ML20076D408
| ML20076D408 | |
| Person / Time | |
|---|---|
| Site: | West Valley Demonstration Project |
| Issue date: | 07/12/1991 |
| From: | Robbins G, Ross C ENERGY, DEPT. OF |
| To: | |
| Shared Package | |
| ML20076D406 | List: |
| References | |
| REF-PROJ-M-32 NUDOCS 9107290136 | |
| Download: ML20076D408 (18) | |
Text
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,I g, DC:91:0084 ATTACHMENT July 12, 1991
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RUN REP 0RT INTEGRATED RADIOACTIVE WASTE TREATHENT SYSTEM I
CAMPAIGN 21, October 31, 1990 - January 11, 1991 l l
Information Contributed By:
G. J. Robbins C. F. Ross SRC4182 9107270136 >lO710 POR PROJ (1 32 PDR
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o,' - DC:9'l:0074 ATTACHMENT July 9, 1991 LIST OF TABLES Table 1 - Summary Table of _Run Statistics Table 2 - Comparison of Statistics from Previous Campaigns to this Campaign'
- Table 3 - Detailed Tables of Run Statistics Table 4 - Drum Testing Results Table 5 - Drum Production Rates Table 6 - STS Process History
' Table 7 - Summary-of Suspect Drums SRC4095 i
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0C:91:0074 July 9, 1991
.. ATTACHMENT-LIST OF FIGURES Figure _1 - Drum Cell Radiation Levels Figure 2 - IRTS High Level Waste Tanks, 80 1 and 80-2 Figure 3 - STS Zeolite Usage l
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1 J ' 1. 00:91:0074_.
' ATTACHMENT- July 9, 1991
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IRTS OPERATIONS' l RUN REPORT CAMPAIGN X
SUMMARY
l Integrated'Radwaste Treatment System (IRTS) campaign 21 was initiated on
- ' October 31, 1990 and concluded on January 11,=1991 after processing 6.306 gallons- of 8D 2 liquid to the Liquid Waste Treatment System (LWTS). The target 3 dilution factor was 3.0:1 with a nominal system flow of 6 gpm. The dilution ratio is based on the original 39 weight percent (wt%) concentration of 8D-2 supernatant.- Cesium removed from 8D-2 solution for campaign 21 was 74 kilocuries. During processing of supernatant to the LWTS, 26 kilocuries were removed. Forty-eight- kilocuries of cesium were removed from 80-2 to fill tan <
80-3 with decontaminated supernatant ano to saturate' lead column A with-cesium. The supernatant which was processed to tank 80 3 remains in the tank.
This solution will be returned to tank 80-2. Due to a temporary suspension of LWTS operations (see discussion section of this report and occurrence report-WVNS-90-0026, LWTS-90-0001), this solution cannot be transferred to the LWTS.
Following campaign 20, column D was sluiced via the J nozzle to remove the bulk of the loaded zeolite from the column. Column D was then sparged'to remove the heel _of. spent zeolite. Two drums of fresh-zeolite were then loaded into the column-for a test of sparge effectiveness. -This test was to be performed at the start of- campaign 21 processing with a column sequence of A-B-C-D. Note that column D had been sparged between processing weeks during campaign 17. That initial sparging provided marginally acceptable performance of column D.
The cesium activity of the-column D effluent was acceptable at the start of campaign-21. However, it. almost immediately started to increase and continued to increase until it became necessary to remove column D from service. With column D out of service, the column sequence became A-B-C with column C-being the final, or polishing column. Column C was the final column during the previous campaign;and could not perform as efficiently as- a fresh column.-
The volume of supernatant processed for campaign 21 was-therefore reduced greatly. Cesium concentration in'the system effluent was. the limiting factor. - Normally, lead column loading is limiting.
Following completion of the campaign, column A was saturated with cesium to provide maximum usage of the zeolite. The bulk of the cesium loaded zeolite was sluiced'_from column A via the J-nozzle. There was no usable hydraulic arm at' the M-4 riser, so it was not 'possible'to service the column A bottom dump
. plug. Therefore, a heel of cesium loaded zeolite remains in the column. This heel will be removed prior to restart of the IRTS.
SRC4095 ,_ , _-
', 00:b1'0074 ATTACHMENT July 9, 1991 l Dilution of the contents of tank 80 2 is causing some premature sludge washing to occur. This results in some constituer; in the sludge, such as fissile material, to enter the supernatant solution. This was not anticipated until sludge _ wash operations, during which steps would be taken to limit the amounts of these constituents in the process stream. During supernatant processing, the STS does not have provision for removal of these constituents from the process stream. The increased concentrations of these constituents of the sludge layer are passed on downstream to the LWTS where they were not projected to be. Because of this undesirable phenomenon, supernatant processing has been declared complete. The total volume of supernatant removed from tank 80-2 during supernatant processing operations was 618,000 gallons. There were 21 supernatant processing campaigns. When IRTS operations resume, the operations will commente as sludge washing.
The total reolite usage at the end of supernatant processing is 34,928 kg dry weight. This includes the two drums of zeolite contained in column D and 4 drums of zeolite used in cold testing prior to the start of_supernatant processing. The maximum zeolite usage goal is 60,000 kg dry weight. To keep within the goal limit, 25,072 kg (dry weight) of zeolite may be used to accomplish sludge washing. This equates to approximately 18 columns of zeolite.
Campaign'21 produced 18,655 gallons of decontaminated supernatant solution, of which 11,593 gallons were evaporated to produce 2,075 gallons of concentrates. As noted above, the decontaminate supernatant contents of tank BD-3 will not be transferred to the LWTS.
The Cement Solidification System (CSS) produced 53 drums at a nominal 40 gallons of waste per drum. The total drum production for supernatant processing is 10,389. Table 1 shows a summary of run statisttes. As previously stated, supernatant processing is complete.
DISCUSSION STS OPERATION Supernatant Treatment System (STS) campaign 21 operations commenced on October 31, 1990. The process was placed in column sequence A B-C-0. Column 0 had been aparged and sluiced to remove the spent zeolite heel and contained only two drums of fresh zeolite. A 30-hour test of the effectiveness of the sparge was to be performed, if this test indicated acceptably low cesium effluent from column 0, the remaining ten drums of zeolite to make up a full column charge would be added. Note that sparging of column D during campaign 17 resulted in marginally acceptable performance from the column, although in third position during campaign 'd, the column exhibited negative DF (effluent cesium concen-tration higher than that of the influent). See campaigns 17 and 18 run reports.
SRC4095 .
lL DC:$1:0074 - ATTACHMENT. July 9,-1991-4 During the' 30 hour-test of column 0 in-campaign 21. initial. analysis of the cesium effluent of column D indicated approximately 6E-2 uCi/ml and increased steadily into the E-1 range. The effluent cesium increased to approximately 4E-1 uti/ml within 20 hours2.314815e-4 days <br />0.00556 hours <br />3.306878e-5 weeks <br />7.61e-6 months <br /> from start of test, at which time column-D was taken I off lire and vented. During this test, the cesium influent to column D was
- nearly. stable at approximately 2E-2 uCi/ml . The remainder of the campaign was operated in a column sequence of A B C, with column D off line and vented.
Column C was the polishing column during campaign 20 and was no longer able to-perform the' polishing function as well as a freshly loaded column could have.
Therefore, the volume of supernatant processed during campaign.21 and the system DF's achieved were much lower than normal. An evaluation of possible reasons for ineffectiveness of the. column D sparge will be performed. It should be noted that there were no obvious anomalies observed during sparging operations 1 which could explain the sparge failure. ,
. Following completion of. campaign 21 supernatant processing, column-A was sluiced- l using the-J nozzle. The heel of spent zeolite remains in column A due to lack '
of a hydraulic arm or camera mast to service the bottom plug _of column A. The two drums of zeolite placed in column D for the test still remain.
' LWT5 OPERATQH The Liquid Waste iceatment System (LWTS) operated acceptably to concentrate the decontaminated supernatant-solution transferred =to it. However, LWTS operations were effected by.a process-phenomenon which involved material balance across-the LWTS evaporator.;
Routine process control sampling. indicate' dilution of the contents of tank 80-2 is causing dissolution of-fissile material from the sludge in the bottom of the tank. The concentration of fissile material as seen in analysis of supernatant
- was slowly increasing as dilution; increased. This phenomenon was anticipated during sludge washing._ Provisions were made to-remove the fissilo material from the sludge wash STS process stream in the ion exchange columns;using titanium
-coated zeolite in the ion-exchange columns.- These provisions were not in place during.supernatant processing. Therefore, this slightly increased fissile material concentration was: unchanged by STS supernatant processing and was passed 'on to the-LWTS. -This fact. is borne out by analyses of-the evaporatnr feed tank 50 158.
While the concentration of fissile material in the evaporator feed was incraas-ing, it was noted that the evaporator concentrates were. indicating-a small variance from-the expected concentrations. there appears to_be a small-accumu--
lation of fissile material in the LWTS evaporator. Calculations showed that even the most conservatively high estimate:of the amount of fissile material accumulation in the. evaporator results in' fissile materia 1' concentrations significantly below the site's criticality limits.
SRC4095 - _ ._ _ . .__ __ __.. _ . _ _
00:91:0074 ATTACHMENT Juiy 9, 1991 Although.no danger of criticality exists, the LWTS was placed in standby until a determination of proper actions to be taken could be developed. A task force was establithed to determine the actions to be performed to enable a resumption 4 of IRTS operations.
It was determined that shd;? 'nshing.had in effect started. Therefore, super- l natant processing is completed with the termination of campaign 21. IRTS sludgc j wash operations will commence in October 1991 with the start of caustic addition for the first sludge wash.
CSS Operation The High Shear Cement Solidification System (HSCSS) produced a total of 53 drums of low-level waste at 40 gallons of waste per drum. Due to the higher than normal STS cesium effluent concentration as noted acove, there were i.o low dose !
shield drums produced during campaign 21. There were no major problems noted I with respect to CSS operations during this campaign, i DRUM CELL OPERATION ,
l Operation of the Drum Cell (DC) continued in support of CSS operations with no major problems noted.
- j TANK LEVELS This campaign completes supernatant processing. Formerly, the target level of tank 8D-2 at completion of supernatant processing was a 32 inch level (approximately 84,000 gallons). However, due to above mentioned considerations, supernatant processing has been terminated following campaign 21. At the completion of supernatant processing the volume in tank 8D-2 was 293,000 gallons and the volume in tank 80-1 was 214,000 gallons. See figure 2 for a graph of the volumes in the high level waste tanks 80-1 and 80-2.
PRODUCT ACCEPTANCE The waste form classification analyses for drums produced is as follows:
Campaigns 1-13, Class C Low Level Waste; verification complete.
Campaign 14, awaiting QA update.
Campaign 15, awaiting QA update.
Campaign 16, awaiting QA update.
Campaign 17, awaiting QA update.
Campaign 18, awaiting QA update.
Campaign 19, awaiting QA update. -
Campaign 20, awaiting QA update.
Campaign 21, awaiting QA update.
SRC4095 July 9, 1991
, DC:91:0074 TABLE 1 i
.4TS CAMPAIGN NO. 21 RUN REPORT
SUMMARY
TalLE OF RUN STATISTICS
- 1. TR l STER $ 80-3 f.) dd-ISB ,
A.Camj. '.gn Nos. I tia a 20 6,181,894 L 1,633,261 gal.
B.Campai[p No. 21 40.489 L 10,696 aal.
l 705Ni TO BA(E 6,222,383 L 1,643,957 gal. l l
- 2. (W11 PRDCESS /0LddES )
l 2.1 Total Feea '.' Evaporator A. Campaign ..os. I thru 20 6,224,023 L 1,644,218 gal. !
S.CampaiQu No. 21 43.884 L 11.593 gal.
TOTAL TO DA!t 6,267,907 L 1,655,811 gal.
2.2 Total Concentrate ,
A. Campaign Nos. I thru 20 1,452,563 L 387,775 gal, !
B. Campaign No. 21 7.854 L 2.075 aal.
TOTAL TO DATE 1,460,417 L 389,850 gal. )
- 3. DRUMS PRODUCED
- A. Campaign Nos. I thru 20 10,336 ;
B. Campaign No. 21 53 TOTAL TO DATE 10,389
- 4. CURIES OF CESIUM 137 REMOVED FROM 80-2 A.lRTS Campaign Nos. I thru 20 5,135.0 KCi B.IRTS Campaign No. 21 74.0 XCi TOTAL 5,209.0 KCi
- 5. PROCESS COMPLETION A. Curies Percent Complete: 0.793 B. Drums Percent Complete: 0.7992 Includes 5 drums removed from pile and core bored (#72847, 72791, 72949, 71004,72813,) which are now located in Lag Storage and does not include 1 drum which was left in the CSS process room.
SRC4095 0C:91:0074 July 9, 1991 TABLE 2 IRTS CAMPAIGN NO. 21 RUN REPORT COMPARISON OF STATISTICS FROM PREVIOUS CAMPAIGNS TO THIS CAMPAIGN CAMPAIGN CAMPAIGN CAMPAIGN NO. 19 NO. 20 NO 21 STS Volume of BD-2 Supernatant(a) 49,186 50,705 6,306 Processed (Gal.)
Total Volume Processed (Includes 123,048 140,985 18,653 flush and dilution Water) (Gal.) ,
Column Breakt . ougn (P.)
Lead Column 97 99.5 n/a 2nd Column 1.2 5.6 n/a Average System DF 94,977 62,909 n/a Average Cs-137 in Effluent (uti/mL) .017 .026 .132 LWTS Concentrates Volume (Gal.) (b) 27,218 26,440 2,075 Average Cs-137 (uCi/mL) ,072 .206 .522 CSS Drums Produced 675 661 53 Average Cs-137/ Drum (Ci) .01 .025 .079 Average Drum Contact Dose Rate (mR/hr) 12 25 70 (a) See Table 6 for volume of supernatant recycled.
(b) Tank heels:
CAMPAJGN 19 CAMPAIGN 20 CAMPAIGN 2.1 50-15Al 20 Gallons 22 Gallons 20 Gallons 50-15A2 2 Gallons 2 Gallons 2 Gallons 70-0-1 68 Gallons 60 Gallons 88 Gallons TOTAL 90 Gallons 84 Gallons 110 Gallons SRC4095 .
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-y ,' . DC:9'1:0074-
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Jul'y 9, 1991 TABLE 3-I-R T S- CAMPAIGN-NO.'21=RUN REPORT DETAILED TABLE OF RUN STATISTICS COLUMN SEQUENCE: A-B-C 1). TRANSFER 80-3 to:50-158 1 2 A. DATE 1990- 11/1 Flush
.B. STS FLOW RATE (gpm)-- _
5.0 Flush C. D-001 SAMPLE NO. 9003142 Flush
'i. Csl37 (uCi/mL.) 409 Flush
- 11. TDS-(wty.)- 9.94 Flush
~
iii . Density (gr/mL) 1.069 Flush D. CESIUM-137. ACTIVITY -
-(COLUMN EFFLUENTS):
- 1. Lead Column A (uCi/mL) 5.94 Flush- l 11.-2ndColumn8(uCi/mL) 0.32 Flush E. COLUMN _ BREAKTHROUGH (f.)
1.. Lead Column A' 1.5 Flush
- 11. 2nd Column B. 5.4 Flush F. 80-3 SAMPLE N0.. 9003150 Flush
.i. "Cs-137 (uci/mL)
-0.1320 Flush
, .ii..TDS_(wtf.)- 5.72 Flush l iii.Dentity (gr/mL) 1.034 Flush ]
G. STS SYSTEM DF i.- Transfer DFi . 1,725 Flush'
- 11. Cumulative DF 1,725 Flush H. 5D-158 SAMPLE NO.- 9003180 Flush
- i. Cs-137 (uCi/mL) 1.27 E-1 Flush 11.'TDSL(wtf.)_
-9.34 Flush
.iii. Density (gr/mL)- 1.064 Flush I. Volume Received-
-(Litres) in 50-158 40,489 Flush J. Cumulative Volume 40,489 Flush SRC4095- -
e s , ,, ., v,, a .un u. , ,, , n w n - - - - . - - - - - - - . - + _ - - - _ _ - - - - - - - . . - -
900:9'l:0074 July 9, 1991 ;
TABLE 4 IRTS CAtlPAIGN NO. 21 RUN REPORT DRUN TESTING RESULTS CONCENTRATES BATCH 84 l
'LWTS TANK SD-15A2 l LAB ANALYSIS NO. 9003221 TOTAL SOLIDS.% 39.86 Cs-137 CONCLNTRATION 5.22E-01 (uCi/mL)
POUNDS CEMENT +CaNo3 24,168 i NUNBER OF DRUNS 53 ,
TOTAL GALLONS 2,120 CURIES PER DRUN (Average)- 0.079 RADIATION DOSE (mR/hr) Per Drum 70 PRESOLIDIFICATION RESULTS >700 PSI
~IN-CELL TEST RESULTS 81,793 DRUM NO / PSI >700 PSI t
Total Cement 24,168 LBS.
Total Number of Drums- 53 Total: Volume Solidifled 2,120-Gallons Total curies. Solidified 4.19 Ci SRC4095 ..
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DC:91:0074-. July 9, 1991'
.- TABLE 5 I R T S -CAMPAIGN NO. 21 RUN REP 08I DEUM PRODUCTION RATES DAILY WEEKLY CUMULATIVE DATI AVERAGE TOTAL . TOTAL Campaign #1 06/01 to 06/17 33 401 l Campaign #2 06/27 to 07/08' 45 783 Campaign #3 07/18 to 08/05 .35 1,347 Campaign #4 08/22 to 09/2d 30 1,681 Campa.ign #6 12/05 to 12/13' 45 2,009
. Campaign #7 01/23 to 02/23 50 2,607 Campaign #8 03/06 to 04/13 60 3,303 Campaign #9; 04/24 to 05/26 58 3,988 Campaign #10 06/19 to 06/22 37 4,136 )
Campaign #11 07/26 to 08/24- 58 4,778 Campaign:#12 09/05 to 10/13 50 5,421 Campaign.#13 10/23 to-11/10 62 5,921 Campaign'#14 11/20 to 12/15 67 6,532 Campaign #15 01/22 to 02/14 59 7,124 Campaign #16 03/12 to 04/16 42 7,808 Campaign-#17- 05/08to06/15 60 8,451 Campaign #18 06/28 to 07/25 45 9,000
' Campaign-#19 08/09 to 09/13 38 9,575 Campaign #20 09/24-to 11/01 45 10,336 Campaign #21 11/13 26 11/14 27 53 10,389 ;
SRC4095 .
I
'ne 9, 1991 DC:91:0074
- j. j TABLE 6 '4 1RTS CAMPAIGN NO. 21 RUN REPORT STS PROCESS HISTORY - -- 1 l
SFHORT#ff PIE)CE5 SED Cs-137 ,
Cs-137 #0 #0- TOTAL - IlWENTGN tmINre. COCD(IRAT104 TRNGIIMD Cs-137 RECYCLfD Cs-137 Cs-137 Dill #104 Wi1Mi QLIM4(S) IN D2 TO IMS RDU4D TO D2 REMMD RDR'EDIll8D-2(a)(b). RDMINIfG C#0AIG4DATE HATIO SEOUDCE OtMTD fuci M ) (Gallons) KCi (Gallons) [KCil (KCi}_ (Vfi) 1 5/88 no dilute. B-C-D-A B 2860 24,185 262 0 0 262' 6,836-2 6/88 no dilute C-D-A-B C 2600 15,800 155 0 0 155 6,681 3 7/88 no dilute D-A-B-C D 2600 26,356 -259 0 0 259 6,422
, 4 8/88 no dilute A-B-C A :2600 17,000 167 4,000 39 206 6,215 5 9+10/88 no dilute lyA .
B8C 2400 0 0 30,200 274 274 5,942 6 12/88' no dilute ' A-B-C-D : A 1980 17,800 133 0 0 133 5,809 '
7 1+2/89 2:1 B-C-D-A.- B 1980 35,342 265 0 0 265 5,544 8 2+3/89 2:1 C-D-A-B. C 1980 34,040 255 0 0 255 5,289-9 415/89 2:1 0-A-B-C D 1980 35,101 263 0 0 263 5,026 10 6/89 2:1 A-B-C A 1885 10,900 78 13,200 31 109 4,917 11 8/89 2:1 B-C A B 1885 35,096 250 0 0 250 4,667 12 10/89 2:1 C-D-A-B C 1885 33,363 238 0 02 238 4,429 13 10+11/89 2:1 D-A-B-C D&A 1855 28,333 199 14,767 42 241 4,188 14 12/89 2:1 B-C-A BBC 1810 33,873 232 19, LED 131 363 3,825 15 1+2/90 2:1 D-A-C 05A . 1810 33,3CO 228 34,434 202 430 3,395 16 3+4/90 3.6:1 C-A-B C 1790 46,578 316 0 0 316 3,079 17 6/90 3.6:1 A-B-C-D A 1790 45,236 315 1,458 7 315 2,764 12 8/3/90 3.0:1 B-C-D-A -B 1790 39,804 270 0 0 270 2.494.
19 9/13/90 ~3.0:1 C-D-A-B C 1090- 47,184 203' 0 0 203 '2,291 20 11/02/90 3.0:1 D-A-B-C 0,C 1090 50,705 209 32,855 119 328 1,963 21 11/31/90 3.0:1 A-B-C A 1090 6.306 26 18,195 48 74' 1,889 618,302 4,323 168,289 893 5,209 (a) Total curies of Cesite-137 nported'in Safety Analysis Report (SAR) nport decayed to 7-21 7,098 KCi minus curies of Cesita-137 pmcessed (b) Includes appmximtely .489 KCi Cesita-137 left in 32-ins heel in Tank ED-2 at the end of strenatant pmcessirs estimated as follows:
Voltre of 32 ind heel = 80,464 gallons Voltre of sapematant in heel = 72,916 gallms Voltre of solids in heel .= 7,548 gallms Curies of CS-137 in heel = 489 KCi (Ref.: 00EA044139-14, Pvje A2) [(7.29 E40% call (3.785 E403 d/c;all(1.79 F403 iCi/d )]
6 10 uCi/Ci
- 'SRC4095 - - - - _ _ _ _ _ _ _ . - .- - _ - _ _ _ - _ _ _ - - _ - _ _ _ - - - - _ _ - _ _
_ _ _ _ . . _ _ . . - . . _ - _ = . - . - . _. . __ - . _ _ _ _ _ _ _ . _ . _
luly9,l?91 . 00:91:0074 TMllIl IRTS C#FAl(N PC. 21 RN k &
SUWRY OF SUSPEL7 DRM
- m._ .
-(ATE CAffAIG4 SERIAL CRITIQUE C MFG W NCE PRTUCED t00ER PUCER f00ER RERPT DESCRIPT104 Cf RSgt C00mm 7/29/88 3 72847 0080E0 tR 88-055 One batdi in antti pmduced ;
2/06/89 7 73033 089013 tR 89-011 without sodlun silicate.
5/10/89 9 74014 009056 WA 4/12/90 16 78922 0 90049 fR 90-017 6/29/90- 18 79835 000077 tVA _ _ _ _
C/11/89 11 75903 009101 IR 89-066 One gallon of raw y. oste added on too of finished nioduct.
1/23/89 7 71397 tJ/A 'R 89-015 Low water to-cmont ratio (i.e.0.526). Accretable range is
,_. 0.54 to 0.70. ;
11/20/89 14 77074 009135 tR 89 148 Incmplete antifoam acdition to !
14 77073 mixer.
14 77314 l
14 77305
'14 77304 14 77405 14 h,131 '
14 77401 1 14 77300 -
14 77333 14 77344 14 77345 14 77402 14 77404 14 - 77403-14 77328 14 77303 14 77399 14 76994 14 77212 14 77228 14 77222 8/27/90 19 80326 000106
' 19 - 80329 19 80198 19 80199-19 80200 19- 80401' 19 80404 19 80403 19 80400 19 80405 19 80398 19 80399
-19 ' 80203 l
i SRC4002 ,_
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July 9,-1991 DC:91:0074 TNILE 7 IRTS CM%I(N PC, 21 RN REPORT SUWRY OF SUSRLT DfUS (C0(TlfMT10N)
\ OFW . . t04- :
MIE C4fAIG1 SERIAL- CRITIOVE- CONF 0 N NCE i i
PRRCED PUBER PUKR t4 M ER REPORT DESCRIPTIOJ OP SUSPECT C30lTIO1 i 19- i i -l 7/05/88 2 71542 0190042 tyA Low water to-camnt ratio.
7/24/E- 3 72539 090042 tyA 8/23/s 4 72331 000042 fVA 10/10/89 12 76392 000042 tyA 11/20/89 14 -77401 062 tyA i 11/20/89 14 77213- 090042 tyA 12/15/89 14 77829 090042- tyA 4 12/14/89 14 77523 0@0042 tVA 9
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