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{{Adams
| number = ML19321A476
| issue date = 07/18/1980
| title = Ecopac Solidification Sys Process Control Program, Revision 4
| author name = 
| author affiliation = TENNESSEE VALLEY AUTHORITY
| addressee name = 
| addressee affiliation = 
| docket = 05000327, 05000328
| license number = 
| contact person = 
| document report number = PROC-800718, NUDOCS 8007230481
| package number = ML19321A475
| document type = TECHNICAL SPECIFICATIONS &amp; TEST REPORTS, TEST/INSPECTION/OPERATING PROCEDURES
| page count = 20
}}

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Sequoyah Nuclear Plant
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ECOPAC SOLIDIFICATION SYSTEM
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PROCESS CONTROL PROGRAM REVISION 4                                                                                                                                 :
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d TABLE OF CONTENTS            ..
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I.       Purpose II.      ECOPAC Solidification System Description              .
: 1. Plant Interface
: 2. Controls and Instrumentation                                                                             l
: 3. Electrical Control Panel                                                                                  l
: 4. Resin Catch Tank and Dewatering                                                                          l S. Waste Loader                                                                                             ,
: 6. A-Set Resin
: 7. Acid Catalyst                                              .                                             <
: 8. Mixing Manifold                                                                                          '
: 9. Liner Filling, Ventilation, and Dewatering
: 10. A-Set Foam                                                             *
: 11. Transporation Cask                                                                                   #
: 12. Containment of Spills                                                                                .-
: 13. System Flushing III. Waste Sample Collection and Analysis
                    . 1. Sample Procedure and Implementation
: 2. Collecting Samples
: 3. Sample Analysis
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IV.      Test solidification          .
: l. General. Solidification Considerations
: 2. Pretreatment
: 3. Test Solidification
: 4. Solidification Acceptability V.      Acceptance Criteria and Storage Specifications
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: 1. A-Set Resin
: 2. Acid Catalyst                          -
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: 3. A-Set Foam VI.      Technical Addendum                                                                                              l l
: 1. Technical Report on Urea Formaldehyde                                                                     l
: 2. ANEFCO, Inc., ECOPAC Systems Procedure for Onsite Solidification of Low-Level Radioactive Waste at Sequoyah Nuclear Plant
: 3. . Experimental Simulations of Radioactive Waste and A-Set Resin Formulations VII. Appendix
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Figure 2.1 - System Control Schematic e
                        . Figure 2.2 - Waste Loader Figure 2.3 - Dry. Disconnect Coupler                                                            '
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Figure 2.4 - ECOPAC Solidification Liner Diagram                                                        ~
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Figure 2.5 - Dewatering System                           ,
Figure 2.6 . Containment and Shielding Enclosure                -     -     -           'a' '
Figure 2.7 - ECOPAC Flow Diagram Figure 2.8 - Resin Catch Tank.             *
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           . Purcose
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The pu: pose of the ECOPAC Solidification System (ECOPAC system) Process                                                                      ._
Control Program (PCP) is to provide reasonable assurance of the complete solidification of processed radioactive wastes and of the absence of free-standing water of the processed waste within the limits as set forth in Federal guidelines. The PCP consists of the processing steps and established process parameters which include but are not limited to pH, oil content, ratio of A-Set solidification agent to effluent waste, water content, and ratio of A-Set solidification agent to acid catalyst for each type of anticipated waste.
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II. ECOPAC Solidification System Description i
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* System Description           -                      -
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Tha ECOPAC syatem rscriv00 radfoactiva WAttsa (filt2r gludgts, spent resins, evaporator bottoms, boric acid solutions, sodium sulfate solutions, and filter media), and combines the radioactive waste with A-Set solidifi-cation agent (A-Set resin) and acid catalyst. . The ECOPAC jiystem incorporates storage and feed provisions for the A-Set resin and acid catalyst, with a                            -
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self-contained trailer mounted process system to feed radioactive waste into the disposal liner, together with controlled proportions of A-Set resin and acid catalyst. The liner to be filled is normally positioned within its shielded transportation cask on a trailer to minimize handling and associated radiation exposure to operating employees.
The A-Set resin is stored in a large volume tank for onsite bulk storage. The a'
A-Set resin storage system also includes the pump, heat-traced piping, and elec-trical interconnects to facilitate metered flow of A-Set resin to the process system. Similar storage and feed provisions are made for the acid catalyst which is supplied in DOT-approved 30-gallon carboys. Additional containment is provided by the utilization of an other container (typically a DOT-approved 55-gallon 17H drum).
The follcwing discussion describes the operation of the ECOPAC system.
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: 1. Plant Interface                                                                                              -l 4
l The ECOPAC system receives radioactive waste at the Tennessee Valley Authority (TVA) Sequoyah Nuclear Plant as discussed herein. The ECOPAC                                          {
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system will be located inside the Sequoyah Nuclear Plant access bay during                                      !
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solidification operations. The ECOPAC system interfaces with plant                                              l equipment according to ANEFCO procedure entitled "ANEFCO, Inc., ECOPAC System Procedure for Onsite Solidification of Iow-Level Radioactive Waste
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at Sequoyah Nuclear Plant," Revision 0 (see Section VI) .
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The ECOPAC system operators will commence solidification. operations only upon receipt of a signed TVA Form SQNP-PCP and will comply with TVA's established health physics programs. The Sequoyah Nuclear Plant health physics' staff will provide health physics coverage and support. As each liner is solidified, TVA will provide the contracror with a Radioactive Material Shipment Record form certifying the volume of waste and total activity transferred to the contractor. TVA will perform radiation and contamination surveys while the contractor will follow approved procedures for cask preparation to ensure compliance with applicable regulations.
Contractor will provide all solidification agents, materials, liners, casks, unshielded van er trailer, and transportation of the solidified waste for disposal. The liner and equipment connections for interface between contractor and TVA will be standardized within TVA and will be of the Cam-Lok safety type or equivalent. The contractor shall be responsible for making the necessary connection to interface his equipment with the
;                   plant equipment.
: 2. Control and Instrumentation l
Figure 2.1 (section VII) depicts the process . system control schematic.
Operation can only be initiated by authorized employees with a key to
                                                                                                                                   .
l activate the power and safety switch. Automatic system shutdown or manual
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shutdown by the operator are initiated in case of malfunction or. unsafe operating conditions using instrumentation and alarms which are provided.                                '
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Filling cf a liner'can only procacd with a linar in pit.ca with proper
* connecticn to the wasts loadu (dircu3 red in subscetion 5).
                ~
Activation           <
cf the START FILL SWITCH Kutomatically opens tha normally closed wasta e
valve. Waste flow rate is monitored (totalized and recorded) by the ratio controllers which control the flow of A-Set resin and acid catalyst in the
_
proper proportion cozunensurate with the waste flow rate. The filling opera-tion causes annunciation by the liquid level probe and limit switch at the 7      .
first set level and then initiates automatic termination of the filling
* operation at the high level setpoint- (level indicator positioned within
* liner top access port as shown in Figure 2.4, section VII). However, the 1                 operator can manually terminate operation at any point by depressing the
]                  emergency shutdown switch (see Figure 2.1, section VII). Liner filling j                 will be monitored via close8 circuit TV (CCTV) (see figure 2.4) .
!                 The control units of the process system for the A-Set resin and the waste j
streams are +/- 54 full scale at the reference conditions ( A :CMd 40% rela-tive humidity). Process variable meter accuracy is +/- 2% full scale. The
 ,                variables are significantly lower than the solidification criteria acceptance i-                range of +/- 25% for the ECOPAC system.                             .
: 3. Electrical Control Panel
                                                                                                                                  ~
The electrical control panel is located in a shielded location within the process system trailer. Electrical service supplied to the control
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panel are 230-volt, 3-phase, 30-amp service, and 110-volt, 30-amp service.
Circuit breakers, motor centrol, and ground fault interrupters (110 volt only) are incorporated in the electrical control panel.
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The' electrical control panel provides both monitoring and process control functions. The monitors displayed on the electrical control panel are CCTV, Radiation Area Monitors, radioactive waste flow rate, A-Set resin flow rate j                  (which is totalized and recorded), and acid catalyst flow rate.
                                                                                                                                    .
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4 Visible and audible annunciation are provided, Indicator lights for i
each control function are green when powered and operating, and red when electrical power is absent, or the system is malfunctioning, or in an
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                -unsafe condition. Control systems which are monitored are:
i A.      Liner fill connection limit switches
                . B.,     Pump / Mixer, acid catalyst pump, and A-Set resin pump power C.      Acid catalyst and A-Set resin flow rate controllers                               -
4' D.      Liner level indicator E.      Radioactive waste, A-Set resin and acid catalyst flow meters
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F.      Radiation area monitors (RAM)
G.      Clc e   Circuit Television (CCTV)
Rapid termination of any phase of operation is always available to the operator by depressing the emergency shutdown switch. Activation of this switch places the system in a' safe shutdown configuration.
: 4. Resin Catch Tank and Dewatering A shielded resin catch tank (see figure 2.8) will be used to receive the
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resin slurry which is pumped to the rCOPAC system. The resin catch tank is fitted with a positive displacement progressive cavity open-throat, breaker-type moyno pump to move the resin tr. the process system. The purpose of the
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resin catch tank is to dewater the resin slurry and mininize the volume of e
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v2tsr cclidifitd. Tha conical shap2 of .thm tank and' tha tugar fasd micht.nica sGrvas to pr;vint' clogging of tha rsein.
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A dewatering filter will remove-the' excess water used to transfer resin from the resin storage tank to the resin catch tank. ,This excess water-                                                         ,
will be returned to the plant's tritiated drain tank.,'                                                        .           '!
: 5. Waste Loader                '
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Transfer of the radioactive waste /A-Set resin mixtute from the process
                   . system trailer to the liner is through the waste loader arm (see Figure 2.2, section VII). The waste loader arm is-a counterbalance swivel jointed pipe assembly which is mounted to the process system trailer. Connection can be
                     .made to_a liner which is positioned from 72 to 92 inches from the process system trailer.
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A dry-disconnect type coupling ~(female end) is attached to the end of the t'
waste loader arm. The dry-disconnect coupler is attached to the adapter i                      (male) which functions as the liner fillport. The cam. arms lock the com-
                               .
ponents together and the lever opens an internal valve to permit filling of the liner when flow is initiated.
: 6. A-Set Resin                                                                                                                   '
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A-Set resin (urea formaldehyde) is the solidification agent utilized in 1
the ECOPAC system for the solidification of radioactive wastes. Controlled amounts of.- A-Set resin (see section VI) are combined with the waste to produce a homogeneogs mixture in the process system. With the addition of an acid catalyst (H ion constituent), polymerization of the A-Set resin
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is triggered which solidifies the waste material within the polymer media.
The degree of reactivity of the A-Set resin can be controlled by the amount and makeup of the acid catalyst. Additional information is presa.nted in the reports entitled " Experimental Simulations of Radioactive Waste and A-Set
                    ' Resin Formulations" and " Technical Report on Urea Formaldehyde" (see section VI). The acceptance criteria for A-Set resin is presented in section V.
: 7. Acid Catalyst The acid ~ catalyst (phosphoric acid) provides the hydrogen ion necessary to
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t produce polymerization of the A-Set resin / waste mixture. The acid catalyst is injected into the liner during filling through a spray nozzle which produces a wide fan spray pattern for even distribution with the A-Set
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resin / waste' mixture. The flow rate of acid catalyst into the liner is
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controlled by ratio controllers as discussed in subsection 2.                                    The acceptance criteria for the acid catalyst is p~ resented in section V.
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: 8. Mixing Manifold                                                                                                                '
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                             "A pump / mixer is mounted inside the process system trailer. The radioactive waste, either directly from-the Sequoyah supply line-or from the resin catch tank, is fed into'the pump / mixer along with a separat,e feed of A-Set. resin..                                                   -
The pump / mixer is a positive displacement device with internal helical screw rotor-and matching stator to continously mix tha radioactive waste and A-Set resin, and pump the resulting mixture through the waste loader for liner filling.                .,
: 9. Liner Filling, Ventilation .and Dewatering i
The ECOPAC system liner diagram, Figure 2.4 (section VII), illustrates the arrangement of the liner within its shipping cask with connections and instrumentation'in' place. The radioactive waste /A-Set resin mixture is i'
transferred via the waste loader to the liner through the fillport. Venting ofdisplacedairdurgngfillingisthroughaventHEPAfilter. The liner
                             - volume will be 80 f t or greater. Acid catalyst flow Anto the liner is through a 3/8-inch stainless steel hydraulic. quick disconnect coupling. As is the waste loader arm, the acid catalyst quick disconnect is leak proof with an automatic internal ball-valve shutoff.
7 l                             The acid catalyst flow rate is proportional to the radioactive waste flow rate which is monitored by an ultrasonic flow sensor mounted outside a
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section of the waste line. The waste flow rate signal is used by a ratio controller to maintain acid catalyst flow at the desired rate.
A dewatering line is placed in the center of each liner and attached to a crossed perforated ' pipe in the bottom of the liner and at the top section.
1 This line is maintained under pressure until the liner has been filled and the contents have solidified. Following this step, the line is attached to I
a vacuum line to remove any water of hydration which could potentially be f                             present.
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: 10. A-Set Foam
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As the final step in the waste solidification, A-Set foam is injected into the void above the liner contents and into the dewatering line. This serves to both fill the void space and provide a secondary barrier for sicking any water of hydration which could potentially be present as the result of the
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chemical reaction.
    .                   11. Transporation Cask I
4 The'ANEFC0 AP-100 cask is licensed to ship loads with an activity limit of 0.05 curies per cubic foot. The cask ig licensed by NRC under Certificate of. Compliance No. 9074. Normally, a 90 f t capacity liner can be accommodated in the cask. However, shipments.with higher specific activity may be permitted
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with a special lead-and~ steel insert. In any event, the cask has a limitation that the contents and secondary containers not exceed 10,000 pounds.
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  .        12. Contninment of Spilla Personnel radiation protection and spill containment provisions are shown in Figure 2.6'(section VII). The dual purpose containment provides lead shielding for process system operator radiation protection. Also, the lower curbing and drainage provisions contain radiological spills                    --
and provide drain capabilities to appropriate containers.
,                The resin catch tank has an upper curb designed to prevent uncontrolled releases of radioactive resin due to spillage. Curbing will be established to contain spillages.
Since the liner is filled within the truck mounted cask, the cask will contain any spills due to inadvertent overflow.      In the event that a spill takes place, a second cask will be utilized. The liner would be remotely decontaminated and transferred to the second cask.
This will allow adequate time for decontaminating the first cask.
The maximum recommended operating pressure for the ECCPAC system is one hundred fifty pounds per square inch (150 psi) . The maximum working pressures of the hoses are from 150 psi to 300 psi.
* Additionally, solidification activities will not commence whenever the Sequoyah Nuclear Plant access bay doors are open.
: 13. System Flushing i
Purging and flushing of the isolated piping and hoses of the process system trailer is a remotely operated function performed by the operator at the control panel. Electrically operated solenoid valves are utilized at flush / purge locations. Utilization of solenoid valves limits personnel                            I radiation exposure in accordance with ALARA principles.
The cask liner liquid level probe and limit switch, signal two alarms (as                              ;
previously discussed in subsection 2) and causes the system to trip. The                               !
first trip / alarm signals when normal filling operations are completed.
The control panel operator then initiates the " flush mode" by depressing
,                the flush switch. The " flush mode" is a preset timed flush utilizing plant water to clear the waste lines while A-Set resin and acid catalyst pumps run in the normal mode.
                                                                                               .
The second trip / alarm signals when the liner is full and the final'" purge mode" is initiated. This alarm trips the " flush mode" and " normal mode" so that both modes are locked out until the liner is disconnected from the system.
i The final flush / purge step utilizing air, purges the waste line (containing water from the flush mode), the A-Set resin line, and the acid catalyst line.
The air purges the waste line from the primary interfacing valve _ to the cask liner and flushes the A-Set resin line to the cask liner. The acid catalyst                            I line is simultaneously purged forward from the acid control valve to the liner and from the control valve back to the storage carboy-(i.e., two directional).
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y III. WASTE SAMPLE COLIICTION AND MIALYSIS
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Waste Sample Collection and Analysis
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The guidelines in this section establish the procedure fer. collecting, analyzing, and evaluating test samples which are necessary to ensure complete .
solidification of each type of wet radioactive waste. The purpose of the test sample is to determine the proper A-Set resin / acid catalyst / waste ratio.
Test solidification serves as a quality control mechanism and as a verification of the proper stoichiometric ratios required to produce solidification.
: 1. Sample Procedure and Implementation 1.1 Verify the solidification of at least one representative test sample from at least every tenth batch of each type of wet radioactive waste (filter sludges, spent resins, evaporator bottoms, boric acid solutions, sodium sulfate solutions, and filter media) .                                          -
1.2 Batch is defined as the amount of waste that can be solidified
       -
in a single liner. There will be two (2) methods of sampling                          ;
the waste as follows.
: 1. For a continuous single transfer, a sample will be obtained from valve V-6 (or ,V-7 for resins) (see Figure 2.7 - section VII) .
: 2. For a multiple transfer to the resin catch tank, a sample of each transfer will be obtained from valve V-7 and a composite sample prepared.
                                                                             .
1.3 Operator shall not commence processing waste from the resin catch tank until the plant has stopped the transfer of waste and until one batch which is to be solidified is obtained.
1.4' If any test sample of resins obtained from valve V-7 fails to solidify, the batch in the resin catch tank shall not be solidified until a new
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test sample can be obtained from valve V-6, alternstive stolidification                 l
                      ' parameters are determined, and a subsequent test verifies solidification.
     .                  Solidification of the batch may then be performed using the alternative
                                                                                          ~
solidification parameters that have been determined.
i 1.5 If the initial test sample obtained from valve V-6 for a batch of              waste         I fails to verify solidification, a second sample will be collected          from valve V-6 and analyzed in accordance with subsection 3 and tested          to demonstrate solidification. After_ verification of solidification          by the preceding, return to the "at least every tenth batch" criteria.                         j
: 2. Collecting Samples
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2.1 Radiological Precautions
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: 1. All samples must be handled in accordance with proper radiological methods to meet as-low-as-reasonably achievable (ALARA) principles and to prevent the spread of contamination.
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: 2. Appropricta prettetiva. clothing shall ba worn while
         .       cellseting, handling, cnd testing all eruples.
: 3. A clean zone and controlled access z6ne shal1 be set up
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to prevent the spread of contamination.          .           .         ..
: 4. Any other requirements set forth by the onsite Health Physics staff must be complied with.
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: 5. A record of volume and description of the samples will be maintained on TVA Form SQNP-PCP as discussed below.
    . 2. 2 TVA Form SQNP-PCP
: 1. A' copy of TVA Form SQNP-PCP is attached to Sequoyah Surveillance Instruction SI-420. The contractor and TVA shall use TVA Form SQNP-PCP to record data from each test sample. In addition, TVA Form SQNP-PCP will be used to rer 4 data for- each solidification batch. The original copies will        i maintained in the plant file.
: 2. The following information is required by TVA Form SQNP-PCP                             ,
* for each test sample:
:
: 1. pH of waste
: 2. Waste oil content
: 3. Waste /A-Set resin ratio
: 4. A-Set resin / Acid catalyst ratio               .
: 3. The following information is required by TVA Form SQNP-PCP for each solidification batch:
: 1. Waste type
: 2. Flow rate
: 3. Total waste received
: 4. Total A-Set resin added
: 5. Total acid catalyst added
: 6. Batch number
: 4. The batch number will range from 1 through 10 and on at least each tenth batch of each type of wet radioactive waste, a-new set of process parameters will be determined.
2.3 Sampling continuous Transfers of Waste
: 1. Evaporator bottoms or other high temperature samples should be collected in stainless steel thermos bottles.
: 2. Resins and filter sludges should be collected in wide-mouth bottles o* other such containers from which the sample may be readily removed.
: 3. In the case of resins in which large volumes of slurry water are involved, scveral consecutive samples may have to be taken and the water decanted from the sample before a sufficient quantity of sample is obtained.         ,
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: 4. . Sample volumes should normally be 1 liter, however if radir'                    '-
levels make this impractical, smaller samples may be obtain          i
.                appropriate.
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                        -that a representative sample is in the transfer line.
2.4    Sampling Multiple Transfers to the Resin C5 itch Tank
                  - 1. The sampling techniques of 2.3 above are applicable.
: 2. Each sample of the partial batch will be placed in appropriate storage until the entire batch of waste has been transferred to the resin catch tank.
: 3. For each partial transfer, flow meter readings (see Figure 2.7 -
section VII) of the volume will be taken and recorded on TVA Form SQNP-PCP. These volumes will be used later to prepare a composite-sample.
: 4. Prepare a composite sample by determining the fraction of which each transfer contributed to the total volume Of resin transferred.
Multiply each transfer fraction by its respective volume to obtain the quantity of each sample to be added to the composite sample.
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: 3. Sample Analvsis
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            .3.1    Specific techniques for radioisotopic identification of samples are included in TVA Surveillance Instruction SI-420. All analytical results are to be recorded on TVA Form SQNP-PCP.
3.2   Evaporator bottoms shall be analyzed for the following and the results recorded on TVA Form SQNP-PCP.
: 1. pH '                                                                         -
: 2. Specific gravity
: 3. Oil
                                                              '
: 4. Sulfates
: 5. Boron 3.3 -Filter and resin sludges shall be analyzed for oil and pH and the results recorded on TVA Form SQNP-PCP.
3.4 Resin beads shall be characterized by analyzing the water surro~unding the beads for oil and pH. The results shall be recorded.on TVA Form SQNP-PCP.
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3.5 Radiochemical analysis will be performed by the Sequoyah Nuclear Plant Chemical Staff on each solidified batch. The analysis will include gross beta / gamma activity, the isotopes present, percent abundance of each isotope, and the total curie content.          _
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: 1. General Solidification Considerations           '
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1.1 ThestandardratiosofA-Setresin/wastewhichahetobeused                                                 .
on the first test solidification 'inless'other data shows different ratios should be used) are as follows:
: 1. Use a ratio of 1:1 for bead resins or other waste with a high percentage of solid material with a defined shape.
: 2. ' Use a ratio of 1:2 for filter sludges, evaporator bottoms, or other waste with a high percentage of dissolved or suspended solids.
1.2 If the pH of any waste is less than two, a caustic shall be added to increase the pH to greater than three before the addition of the A-Set resin. The sample size and the amouht of caustic added to the sample shall be recorded on TVA Form SQNP-PCP.
1.3 If foaming occurs in the waste sample, an antifoaming agent shall be added to the waste before addition of the A-Set resin. The sample size and the amount of antifoaming agent added to the se.mple shall be recorded on TVA Form SQNP-PCP.
1.4 If the oil analysis indicates oil concentrations of greater than 1%, attempts to remove the oil should be initiated.
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: 2. Pretreatment Pretreatment of radwaste is performed af ter a batch test sample indicates that action is required. 1Rua following conditions indicate the need for pretreatment and the corresponding action for the condition.
2.1 pH range is not between 3-7: Waste is normally transferred to the ECOPAC system at a pH of 8.5-10.0.      Therefore, the pH must be adjusted to the acidic side between 3-7 for solidification. This has a direct relationship to the Hammond acidity function. The pH is monitored by the use of a standard pH meter. The proper amount of acid (phosphoric) required to adjust the pH is determined using this meter readfhg. The acid is added in the mixing manifold thus ensuring uniform mixing and the desired resultant pH of 3.0-7.0.
2.2 Foaming action: An antifoaming agent shall be addad to the evaporator
                     - bottoms before solidification, if required.
2.3 Boron, SO4 , and other radicals: No action required for the waste since the material will be treated with hydrogen ion constituents before solidification.
2.4 Oil / Water / Solid ratio disproportionate: Absorption of the oil content of resins will occur in the resin catch tank during prejelling action.
2.5 011 content exceeds 1% by volume: The oil content will be reduced
                     - through mechanical separation before solidification. A new batch analysis shall be performed.
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     ?. Tret Solidifiertion 3.1 'Whenever pretreatment is necessary for a batch, the waste sample shall have the required pretreatment accomplished prior to the
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test solidification.                                                             ,
3.2  Prepare the test solidification vessel (normally a 1000-m1 disposable beaker) with a mixing device. This may be a disposable magnetic stirrer, a miniature air sparge system, or other mechanical means which may be used to mix the waste with A-Set resin.
3.3  Transfer a known representative volume of the waste to the test
* solidification container. A typical volume is normally 400-ml.
3.4 Add the appropriate amount of A-Set resin in accordance with the applicable ratios discussed in the general colidification considerations.
above. For example, 200-m1 of A-Set resin would be added to 400-m1 of evaporator bottoms.                                .
3.5  Initiate mixing of the waste and A-Set resin. After a homogeneous mixture is obtained (normally allow at least 10 minutes), begin the                       ,
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addition of acid catalyst until a pH of 3.0-7.0 is obtained.
3.6 As soon as the test sample begins to solidify, stop mixing and allow the sample to remain undisturbed for at least 30 minutes.
3.7  If any free-liquid is noted on the top of the sample, decant the liquid into a clean-disposable volumetric beaker and record the amount of liquid transferred. Calculate the percent.of free-liquid present and record the data on TVA Form SQNP-PCP, i.e.,~6-ml of liquid obtained from a test sample with a total volume of 600-ml would represent 1% free water.
3.8 Add a sufficient quantity of A-Set foam to the licuid in the beaker to absorb all the liquid. Record the amount of absorbent added.
Note and record if any liquid remains. Calculate the percent of free-liquid for the entire volume of solidified waste if any liquid was present and record all the results on TVA Form SQNP-PCP.
: 4. Solidification Acceptability                                                 -
4.1 The test sample solidification will be considered acceptable frcm a free-liquid standpoint, if the amount of free-liquid following the addition of A-Set foam is less than one half of 1% by volume.
4.2  The test sample solidification will be considered acceptable from a solid mass standpoint, if it is evident from its physical appearance that the solidified waste would maintain its shape if removed from the container.
4.3  If either or both of the above checks fail to meet-the stated criteria, alternative solidification parameters must be determined before solidification can proceed. This will also require the initiation of additional solidification testing requirements as discussed in section III.                  '
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* O PTMG mps AND STORAGE SPECIFICATIONS                    *
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* Acesptenca Criteria and Storag,Spreifications
: 1. A-Set Resin A sample.shall be analyzed for specific gravity and pH for each new shipment of A-Set resin and each 30 days thereaf ter f6r A-Set resin while -
in storage. Also, record the manufacturer's lot numbers and production dates on TVA Form SQNP-PCP. The normal storage life of the A-Set resin is 60 days. Thereafter, the shelf life may be extended in 30-day incre-ments by the addition of water to the A-Set resin to maintain viscosity.
Certification and testing of A-Set resin is performed at the manufacturing plant before shipment. A-Set resin contains urea-formaldehyde and is
(           currently acceptable as a solidification agent at the commercial burial grounds.
An A-Set resin bulk storage tank will be located in accordance with Drawing No. 2 of ANEFC0 procedure "ANEFCO, Inc., ECOPAC System Procedure for Onsite Solidification of Low-Level Radioactive Waste at Sequoyah Nuclear Plant," Rev. O, 1/31/80 (see section VII). The effective range of pumping and discharge temperature for A-Set resin is 50 F to 90 F.
                                                                                                      ,
Control of temperature and relative humidity should keep A-Set resin stable during normal storage. Reference conditions for A-Set resin is 25 C and 40% relative humidity. At 35 C (95 F), viscosity will increase
    -
rapidly during storage. For this reason, the bulk storage tank will be located indoors to prevent exposure to direct sunlight. Also, in low ambient temperatures, indoor storage is required to maintain the proper viscosity for effective pumping.
The following is a set of acceptance specifications for the A-Set resini Specification:     A-Set Resin Viscosity 025C:                                    700-1,400 Cps Specific Gravity #25/25 C:                         1.290-1.310 pH:                                                7.4-7.7 N1n-Volatile:                                      64-66%
Solvent:                                           Water Solids %:                                          66 + 1                '
Free Formaldehyde:                                 3% Eax.
Specific gravity is tested by use of a hydrometer and pH is determined by use of a standard pH meter. Specific gravity is tested initially upon arrival and before each use in solidification. The results shall be recorded on TVA Form SQNP-PCP.
: 2. Acid Catalyst The following is a set of acceptance specifications for the acid catalyst.                  j Specification: Acid Catalyst Specific Gravity:                                  1.639-1.694                              l Non-Volatile:                                      80-85% (H3 PO4 )
lbs/ gal:                                          14.1                                     1
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: 3. A-Set Foam Physical Properties                  ,
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Density                                   0.8 lbs/cu. ft.
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Ash content                             - 0.7%
Free formaldehyde                         1%
Setting time                              10-30 seconds Electric resistivity'                     5.00 ohms /cm wicking
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Water absorption                          3.8 hrs. 9 15% by weight ASTM Method                               6 1/6.9 e
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