ML19353A425
| ML19353A425 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 12/15/1980 |
| From: | ALABAMA POWER CO. |
| To: | |
| Shared Package | |
| ML19353A424 | List: |
| References | |
| FNP--RCP-800, FNP-0-RCP-800, NUDOCS 8101090030 | |
| Download: ML19353A425 (30) | |
Text
.
O FNP-0-RCP-800 December 15, 1980 Revision 0 FARLEY NUCLEAR PLANT RADIATION CONTROL AND PROTECTION PROCEDURE FNP-0-RCP-800 MOBILE CEMENT SOLIDIFICATION OPERATION (HITTMAN)
Approved:
[ [?> Y C&FP Supervisor Date Issued: / ~. '2.0 - ? O List of Effective Page Page Rv. #
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FNP-0-RCP-800 TABLE OF CONTENTS 1.0 Scope 1.1 Applicability 2.0 References I
3.0 System Description
3.1 Waste Transfer System 3.2 Resin Transfer and Dewatering System 3.3 Vent 3.4 Electrical Control Panel 3.5 Fill head assembly 4.0 System Requirements and Precautions 5.0 Operating procedure 5.1 Initial Conditions 5.2 System Preoperational Checks 5.3 Radioacti e Liquid Waste Transfer and Disposable Liner Filling 5.4 Solidification 5.5 Post Solidification 5.6 Cask Closure and Shipment 5.7 Hydrostatic Test Procedure
FNP-0-RCP-800 MOBILE CEMENT SOLIDIFICATICN OPERATION (HITTMAN) l 1
1.0 Scone This document provides a detailed system description. !
The description explains the function and purpose of each system, major compoents of the system, and operating ,
instructions. These are necessary for the safe operation !
of Hittman Nuclear and Development Corporation (HNDC's)
Field Services in-container cement solidification unit. The instructions contained in this manual are to be used to operate HNDC's field unit at the Farley Nuclear Plant. These instructions are to be strictly adhered to at all times. Appendix A of this procedure constitutes the Farley Nuclear Plant Process Control Program as required by Farley Standard Technical Specifications.
2.0 References 2.1 American National Standard Quality Assurance Program Requirements for Nuclear Power Plants -
N45.2-1971.
2.2 American National Standard Administrative Controls and Quality Assurance for the operational phase of Nuclear Power Plants - N187-1976 2.3 Code of Federal Regulations Title 49 2.4 NUREG 0472, Model Radiological Effluent Technical Specifications for PWR's 2.5 NUREG 0133, Preparation of Radiological Effluent Technical Specificaions for Nuclear Power Plants.
2.6 ANSI N199, Liquid Radioactive Waste Processing Systems for Pressurized Water Reactor Plants 2.7 ANSI N197 and N198, Liquid Radioactive Waste Processing Systems for Boiling Water Reactors and Pressurized Water Reactor Plants 2.8 Hittman Nuclear and Development Corporation's Field Services Solidification Procedures for Resin and Liquid Waste -1980 2.9 Hittman Nuclear and Development Corporations Process Control Program in-container Solificiation for Bed Resin 1 Rev. 0 9
FNP-0-RCP-800 3.0 System-Description The Hittman Nuclear and Development Corporation's Field Services in-container cement solidification process utilizes cement with additives to chemically combine with a broad range of liquid radioactive wastes to produce a solid free-standing monolithic mass.
The solidification medium (cement and additive) is transferred from a hopper through a power driven Flexicon mechanical conveyor and is mixed with the radioactive liquids through a drive and fill flange assembly. The radioactive liquid waste and cement with additives are introduced into the ENDC in-container
- solidification liner which is supplied with internal mixing devices to provide thorough mixing of the entire liner contents. A mixing motor mounted on top of the liner continues mixing the entire contents until the medium is solidified.
The solidification unit is a portable unit designed to normally be set up on a scaffolding arrangement. The unit consists of but is not necessarily limited to a hopper assembly, a flexicon mechanical conveyor, a drive and fill-flange assembly, an in-container solidificatio:
liner with internal mixing device, a vent air filter subsystem, a control panel, and associated lines, valves, cables etc.
3.1 Waste Transfer System 3.1.1 The major component of the Waste Transfer System is the ENDC flexible hose which acts as a transfer path for the waste.
The APCO Waste manifold and associated valves and the ENDC stainless steel waste fill head complete the unit.
3.1.2 The hose connects FNP's boundary discharge valve to HNDC's drive and fill flange assembly.
3.2 Resin Transfer and Dewatering System 3.2.1 The major components of the resin transfer system are the stainless steel drive and fill flange or the alternate high level resin fill flange and the waste transfer hose.
2 Rev. 0
FNP-0-RCP-800 3.2.1.1 The inlet pipe allows resin and flush water to fill flange assembly.
3.2.1.2 For high level resin transfers where it is radiologically beneficial the drive and fill flange assembly can be replaced with a high level resin fill flange assembly.
3.2.2 The dewatering system consists of a dewatering line, pump, and waste transfer line.
3.2.2.1 The dewatering pump is an air driven, positive displacement pump. The pump is powered by the FNP's supply air. The pump's discharge pressure is directly proportional to the pressure of the supply air to the pump. By controlling the air pressure to the pump it will control the discharge pressure of the pump (Figure 2). The air supply pressure to the pump is controlled by a regulator which controls the pump's speed.
3.2.2.2 The dewatering fluid can be returned to one of two places; either A) to the plant via the waste manifolds or.b) when performing " secondary dewatering" l the liquid flows from the
( solidified liner to a pre-selected receipt liner.
I l
3.3 Vent Air Filter Subsystem 3.3.1 The fill head includes an elbow vent line which is hard piped to the j edge of the cask or liner where hoses j can be conntected to allow the air being
' vented from the cask to be conveyed to the vent air filter.
l l
l l 3 Rev.'O l
I FNP-0 RCP-800 3.4 Electrical Control Panel The electrical control sys m for the field unit is powered by 440 volt AC All motor functions are energized from this panel (Figure 5).
3.5 Fill Head Assembly 3.5.1 The fill head and drive assembly is mounted on top of the disposable liner and directs the drive unit as well as the flow of waste or resin and cement to t the liner.
l l The fill head also directs any dust i through the filterswhich are installed
( in the air vent subsystem.
3.5.2 The fill flange and drive unit assembly is fitted to act as a seal between the fill head and liner top.
3.5.3 The fill head is equipped with a waste inlet line, a dewatering line, a level alarm probe, a mixer drive assembly with drive motor, and a cement feed assembly with valve and drive motor.
4.0 Svstem Recuir,e,ments and Precautions 4.1 S.n changes to e '
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4.2 The ENDC W solidification system requires the I.fes dack. C1 m j/,fca.
j Jf following support services:
(ff// fn 4.2.1 Electrical Power: 70 ampp at 480 \/A6 g w,1 1 supplied from adh 600 Yolt load denterst a ce. ,r
. preaker ENO3 via transformer and receptacle
- M ' 8- 4 8- 7. /h'b : M wad. NSR186007).
b /W f I 4.2.2 Servi e Air; 25 SCFM at 90 + 20 psig (supplied from N1P18V011A or B).
e x . A ,.A . - % s any b e odyk~kd b Alto x noc. All suuL e%s ~:ll be reswed by s sk.i n <d i S y-<dw nd b HNbc fmjed Qew. (lea -gs JlI be ,Qk aded
& a ec.wdu w,b. MA4-4/-) .
4 Rev. O
FNP-0-RCP-800 4.2.3 Service Water (supplied from demineralized water header via N1PilV036).
4.2.4 Electrical Power: 30 amp, 110 vac, single phase.
4.3 After the above services are provided to the solidification system, t'-- :: . .e c a .. . ___
^ - ' -
1 _ . . , _ _ _ _ . - f the system h w/// de e"--
: ::_. 2i_m -___..y-_.m under the Y%Q direction of the aspur Wastepection Supervisor.
r Occon 4.4 't
. :11 ti... , . :2 N _ y__m.. u .- ^ '1 4go Q ggg follow the proper radiological precautions to minim 1:e the spread of contamination and to P " g 54"N limit personal exposure to ionizing radiation.
- =.;1_ _-di2ti-- -^-t _1 ,;__ - -.=s 4.5 During all processing evolutions, the solidification system operator shall adhere to the proper radiological controls as specified by Afde radiation work permitg ($1othinganddosimetry),
4.6 Prior to receiving wast fr sol ldofrNon s1 S ofkSS visually check all hoses for signs of wear and possible leakage .
N 5.0 Operating-Procedures 5.1.1 Obtain a radiation work permit (RWP) from the FNP ttealth Shysics .some==mme tecdieu .
NOTE: Steps 5.1.2 through 5.1.9 may be l performed in any sequence.
5.1.2 Monitor the area to be utilized for operation of the solidification unit for surface contamination and radiation levels. Immediately report any unusual or excessively high dose rate readings
-to .auen health physics.deoeemme=rm sac.A results shall ba verified by h health physics personnel.
l l
5 Rev. 0
FNP-0-RCP-800 5.1.3 Position the solidification unit, and disposable liner in the area assigned by the FNP representative.
5.1.4 Establish the following services to the solidification system as described in section 4.0, System Requirements:
- 1. Electrical Power
- 2. Service Air
- 3. ServiceWater(Dem,'au.J,iedLAla.
5.1.5 Verify that the required amount of cement, metso beads, disposable liners, and lids are available. Reference Appendix A, " SOLIDIFICATION CALCULATION SHEET".
5.1.6 With the crane, lift the filling flange required and place it into position for connection of services between the fill head and the field unit.
5.1.7 Following proper radiological precautions, and with a facility H.P. technician present, remove any blank flanges from the waste transfer hose and the FNP radwaste connection, if necessary.
l l 5.1.8 Connect the waste transfer hose between the FNP rad-waste connection and the waste inlet line, if necessary.
5.1.9 Connect the dewatering return line i
between the dewatering effluent line on the fill head and the FNP dewater return connection. For secondary dewatering, the dewater return line shall discharge l to the next consecutive disposable liner l or a 55 gallon drum (DOT 17H), or equivalent.
5.2 System Preoperation Checks l
NOTE: Complete all sections of pre-operational l check off sheet as required.
5.2.1 If a cask is used, remove the cask primary lid and secondary container as per "CASI* CERTIFICATION MANUAL" (if present) and inspect for water and lid seals. There must be absolutely no free liquid inside the cask. Any liquH present must be sampled by the H.P.
personnel and removed.
6 Rev. O
ENP-0-RCP-800 5.2.2 Remove the barrel top from the disposable liner and inspect for foreign material and damage. Report any damage to sesEF Waste,,JSupervisor or senior APCo representative.
%DeLos CAUTION: Interal pressure could build up inside the disposable liner. Remove the barrel top with care.
5.2.3 If cask is used, re-install the primary cask lid and torque to specs. Remove the cask secondary lid (if present),
inspect seal, and install " sleeve" assembly if needed to allow the use of the Primary lid as shielding.
5.2.4 Carefully position the appropriate solidification filling flange assembly over the liner opening and in-container mixing unit.
5.2.5 Properly position the filling flange assembly onto the liner and mixing unit.
5.2.6 Check for proper operation of the drive units and alarms.
NOTE: Prior to any discharge, the waste to be discharged will be samplqd by C&HP personnel in accordance with Appendix A, Section 6.1. Analysis will be performed as per Appendix A, Sections 6.5 and 6.7.
5.2.7 Obtain from the FNP Radwaste System Operator the amount of waste to be transferred and the expected flow rate of the pump that is to be used during dischargeg. Estimate the time required to transfer the waste.
5.2.8 After all connections and system checks have been made inform the FNP Radioactive Waste System Operator that the solification unit is ready to receive the waste.
5.3 Radioactive Liquid Waste Transfer and Disposable Liner Filling 7 Rev. O
FNP-0-RCP-800 5.3.1 Prior to receiving a radioactive waste transfer, verify that all initial conditions and preoperational checks are complete.
Document in daily log.
5.3.2 Verify that the transfer of radioactive waste has begun and inform the FNP Radioactive Waste System Operator that the Solidification System is receiving waste. Record the date and time the ENDC unit begdnvreceiving waste. '
g 5.3.3 Perform radiation surveys of the field solidification unit operating space, waste filling flange, and cask prior to, during, and after the transfer.
5.3.4 When transfer is completed or when the waste reaches the level set by the disposable level detector, secure the waste tranc#er and have the FNP radioactive waste systek operator secure pumping operations. Ensure that the vent air filtersub-systemissecuep.Y NOTE: If the END eems it necessary to termina flow to liner, he should immediately notify unit operator to shut flow off or close isolation valve at Bulk Loading Facility. These valves are:
Chemical Drain Tank V303',342 Waste Evaporator V315 Primary S.R.S.T. V3C6 Secondary S.R.S.T. V169 5.3.5 When the transferring operation is complete inform the FNP radioactive faste $ys, tem $perator to perform the l
necessary valve lineup to flush the
! waste transfer line and fill flange i assembly with low-activity water.
5.3.6 Commence flushing and continuously monitor the liner level during flushing operations.
5.3.7 Monitor the waste transfer hose and filling flange for radiation levels during the flushing operation. When
, radiation levels on the waste transfer l hose and filling flange approach background or at FNP's discretion, secure flushing. ;
8 Rev. O
9 ENP-0-RCP-800 5.3.8 After the flushing operation has taken place secure all equipment and hoses.
5.3.9 Obtain the FNP representative's concurrence on the volume of waste received. Record the information in the daily operating log and on the monthly processing report.
Send the discharge data to the FNP counting room to complete a discharge report.
5.4 Resin, Sludges, and Miscellaneous Media 5.4.1 Presolidification operations 5.4.1.1 ENDC personnel will make electrical connections from the Cc: trol Panel to the Electric Mixer Drive Assembly, Flexicon Drive Motor, and the Dust Collector.
5.4..l.2 The Dust Collector vent line will be connected to the Electric Mixer Drive Assembly vent line by use of the quick disconnects.
5.4.1.3 t e hose from the water addition pump will be connected to the p
underdrain via the quick disconnect in the dewatering hose. The appropriate amount of water will be pumped through the underdrain into the liner.
The amount of water to be added to the liner will be determined in Section 8 of the
" SOLIDIFICATION CALCULATION SHEET".
NOTE: For resin, water tv-must be added through the underdrain to help sparge the resin bed. In addition, it will prevent air pockets from being trapped in the bed.
9 Rev. O
FNP-0-RCP-800 5.4.1.4 As soon as the water is added, the connection will be broken at the quick disconnect and at the dewatering hose. (No EXCEPTIONS) 5.4.2 Solidification Operations 5.4.2.1 Start the Electric Mixer in accordance with the Electric Mixer Head Drive ?. m .. h Field Assembly __ i::' '- ... ..
and Operating Procedure (HNDC-TS-1900 NOTE: Mixer must run for five minutes prior to starting cement addition.
adj etm4M 5.4.2.2 Start conveyor andAt'o11owing fhe Cement Feed System Procedure.
h NOTE: The amount of cement and additives will have been determined in advance a per Appendix A, h
Sect l.on 6.7.
5.4.2.3 Start the dust collector.
5.4.2.4 After approximately one half of the required cement has been adde cement additioncwed 54p;4 I
= mete-se al $heconveyor and dust co lector,wsks-we Pla g W .'- $he circulation pump u" ,-
---f on top of the cask. vThe dewatering hose 6 Qttach $ to the suction side of the pu-n 4 e discharge hose emmentes G** Nc te the resin fill line of the Electric Mixer Drive Assembly. ghe pump e star anc run until suction is lost.
5.4.2.5 After suction is lost fpump m Gi s connec t- andaresin fill line anc cewaterinc, hose.
6 . ine purpose of the c. vulation pump is to 10 Rev. O
FNP-0-RCP-800 pull cement laden water into the underdrain system to solidify water that may be trapped.
5.4.2.6 Restart conveyor and dust collector and add the remaining cement.
5.4.2.7 After all the cement has been added, repeat step 5.4.2.6.
While the circulation pump is running, disassemb18,the Flexicon Cement Feed System and Dust Collection System.
NOTE: Mixing will continue during the circulation operations. If the circulation cperation lasts less than 20 minutes, the mixer will be allowed to run until this time has expired.
5.4.2.8 After the Mixer Head Drive Motor has mixed for the proper time, '
stop W and unpluggue.
5.4.2.9 p hlidification area h j 'cleanAE anq9 equipment properly, i
g.
5.4.2.10 ;1_..,___---'
esemove. eb Mixer Head Drive Motor Assembly - TOhmov e in accordance with the Field
! Assembly & Operating Procedure.
NOTE: The electric motor will not be removed.
5.4.2.11 sk, if required, ___m-recafBd for shipment in accordance with the appropriate cask loading procedure.
11 Rev. O
FNP-0-gcy_ggn 5.5 After Solidification Procedure 9 5.5.1 All equipment will be cleaned and any required FM will be accomplished.
Equipment will be put away in such a state that it will be ready for the next operation.
5.5.2 An equipmht/ tool inventory will be conducted and any deviations noted.
5.6 Cask closure and shipment release (if applicable) 5.6.1 Two bolts in both the secondary and primary lid shall have lead wire security seals attached after bolt torquing is complete.
5.6.2 The FNP representative shall provide a radioactive shipment record which certifies the total volume of waste and the curie content for each cask or for each liner if a cask ups not necessary, 15 5.6.3 The HNDC operator shall complete all applicable forms prior to transportation of the waste shipment.
5.6.4 The radioactive shipment record shall be submitted as peraRCP-56.
puAd- . gpd#
vnTE: The FNP Gedbbste5 5 ucervisor h ange % da.IIS ,
alA shipment surveys which are required by local or state agencies prior to transporting the shipment for burial.
5.7 Hydrostatic Test Procedures NOTE: Prior to any hydro test on any line, all bolts on flanges will be checked for tightness.
5.7.1 A Hydrostatic test is required wsanever the hose connection to one of the three bulk disposal manifolds is broken and made backup.
(v i
12- Rev. O
FNP-0-RCP-800 5.7.2 The APCo bulk disposal manifold valves will be aligned as follows for the appropriate line to receive a hydrostatic test. See Figure 4.
Manifold 1 -Chemical Drains and Waste Evaporator Discharge QV-303 Chemical Drain Isolation Shut QV-342 Chemical Drain Isolation Shut QV-315 Waste Evaporator Discharge Shut Isolation QV-343 Drain / Hydro Connection Open Manifold 1-Spent Resin Discharge NV-169 Steam Generator Blowdown Shut Resin Isolation QV-344 Drain / Hydro Connection Open NV-322 SGBD/ Primary Selector SGBD QV-306 Primary Resin Isolation Shut Manifold 3 - Dewater Return NV-174 Steam Generator Blowdown Shut Dewater Isolation QV-299 Primary Dewater Isolation Shut NV-323 Drain / Hydro Connection Open 5.7.3 Upon completion of the bulk disposal manifold valve lineup, the HNDC operator shall secure a valve or a blank flange at the opposite end of the appropriate hose.
5.7 4 Upon completion of the valve lineup, the HNDC operator shall connect the discharge piping of the hydrostatic test pump to the appropriate hydrostatic test connection on the appropriate rad waste manifold.
5.7.5 At this time, the HNDC operator shall obtain permission from the FNP representative to start the hydrostatic test. An APCo representative must be present.
13 Rev. O
ENP-0-RCP-800 5.7.6 When permission has been granted to start the test, the ENDC operator shall start the hydrostatic test pump and gradually increase the pressure in 25 psi increments until 125 psi has been attained.
NOTE: After each 25 psi increase in pressure, the ENDC operator shall check all piping and valves in the waste transfer system that are or could be affected by this test.
5 . 7 . ~/ When the hydrostatic pressure is at 125 psi, the operator shall again check for leaks. Once the operator is satisfied that no leaks exist, the ENDC operator shall wait for 30 minutes while holding the hydrostatic pressure at 125 psi.
During this 30 minute period, the ENDC operator shall make another system check at midpoint (15 minutes into the test) and after 30 minutes make a final check.
5.7.8 If after 30 minutes, a pressure of 125 psi was maintained with zero(0) leakage to the environment, the test may be considered complete and the ENDC operator shall notify the APCo representative of the results and return the valve alignment to normal.
5.7.9 The results of this test shall be included in the ENDC routine report to the field services management, and reported to the FNP Emmeiweege Supervisor.
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Ussale Liner Volume, ft 156 155 156 55 79 Max. Solicified Was:a --
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Was:q 'ici. Founds '
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POWUERED RESINS - a" HN-100 Series 1 Series 2 HN-1005 HN-200 HN-500 3
Usaole Liner Volune, ft 109 149 149 54 72 Max. Solidified Waste '
Vol. f 3 120.5 115.7 145 54 72 Max. Was.e Vol., f 3 37.0 53.3 104.0 . 115 51.5 Cemen: Acced at Max.
Was e Vol. #cunas 5733 5489 5530 3031 3 14 t
f if3 ags 51 53 73 32.2 35.3 M.5. A00ed at Max.
Waste Vol. Pcunes 574 549 589 304 342
- I f: bags 5. 7 5.5 5.9 3.0 3.a l
l Max. Radiaticn Level i
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SUM 11ARY Fcr the :nree waste ty:es investigated in :nis calculation. Oeac resin.
cwcerec resin anc 12 .v/c toric acid anc licensec cask 03ylcac is limi ing in all cases for the Hf:-!CO Series 1, Hri-1CO Series 2 anc H i-1COs.
Weignt is limi:ing fer :ne Hti-1COs anc Hti-ZCO caly for Concentra:ec Waste (5vaccra:ce Sc;; cms). Weign: is not a limiting fac:ce for tne Hii.
500.
Sead Resin Series 1 Series 2 Hi!-1CCS -r;-200 H:(-500 Usacle Liner Voicme, f:' 149 109 109 Go 72 M.ax. Sciidified Waste Volume ft' 127.2 122.0 109 54 72 Max. Resin Volu=e .. . , .-
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Cenen: 5399 5173 5325 2178 3057
, .4ddec
. bagsPounds
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ce
.o, a c, Me:sc Acced Pouncs 540 '517 533 272 306 1 f %ags 5.7 5.5 5.7 2.9 3.2 l
Max. .'acia
, tion Level R/hr. Contac 12 12 5 300 100 e
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