ML20235A892

Rev 6 to, Process Control Program for Processing of Radioactive Wet Waste

ML20235A892
Person / Time
Site:	Quad Cities
Issue date:	07/31/1988
From:	COMMONWEALTH EDISON CO.
To:
Shared Package
ML20207G213	List: ML20207G206 ML20235A892
References
PROC-880731, NUDOCS 8808240089
Download: ML20235A892 (19)

Text

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.00AD-CIT'IES STATION

. PROCESS CONTROL PROGRAM FOR PROCESSING OF RADIOACTIVE WET' WASTE ,

1 4 REVISION 6 JULY 1988 l ,

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1. PURPOSE' '!

The purpose of this Process Control Program (PCP) is to' insure that  !

L all low level' radioactive. wet. wastes solidified or dewatered at

'Ouad-Cities Nuclear Power Station meet the applicable federal, state and burial site requirements. This PCP sets.forth the steps:used to solidify or dewater radioactive wet wastes and to verify the final product meets the applicable requirements. This program covers the in-plant cement, vendor cement, vendor dewatering and vendor encapsulating systems. ' Wet wastes at Quad-Cities Station consist of filter media (powdered resin and fiber) and bead resin. When expended, these wastes are' transferred to various storage tanks or in some cases these wastes are transferred directly into a liner for processing. Vendor processing of the waste is done in either a transportation cask or a process shield and offers the advantage of reduced radiation exposure to personnel involved in -

performing the necessary package handling operations.

II. IN-PLANT CEMENT SOLID WASTE SYSTEM A. D J scription (Class A unstable waste form only)

The resin slurry is transferred to one of two centrifuges for dewatering. The centrifuges have a capacity of 25 gpm. The solids are separated from the water and drop into a hopper associated with each centrifuge. The water is routed back to a storage tank.

Each hopper has a 40 cubic foot capacity. At the bottom of-the hopper there is a hopper discharge valve. This is a remotely l l

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operated, air operated, fail closed valve. Connected to the hopper discharge valve is the sludge chute and the drum feed valve. The sludge chute is 8 inches in diameter and 6 feet 5 inches long, with a capacity of 2.2 cubic feet. The drum feed valve is also remotely operated, air operated, and fail-closed. The hopper discharge valve 01530/0229Z W

and the drum feed valve are interlocked to prevent both valves from being open simultaneously. "

Cement is added to a drum from the cement silo. The cement hilo has a capacity of 620 cubic feet. Cement is fed through a rotary feeder down a transfer tube through the mixer head, into the drum.

The mixer goes into the drum and forms a seal to prevent dispersion of cement dust or spillage during mixing. The mixer has two speeds, 100 rpm and 200 rpm, that are programmed into the mix cycle.

Drums are capped at the load-out conveyor area before loading into a shipping vehicle. A cap is set in place and a seal ring is snapped over it. A threaded bolt is used to tighten the seal ring.

Drum storage consists of three conveyor lines, with room for 25 drums on each line. Drums stored on the storage lines are removed and either shipped, stored in storage bins located in the radwaste facility, or stored in the Interim Radwaste Storage facility.

B. Operation of the In-Plant Cement Solid Waste System in order to insure solidification of spent resins with no free water, tests were conducted at Quad-Cities Station using unspent resin. Fresh resins were mixed up in the proportions that would be expected to be normally processed. These resins were then put into a drum and the drum was processed through the cement system. The drum was capped as normal and allowed to set in storage for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.

After 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, the drum was cut open lengthwise and inspected. Th'e results of the inspection resulted in a change of the proportions of water and cement until the final product was solid and free of water. A series of drums were processed using spent resins, and the drums were visually inspected for no free water prier to shipping.

No free water was observed. ,

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The general _ proceduro that is followed to process spent' resins 3 is described below.

Speci fic plant operating procedures are -followed. ,

-by the' operator. .

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1 The empty drum is covered with a plastic bag and taped in place to prevent external contamination.

2.

A half of a bag of dry cement is added to the empty drum.

3. The empty drums are loaded on a conveyor.

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One empty drum f rom the conveyor is loaded on a trans fer cart i i

(remote operation). ,

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The transfer cart is advanced to the selected hopper station

, (remote operation).

6.

The drum is filled with resins to a' prescribed level (remote operation).

The resin is transferred from the hoppe'r to the drum through the sludge chute. The discharge valve on the .

sludge chute is a manually operated remote valve. The operator views the drum through a mirror and fills the drum to between the first and second roll hoop from the top of the drum.

Although this method of adding resin to the drum is not precise, it can be controlled to a high degree. I f an operator determines that the quantity of resins varies f rom the prescribed level, he can compensate with water and/or cement.

7.

Water is added (remote operation). Normally 16-20 gallons of water are added to each drum. This amount can be varied if necessary for complete solidification. The amount of water required is selected, and a flow integrator gives the inlet valve a closed signal when that amount is delivered.

8. I The drum is transferred to the mixing station (remote operation).

9. The cement timer is set.

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10. The mixer cycle (remoto operation) is started. The mixer lowers into the drum and forms a tight seal. The mixer will begin to

. rotate at slow speed. The air slide blower and dust collector are. started. The cement feeder and vi,brators start and cement is metered to the drum. The mixer increases to fast speed. The cement feeder stops and the air slide blower and dust collector stop. When the mixer completes the cycle, the RPM meter will start to decrease. At this point, the mixer control switch is l

moved f rom AUTO to FAST and the mixer is givm an additional 5 )

minutes on fast speed. The switch is then returned to AUTO, and the mixer cycle is complete.

11. The drum is transferred to the inspection station (remote operation).

12. The mixed drum contact radiation reading are logged and the .

contents of the drum are observed. If it is determined that more cement is required, the drum is returned to the mixer and additional cement is added. When the mix is satisfactory, the drum is transferred to the drum storage lines.

C. Veri fication of in-Plant Cement Syste.n Solidi fication The solidified drum is verified to be void of free water prior to shipping or storage. The drum is transferred from the storage lines to the load-out conveyor. At this point, the drum is visually inspected to verify it is void of free water and the contents solidified. The protective plastic bag is removed, and the drum is capped. The drum is then surveyed for smearabla contamination and dose rate. The drum is then loaded into the shipping vehicle or placed in storage. ,

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If a drumlis found to contain' free water, dry cement willibe-

.added to solidify the free water.or the dru, will be recycled through the mixing line as required. The drum will not be shipped with more than 0.5 percent freestanding water.

Ill. VENDOR SUPPLIED S0LlDIFICATION SYSTEM (Stable Waste Forms)

A. Description Contractor solidification services are utilized at the Station for wastes which are required to be classifled as stable waste per'10 CFR 61 and/or burial site licenses. The contractor must have a PCP (Process Control Program) to produce a waste form which is stable as defined in 10 CFR 61. A copy of the vendor's procedures (which states station interface requirements), Process Control Program and NRC Approved Topical Report are submitted to an on-cite review prior to use to assure compatibility with Station Systems, procedures,'and

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Technical Specifications. Specific station procedures are then developed from this v'endor information and approved prior to use.

Normally, a batching tank is utilized to collect the radwaste to be solidified. The tank can be filled from any of the following:

1. Condensate Phase Separators.

2. Cleanup Phase Separators.

3. Spent Resin Tanks.

4. Waste Sludge Tank.

Af ter the tank is filled with radwaste, a decant pump is used to remove water from the top of the settled sludge. When the decanting operation is completed, the tank contains about 1,900 gallons of sludge, i

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uThe,' mixing' tank can be operated on1 recirculation to allow a tank' l sample'to be taken for analysis'and sample so'lidification tests'.as requi' red.

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r in certain cases, for example, wastes resulting f rom chemical decontamination, the wasteLis sent.directly to a liner in which the solidification will take place. In this case a PCP same'e is taken l

out-of the liner after it has been properly mixed prior to '3dding solidification chemicals. The recipe for solidification'will be determined based on a successful solidification demonstration using-the sample taken from the liner.

A temperature monitor'in the liner is used to note the maximum temperature during.the exotherm. After sufficient cooling the liner is prepared for shipment or storage.

B. Operation of the Vendor Solidification System -

A liner is' prepared for use by installing a thermocouple and tubing for level indication. The fill head is placed over the liner and locked in-place.

The radwaste is added to the liner. The mixing tank, if used, is first mixed for about 10 minutes. The proper amount of radwaste is delivered by a radwaste pump or slurried from portable processing equipment. Waste flow to the liner is monitored by a'TV camera. The radwaste pipe lines and waste transfer hose to the fill head are then -

1 flushed.

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After,tho radwaste has been put into'tho'l~iner the'processf i s f '*

1 completed by the contractor. The contractor adds cement and additives

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in accordance with their approved PCP. After final mixing the temperature is monitored and the maximum temperature is noted. When 1

the solidified liner has sufficiently cooled, the contractor and Station personnel visually inspect the product and' verify thatiit is an acceptable product. The liner is then covered with a lid, secured, surveyed and shipped or stored in the Interim Radwaste Storage Facility.

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C. Verification of Vendor Supplied Solidification System l

. Verification of solidification first involves sampling the  !

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radwaste prior to solidification in order to determine the proper 1 proportions of the ingredients that will produce an acceptable -

product. A representative laboratory sample of waste is taken. In accordance with the vendor's PCP program, small, scaled-down amounts of cement and additives are added in the proper quantities. Based on an acceptable product, scale-up factors are developed for the full scale solidification.

To further verify solidification, a visual inspection of the liner is performed by both the vendor and station personnel prior to installing the lid. The visual inspection verifies that the product is acceptable per the contractors PCP.

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IV. VENDOR SUPPLIED DEWATERING SYSTEM (STABLE CASTE FORMS)

A. . Description.

, Contractor dewatering services may be utilized at the Station in lieu of solidification for stable waste forms as directed by station operating personnel. The contractor must have a Process Control Program (PCP) to produce a waste form which meets all the requirements.

of 10CFR61 and the applicable burial site criteria. A copy 13f the vendor's' procedures (which states station interface requirements),

Process Control Program and NRC Approved Topical Repor't are. submitted to an on-site review prior to use to assure compatibility with Station c Systems, p'ocedures, r and Technical Specifications. . Specific station procedures are then developed from this vendor information and approved prior to use.

A mixing tank is utilized to collect.the radwaste to be -

dewatered. The tank can be filled from any of the following:

1. Condensate Phase Separators

2. Cleanup Phase separators

3. Spent Resin Tanks

4. Waste Sludge Tank After the tank is filled with radwaste, a decant pump is used to remove water from the top of the settled sludge. When the decanting operation is completed, the tank contains about 1,900 gallons of sludge.

The mixing tank can be operated on recirculation in order to allow a tank sample to be taken for analysis il required.

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j A High Integrity Container (HIC) is prepared for use by installing a thermocouple, if not already installed, and inspecting dewatering elements and thermocouple leads, if installed. The fill-head is placed over the Hl0 and locked in-place.

The radwaste is added to the' HIC. The mixing tank is first' mixed for.approximately 10 minutes.

The proper. amount of radwaste is delivered by the.radwaste pump. s Wa'te flow to the HIC is monitored by-a TV camera.

The radwaste pipe lines and waste transfer hose to.the fill head are then flushed.

After the radwaste has been put into the HIC, the balance of the

. dewatering process is completed by the contractor. .The contractor dewaters in accordance with their approved PCP until the acceptance criteria is met. When the process is complete, the contractor ~and -

Station personnel verify that it is an acceptable product and samples are taken from the HIC.

The HIC is.then covered with a iid, secured,-

surveyed and shipped or stored in the Interim Radwaste Storage Facility.

C.

' Veri fication of Vendor Supplied Dewatering System Verification of an acceptacle dewatered product is delineated in the contractors Process Control Program and operating procedures. The criteria is dependent upon the type of dewatering system used and the material dewatered.

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V. , VENDOR ENCAPSULATION OF CASTE'ISTABLE WASTE' FORMS) ,

'A.  : Desc r ip t ion

. Contractor encapsulation services may be utilized at the Station-

.for stable waste forms as directed by station operating personnel.

The contractor must have a Process. Control Program (PCP) to produce a waste form which meets all the requirements of 10CFR61 and'the applicable burial site criteria. Vendor procedures are used to 1

prepare specific Station procedures which are submitted to an on-site review prior to use..

B. Vendor Encapsulation Method A liner is prepared by the vendor which has a prepoured bottom and partial sides. The item to be encapsulated is placed inside.the prepour and the remaining portion of the liner is filled with a-stable formula of cement. -

When the encapsulation has sufficiently cooled, the contractor and Station personnel visually inspect the product and veri fy that it is an acceptable product. The liner is then covered with a lid, secured, surveyed and shipped or stored in the Interim Radwaste Storage Facility.

C. Veri fication of Vendor Encapsulation To verify solidification, a visual inspection of the liner is performed prior to installing the lid. The visual inspection verifies that the product is acceptable per the contractors PCP.

VI. HIGH INTEGRITY CONTAINER USAGE High Integrity container (HIC's) are used at the Station for various approved waste packaging. The vendor which supplies the HIC must provide l

the Station with a copy of the Certificate of Compliance for the HIC which details specific limitations on use of the HIC.

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Vll. WASTE CLASSIFICATION

• Station wastes will be classified as Class A, Class B, or Class C'to determine the acceptability for near-surface disposal and for the purpose of segregation at the disposal site. The waste class will be based on the concentration of certain radionuclides in the waste as outlined in 10CFRG1.55.

Radionuclides concentrations will be determined based on the vo$ume" or weight of the final waste form as discussed in Section C.2 of the Branch Technical Position Paper on Waste Classification.

Of the four. suggested methods .for determining radionuclides concentration, the one most commonly used is the direct measurement of

. individual radionuclides (gamma emitters) and the use of scaling factors to determine the radionuclides concentration of difficult to measure radionuclides (normally non-gamma emitters). The use of the other suggested methods; material accountability, classification by source or gross radioactivity measurements may occur if the situation best fits the use of that methodology.

Approved Station procedures are used in the determination of radionuclides concentration for difficult to measure nuclides (normally non-gamma emitters) and for the classification of radioactive waste for near-surface burial.

Vll. SHIPMENT MANIFEST Each shipment of radioactive waste to a' licensed land disposal facility will be accompanied by a shipment manifest as required by 10CFR20.311(b) and 10CFR20.311(c). The manifest wilI contain the name, address, and telephone number of the waste generator. The manifest will also include the name, address, and telephone number or the name and EPA hazardous waste identification number of the person transporting the waste to the land disposal facility.

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. The manifest <will also indicate'to the'ex' tent practicable: a physical ~

' description of the waste; tho' volume; radionuclides identity and quantity; the total radioactivity; and the principal ~ chemical form. The solidificationLagent, i f applicable, will be identi fied.

Waste containing more than 0.1%. chelating agents by, weight will be-identi fied and .the weight percentage 'o f the chelating ~ agent' estimated; Waste classification Class A, 8, or C, will be clearly indicated on the mani fes t. . The total . quant i ty of the radionuclides H-3, C-14 Tc-99, and 1-129 will be shown on the mani fest.

.Each manifest will include a certification by the waste generator that the transported materials are properly classified, described, packaged, marked, and labeled, and are in proper. condition for transportation

according to the applicable regulations of the Department of Transportation and the NRC. A representative of the Station will sign and date the -

mani f es t .

Approved Station procedures are used for the preparation of burial site radioactive shipping manifests.

The Station will maintain a manifest recordkeeping and tracking system that meets the requirements of 10CFR20.311(d).

IX. ADMINISTRATIVE CONTROLS A. Training A training program will exist to ensure that waste processing will be performed according to Station procedures and in accordance.

with the requirements of the PCP. An individual's training record will be maintained for audit and inspection. The processing and h

shipment of radioactive material will be performed by qualified and trained personnel.

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... 8 '. Record Retention i

Records of processing data, test and analysis results, documents. j I

results of training, inspections and audits will b; retained in l j accordance with company quality assurance requirements for record l

l retention.

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l C. Documentation Control

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Licensee initiated changes may be made to the PCP in accordance j with Section 6.9 of the Technical Specifications and shall become ef fective upon review and acceptance by the On-site Review function.

Radioactive waste that does not fall within previous waste processing experience will be evaluated and, if necessary, included in the PCP prior to final processing and disposal.

D. Quality Control Licens~ee procedures ensure that a vendor processing radioacti:ve waste, for burial, adhere to their procedures and that an acceptable product that meets regulatory requirements and burial site criteria results. This procedure addresses the requirement to assess the impact of changes in a vendor's PCP or the Station's PCP and requires a 10CFR50.59 safety evaluation for any changes in the vendor's PCP.

F 01530/0229Z QAP'1400-T1' Revision'2 QUAD CITIES STATION ONSITE September'1985 REVIEW ASSIGNMENT DATE /2/$~(([

REVIEW NO. ~[0 REVIEW PARTICIPANTS:

J. R's ce bl/20 t/

J. Foeiees6 f.l8TAl P seheens ASSIGNMENT:

Pll/f 60 YeV/3lIM Y 0h hdA {mp3 lDi ocess Ccvreel Pxopum la Pxocewh7 e/

A /0//CFlVe fh hMhe ~k AGSc)M / lfjCbhj AM //1;W O CG/Xf $df d/AbM S.

Cl)d/dhfh l7)$ $ M &J EAlb h STATION MANAGER d ,,/ " l APPROVED OCT 01985 (final) 0. C. O. S. R.

9/0321a _1 4

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QAP 1400-T2 QUAD-CITIES STATION Revision 4 ON-SITE REVIEW REPORT November-1987 Reference Information: OSR Recuest Originator:

OSR No: Ah' Station Off-SiteReview[

Review Date: NLA Other' Request Date: NFS BWR Engineering Sub1ect; & gh b { f fffj lgcct$f kic,,

jptr_ff/rlf 0 I hN/McfM hgf h ,ppgo/h A$hth ey(p ftl

?77 Reason for Review:

Tech. Spec. 6.1.G.2.a / (On-Site)

Tech. Spec. 6.1.G.l.a (Off-Site)

Other: NRC Bulletin Station f

On-Site Reference Mater'als (attach):

SafetyEvaluationg!fh/d)-#J Procedures Affected Tech Spec Pages FSAR Pages AIR Number ,

I Other Disposition; i Routine Report Off-Site Review for Concurrence (T.S. 6.1.G.2.a.(S))

AIR Issued (# )

NRC Submittal Needed Technical Specification ~ Change Unreviewed Safety Question

/ n ft y1thl/l f b/mi MMAI A j'WI i

Other / l No Further Action f M / O n t /r/i m t /r/tDiv' het M . 4.9. C. l l Other I APPROVED 9/0322a NQy 281987 0.C.O.S R

l

QAP 1400-T2

., Revision 4 f

QUAD-CITIES STATION ON-SITE REVIEW REPORT OSR NO N'hd ON-SITE REVIEW

SUMMARY

!/ Y 9  ! hyA ' I?] /4C8d5 ff717A0 kA hi dOC!&S/Nf of $$c/ijger/Ve IOef Wpg/e /rnetfs fje ,,

o / ,s// q p he M k de9okhins As psocess9 s e fpdio erin is4f Mx' les.

ON-SITE REVIEW RECOMMENDATION: hggg g //gd/?/7//N N f e t'6?V/el 01h/tJ vl A*cl onerire ShMl//n PAoCr5S Cnrrao/ D eo9 w r>r AA' 9 P i

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betserwe r/V/rud /sArte /;ss4I,we 7fcA fpu. d.9,c./

i PARTICIPANTS: l.# M A- e * ~ " -

NLC l, qIL155b l Approved: A Station Mana@r/  !

ATTACHMENTS:

Date: / 2 /6!?I APPROVED NOV 251987 (fin &l) 9/0322a 0.C.O.S R l

Rev.' O

. . 1-1-87 OSR FORM RECORD OF REOUEST FOR OFFSITE REVIEW fCV 7 o k t)A (If/PJ hAb/M he & peg Sub]ecc W o WZA??? lC/t P'/20Q*SS//h A l M cll M c r/ & I h /A/4{o{e Station 8/14 [/w#f onsite Review No. b Submitted by ] oDAGE Dats /2 N Test or experiment not involving an unreviewed safety question.

Proposed test or experiment involving an unreviewed safety question Proposed change'to procedure, equipment or systen involving an unreviewed safety question.

/ Proposed change to Tech. Spec. or license.  !

Unanticipated deficiency of design or operation of safety related structures, systems, or components.

Proposed chenge to GSEP.

Referral by T. 5. Supervisor, Station Manager, Assistant Vice President and General Manager of Nuclear Stations Division, or Manager of Quality Assurance

.dditional subject description: II /M//[#1 A Wae#

1. # /PM h b A//bcd &A17 wad 7tvl Gb eAb/tv1 n $/ $b) bst Supporti g documents attached:

Date required for offsite Review completion:

Reason for specified date:

Received by Data Senior Participant offsite Review No.

IV-16 I l

, , OAP 1100-713 Revision 3 e SAFETY EVALUATION CHECKLIST Septemeer 1938

.nn A CC . I A f!

saf ety Eva1 agn su m b/

an uu system o g

Title:

f [Ad / / NbM l.a.bscribpl y ton f the conce CA URL 4T k dd////Yb" f $n1T/20l $A?H CW4WJ lstyv/

' cgg/ OTMG 1.c. sy ems and c y h:gpon.;;;:noe ents affected; g

<ied44C77d/.S.,4, g

//Wago,s />7Ws wee.uc+f6 rs 1.d. Is this evaluatton a JC0 (see QAP 1100-12 step C.I.b.)? Yes No

2. List reference documents reviewed which describe the components or administrative cor.trols applicable to the subject of this evaluation.

REFERENCE DOCUMENTS REVIEWED

4. FSAR Section(s) k '

f. Fire Protection Progr 00Cu Pkg Section(s) V

b. SER Section(s) g. Code of Federal Regulations

c. Tech Specs _a n. Reg. Guides

d. Previous safety Evaluations k 1. Procedures

e. Unit Operating License j. Other k

3. State the effects on the following functions:

4. Site or Security  %

b. Mechtnical l

c. Structural ,/

d. Electrical ./

e. Instrument and Control / i .

f. Fire Protection I _ A u A/

g. Radiological I ' l/ O '

h. Flood Protection \# .__ _ . .

1. Administrative Control \ M_//Mu? -Inl/elallMf//M. J et/W /A) M i  ;

4. If this evaluation is for a procedure, does the procedure or procedure revision constituja a change to a procedure as described in the FSARf Explain; fjM YES ( )NO([

5.

boeJ Does the /1/suoject

$ ACS48 of thisY)ft Cf U [mTASl evaluat tofinvolve operatinghA09AO71 methods or configurations contrary{ to

! jth intent described in the FSAR and further specified in the Tyh Specs? Explain; ff g syf/q jfggjQf Wh & f]AYd YE5 ( ) N0 ( /

6.

Isa!fch.

A ocess Spec.

C4rsof pas 9wn,/ppy angerequirydt Explain: 7 YES ( ) NO (d le7 war  % kNr$. A yewSS d>n i e If ALLSo the answers in 4

. or 6 are NO. this eva ion i o ,p e.

• If A_H. of the answers in 4 5. or 6 are YES, answer the 10 CFR 50.59 questions on Q.P. 3-51-2. (QAP 300-$13, QAP 1100-T12. or CAP 1500-$12)

• Send a copy of this checklist and any applicable 10CFR50.59 review forms to the Tecn l Staff Clerk.

PREPARED BY: - / 21 OATE:  !

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Tss 0.E. [ OATE: /2 ff' SEP 261988 i 18/0 b' (final) 0. C. O. S. R

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