERY SYSTEM REQUIREMENTS

Assuming a two-stage approach as described in Section 4.1, an inspection tool robotic delivery systemwill be used to deploy and retrieve the inspection technology. It will serve to keep the inspection technology payload physically secured, supply utilities, and provide general protection against damage to the inspection technology during operations. While positioning for inspection system delivery, the deployment systems must perform their operations without damaging the inspection technology or the tertiary leak detection system, interfering with operation of the inspection technology, or creating environmental risks. The robotic deployment systems must also provide adequate information feedback to enable safe and effective remote operation of the inspection technology.

4.4 MOTION AND FORCE REQUIREMENTS

The robotic delivery system with inspection technology payload will be transported to the field from a protected storage location for any inspection campaign. It will be deployed through the 24” leak detection pit well from grade by appropriate means dependent upon weight and complexity. Equipment as lightweight as cameras are often deployed by hand, while ultrasonic testing crawlers can require electric hoists or cranes.

A robotic delivery system with an inspection tool payload will be installed through the LDP well andlowered down to reach the drain line interconnection. The delivery system will need to be positioned and

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secured to support inspection tool deployment. Upon deployment, the inspection tool will need to travel through the drain line and concrete foundation drain slot radius as described in Section 3.0.

Robotic delivery systems are responsible for providing rotation and lift/lower actuation to support inspection tool positioning, as applicable. The inspection tool will require forward and reverse movement capability. Depending upon the design, rotational movement may also be warranted.

Full retrieval of the entire system is required at the conclusion of an inspection campaign, in the event of system failure, or other upset conditions. System failure includes failure of a crawler component, complete power failure, or arrested function due to an encountered condition. Tethers and cables must be connected to the system that incorporate a strength element that supports the forces necessary to withdraw the system while protecting the integrity of power and data cables. System components should have appropriately tapered shapes to enable withdrawal of a disabled system. In the event of loss of contact or power while the system is suspended in or traveling down the LDP riser, the tether/cable and its connections to the system shall prevent the system from falling to prevent damage to the delivery system, the inspection tool, or the LDP.

4.5 CONTROL AND FEEDBACK

Tank Operations Contractor (TOC) operators will control deployment of the complete inspection system and will require near real-time video feedback upon which to base movement decisions. The Operator will use a joystick or other handheld controller along with video feedback that facilitates responsive interaction with and control of the system. This system control will occur from outside the tank farm fence line. Distance from the center bottom of the tank to grade in the tank farm through the inspection path is conservatively estimated at 150 feet. An instrument tent will be available in the tank farm to house and protect any equipment local to the deployment location. Control personnel will be outside the tank farm in a trailer approximately 300 feet away. System tether design will need to accommodate this total distance of approximately 450 feet. Use of a simple control system, not requiring computer software is preferable.

Systems may use the LDP riser or drain line to support reaction (bracing) loads during deployment,system positioning and operation. Forces involved with deployment may include those involved with the robotic delivery platform or the inspection tool and should not cause deformation or damage to the tertiary leak detection system.

Table 4-1. Tertiary Leak Detection System Examination Tool Requirements

Requirement ID Requirement

R-1The inspection tool will provide visual inspection using a camera system with recording capability.

R-2The combination delivery and inspection system will provide adequate lighting to facilitate placement in the LDP riser and inspection through the drain line and slot.

R-3Systems shall be capable of satisfying their respective functional and performance requirements in temperature conditions up to 140°F.

R-4Systems shall be capable of satisfying their respective functional and performance requirements while receiving a radiation dose of up to 50 R/hr.

R-5Systems shall be capable of satisfying their respective functional and performance requirements while submerged in no more than 12” of water.

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R-6Batteries shall not be used inside the deployed environment of the tertiary leak detection system. Batteries may be used in the deployment tent located nearby the riser deployment location at grade.

R-7

LDP drain line inspection systems shall be comprised of materials that are either known to be chemically compatible with the DST materials that they will contact (carbon steel and concrete), or that have been demonstrated to be compatible through testing.

Chemical compatibility is defined as not causing corrosion or any other form of chemical degradation that is known to compromise material strength or structural/leak integrity.

R-8System electronics and control systems shall be certified by a Nationally Recognized Testing Laboratory (NRTL).

R-9

The power and power receptacle required by the system will be provided. It is preferable that systems require only single-phase AC power with maximum voltage of 120 volts, frequency of 60 hertz and current of 15 amps and have a grounded 3-pin Type B (NEMA 5–15) plug.

R-10 The system shall not cause visually apparent damage during operation.

R-11No debris or foreign material may be introduced into the LDP or into the drain line/slot region during system deployment and use.

R-12The system, cables, and co-deployed electronics shall be robust enough to satisfy their function and performance requirements for repeated deployments (up to 10 deployment evolutions).

R-13System design and materials shall be selected that maximize the chance of successful radioactive decontamination.

R-14System shall be configured in a manner that lends to it being lifted/lowered by a hoist, deployed through and retrieved from the leak detection well risers configuration.

R-15Tether lines shall be included on the system that incorporate a strength element that supports the forces necessary to withdraw the system while protecting the integrity of power cables.

R-16System components shall have appropriately tapered shapes to enable withdrawal of a disabled system.

R-17Pinch points, compressed gasses, entanglement and other hazards shall be minimized, mitigated, and labeled in order to minimize risks to inspectors and personnel transporting or operating the system.

R-18 The design of the system shall allow for replacement of consumable components.

R-19The system shall provide provisions for cable management to mitigate risk of entanglement and impeded operation.

R-20System shall be capable of providing adequate locomotion and articulation to navigate slick or muddy surfaces and minor obstacles present in the LDP drain line or foundation drain slot.

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R-21The system shall be capable of inspection from the drain line entrance at the leak detection well, through the drain line, and through the full concrete foundation drain slot radius.

R-22The system shall be capable of providing adequate translation, lift and lowermovements to navigate the LDP riser and into the associated drain line.

R-23

The system tether length shall cover a distance of 150 feet from an instrument tent at grade in the tank farm to the center bottom of the tank foundation drain slot. The tether shall have an interconnect at grade and continue with 300 feet of additional length to a control trailer outside the fence line of the tank farm where operations personnel will be stationed. Provisions shall be incorporated into tether and cable design to allow for modularity and replacement.

R-24The system shall facilitate the transmission of feedback data to control trailer at the surface in near real-time.

R-25A controller unit shall be provided that facilitates responsive interaction with,and control of the robotic system by an operator. Delays in actuation shall not exceed 2 seconds.

R-26

At a minimum, feedback provided by robotic deployment systems shall include video feedback. At least one camera with lighting shall be integrated for visual feedback on its position and allow for recognition of obstructions in front of the system.

R-27 Cables shall be as small and as flexible as possible while preserving robustness.

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5.0 REFERENCES

H-2-70305, 1980, “Structural Concrete Tank Foundation Plans and Details,” Rev. 2, Vitro Engineering Corporation, Richland, Washington.

H-2-70306, 1977, “Civil Leak Detection Drain and Sump Plans and Details,” Rev. 2, Vitro Engineering Corporation, Richland, Washington.





RPP-RPT-56464, 2013, “241-AY-102 Leak Detection Pit Drain Line Inspection Report,” Rev. 0, Washington River Protection Solutions LLC, Richland, Washington.

TFC-ENG-STD-02, 2017, “Environmental/Seasonal Requirements for TOC Systems, Structures, and Components,” Rev. A-12, Washington River Protection Solutions LLC, Richland, Washington.

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