ML20081C220
| ML20081C220 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 02/28/1984 |
| From: | Hamilton G, Schnell D UNION ELECTRIC CO. |
| To: | Harold Denton Office of Nuclear Reactor Regulation |
| References | |
| PROC-840228, ULNRC-759, NUDOCS 8403120182 | |
| Download: ML20081C220 (22) | |
Text
"PCP" t
Date February 28, 1984 m
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CALLAWAY PLANT PROCESS CONTROL PROGRAM PCP b.W NAmdtod RESP. DEPT.
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DATE ISSUED This procedure contains the following:
Pages 1
through 11 Attachments 1
through 5
Appendices through checklist through INFORMAi
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M CONTROLLD C0?Y B403120182 840228 PDR ADOCK 05000483 A
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"PCP" Dsto February 28, 1984 Table of Contents Section Page Number
1.0 Purpose and Scope
1 2.0 Definitions 1
! 3.0 10CFR61 Compliance Methodology 1
4.0 Precautions and Limitations 1
5.0 Collection and Analysis of Samples 2
5.1 General Requirements 2
5.2 Collection of samples 3
5.3 Chemical Analysis of Waste Samples 5
5.4 Radiochemical Analysis of Waste Samples 5
6.0 Test Solidification and Acceptance Criteria 5
6.1 Waste Conditioning 5
6.2 Test Solidification 6
6.3 Solidification Acceptability 7
7.0 Process Formulations 8
7.1 Spent Resins 8
7.2 Chemical Drain Tank Wastes 8
7.3 Evaporator Bottoms 9
8.0 Solidifying Agents 10 9.0 References 10 Attachment l'- WASTE SOLIDIFICATION DATA SHEET - Tests for Portland Cement - Spent Resin Solidification - Borated Wahte Solidification - Non-Borated Waste Solidification i
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"PCP" Date February 28, 1984 CALLAWAY PLANT PROCESS CONTROL PROGRAM MAIRJAL (PCP) 1.0 PURPOSE AND SCOPE 1.1 The purpose of the Process Control Program (PCP) for radwaste solidification is to provide reasonable assurance and documenta-tion of the complete solidification of processed radioactive wastes and of the ab-sence of~ free-standing water of the processed waste within the limits as set forth in 10CFR20, 10CFR61, 10CFR71, the Radiological Effluent Technical Specifica-tions, Federal and State regulations, burial i
ground requirements, and other requirepents governing the disposal of the radioactive i
wastes.
1.2-The PCP contains the sampling, tests, analyses, and formulation determination by which waste classification and solidifica-tion of radioactive wastes from liquid sys-tems is assured.
2.0 DEFINITIONS 2.1 Solidification - The conversion of wet
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wastes into a form that meets shipping and burial ground requirements.
2.2 Batch - A specified quantity of waste material requiring soldification any portion of which would have the same physical and chemical characteristics as the whole.
!- 2.3 Waste Classification The determination of waste class as outlined in 10CFR61 by radionuclide isotopic analysis and/or correlation with measured nuclides.
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"PCP" Date February 28, 1984
! 3.0 10CFR61 COMPLIANCE METHODOLOGY
! 3.1 All solidified radioactive wastes generated at the Callaway Plant shall meet the requirements of Title 10 Code of Federal Regulations Part 61 (10CFR61).
! 3.2 Waste Classification (10CFR61.55) require-ments shall be met by the. methodology esta-blished in RDP-ZZ-00004, Waste Classification.
! 3.3 Waste Characterization (10CFR61.56) require-ments shall be met by a combination of the methodology stated in the. Process Control Frogram (Section 6.0) and related Callaway Plant Operating Procedures.
Stability I
requirements stated in 10CFR61.56 (b) and by burial site shall be met and ensured prior to shipping solidified radioactive waste offsite for burial.
4.0 PRECAUTIONS AND LIMITATIONS 4.1-All samples shall be handled in accordance with applicable Callaway Plant procedures and in keeping with ALARA principles.
4.2 Test samples ccntaining radioactive waste shall be disposed of as radioactive waste.
5.0 COLLECTION AND ANALYSIS OF SAMPLES 5.1 General Requirements 5.1.1 As required by Radiological Effluent Techni-cal Specification 3.11.3, the PCP shall be used to verify ~ the solidification of at least one representative test sample from at least every tenth batch of each type of wet radioactive waste processed.
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"PCP" Dato February 28, 1984 5.1.2 For the purpose of' the Callaway Plant PCP, a batch shall censist of a particular amount of liquid wastes / sludges requiring solidifi-cation (ie., the amount of waste content within a tank requiring solidification, or, the amount of waste content within two tanks requiring solidification if the contents of the two tanks are to be solidified together within a common drum).
If new material is added to a tank's contents which is curren-tly being processed, a new batch is created and further sampling must be performed prior to solidification.
5.1.3 If any sample fails to solidify, solidifica-tion of the batch under test shall be suspended until such time as additional test samples can be obtained, alternative solid-
-ification parameters can be determined in accordance with the Process Control Program, and a subsequent test verifies solidification.
Solidification of the batch may then be resumed using the alternative solidification parameters determined.
5.1.4 If the initial test sample from a batch of waste fails to verify solidification, then representative test samples shall be col-lected from each consecutive batch of the same type of waste until three (3) conse-cutive test specimens demonstrate solidifi-cation using the alternate parameters of step 6.3.3.
5.1.5 For high activity wastes, where handling samples could result in personnel radiation exposures which are inconsistent with ALARA principles, representative non-radioactive samples may be test solidified.
These sam-ples shall be as close to the actual waste and chemical properties as possible.
Typi-cal unexpended mixed bead resin may be used
.to simulate the spent bead resin.
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"PCP" Date February 28, 1984
! 5.1.6 Where practical, all chemicals used to con-dition or solidify waste (or simulated waste) in solidification tests shall be identical to the actual chemicals to be used in full scale solidification.
5.2 Collection of Samples 5.2.1 WASTE SOLIDIFICATION DATA SHEET (Attachment 1)
. 5.2.1.1 The WASTE SOLIDIFICATION DATA SHEET will contain pertinent information on the charac-teristics of the test sample solidified in order to verify solidification of subsequent batches of similar waste without retesting.
5.2.1.2 The test sample data for waste shall in-clude, but is not limited to:
the type of wastes solidified; percent total dissolved solids; pH; volume of sample; amount of oil in the sample; the waste to portland cement ratio; the portland cement to sodium meta-silicate ratio.
5.2.1.3 The WASTE SOLIDIFICATION DATA SHEET will in-clude the batch number, batch volume, waste type, waste classification, total waste received, total portland cement added, total sodium metasilicate added and the date solidified.
5.2.1.4 If waste pretreatment is necessary prior to actual batch solidification per the results of step 6.1, the agent used and amount added shall be denoted in the remarks section of the WASTE SOLIDIFICATION DATA SHEET.
5.2.2 Taking Samples 5.2.2.1 A sample (s) of the waste tank's contents requiring solidification must be taken in order to determine the actual process formu-lation for solidification, any pretreatment of the waste needed prior to solidification, I
and the waste classification of the tank contents to be solidified.
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"PCP" Data February 28, 1934
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5.2.2.1.1 Sample sizes, as determined by the Radwaste Department, snall be compatible with the standard size samples used for radioactivity and chemical analysis.
5.2.2.1.2 If the radioactivity levels are too high to permit full size samples to be taken, then smaller samples shall be taken with the results corrected accordingly.
5.2.2.2 Sufficient sampling lead time should be al-lotted prior to the planned vaste solidifi-cation of a batch to allow adequate time to complete the required testing and verifica-tion of solidification, as applicable.
5.2.2.3 The contents of the waste tanks that are to be solidified should be recirculated (mixed) prior to sampling to ensure that a represen-J tative sample is obtained.
5.2.2.4 If the contents of more than one tank are to be solidified in the same drum, then repre-sentative samples of each tank should be drawn.
5.2.2.4.1-These samples should be of a sufficient com-position that if "X" percent of the total waste to be solidified is to be taken from one of the tanks, then the sample taken from that tank should be the same percentage in the composite sample.
5.2.2.4.2 The samples taken of each should be mixed in the proper proportions to yield a standard size sample as described in 5.2.2.1.1.
5.3 Chemical Analysis of Waste Samples 5.3.1 Evaporator bottoms and chemical wastes shall be analyzed for total dissolved solids, oil content, boric acid concentration and pH and the results recorded on the WASTE SOLIDIFI-CATION DATA SHEET.
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uPCP" Dato February 28, 1984 5.3.2 Spent resin beads and charcoal shall be characterized by analyzing the water sur-rounding the beads and charcoal for oil con-tent and pH.
Boric acid concentration of spent resin beads shall be determined by an assay of the boric acid separated from the anion bead resin.
The results shall be recorded on the WASTE SOL DIFICATION DATA SHEET.
5.4 Radiochemical Analysis of Waste Samples 5.4.1 A gamma isotopic analysis will be performed on each batch to be solidified.
b.4.2 This analysis will be used to determine ac-ceptability for solidification as well as I
waste classification of the waste to be i
solidified (see Step 7.0).
5.4.3 The results of the gamma isotopic analysis shall be attached to the WASTE SOLIDIFICA-TION DATA SHEET.
6.0 TEST SOLIDIFICATION AND ACCEPTANCE CRITERIA i6.1 Waste Conditioning 6.1.1 Prior to the test sample solidification, the pH of the samplc shall be adjusted to a range of 7 to 10.
6.1.1.1 Should adjustment be necessary, the agent and quantity used shall be recorded on the WASTE SOLIDIFICATION DATA SHEET.
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6.1.2 If oil is present in quantities greater than
'% by volume, dilution of the batch to below 1% is required prior to solidification.
6.1.2.1 If reduction of the oil content is impossi-ble or impractical, solidification of the batch shall not be attempted using the Stock Solidification System, but shall be accom-plished using a bulk processing method.
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"PCP"
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Data February 28, 1984 6.2 Test Solidification 6.2.1 Whenever pretreatment of a batch is neces-sary, the waste sample shall have the required pretreatment accomplished prior to the test solidification.
6.2.2 Prepare the test solidification vessel (suitably sized disposable beaker) with a mixing device.
6.2.3 Transfer a known representative volume of the waste to the test soldification container.
6.2.4 Add the appropriate proportional amount of portland cement and sodium metasilicate, as applicable, determined from the appropriate attachments (3, 4 and/or 5) found at the back of this manual.
6.2.5 Initiate mixing of the waste, portland cement and sodium metasilicate.
After 10 (10) minutes of mixing or when a homogenous mixture is obtained, allow the waste to stand for.a minimum of 30 minutes.
6.2.6 If any free liquid is observed on the top of the sample, decant the liquid into a clear volumetric beaker and record the amount of liquid transferred.
Calculate the percent of free liquid and record the data on the WASTE SOLIDIFICATION DATA SHEET.
! 6.3 Test Solidification Acceptability 6.3.1 The test sample solidification will be con-sidered acceptable from a free liquid stand-point if the amount of free liquid is the lessor of either 1% by volume or burial site limits. t~=
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"PCP" Dato February 28, 1984 6.3.2 The test sample solidification will be con-sidered acceptable from a solid mass stand-point (i.e., structural stability) if it is evident from it's physical appearance that the solidified waste maintains its shape when removed from the container.
6.3.3 If either or both of the above checks fail to meet the stated criteria, alternative solidification parameters must be determined before solidification can proceed.
6.3.4 If the initial test sclidification of a batch is unacceptable, then a representative sample shall be test solidified on each sub-sequent batch of the same type of waste un-til three consecutive test samples verify solidification using the alternate paramet-ers of step 6.3.3.
6.3.5 If a test sample fails to provide acceptable soldification of waste, mix equal volumes of dry cement and water to ensure that the pro-blem is not due to a bad batch of cement.
7.0 PROCESS FORMULATIONS Prior to actual solidification of the waste to be solidified, classification and accept-ability for near-surface disposal shall be determined as per RDP-ZZ-00004, WASTE CLASSIFICATION.
This will involve calculat-ing the activity within the projected waste drums using che isotopic analysis determined in step S.4 and the solidification formulas determined below.
7.1 Spent Resins 7.1.1 Solidify spent resins per formulas stated in,
Spent Resin Solidification, and operating sequences specified in RTN-HC-00005, Decanting and Drumming Station Operation. c-
"PCP" Data February 28, 1984 7.1.2 If the chemical analysis from Step 5.3 yields boric acid concentration in excess of J3* in the spent resin to be solidified, determine the amount of sodium metasilicate required for solidification from Attachment 4, Borated Waste Solidification, and add this to the formula (s) in Step 7.1.1.
7.2 Chemical Drain Tank Wastes 7.2.1 If the chemical analysis from step 5.3 yields boric acid concentration in excess of 3 in the chemical waste to be solidified, solidify chemical wastes in accordance with the formulation determined in Attachment 4, Borated Waste Solidification, and operating sequences specified in RTN-HC-00005, Decant-ing and Drumming Station Operation, and RTN-HB-00008, Chemical Drain Tank Operation.
7.2.2 If the chemical analysis from step 5.3 yields less than 3% boric acid concentra-tion, solidify chemical wastes in accordance with the formulation determined using At-tachment 5, Non-Borated Waste Solidifica-tion, and operating sequences specified in RTN-HC-00005, Decanting and Drumming Station Operation, and RTN-HB-00008, Chemical Drain Tank Operation.
7.3 Evaporator Bottoms 7.3.1 If the chemical analysis from step 5.3 yields boric acid concentration in excess of 3% in the evaporator bottoms to be solidi-fled, solidify evaporator bottoms in accord-ance with the formulation determined using,
Borated Waste Solidification, and operating sequences specified in RTN-HC-00005, Decanting and Drumming Station Operation, and RTN-HC-00012, Evaporator Bot-toms Tank Operation.
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"PCP" Dato Fcbruary 28, 1984 7.3.2 If the chemical analysis from step 5.3 yields less than 3% boric acid concentra-tion, solidify evaporator bottoms in accord-ance with the formulation determined using, Non-Borated Waste Solidifica-tion, and operating sequences specified in RTN-HC-00005, Decanting and Drumming Station Operation, and RTN-HC-00012, Evaporator Bot-toms Tank Operation.
8.0 SOLIDIFYING AGENTS As part of the operational Process Control Program, the fo'llowing requirements shall be set forth in the purchase specifications for the cement and sodium metasilicate.
8.1 Cement 8.1.1 Portland cement ASTM C-150, Type II or Type.
III 8.1.2 The tests listed in Attachment 2 may be used to differentiate'between types I, II and III of Portland cement.
8.2 Sodium Metasilicate 8.2.1 Sodium Metasilicate, anhydrous, granular (crystalline), commercial grade.
9.0 REFERENCES
9.1 ASTM Standards Part 13 9.2 STOCK EQUIPMENT COMPANY, General Process Control Program 9.3 RTN-HC-00005 9.4 RTN-HC-00012 9.5' RTN-HB-00008 9.6 10CFR20 "PCP" Date Fr.bruary 28, 1984 9.7 10CFR61 9.8 10CFR71 9.9 Reg. Guide 8.8 9.10 RDP-ZZ-00004 9.11 Radiological Effluent Technical Specifica-tion 3.11.3 0
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l WASTE SOLIDIFICATION DATA SHEET Batch No. :
Sample No. :
Date:
I Prepared By:
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Prior Batch Sample Solidification
~ Verify prior batch sample solidification performed. Check one below and show date and batch number of sample.
Evaporator Bottoms (Primary Date:
Batch No.
Evaporator Bottoms (Secondary) Date:
Batch No.
Chemical Wastes Date:
Batch No.
Resins'(Primary)
Date:
Batch No.
Resins (Secondary)
Date:
Batch No.
Other Date:
Batch No.
II.
Batch Sample Analysis-t A.
Lab Results-Sample Volume pH of Waste ess than 7 or greater than 10 refer to Section 6.1.1 of PCP.
Percent Total Dissolved Solids Boric Acid Concentration-
-Specific Gravity Waste Oil Content If greater than 1% refer to Section 6.1.2 of PCP.
- Radiocuclide Content Attach copy of isotopic gamma analysis Waste Classificatiod Printout.
B.' Waste Pretreatment pH - Identify agent used and quantity to adjust pH of the waste in the sample.
Agent / Quantity
-Adjusted pH'value' Performed by:
Date:
III.
Sample Solidification- (Required on at:least. every tenth batch of each type of wet i
radioactive waste.)
A.
Test Solidification Formula LVolume of Waste:
Volume.of Cement:
Volume of Sodium.Metasilicate:
-Waste /Ce=ent Ratio:
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' Attachment 1 Page 1 of 2
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l Cement / Sodium Metasilicate Ratio:
Total Volume:
B.
Free-Standing Water Analysis Volume of Decanted Water:
Volume of Sample:
% Free-Standing Water:
C.
Solidification Acceptability 1.
Percent of free-standing water calculated in Section III.B (above) must be less than disposal facility criteria.
2.
Visual physical appearance:
Verify that the solidified waste would maintain its shape if removed from the container.
3.
Other (state additional results here)
Performed By:
Date:
'IV.
Batch Solidification A.
Formula (Per Drum Basis)
Waste to be solidified (gallons)
Cement added (pounds)
Sodium Metasilicate (added)
B.
Remarks Performed by:
Date:
Reviewed by:
Date:
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"PCP" Dato Fcbruary 28, 1984 TESTS FOR PORTLAND CEMENT I
II III 1.
Appearance Light Medium Light (color)
Greyish brown Greyish brown Greyish brown 2.
Median Particle 200 300 60 Size (Microns) 3.
Consistency at water + cement = 0.45 Beef gravy Beef gravy Stiff mortar water + cement = 0.3 Thick mortar Dry mortar Dry, crumbly 4.
Cup (Loose) 3 Density (gm/cm )
1.16 1.04 0.93 (ASTM 488-78) 5.
Formulation (by weight) 33% of 12% boric acid (pH=10) + 58% cement
+ 9% sodium carbonate Consistency Thin crack Thick beef Soupy mortar filler gravy Set time 4 days I hour 10 minutes 6.
Chemical Test -
Example:
Tricalcium Aluminate 7 - 14%
4 - 7%
7 - 14%
Dicalcium Silicate 15 - 24%
23 - 33%
10 - 22%
-ATTACHMENT 2 Page 1 of 1
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PCP SPENT P2 SIN SOLIDIFICATION Percent Free Founds of Gallons of Standing Water Type III Cement Resins Slurry
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240 lbs 40.0 gals 15%
275 lbs 39.0 gals 20%
250 lbn 39.0 gals l
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~1 typical solidification would be to add two-thirds (2/)
3 of the waste en the first fill, tumble for two (2) minutes, the remainder:od the volume on the seconci fill, followed by an eight (8) minute tumble.
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38&oERAM FOR BORATED waste SOLIDIFICATION Brric 0
50 100 150 IJO 250 275 g
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20 30 40 3ri vogt 0
10 H Decreasing H Sod iten 55 43
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8 8 8 ' !8 3 5 8 18
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enhydrous
~2 rounda 10 20 30 40 50 55 63 50 6b 70 80 90 100 Units:
102 0
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Gite L l 3 I a l I' l 6 l I l 3
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31 32 0.5 Cellome 21 22 23 24 25 26 2T 78 29 32.5 29 28 30 20
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-Decreasing a
390 330 i
380 370 360 350 J40 l
"* Ch*"8' Cement No Change
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No Change I.
'l'I*I'iT TI31 ' PI gy, gg
' Units:
340 350 360 370 380 330 030 5 Founde 390 330 330 330 Bor ic I
10 20 30 4D 5n h*e
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0 50 100 150 2
Drs= streight line between top end bottco ocales To Use Thle Mc=nogree:
et seasured boric acid concentration.
, Page 1 of 1
PCP NOM 0 GRAM FOR NON-BORATED WASTE SOLIDIFICATION hercent Percent Totat Va.:c Type 111 Total Solids Str(as Cement Solids 0-3 r.. n --
375 0
.m 4 m M. s.
- 375 10 7
370
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- 50 each smil each small esd. Small each soll division equ.sla division equals d'e v ton equals division equala
.2 percent 0.1 gellen
'. wals, 2 percent At tache.en t 5 Page 1 of 1
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UNION ELECTRIC COM PANY 1908 GRATIOT STREET ST. Louis, MISSOURI MAIL 4NG ADDRESS:
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March 8, 1984
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Mr. Harold R.
Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Nashington, D.C._20555
Dear Mr. Denton:
ULNRC-759 DOCKET NUMBER 50-483 CALLAWAY PLANT, UNIT 1 PROCESS CONTROL PROGRAM
Reference:
ULNRC-694 dated December 2, 1983 The referenced letter transmitted the Process Control Program for Callaway Plant, Unit 1.
Comments were generated as a
" result of NRC review of this submittal and informally given to UE on February 23,.1984.
As a result of those comments, the Process Control. Program has been revised and five copies are provided as an enclosure to this letter.
If;there are any questions, please contact us.
Very truly yours, t
O q Donald hnell DS/lw En":losure (5. copies) i
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' STATE OF MISSOURI
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Robert J. Schukai, of lawful age, being first duly sworn
.upon oath says that he is General Manager-Engineering (Nuclear) for Union Electric Company; that he has read the foregoing document and knows the content thereof; that he has executed the same for and on behalf of said company with full power and authority to do so; and that the facts therein stated are true and correct to the best of his knowledge, information and belief.
By Rober J. S hukai Genera nager-Engineering Nuclear SUBSCRIBED and sworn to before me this [ E day of b, 1984.
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BARBARA J. PFAFF NOTARY PUBUC. STATE OF MISSOURI W COMMISSION EXPIRES APRIL 22, 1925 ST. LOUIS COUNTY 1
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Glenn L. Koester Vice President Operations Kansas Gas & Electric P.O. Box 208 Wichita, Kansas 67201
~ Donald T. McPhee Vice President Kansas City Power and Light Company 1330 Baltimore Avenue Kansas City, Missouri 64141 Gerald Charnoff, Esq.
Shaw, Pittman, Potts & Trowbridge 1800 M. Street,.N.W.
Washington,-D.C. 20036 Nicholas A. Petrick Executive Director SNUPPS 5 Choke Cherry Road Rockville, Maryland 20850 John H. Neisler-Callaway Resident Office U.S. Nuclear Regulatory Commission RRil Steedman, Missouri 65077 J. E. Konklin Division of Projects and Resident Programs, Chief, Section lA U.S.' Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, Illinois 60137 l
J. Holonich (NRC)
R. Fell (NRC) y e
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