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Accession #: Dl95061594

Document #: SD-W058-MAR-001

TitlelDesc: MISSION ANALYSIS FOR CROSS SITE TRANSFER

Pages: 25

2. lo: ( R o # m l v i n g ~ n i z a t i o n ) 3. frm: (Originating Ormnimtion) West Tank Farms Transi t ion Project P1 ant Projects

W - 058lTrans i ti on S. D. R i esenweber ProjectsITWRS

The Mission Analysis Report describes the requirements and constraints associated w i th the cross s i t e Transfer Waste Function sup o r t i n g the Manage Tank Waste, Retr ieve Waste,

020, Tank Waste Remediation Systm (TWRS) Functions and Requirements Document and DOE-RL 92-60, Revision 1. TWRS Functions and Requirements Document, March 1994.

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Maintenance Programs and

5. Proi./Prog./Dm./Div.: 6. Cog. Engr.:

8. Origintor Rrarrks:

and Process 7 ank Waste Functions described i n WHC-SD-WM-FRD-

11. Rmiver R r r k s :

1 .m~ 606462 4. Related ED1 No.:

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7. Purchase Order No. : N/A

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Cross-Site Transfer system

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12. Hajor ALM. Dng. No.:

13. Pen i t lPemi t -tication Yo.:

14. Required RNpofue Date:

I I I I I I I I r e v

RELEASE AUTHORIZATION

I Document Number: WHC-SD-W058-MAR-001, Rev. 0

Document Title:

Release Date: 11/09/95

Mission Analysis f o r Cross-Site Transfer

This document was reviewed following the procedures described in WHC-CM-3-4 snd is:

APPROVED FOR PUBLIC RELEASE

I WHC Information Release Administration Specialist:

d , * 11/09/95 / Janis Bishop

TRADEMARK DISCLAIMER. Reference herein t o any spec i f i c comnercial product, process. o r service by t rade name, trademark, manufacturer, o r otherwise, does not necessari ly cons t i tu te o r imply i t s endorsement, recomendation. o r favor ing by the United States Government o r any agency thereof or i t s contractors o r subcontractors.

'

This report has been reproduced from the best avai lab le co y paper copy. Pr inted i n the United States o f America. To o l t a i n copies o f t h i s report , contact:

Westinghouse Hanford Com any P.O. Box 1970, Mailstop R6-08: Richland, WA 99352 Telephone: (509) 372-2420; Fax: (509) 376-4989

Avai lable i n

Document Control Services

A-6001-400.2 (09194) YEW56

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I SUPPORTING DOCUMENT 3. Y m r

WHC-SD-WO58-MAR-001

I 1. 1ot.l P.W 21

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Mission Analysis f o r Cross-Site Transfer

Mission Analysis, Cross-site t rans fer , Transfer Waste Function, Functions and Requirements Document

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OramintiWCharpe Cod. 77680/N58MB

The Mission Analysis Report describes the requirements and constraints associated w i th the Transfer Waste Function as necessary t o support the Manage Tank Waste, Retr ieve Waste, and Process Tank Waste Functions described i n WHC-SD-WM-FRD-020, Tank Waste Remediation System (TWRS) Functions and Requirements Document and DOE-RL 92-60. Revision 1, TWRS Functions and Requirements Document. March 1994. It fur ther assesses the a b i l i t y o f t he " i n i t i a l s ta te" (or current cross-s i te t rans fer system) t o meet the requirements and constraints.

8 . RELEASE STAMP

MISSION ANALYSIS FOR CROSS-SITE WASTE TRANSFERS

Prepared f o r

Westinghouse Hanford Company Project W - 058

Replacement o f Cross-Site Transfer System WHC-SO-W058-MAR-001. Rev. 0

November 7 . 1995

Prepared by

Robert L. F r i t z Larry E. Shipley ARES Corporation

WHC-SD-W058-M4R-0011 Rev . 0

MISSION ANALYSIS FOR CROSS . SITE WASTE TRANSFERS

Jable of ContenQ

1.0 INTRDDUCTION/PURPOSE

2.0 BACKGROUND . . . .

1

. . 1

3.0 MISSION AN0 NEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.1 Mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.2 Problem Statement . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2.1 Manage Tank Waste . . . . . . . . . . . . . . . . . . . . . . 3 3.2.2 Retrieve Tank Waste . . . . . . . . . . . . . . . . . . . . . 4 3.2.3 Process Tank Waste . . . . . . . . . . . . . . . . . . . . . 4

3 .3 Boundaries and Interfaces . . . . . . . . . . . . . . . . . . . . . 4 3.4 I n i t i a l State 6 . . . . . . . . . . . . . . . . . . . . . . .

4.0 ACCEPTABLE SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . 7 4 .1 Acceptable End State 7 4.2 Constraints and Requirements . . . . . . . . . . . . . . . . . . . 7

4.2.1 TWRS Operational Constraints 7 8

4.2.2.1 SST S tab i l i za t i on . . . . . . . . . . . . . . . 9 OST Retrieval . . . . . . . . . . . . . . . . . 9 4.2.2.2

4.2.2.3 Phase 1 Retrieval (SST SolidsISludge Retrieval t o 200 East Storage) . . . . . . . . . . . . . . . . . 10

4.2.2.4 Phase 2 Retrieval (SST Solids/Sludge Retrieval t o Waste Processing i n 200 East) . . . . . . . . . 10

4.2.2.5 Pretreatment Out Flow . . . . . . . . . . . . . 11 4.2.2.6 New WastelSystem Generated Waste . . . . . . . . 11

12 4.2.3.1 The T r i -Party Agreement (TPA) . . . . . . . . . 12 4.2.3.2 Washington Administrative Code (WAC 173-303-640)

Dangerous Waste Regulations . . . . . . . . . . 13 4.2 .. 3.3 DOE Orders . . . . . . . . . . . . . . . . . . . 14

4.2.4 Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3 Life-Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.0 SUFlMARY . . 16

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . 4.2.2 Primary Constraints and Requirements From Systems Engineering

. . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 External

. . . . . . . . . . . .

6.0 REFERENCES 16

i

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WHC-SD-W058-MAR-001, Rev. 0

confirmed as leaking by the year i n which they were i den t i f i ed . One o f the a c t i v i t i e s tha t i s current ly ongoing w i th in the TWRS i s the i n te r im s tab i l i za t i on program under which the l i q u i d waste stored i n the SSTs i s reroved from the tanks (thereby s ign i f i can t l y reducing the l i ke l i hood o f a leak). and transferred t o DSTs. There are 28 DSTs located i n the 200 Area. w i th only three o f the 28 located i n 200 West Area. O f those three, only one current ly has avai lable storage capacity and tha t tank (Tank 102-SY) i s planned t o be used as a staging tank f o r a l l near term t ransfer purposes. Since the SST waste must be transferred t o DSTs i n accordance w i th Tr i -Par ty Agreement (TPA) milestones. the major i ty o f the l i q u i d waste i n the SSTs i n the 200 West Area must be transferred t o DSTs i n the 200 East Area, located s i x miles t o the east, f o r treatment and imnobi l izat ion. The s o l i d waste contained w i th in the SSTs i s planned t o be r o b i l i z e d i n t o a s lu r r y and 200 West Area wastes are t o be transferred t o the 200 East Area f o r eventual processing and disposal. The t ransfer funct ion i s a v i t a l step t h a t bridges the gap between waste stored or generated i n the 200 West Area and the storage, treatment, and imnobi l izat ion functions tha t w i l l take place i n the 200 East Area.

An ex is t ing underground p ipe l ine [ex is t ing cross-s i te t ransfer system (ECSTS)] has been used t o t ransfer l i q u i d wastes from 200 West t o 200 East Area f o r the past 40 years. The ECSTS i s a t (or beyond) the end o f i t s o r i g ina l design l i f e , and four out o f the s i x l i n e s are out o f service and unavailable t o perform t h i s funct ion due t o p r i o r leaks and/or plugging tha t block the l i nes . The two remaining unplugged l i nes do not meet the current regulatory requirements f o r waste t rans fer . The Washington State Department o f Ecology (Ecology) i s allowing continued use o f the ECSTS contingent upon a demonstrated program toward a replacement system. I n addi t ion, the p ip ing was not designed t o operate w i th in the parameters expected t o be required f o r s lu r r y t ransfers a t the current ly ant ic ipated d i l u t i o n ra t ios . Any replacement system f o r the ECSTS must be designed and constructed i n f u l l compliance w i th the current regulatory requirements and provide a f u l l range o f functions tha t would support l i q u i d and s lu r r y t ransfers .

R a i l tanker cars and t r a i l e r tanker t rucks have been used successfully i n the past a t the Hanford S i t e t o t ransfer low-level waste cross s i t e . The ex i s t i ng surface vehic le and loadinglunloading f a c i l i t i e s do not meet current regulatory requirements. Any use o f a surface transportat ion method t o perform the t ransfer function w i l l require additional loading/unloading f a c i l i t i e s and vehicles tha t would have t o be designed and constructed i n order t o comply w i th current regulatory requirements f o r the t ransfer o f h igh- level waste. Further, surface t ransfer methods could not support the a b i l i t y t o t ransfer the volumes necessary t o make an emergency t ransfer i n the event o f a DST leak i n the SY Farm (Staging Tanks).

U.S. Department o f Energy, Richland Operations Of f i ce (DOE-RL) document DOE-RL 92- 60. Revision 1. WRS Functions and Requirement Document. March 1994 (Ref 2) provides upper-level requirements associated w i th current operations and fu tu re TWRS a c t i v i t i e s . A current rev is ion i s being developed (proposed document number i s WHC-

WHC-SO-W058-MAR-001, Rev. 0

SD-WM-FRO-020. but t h i s document has not been completed and has not received DOE-RL approval) t ha t w i l l provide addi t ional information for the mission analysis since the Transfer Function and Requirements are developed more f u l l y . The requirements o f both the current F&RDs and the d r a f t rev is ion w i l l be re fer red t o w i th in t h i s analysis .

3.0 MISSION AND N E D

3.1 Mission

Provide a safe, re l i ab le . cost -ef fect ive system f o r the t ransfer o f h igh- level radioactivehnixed waste ( l i q u i d and s lu r r y ) from the 200 West Area t o the 200 East Area i n support o f the appropriate Manage, Retrieve, and Process Waste Functions defined i n the document WHC-SO-WM-FRO-020, TWRS Functions and Requirements. This system shal l be compliant w i th environmental, regulatory, and U.S. Department o f Energy (DOE) requirements. and w i l l be capable o f supporting the current and fu ture TWRS a c t i v i t i e s .

3.2 Problem Statement

There i s current ly no method o f t rans fer r ing high- level radioact ive and mixed-tank waste from the 200 West Area t o the 200 East Area which i s compliant w i th the safety and regulatory requirements and which meets the current ly i d e n t i f i e d and fu tu re mission and operational constraints. The current system (ECSTS) i s non-compliant and has exceeded i t s o r i g ina l design l i f e . i s unrel iable, i s not supportive o f fu tu re mission needs. and has been found t o be very labor intensive t o operate. Figure 1 depicts the types and volumes of waste requi r ing t rans fer , the program these transfers support. and the t iming f o r these t ransfers .

The requirements o f each major element o f the TWRS program formed the basis f o r the problem statement. These requirements are sumnarized below.

3.2.1 Manage Tank Waste

The Manage Tank Function requires safe. re l i ab le , cost -ef fect ive, and compliant capab i l i t y t o transfer l i q u i d and s lu r r y wastes c ross-s i te between now and the year 2028. Up u n t i l the year 2005. the predominance o f waste t ransfers associated w i th t h i s funct ion w i l l be l i q u i d from the SST s tab i l i za t i on process. After the year 2005. the newly generated wastes from the Plutonium Finishing Plant (PFP). T-plant. and the 222-S Labs w i l l produce the major i ty o f 1 iquids requi r ing cross-si t e t rans fer .

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WHC-SD-W058-MR-001, Rev. 0

3.4 I n i t i a l State

For purposes of the Mission Analysis, the i n i t i a l s ta te was defined i n terms o f the a b i l i t y o f the ex is t ing s i t e in f rast ructure t o f u l f i l l the current, short-term and long-term requirements o f the Transfer Function, including compliance w i th safety and regulatory requirements. Short term shal l be defined as 1995-2005 and long term as 2005-2028.

The ECSTS consists o f s i x , three-inch, schedule 10s pipes contained i n a reinforced concrete encasement. This encasement i s i n the form o f a channel shaped lower por t ion tha t contains a l l s i x l i nes s i tuated adjacent t o each other i n a hor izontal plane. A concrete cap covers the top o f the encasement and a caulking material i s used between cap pieces t o seal the encasement from moisture in t rus ion. The concrete i s coated w i th a minimum o f four coats o f a moisture proofing mater ia l . The piping i s not heat traced, insulated, o r coated.

One o f the ex is t ing pipes was pressure tested i n the spring o f 1995 and subsequently used f o r a t ransfer of 430,000 gallons of l i q u i d waste from 200 West t o 200 East Area. The status o f the second avai lable ECSTS pipe i s not known a t t h i s time. A pressure t e s t i s scheduled f o r the spr ing o f 1996. It has been the past pract ice t o perform a pressure t e s t t o v e r i f y p ip ing i n t e g r i t y p r i o r t o each t ransfer . I n one recent t e s t , it took over one year t o plan. obtain the appropriate approvals. assemble the inspectors/viewers, conduct the tes t . and submit the reports necessary t o accomplish the recent t ransfers . An analysis o f the ECSTS from a r e l i a b i l i t y perspective was performed (G. A. Coles. 1995-Risk and R e l i a b i l i t y Information About the Cross-Si t e Transfer System-GAC-8M400-95-002). This analysis concluded tha t even w i th the second 1 i ne pressure tested and avai 1 ab1 e. a re1 i abi 1 i ty o f only approximately 16 percent over the next ten-year period could be expected.

The ECSTS has leak detection capab i l i t y a t the end points o f the s ix-mi le p ipe l ine and depends on a leve l a l a r m f o r the leak detection funct ion. This alarm system does not meet current Washington State o r DOE requirements. There i s no secondary containment i n the current regulatory sense and there i s no method t o t e s t the i n t e g r i t y o f the concrete conduit. Thus. under the current s ta te, leaks t o the environment could occur and go undetected f o r the period o f time it took the waste t o reach the leak detectors or u n t i l the mass balancing procedure u t i l i z e d during t ransfers t o monitor waste flow could detect a loss of mater ia l . This condi t ion i s unacceptable t o regulatory requirements for extended operations. Ecology i s allowing the use o f the ECSTS u n t i l the Replacement CSTS (RCSTS) ' i s avai lable i n 1998. provided continued progress i s made toward t h i s end.

Railroad cars o r container trucks have been used t o t ransport the waste a t the Hanford S i t e i n the past. Surface transportat ion vehicles must comply w i th the U.S. Department o f Transportation (DOT) standards o r WHC requirements. There i s current ly no compliant vehic le for the t ransport of h igh- level waste avai lable.

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WHC-SO-W058-MAR-001, Rev. 0

Surface transport would require a loading f a c i l i t y i n 200 West Area tha t complies w i th appropriate regulat ions. Also. addi t ional underground t ransfer p ip ing from Tank 102-SY t o the s ta t ion would be required. The unloading s ta t ion i n the 200 East Area (204 AR Vault) i s not designed f o r receipt o f s lu r r y wastes. The DOT qua l i f i ed ra i l road tankers are not shielded and ALARA considerations may cause problems f o r t h i s method o f surface transfer when high- level waste i s being moved.

Container trucks hold 1.000 gallons o f waste whi le the non-shiel ded r a i 1 road cars hold a nominal 20.000 gal lons. High-level waste w i l l s i gn i f i can t l y reduce the amount of waste tha t can be carr ied a t any one time by r a i l cars due t o exposure considerations. Unloading the tanker cars has required a t h ree -sh i f t e f f o r t i n the past. The loadinghnloading connection and disconnection current ly requires a hands-on operation. thus, increasing worker exposure. The capab i l i t y o f the tanks on surface vehicles t o contain the gas generated by the waste whi le i n t r a n s i t requires invest igat ion. I

The i n i t i a l s ta te provides a non-compliant system o f low r e l i a b i l i t y which does not support a l l near-term needs and i s unacceptable f o r long-term mission support.

4.0 ACCEPTABLE SYSTEM DESCRIPTION

4 .1 Acceptable End State

The acceptable end s tate must provide a t ransfer system which i s re l i ab le , cost e f fec t i ve t o design. construct. and operate. compliant w i t h safety and environmental c r i t e r i a , and which supports the t ransfer o f high-level radioact ive waste i n l i q u i d and s lu r r y form from 200 West t o 200 East Area f o r the durat ion o f the TWRS mission. The method(s1 o f t ransfer must meet the Manage, Retrieve, and Process Tank Waste requirements from the present t o 2028 (when f i n a l closure a c t i v i t i e s are scheduled t o be completed).

4.2 Constraints and Requirements

4.2.1 TWRS Operational Constraints

The needs o f the customers were i d e n t i f i e d through interviews w i th ind iv iduals representing: Operations Management (East and West), Waste Volume Projections, Environmental Compliance. Waste Retr ieva l , Programs, Operations Engineering, and Retrieval Projects Management. and through document review. The major needs iden t i f i ed during those interviews are sumnarized below, and f o r purposes o f Mission Analysis, are considered t o be constraints.

I - _ _

WHC-SD-WO58-MAR-ODl. Rev. 0

This funct ion does no t include the removal o f previously re t r ieved waste from t h e DSTs (see the Store In-Process Waste funct ion). This funct ion also includes treatment/preparation o f l i q u i d , gaseous and s o l i d waste generated during re t r i eva l o f tank wastes. ”

Both documents are referenced here t o allow the t ransfer waste requirements t o be traceable t o the current TWRS documentation, and t o i d e n t i f y where these same requirements w i l l reside upon approval o f the proposed revis ions.

Beginning i n 1998. the so l ids and sludge i n Tank 102-SY w i l l be mobil ized i n t o a s lu r r y and removed and transferred t o the 200 East Area. The means t o a f f e c t t h i s t ransfer must be provided. since the ex is t ing system does not have the capabi 1 i t y . The DST waste i n Tanks 101 SY and 103 SY w i l l be removed and transferred t o the 200 East Area beginning i n 2003 (Ref 4).

4.2.2.3 Phase 1 Retr ieva l (SST Solids/Sludge Retr ieval t o 200 East Storage)

The Retrieve Tank Waste funct ion i n the current TWRS F&R states that :

“ R m v e tank waste fm S T , DSTs and m i sce l l aneous tanks, and remove the cesium and strontium capsules from storage f o r t ransfer t o other f a c i l i t i e s . Wastes t o be removed from the tanks include l i q u i d , s a l t cake, sludges, s lu r r ies , and so l ids (e.g., f a i l e d equipment, concrete. rocks, lead br icks. samarium ba l l s , and cobal t s lugs). Solids w i l l be reroved only t o the extent necessary t o prevent interference w i th the re t r i eva l o f the wastes or as required t o al low completion o f closure a c t i v i t i e s . ”

Phase 1 o f the SST s o l i d waste re t r i eva l w i l l begin i n 2002 and end i n approximately 2005 and w i l l requi re tha t the capab i l i t y t o perform a s l u r r y waste t ransfer through qua l i f i ed system from 200 West t o 200 East Area be avai 1 ab1 e.

4.2.2.4 Phase 2 Retr ieva l (SST Solids/Sludge Retr ieval to Waste Processing i n 200 East)

The Retrieve Tank Waste function i n the current TWRS F&RDs states t h a t :

“Rcraove tank waste fm S T , DSTs and m i scel 1 aneous tanks, and remove the cesium and strontium capsules from storage

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WHC-SD-W058-MAR-001, Rev. 0

Provided w i th a leak detect ion system tha t i s designed and operated so tha t i t w i l l detect the f a i l u r e o f e i ther the primary o r secondary containment s t ructure o r the presence o f any release o f dangerous waste o r accumulated l i q u i d i n the secondary containment system w i t h twenty-four hours, o r a t the e a r l i e s t pract icable t i m e . . .

Sloped or otherwise designed or operated t o dra in and remove l i qu ids resu l t ing from leaks, s p i l l s , o r p rec ip i ta t ion . Sp i l led or leaked waste and accumulated prec ip i ta t ion must be removed from the secondary containment w i th in twenty-four hours, o r i n as t imely manner as i s possible t o prevent harm t o human heal th and the environment, . . . ”

4.2.3.3 DOE Orders

The DOE Orders provide spec i f i c requirements regarding dangerous wastes. DOE Order 5820.2A. Radioactive Waste Managmnt requires:

“ A l l new high- level waste handling, t ransfer , and storage f a c i l i t i e s (e.g., tanks. b ins. p ipel ines. and capsules) shal l be doubly contained.

Secondary containment systems shal l be capable o f containing l i qu ids tha t leak i n t o them from the primary system and shal l be equipped w i th t rans fer capab i l i t y t o re t r ieve the leaked l i q u i d .

Leak detection systems shal l be designed and operated so tha t they w i l l detect the f a i l u r e o f the primary containment boundary, the occurrence o f waste release, o r accumulated l i q u i d i n the secondary containment system.

Singly contained p ipe l ines may be used rou t ine ly f o r l i q u i d waste tha t has a t o t a l radioact ive concentration o f less tha t 0.05Ci/gal. They may be used on a temporary basis f o r higher a c t i v i t y waste i f appropriate design and administrative controls are i n place t o mi t iga te adverse e f fec ts from a p ipe l ine f a i l u r e .

For emergency s i tua t ions invo lv ing l i q u i d high leve l waste, spare capacity w i th adequate heat d iss ipat ion capab i l i t y shal l be maintained t o receive the largest volume o f l i q u i d contained i n any one tank. Adequate t ransfer pipel ines also shal l be maintained i n operational condition. Interconnected tank fa rms w i th adequate t rans fer capab i l i t ies and spare capacity may be

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5.0 SumARY

The major r i sks are associated w i th lack o f action. The current condi t ion i s unacceptable f o r long-term e f fo r t s , and increases health. environmental, and programnatic r i sks due t o the lack o f r e l i a b i l i t y and compliance.

This Mission Analysis determines tha t a safe. re l i ab le , compliant t ransfer system i s required t o support the TWRS Mission. This system must be capable o f supporting l i q u i d and s lu r r y transfers from the 200 West t o the 200 East areas from 1998 u n t i l the f i n a l closure and D&D of a l l tanks and f a c i l i t i e s located i n the 200 West Area.

The operational constraints and functional requirements necessary t o accomplish t h i s e f f o r t are well defined a t the upper l eve l .

6.0 REFERENCES

1.) Report, Hanlon. June 30. 1995.

Westinghouse Hanford Company (WHC) document WHC-EP-0182-87, Waste Tank Sumnary

2.) U.S. Department of Energy (DOE) document DOE-RL 92-60. Revision 1, TWRS Functjons and Requirements Document. March 1994.

3 . ) Remediation System ITWRS) Functions and Requirements Document. DRAFT.

Westinghouse Hanford Company (WHC) document WHC-SD-WM-FRD-020, Tank Waste

3 . ) Operational Waste Volume Project ion.

Westinghouse Hanford Company (WHC) document WHC-SR-WM-ER-029, Rev. 21.

WHC-SD-W058-MAR-001. Rev. 0

APPENDIX 1 WASTE VOLUME I N 200 WEST SST

200 West SST Tank Farms

T TY TX U S sx

2022 638

7009 3550 5510 4425

23154 (Kgal) Tota l West Area Waste

200 East SST Tank Farms

BY B BX c AX A

4680 2057 1501 2122 906

1537 12803 (Kgal) To ta l East Area

I 35957 (Kgal) Tota l SST Waste 1 64 .39% o f To ta l SST Waste i n West

Area Farms

Reference: Westi nghouse Hanford Company. WHC-EP-0182-87, Waste Tank Sumary Report, Hanlon. June 30. 1995

17

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WHC-SD-W058-MAR-001, Rev. 0

APPENDIX 2

NUMBER OF LEAKING SST BY YEAR

I * 2

0 1955 1960 1965 1970 1975 1980 1985 1990

Year

Reference: Westinghouse Hanford Company, WHC-EP-0182-87. Waste Tank Sumry Report. Hanlon. June 30, 1995. Table E. " Inventory and Status."

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