ML20133F799
| ML20133F799 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 08/01/1985 |
| From: | Cochnar R, Schwenk A, Waldron J CLEVELAND ELECTRIC ILLUMINATING CO. |
| To: | |
| Shared Package | |
| ML20133F793 | List: |
| References | |
| PROC-850801, NUDOCS 8508080440 | |
| Download: ML20133F799 (13) | |
Text
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OH12E: PCP Page :
i Rev. :
2 THE CLEVELAND ELECTRIC ILLUMINATING COMPANY PERRY NUCLEAR POWER PLANT OPERATIONS MANUAL Process Control Program TITLE:
PROCESS CONTROL PROGRAM (PCP) l i
REVISION:
1 EFFECTIVE DATE:
9/27/85 4
DATE l
PREPARER:
Richard M. Cochnar/ Alan K. Schvonk 7/,7,fpf
/ (([ fjf 7/yA f REVIEWER:
/
/
PORC MEETING No.:
85-64 8/01/85
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2 Process Control Program (PCP)
Tabic of Contents Section Title Page
1.0 INTRODUCTION
1 1.1 Definitions 1
2.0 WASTE TYPES 2
2.1 Evaporator Concentrates (Bottoms) 2 2.2 Bead Resins 2
2.3 Filter Demineralizer Media Sludge 2
2.4 Traveling Belt Filter Cake 3
2.5 Filter Cartridges 3
3 2.6 Oily Waste 2.7 Dry Active Waste (DAW) 3 2.8 Other Materials 3
3.0 PROCESS DESCRIPTION 3
3.1 Filling of Tanks 3
4 3.2 Sampling / Analysis 4
3.3 Preconditioning 4
3.4 Mixing Ratios l
4 3.5 Dewatering 3.6 Solidification Processing 5
3.7 Cartridge Filters 5
5 3.8 Dry Active Waste 4.0 PRODUCT CONTROL 6
4.1 Test Solidification 6
6 4.2 Product quality 7
4.3 Acceptability 5.0 WASTE CLASSIFICATION AND CilARACTERIZATION 7
5.1 i'aste Classification 7
5.2 Waste Characterization 7
6.0 ADMINISTRATIVE CONTROLS 8
8 7.0 QUALITY ASSURANCE 8.0 RECORDS 8
REFERENCES 9
k OM12E: PCP Page : iii Rev. :
2 f-SCOPE OF REVISION:
Rev. 1-Change definitions for acceptable envelope and batch,.
clarification of requirc~ents for test solidification, and grammatical changes.
Rev. 2 - Change test solidification frequency and support testing for solidification mixing formulae.
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2 PROCESS CONTROL PROGRAM (PCP)
1.0 INTRODUCTION
The Process Control Program (PCP) is designed to provide administrative control and guidance for the solidification, dewatering and other processing of applicable forms of radwaste for ultimate disposal. The PCP contains information pertaining to the current formula (mixing ratio), sampling, analyses, tests, and determinations to be made to ensure that the processing and packaging of radioactive wastes, based on demonstrated processing of actual or simulated wet solid wastes, will be accomplished in such a way as to ensure compliance with 10CFR20, 10CFR61, 10CFR71, Federal and State regulations, burial ground requirements and other requirements governing the disposal of radioactive waste.
The PCP is applicable to the installed PNPP radwaste system and to any temporary systems and equipment supplied by vendors for solidification and dewatering of applicable waste foras.
Numerous features have been incorporated into the design of both the installed solid radioactive waste system and the building housing this system to insure that exposures of operating personnel to radiation will be kept within ALARA guidelines.
j 1.1 Definitions The following definitions are applicable to the sections that follow:
ACCEPTABLE ENVELOPE (of solidification / dewatering):
specific properties of wastes that fall within the limits of the parameters required for solidification. These parameters are established within the test solidification instruction for each applicable waste type.
BATCH:
the volume of isolated waste contained in a tank that will be processed for solidification or dewatering.
CONTAINER:
the physical container in which the final waste product is deposited.
HIGH INTEGRITY CONTAINER (HIC); an approved container for burial having an expected life of 300 years.
SOLIDIFICATION: the conversion of radioactive materials from liquid and solid systems to a monolithic, immobilized solid with a definite volume and shape, bounded by a stable surface of distinct
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2 outline on all sides (free standing), with a free water content of less than 0.5% by volume.
2.0 WASTE TYPES There are numerous types of radioactive material expected to be generated at PNPP that will require processing, including solidification or dewatering, prior to their disposal. These radwaste types can be categorized based on their chemical and physical properties. The waste types expected at PNPP are evaporator concentrates (bottoms), bead resins, filter demineralizer media sludge, traveling belt filter cake, filter cartridges, oily waste, and dry active waste (DAW).
The following waste types (other than DAW) may be solidified individually or in combination, with the provision that the chemistry of the waste falls within the acceptable envelope for.
solidification.
2.1 Evaporator Concentrates (Bottoms)
Evaporator concentrates (bottoms) result from the processing of the chemical waste tanks which contain condensate demineralizer regeneration solutions and/or low concentrations of the following:
trisodium phosphate, minute amounts of other chemicals used for chemistry analyses, or decontamination solutions. They will normally be in the range of 5% to 25% sodium sulfate by weight.
2.2 Bead Resins I
Bead resins are collected from the condensate, liquid radwaste, and suppression pool demineralizers and stored in the spent resin tank.
1 2.3 Filter Demineralizer Media Sludge Sludge is the waste product generated by the backwash of the condensate filters, the reactor water cleanup filter /demineralizers, and the fuel pool filter /demineralizers.
Sludge may consist of powdered ion exchange resin at varying degrees of exhaustion, fibrous filter media, and small concentrations of various solids and corrosion products. The media are decanted to approximately 10% by weight prior to solidification / dewatering in the appropriate settling tank.
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2 2.4 Traveling Belt Filter Cake This is the product remaining on the liquid radwaste traveling belt filters used to process waste water streams. It consists of one or more of the following; diatomaceous earth or powdered resin, various solids, dirt, and corrosion products in small concentrations.
2.5 Filter Cartridges Filter cartridges from the detergent drain tank-system, CRD pump suction and discharge filters, and any other disposable-type filter cartridge that may be used in permanent or temporary, plant or vendor systems are included in this category.
I 2.6 Oily Waste Oily waste is that oil collected in liquid radwaste systems as a resulting from leakage and maintenance on various lubrication and hydraulic systems.
2.7 Dry Active Waste (DAW)
Contaminated air filters, paper, rags, clothing, tools, equipment j'
and parts..that cannot be effectively decontaminated are contained in this category. Also included are laboratory wastes.
2.8 Other Materials Various other materials not specifically identified above, will be evaluated for solidification or dewatering on a case-by-case basis.
3.0 PROCESS DESCRIPTION The following process descriptions apply to both plant and vendor supplied systems. Any differences between the two have been noted.
3.1 Filling of Tanks Once a liquid radwaste system batch tank has been filled l
(constituting a batch), it will be recirculated to ensure a homogeneous mixture.
Eductors inside the tanks enhance the mixing capabilities. The waste is then transferred from the batch tank or traveling belt filters to one of the redundant solid radwaste mixing tanks on a batch basis. After the transfer, the fill isolation valve is closed and the fill line is backflushed to the tank from which the waste originated.
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2 3.2 Sampling / Analysis Samples will be obtained and analyzed for each batch of waste in accordance with OM12A:
CHI-42, OM12A: CHI-78, and RAP-1101, respectively for the plant syscem, or vendor procedures and PCP for vendor supplied systems. Prior to sampling, tanks will undergo sufficient mixing and/or recirculation to ensure representative sampling (as per OM13A: RWI-14). At a minimum, analyses will be performed for radionuclide content, pH, oil content, settled solids, and temperature in order to ensure the waste falls within the acceptable envelope for solidification / dewatering.
3.3 Preconditioning Waste preconditioning is the chemical or physical adjustment of the waste to bring it within an established acceptability envelope to ensure solidification. The need for and type of preconditioning shall be determined using sample analysis results and will be performed in accordance with OM12A: CHI-78 or vendor procedures and PCP. Upon completion of waste preconditioning, additional samples shall be obtained, as required, to determine solidification mixing ratios.
Oily wastes may require special preconditioning. Handling of oily wastes will be conducted in accordance with burial ground requirements.
3.4 Mixing Ratios Mixing ratios give the respective amounts of waste and solidification agents required for acceptable solidification. The determina~ ton of mixing ratios shall be performed for each batch of waste to be solidified. Solidification mixing ratios are dependent The upon percent settled solids and sodium sulfate concentration.
vaste type and ratios of cement, vaste, sodium sulfate (for Class A waste), and water are determined in OM12A: CHI-78 or vendor procedures and PCP.
3.5 Dewatering Dewatering is the removal of water from solid material to a concentration of less than 0.5% or 1.0% by volume, as applicable to containers used and burial site limits. Dewatering of radioactive spent resins and filter sludges shall be performed in accordance with approved operating procedures which are based up on documented I
test data demonstrating the ability to achieve drainable water l
limits as specified in applicable regulations.
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2 3.6 Solidification Processing Solidification will be performed using either a vendor supplied system or the plant system. The vendor supplied system will be discussed in the vendor manuals. The following description applies to the plant installed solid radwaste treatment system.
The plant solidification spstem allows for remote handling of the mixing and packaging of solidified waste, using closed-circuit TV and remote handling equipment.
After the proper amount of waste has been transferred to the waste mixing tank, the tank is decanted to remove excess free water (except when the waste being handled is traveling belt filter cake, in which case a predetermined amount of water or other approved aqueous solution is added to the tank for slurry transfer of the contents and for mixing with cement). The waste slurry is transferred at a preset rate to a waste / cement mixing pump into which cement is added via a vibrating screw feeder.
The waste / cement mixture is then transferred at a preset rate to the shipping container fill port station where it is loaded into approved containers. The vaste/cemant mixture is sprayed into the container through the waste fill no::zle while sodium silicate is
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metered through a second nozzle, ensuring thorough mixing. When a preset level in each shipping container is reached, feed valves are automatically closed and the feed lines flushed. The flush water generated by this operation is directed into the shipping container, where it is solidified with the radioactive waste.
I After the container is filled it is remotely capped, swipe tested, and then indexed to the decontamination / pick-up station.
If the container is contaminated, a remotely controlled set of water spray nozzles is used to wash down the container. Following decontamination, the container is dried with hot air to accelerate the drying process. The container can then be transferred to an onsite short-term storage area or prepared for shipment.
3.7 Cartridge Filters Cartridge filters may be disposed of by emplacement in a cement matrix in steel drums or liners.
Cartridge filters may also be disposed of by placement in HIC's.
3.8 Dry Active Waste Potentially contaminated dry wastes will be collected in containers located throughout the radiologically controlled areas within the plant. The waste will be periodically collected and transported to
)
a temporary storage area prior to waste segregation (as per
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2 OM1A:
PAP-1901). Waste segregation will be performed to reduce vaste volume and to recover reusable materials.
Compressible wastes will be compacted into shipping containers using a hydraulic ram to reduce the waste volume with caution taken to avoid items that would cause free water formation was well as other compressibility hazards. Noncompressible wastes will be loaded manually into suitable shipping containers.
4.0 PRODUCT CONTROL Solidification processes will be conducted by qualified PNPP or vendor personnel in accordance with approved plant and/or vendor operating instructions and procedures.
4.1 Test Solidification Test solidifications are performed on waste stream samples to verify plant and/or vendor calculated solidification formulae.
Test shall be performed to support solidification mixing formulae as follows:
(1) every batch of the same waste type; (2) when sampling analysis falls outside the normal established envelope
)
and preconditioning is ineffective, (3) following any line of the same waste type where solidification has been determined to be unacceptable; (4) when it is believed that some unexpected or abnormal contaminant may be present; or (5) when requested by Chemistry Supervision. A batch that requires test solidification shall not be processed until such time as the test solidification proves acceptable.
Upon f ailure of a test solidification, hdditional samples shall be obtained and testing will continue until a successful solidification has been performed with revised mixing ratios as determined by Chemistry Supervision.
Solidification of the batch may then be continued using the alternate solidification parameters defined by testing.
4.2 Product Quality Solidification process product quality shall be ensured by the use of predetermined mixing ratios of waste and solidification agents.
Mixing ratios are based upon laboratory testing of non-radioactive waste materials and are supported by (1) the test solidifications performed periodically, as mentioned aborie, and (2) periodic checks,visualandphysical,ofactualprocessedcontainersfilled with solidified waste.
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2 4.3 Acceptability The acceptability of the solidified product shall be verified by ensuring that less than 0.5% free standing water exists and that the solidified product appears to be able to hold its shape if it were to be removed from the container.
Unacceptable solidified waste shall be handled as follows:
(1) if the reason for unacceptability is free standing water, the free standing water will be removed or extra cement / sodium silicate will be added to solidify the free water; (2) if all or portions of the product did not solidify, the waste container will be capped and placed in a storage location in the Radwaste facility and periodically checked until such time that the product is acceptable or it is determined that additional solidification agents can be added to achieve satisfactory solidification. This will be determined by Chemistry Supervision. The handling of unacceptable solidified waste will be on a case-by-case basis.
5.0 WASTE CLASSIFICATION AND CHARACTERIZATION 5.1 Waste Classification I
All wastes shall be classified in accordance with the requirements of 10CFR61.55, as implemented by OM1A: PAP-1309 and OM1E: RAP-1102.
Analyses shall be performed on the waste streams at least annually (biannually for Class A waste), to determine the isotopic abundance of non-gamma emitting isotopes in the streams.
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Scaling factors, for the non-gamma emitting and transuranic constituents, will be developed from these analyses.
The activity of each radionuclide in the radioactive waste shall be determined by a calculational method employing the isotopic analysis of the waste and scaling factors.
For DAW, a dose-to-curie conversion factor, percent fraction of the radionuclides, and scaling factors will be used to determine activity.
5.2 Waste Characterization All wastes shall meet the characteristic requirements of 10CFR61.56(a) and (b), as applicable, and waste packages shall be marked to identify the waste class. The manifesting requirements of 10CFR20.311 shall be implemented and records maintained in accordance with 10CFR71.91. These records will be identified in the Records Retention / Disposition Schedule.
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2 6.0 ADMINISTRATIVE CONTROLS Compliance with applicable state and federal regulations, and with burial site criteria is ensured by compliance with the solid radioactive waste surveillance instructions, OM7A: SVI-G51-T5283 and SVI-C51-T5284.
The implementing instructions and procedures for radioactive waste solidification, dewatering, and segregation describe the requirements which must be met prior to processing radioactive waste, as well as the expected condition of the resultant waste form. Test solidifications, full scale calculations and operation of solidification, dewatering and segregation equipment shall be performed by qualified plant staff or vendor personnel. Plant staff personnel shall provide Health Physics and Quality Assurance coverage, operate plant radioactive waste systems, collect waste stream samples, and perform isotopic analyses. Copies of all referenced documents are available onsite for use by personnel engaged in vaste processing activities.
Any changes to the Process Control Program shall be reviewed by the Plant Operations Review Committee (PORC) and shall be detailed in the Semiannual Radioactive Effluent Release Report covering that period.
7.0 QUALITY ASSURANCE Quality Assurance related activities for the solid radwaste program are implemented as described in the Perry Nuclear Power Plant Quality Assurance Plan. These activities shall provide verification that all solid radioactive vastes meet applicable State and Federal regulations and burial site criteria.
8.0 RECORDS The following documents are generated by this program:
Quality Assurance Rec)rds None Non Quality Records None Waste classification records, vaste form records, and other records required for the preparation of the Semiannual Radioactive Effluent Release Report shall be prepared and retained in accordance with 10CFR71 requirements.
i
4 OM12E: PCP Page : 9 Rev. :
2 REFERENCES 1.
Title 10. " Energy," Chapter 1, Code of Federal Regulations, Parts 20, 50, 61, and 71, U.S. Government Printing Office, Washington, D.C.
20402, January 1, 1984.
2.
Title 49, " Transportation," Chapter 1, Code of Federal Regulations, Parts 170-178, U.S. Government Printing Office, Washington, D.C.
20402, November 1, 1983.
3.
U.S. Nuclear Regulatory Commission, " Standard Radiological Effluent Technical Specifications for Boiling Water Reactors," USNRC NUREG-0473, Revision 3. Washington, D.C.
20555, September 1982.
4.
U.S. Nuclear Regulatory Commission, " Low-Level Waste Licensing Branch Technical Position on Radiaoctive Waste Classification,"
Revision 0, May 1983.
5.
U.S. Nuclear Regulatory Commission, " Technical Position on Waste Form," Revision 0, May 1983.
6.
" Perry Nuclear Power Plant Unit 1 Technical Specifications,"
Revision 0, The Cleveland Electric Illuminating Company, Perry, Ohio 44081, March 5, 1985.
7.
Perry Nuclear Power Plant Units 1 and 2, " Final Safety Analysis Report," Amendment 14, The Cleveland Electric Illuminatihg Company, Perry, Ohio 44081, August 1984.
8.
" Perry Nuclear Power Plant Quality Assurance Plan," The Cleveland Electric Illuminating Company, Perry, Ohio 44081, March 8, 1984.
9.
"Barnwell Waste Management Facility Site Disposal Criteria,"
Document S20-AD-010, Revision B, Barnwell, South Carolina 29812, January 1, 1982.
10.
" Radioactive Materials License WN-I-019-2," Amendments 13 and 14, U.S. Ecology, Inc., Hanford Reservation, Richland, Washington 99352, December 23, 1983.
11.
Perry Nuclear Power Plant Operations Manual, " Solid Radwaste Solidification System," OM13A:
RWI-14, The Cleveland Electric Illuminating Company, Perry, OHIO 44081, October 17, 1984.
12.
Perry Nuclear Power Plant Operctions Manual, "Ra'dwaste Solidification Testing," OM12A: CHI-78, The Cleveland Electric Illuminating Company, Perry, Ohio 44081.
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OM12E: PCP Page :
10 - LAST Rev. :
2 REFERENCES 13.
Vendor Procedures and Process Control Program (Later).
14.
Perry Nuclear Power Plant Operations Manual, "Radwaste Volume Reduction Program," OM1A: PAP-1901, The Cleveland Electric Illuminating Company, Perry, Ohio 44081.
15.
Perry Nuclear Power Plant Operations Manual, "10CFR61 Compliance Sampling," OMlE:
RAP-1102, The Cleveland Electric Illuminating Conpany, Perry, Ohio 44081.
16.
Perry Nuclear Power Plant Operations Manual, " Radioactive Shipment Criteria," OM1A: PAP-1304, The Cleveland Electric Illuminating Company, Perry, Ohio 44081.
17.
10CFR61 Compliance Software Program (Later).
18.
" Records Retention / Disposition Schedule," The Cleveland Electric Illuminating Company, Perry, Ohio 44081.
19.
Perry Nuclear Power Plant Operations Manual, " Process Control Program Waste Stability Requirements," OM7A:
SVI-G51-T5283, The Cleveland Electric Illuminating Company, Perry, Ohio 44081..
20.
Perry Nuclear Power Plant Operations Manual, " Process Control Program Solidification," OM7A: SVI-G51-T5284, The Cleveland Electric Illuminating Company, Perry, Ohio 44081.
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