ML19262C553
| ML19262C553 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 02/07/1980 |
| From: | TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML19262C552 | List: |
| References | |
| PROC-800207, NUDOCS 8002140426 | |
| Download: ML19262C553 (18) | |
Text
{{#Wiki_filter:. SEQUOYAH NUCLEAR PLANT PROCESS CONTROL PROGRAM TENNESSEE V ALLEY AUTHORITY 80 0214 0 9 L E
4 1 ECOPAC SOLIDIFICATION SYSTEM PROCESS CONTROL PLAN e e I a 0 e-
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TABLE OF CONTENTS 1.0 PURPOSE 2.0 SYSTEM DESCRIPTION 2.1 Waste Loader System 2.2 Resin Catch Tank and Dewatering System 2.3 Acid Addition System 2.4 Liner Vent System 2.5 Controls and Instrumentation System 2.6 Electrical Control Panel 2.7 Mixing Manifold 3.0 SAMPLE COLLECTION AND ANALYSIS 3.1 Sample Procedure and Implementation 3.2 Collecting Samples 3.3 Sample Analysis 4.0 TEST SOLIDIFICATION AND ACCEPTANCE CRITERIA
, 4.1 General Solidification Considerations 4.2 Test Solidification 4.3 Solidification Acceptability 0
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e 1.0 Purpose The purpose of the Process Control Progrdm is to provide reasonable assurance of the complete solidification of - processed wastes and of the absence of free standing water,of the processed waste within the limits as set forth in Federal quidelines. The Process Control Program consists of the processing steps and established process parameters which include but are not limited to pH, oil content, ratio of solidifica_ tion agent to effluent waste,, water content, and ratio of solidification agent to chemical additive for each type of anticipated ~warte. O 4 e 0 1 e SNEFCC 0 g, I' 1 , ,
2.0 SYSTEM DESCRIPTION The ECOPAC solidification system receives radioactive wastds (filter sludges, spent resins, evaporator bottoms, - boric acid solutions, sodium sulfate solutions, and filter media) , and incorporates the radioactive waste with A-SET - solidification agent and acid catalyst. The ECOPAC solidification system consists of storage and feed provisions for the A-SET solidification agent and acid catalyst, and a self contained trailer mounted process system to feed radioactive waste into the disposal liner, together with controlled proportions of A-SET solidifiction agent and acid catalyst. The liner to be filled is normally positioned with-in its shielded transportation cask on a trailer to minimize handling and associated radiation exposure to operating personnel. The A-SET solidification agent is supplied in a large volume (3000 gallon) tank for on-site bulk storage. The A-SET storage system also includes the pump, and piping and electrical interconnects to facilitate metered flow of A-SET solidification agent into the ECOPAC solidification system. Similar storage and feed provisions are made for the acid catalyst which is supplied in 30 gallon en; boys, The following discussion describes t1e operation of
.the trailer mounted ECOPAC solidification system.
2.1 Control and Instrumentation System Figure 2.1 depicts'the system control schematic. Operation can only be initiated by autho'rized personnel with a key to activate the. power switch. Aut3matic system shut-down, or manual shutdown by the operator are initiated in case
- of malfunction or unsafe operating conditions usin, instru-mentation and alarms that are provided.
Filling can only proceed with a liner in place with proper connection to feed lines (waste toader) . Activation of the START FILL SWITCH automatically i) pens the normally closed waste valve. Waste flow rate is monitored (totalized and recorded) by the ratio controllers to control flow of A-SET solidification agent and acid catalyst in the proper proportion to be comensurate with the waste flow rate. The filling operation causes annunciation at the first set level and then will be automatically terminated at the high level set point (level indicator positioned within liner top access port) .- The operator can manually terminate operation at any point.
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Manual flushing of the waste line is initiated by the operator. Pressurized air will be used at the end of the A-SET and acid catalyst pipes to return those liquids to their respective storage tanks. All process piping at the end of the liner filling and . flush operation will be empty. Instrumentation for the ECOPAC solidification system includes the fo?. lowing items as discussed in the subsequent presentation. A. CCTV (Closed Circuit Television) B. 5 channel radiation area rate meter and recorder C. Ultrasonic flow meters, totalizer and recorders for waste and A-SET D. Cootrollers for A-SET and acid catalyst flow rate E. Liner liquid level controller F. Position switch for piping attachments to liner 2.2 Resin Catch Tank and Dewatering System A resin catch tank will be used as requested to receive the resin slurry which is pumped to the ECOPAC solidification system. A dewatering filter will remove the excess water (used to transport the resin storage tank to the ECOPAC solidification system) . Therefore, essentially a maximization of rcsin versus water will be solidified rather than the
. large bulk of associate water which is only mildly radio-active and water will be returned for subsequent slurry operations between the resin storage tank and the ECOPAC solidification system.
2.3 Mixing Manifold The radioactive waste, either directly from the SNP feed to the ECOPAC solidification system or from the recin catch tank, is fed into a pump / mixer along with a separate feed of A-SET solidification agent. The pump / mixer is a positive displacement device with internal helical screw rotor and matching stator to continuously mix the radioactive waste and A-SET solidification agent, and pump the resulting intimate mixture into the waste loader system for liner filling.
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2.4 Waste Loader System Transfer of the radioactive waste /A-SET mixture from the ECOPAC solidification system trailer to the liner is through the waste loader arm-see Figure 2.2. The waste loader - (pantograph) arm is a counterbalanced swivel jointed pipe assembly which is mounted atop the ECOPAC solidification system trailer. Connection can be made to a liner which is positioned from 72 to 92 inches from the ECOPAC solidification system trailer. , A dry-disconnect type coupling (female end) is attached to the end of the waste loader arm. As depicted in Figure 2.3, the dry-disconnect coupler is attached to adapter (male) which functions as the liner fillport. The cam arms lock the com-ponents together and the lever opens the internal valve to permit filling of the liner when flow is initiated. 2.5 Acid Addition System Acid catalyst flow into the liner is through a 3/8" stainless steel hydraulic quick connect coupling. As for the radioactive waste /A-SET loader system, the acid catalyst quick connect is leak proof with an automatic internal ball-valve shutoff. The acid catalyst flow rate is proportional to the radioactive waste flow rate which is monitored by an ultra-sonic flow sensor mounted outside a section of the waste line . The waste flow rate signal is used by a process Controller to maintain acid catalyst flow at the desired rate. 2,6 Liner and Vent System The attached ECOPAC solidification system liner diagram, Figure 2.4, illustrates the arrangement of the liner within its shipping cask with connections and instrumentation in place. The acid catalyst connection within the liner is terminated with a spray nozzle with a wide fan spray pattern for even distribution of the acid catalyst. The liquid level probe is attacned to the waste loader pipe as is the limit switch which interlocks the liner filling operation. A separate feed of A-SET foam may be introduced after the liner has been filled and solidification has progressed to completion. This introduction of A-SET foam serves to wick f~lNEFCC
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the trace quantity of water that may remain for certain radioactive wastes. 2.7 Electrical Control Panel The electrical control panel is located in a shielded location within the ECOPAC solidification system trailer. Electrical service to be supplied to the control panel are 230 Volt, three phase, 30 amp service, and 110V, 30 amp service . Circuit breakers motor control, and ground fault , interrupters (110V only) are incorporated in the electrical control panel. The electrical control panel provides both monitoring and process control functions . The monitors displayed on the electrical control panel are CCTV, Radiation Area Monitors , waste and A-SET flow rate (which are totalized and recorded), and acid catalyst flow rate . Visible and audible annunciation are provided. Indicator lights for each system are Green when powered and operating, and Red when electrical power is absent, or the system is malfunctioning or in an unsafe condition. Systems which are monitored are: A. liner fill connection limit switches D. mixer, acid puap and A-SET power C. acid catalyst and A-SET flow rate controllers D. level indicator E. waste, A-SET and acid catalyst flow meters F. remote area monitors (RAM) G. CCTV A key switch is 'used to limit operation only to authorized
. personnel which have the proper key, Rapid termination of any phase of operation is always available to the operator by depressing the Emergency Shutdown switch. This switch leaves the system in a safe shutdown configuration.
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3.0 SAMPLE C,OLLECTION AND ANALYSIS 3.1 Sample Procedure-and Implementation 3.1.1 This section and Section 4 of the Process Control Program establishes the program of sampling, analysis, test solidification, . and evaluation which is necessary to insure complete solidification of each type of wet . radioactive waste. 3.1.2 Verify the solidification of at least one representative test sample from at least every tenth batch of each type of wet
- radioactive waste (filter sludges, spent resins, evaporator bottoms, boric acid solutions, sodium sulf a te solutions, and filter media).
3.1.3 Datch is defined as the amount of waste that can be salidified in a single liner. There will be two (2) methods of sampling the waste:
- 1. For a continuous single transfer, a sample will be obtained from valve V-6,
- 2. For a nultiple transfer to the resin catch tank, samples will be obtained from valve V-7 and a composite sample prepared.
3.1.3.1 Vendor shall not commence processing waste from the catch tank until the plant has stopped the transfer of waste to the catch tank and until one volume of waste which is to be solidified in a liner is obtained. 3.1.4 If any test sample fails to solidify, the batch in the resin catch tank should not be solidified until a neu test sample can be obtained from valve V-7, alternative solidification parameters can be determined, and a subsequent test verifies solidification. Solidification of the batch may then be resumed using the alternative solidification parameters determined. 3.1.5 If the initial test sample from a batch of waste fails to verify solidification, a sample vill be collected from either valve V-6 or V-7 and analyzed in accordance with the Process Control Program from each con-secutive batch of the same type of wet waste until at least three (3) consecutive Aftertest samples demonstrate solidification. verification of solidification by the preceding, return to the "every tenth batch" criteria. l- . tNEF:CO -
3.0 SA"PLE COLLECTION AND ANALYSIS (CONTD) 3.2 collecting Samples 3.2.1 Radiological Pricautions
- 1. All samples must be handled with proper radiological considerations to meet with
- ALARA and to prevent the spread of contamination.
- 2. Appropriate Protective Clothing shall be worn while collecting, handling, and testing all samples. .
. 3. A clean zone and controlled access zone shall be set up to prevent the spread of contamination.
- 4. Any other requirements set forth by the Health Physics Staff must be complied with.
- 5. A record of volume and description of the sample will be maintained on the PCP data sheet.
3.2.2 TVA Form SON: -PCP
- 1. The contractor and TVA shall use TVA Foru SONP-PCP to record data from each test sample and will maintain the original copy in the plant file. A copy of TVA Form SQNP-PCP will be maintained for each of the types of wet radioactive waste.
- 2. *The following information is required on each test sample:
- 1. pH of waste
- 2. Faste oil content
- 3. Waste /UF ratio
- 4. UF/ Acid ratio
- 3. The following information will be required for each solidification batch.
- 1. Waste type
- 2. Flow rate
- 3. Total waste received
- 4. Total UF added
- 5. Total catalyst added
- 6. Batch nunber
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3,O SAMPLE COLLECTIOh AND ANALYSIS (CONTD) Obtaining Test Samples (Contd) 3.2 3.2.2 TVA Form SOMP-PCP (Contd)
- 4. The batch number will range from 1 through 10 and on each tenth batch of each type.of-wet radioactive waste, a new set of process parameters be determined. This practice .
will be followed for each type of wet radioactive waste. 3.2.3 Sampling Continuous Transfers of Waste
- 1. Evaporator bottoms or other high tempeYature
- samples should be collected in stainless steel thermos bott1cs.
- 2. Resins and other sludges should be collected in wide mouth bottles or other such con-tainers from which the sample may be readily removed.
- 3. In the cases of resins or other waste in which large volumes of flush water are involved, several consecutive sampics may-have to be taken and the flush water decanted from the sample before a sufficient quantity of sample is obtained.
- 4. Sample volumes should normally be 3 liter, however, if radiation levels nake this impractical, smaller samples may be obtained as appropriate.
- 5. Obtain the sample from either valve V-6 or
.V -7 af ter sufficient waste has been transfer-red to the contractors so that a representa-tive sample is in the transfer line. In any case, at least 1/5 of the anticipated folume of waste to be transferred should have been received prior to taking the 53 G. *-
3.2.4 Sampling Multiple Transfers of Maste Per Batch
- 1. The sampling techniques of 3.2.3 above are applicable.
- 2. Each sample of the partial batch will be placed in appropriate storage until the entire batch of waste has been transferred to the contractor.
- 3. For each partial transfer flow meter readings of the volume will be made and recorded on
, data sheet later.
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3.0 SAMPLE COL,LETION AND ANALYSIS (CONTD) 3.2 Obtaining Test Samples (Contd) 3.2.4 Sampling Multiple Transfers of Uaste Per Batch (con
- 4. Prepare a composite sample by determining
- the fraction of which each transfer contributed to the total batch. Using .
the total sample volume required, multiply each transfer fraction by this volume to give the volume of each sample which is to be added to the composited sample. 3.3 Sample Analysis 3.3.1 General Sample Analysis Considerations
- 1. Specific Techniques for chemistry analysis are included in appropriate TVA' Technical Instructions.
- 2. All analytical results are to be recorded on data sheet.
3.3.2 Each new shipment of UF and 30 days thereafter for UF and storage. a sample shall be analyzed for specific gravity and pH. Record manufac-
. turers lot numbers and production dates on data sheet.
3.3.3 Each container of catalyst prior to use shall be analyzed for specific gravity and color (visual) and the results recorded on data sheet. 3.3.4 Evaporator bottoms shall be analyzed for the following and the results recorded on data sheet.
- 1. pH
- 2. Specific gravity
- 3. Oil
- 4. Sulfates
- 5. Boron 3.3.5 Filter and other sludges shall be analyzed for oil and the results recorded on data sheet.
3.3.6 Resin beads will be characterized by analyzing the water surrounding the beads for oil, and pH. l flNEFCO
4.0 TEST SOLIDIFICATION AND ACCEPTANCE CRITERIA 4.1 General Soldification Considerations 4.1.1 The standard ratios of UF/ Waste which are to - be used on the first test solidification (un'. css other data shows dif ferent ratios shoold be used) are as follows: -
- 1. hasin beads or other waste with a high pc centage of solid material with a defined shape, use a ratio of 1:1.
- 2. Filter sludges, evaporator bottoms or other waste with a high percentag, of dissolved or suspended solids use a ratio of 1:2.
4.1.2 If the pH of any waste is less than two, a caustic shall be added to increase the pH to greater than three prior to the addition of the UF. Record the sample size and the amount of caustic added on data sheet. 4.1.3 If' foaming occurred in the waste sample, an antifoaming agent shall be added to the waste prior to the addition of the UF. Record the sample size and the amount of antifoaming agent added on data sheet. 4.1.4 If the oil analysis indicated oil concentrations greater than 1%, attempts to remove the oil should be initiated. 4.2 Test Solidification 4.2.1 The w'aste sample shall have the required pre-treatment accomplished prior to the test solidification. 4.2.2 Prepare the test solidification vessel (normally a 1000-ml disposable beaker) with a mixing devico. This may be a disposable magnetic stirrer, a mi.iiature air sparge system or other mechanical means of mixing the waste to UF. 4.2.3 Transfer a known representative volume of the waste to the test solidification container. ?. typical volume is normally 400-ml. 4.2.4 Add the appropriate amount of UF as determined by the applicable ratio. For example, 200-ml of UF would be added to 400-ml of evaporator bottoms.
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4.0 TEST SOLIDIFICATIOti AND ACCEPTAllCE CRITERIA (cot 1TD) 4.2 Test soldification (Contd) 4.2.5 Initiate mixing the waste and UF and after a - homogeneous mixture is obtained (normally allow ~ at least 10 minutes); Begin the catalyst addition until a pH of approximately 3 is obtained at which time discontinue the addition of the catalyst. 4.2.6 As soon as the mixture begins to solidify, stop mixing and allow the sample to remain undisturbed for at least 30 minutes. 4.2.7 If any free-liquid is noted on the top of the sample, decant the liquid, into a clean-disposable volumetric beaker and record the amount of liquid transferred. Calculate and record the percent of free-liquid present on data sheet. i.e. 6-ml of liquid was obtained from a 600-ml total volume, this would represent 1% free water. 4.2.8 Add a sufficient quantity of absorbent material to the liquid in the beaker to absorb all the liquid. Record the amount of absorbent added. Note and
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record if any liquid remains. Calculate the percent of free-liquid of the entire volume of soldified waste if any liquid was present and record the result on data sheet. 4.3 Solidification Acceptability 4.3.1 The sam'ple solidification will be considered
. acceptable if the amount of free-liquid following absorbent addition is less than 1% by volume.
4.3.2 The waste solidification will be considered acceptable from a solid mass standpoint, if it is evident from its physical appearance that the solidified waste would maintain its shape if moved from the container. 4.3.3 If one or more of the above tests fails to meet the stated criteria, additional solidification parameters must be determined. This will also require the initiation of the additional soldification testing requirements for the next three batch types of waste which fail to solidify. O}}