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i ULNRC-20.70 l-l i
          .  .,..                                                                                                                            Attachment 5 ULNRC- 20.70                                                 '
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i PROCESS CONTROL PROGRAM MANUAL                                                                                                                           l
i PROCESS CONTROL PROGRAM MANUAL l
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APA-ZZ-01011 Revision O     i July 24, 1989 NUCLEAR FUNCTION ADMINISTRATIVE PROCEDURE A.PA-ZZ-01011 PROCESS CONTROL PROGRAM MANUAL (PCP)
APA-ZZ-01011 Revision O i
RESPONSIBLE DEPARTMENT Ernisbsf     Ed(;jde_
July 24, 1989 NUCLEAR FUNCTION ADMINISTRATIVE PROCEDURE A.PA-ZZ-01011 PROCESS CONTROL PROGRAM MANUAL (PCP)
f       I PREPARED BY       .    . 3.& jn               DATE 71     87 APPROVED BY                                       DATE DATE ISSUED This procedure contains the following:
Ernisbsf Ed(;jde_
Pages                   1           through         17 Attachments             1           through         4 Tables                               through Figures                               through Appendices                           through Checkoff Lists                       through 4
RESPONSIBLE DEPARTMENT f
I PREPARED BY 3.& jn DATE 71 87 APPROVED BY DATE DATE ISSUED This procedure contains the following:
Pages 1
through 17 Attachments 1
through 4
Tables through Figures through Appendices through Checkoff Lists through 4


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APA-ZZ-01011
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1-4 DISCLOSURE STATEMENT The Formulations contained in this document are considered.
    . ,                          4 DISCLOSURE STATEMENT The Formulations contained in this document are considered.
proprietary to Union Electric Company and its installed Solid
proprietary to Union Electric Company and its installed Solid
:Radwaste System supplier and shall not be duplicated, used, or disclosed outside the Nuclear' Regulatory. Commission or Union Electric Company'in whole or in part.
:Radwaste System supplier and shall not be duplicated, used, or disclosed outside the Nuclear' Regulatory. Commission or Union Electric Company'in whole or in part.
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APA-ZZ-01011 Rsv. O TABLE OF CONTENTS l
APA-ZZ-01011 Rsv. O TABLE OF CONTENTS l
p                         Section:                                                   Page Number
p Section:
Page Number Purpose and Scope 1
1.0 2.0 Definitions 1
3.0 10CFR61 Compliance Methodology 2
4.0 Administrative Controls 3
i 5.0 Radioactive Waste Processing Using Installed Solidification System 4
5.1 Collection.and Annlysis of. Samples 4
5.1.1' + General.. Requirements.
4 5.1. 2 '
. Collection of Samples 5
5.1.3 Chemical Analysis of Waste Samples 7
5.1.4 Radiochemical Analysis of Waste Samples 7
5.2 Test Solidification and Acceptance Criteria 7
5.2.1 Waste conditioning 7
5.2.2 Test Solidification 8
5.2.3
. Test Solidification Acceptability 9
5.3 Process Formulations 10 5.3.1 General Requirements 10 5.3.2 Spent Resins / Charcoal 10 5.3.3 Chemical Drain Tank Wastes 10 5.3.4 Evaporator Bottoms 11 6.0 Radioactive Waste Processing Using 11 Bulk Disposal Methods 6.1 Radioactive Waste Processing Using 11 Contracted Vendor Services 6.1.1 General Requirements 11 6.1.2 Control of Vendor Procedures and Documentation 13 6.2 Radioactive Waste Processing Using 14 In-House Bulk Disposal Options 6.2.1 General Requirements 14 6.2.2 Waste Sampling 14 6.2.3 Packaging of Spent Filter Cartridges 15 6.2.4 Packaging of Spent Ion Exchange 16 Bead Resin l
7.0 References 16


==1.0        Purpose and Scope==
s.
1 2.0        Definitions                                          1 3.0        10CFR61 Compliance Methodology                      2 4.0        Administrative Controls                              3            i 5.0        Radioactive Waste Processing Using Installed Solidification System                      4 5.1        Collection.and Annlysis of. Samples                  4 5.1.1' + General.. Requirements.
l:
4 5 .1. 2 ' . Collection of Samples                                5 5.1.3      Chemical Analysis of Waste Samples                  7 5.1.4      Radiochemical Analysis of Waste Samples              7 5.2        Test Solidification and Acceptance Criteria          7 5.2.1      Waste conditioning                      .            7 5.2.2      Test Solidification                                  8 5.2.3    . Test Solidification Acceptability                    9 5.3        Process Formulations                                10 5.3.1      General Requirements                                10 5.3.2      Spent Resins / Charcoal                            10 5.3.3      Chemical Drain Tank Wastes                          10 5.3.4      Evaporator Bottoms                                  11 6.0        Radioactive Waste Processing Using                  11 Bulk Disposal Methods 6.1        Radioactive Waste Processing Using                  11 Contracted Vendor Services 6.1.1      General Requirements                                11 6.1.2      Control of Vendor Procedures and Documentation      13 6.2        Radioactive Waste Processing Using        :  -
l' APA-ZZ-01011 Rcv. O Attachment'l - Resin Solidification Formulations
14 In-House Bulk Disposal Options 6.2.1      General Requirements                                14 6.2.2      Waste Sampling                                      14 6.2.3      Packaging of Spent Filter Cartridges                15 6.2.4      Packaging of Spent Ion Exchange                    16 Bead Resin                                                        l 7.0        References                                          16
.(PROPRIETARY) 1 Page - Concentrated Wastes (Non-Borated)'
: s.      .
Solidification (PROPRIETARY) 1 Page.- Concentrated.Wates (Borated) Solidification
l:         -      -
'(PROPRIETARY)
l'                                                                               APA-ZZ-01011 Rcv. O Attachment'l - Resin Solidification Formulations
'l Page' - Sodium Metasilicate Addition (PROPRIETARY) 1 Page O
                                      .(PROPRIETARY)         .
h
1 Page Attachment 2 - Concentrated Wastes (Non-Borated)'
-111-
Solidification (PROPRIETARY)                   1 Page Attachment 3.-   Concentrated.Wates (Borated) Solidification
                                      '(PROPRIETARY)                                 'l Page' O
Attachment 4 - Sodium Metasilicate Addition (PROPRIETARY)       1 Page h
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APA-ZZ-01011 Rev. O RECORD OF REVISIONS Revision Number                                   Revision Date       Reason for Revision Process Control Procram (PCP)
APA-ZZ-01011 Rev. O RECORD OF REVISIONS Revision Number Revision Date Reason for Revision Process Control Procram (PCP)
Rev. O                                     October 1983         Initial issue.
Rev. O October 1983 Initial issue.
Rev. 1                                     February 1984       Incorporation of NRC review comments.
Rev. 1 February 1984 Incorporation of NRC review comments.
Rev. 2                                     December 1984       Revised to generic, non-procedural format; updating of formulations' for solidification of wastes.
Rev. 2 December 1984 Revised to generic, non-procedural format; updating of formulations' for solidification of wastes.
Rev. 3                                     March 1985           Added solidification nomogram for concentrated borated wastes and renumbered attachments; clarified sample analyris documentation requirements.
Rev. 3 March 1985 Added solidification nomogram for concentrated borated wastes and renumbered attachments; clarified sample analyris documentation requirements.
Rev. 4-                                     August 1985         Incorporated Class A " unstable" resin solidification formulation (based upon in-plant testing).
Rev. 4-August 1985 Incorporated Class A " unstable" resin solidification formulation (based upon in-plant testing).
Rev. 5                                     March 1986           Update solidification formulation nomegrams; revised covershe'st and
Rev. 5 March 1986 Update solidification formulation nomegrams; revised covershe'st and
                                                                                                              " preface # portion of document; removed section dealing with solidification agents from document; made formulations propietary documents.
" preface # portion of document; removed section dealing with solidification agents from document; made formulations propietary documents.
Rev. 6                                     April 1986           Incorporated section dealing with control of vendor services for packaging of solid radioactive wastes; revised purpose to agree more closely with wording shown in Technical Specification definition for         ,
Rev. 6 April 1986 Incorporated section dealing with control of vendor services for packaging of solid radioactive wastes; revised purpose to agree more closely with wording shown in Technical Specification definition for
                                                                                                              " Process Control Program"           )
" Process Control Program"
                                                                                                        -iv-
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APA-ZZ-OlOll Rsv. O Rev. 7 ' June 1987       ' Revised'section. dealing with contracted vendor services to clarify type.of. services involved.
APA-ZZ-OlOll Rsv. O Rev. 7
Rev. 8 September 1987     Revised recorded boundary R
' June 1987
conditions / ratios for batch solidification; revised acceptance criteria for structural stability incor-porated wording regarding full scale test solidi-fication; minor text wording changes.
' Revised'section. dealing with contracted vendor services to clarify type.of. services involved.
Rev. 9 December 1988     Revised format to reflect actual use of document (program vice procedure);
Rev. 8 September 1987 Revised recorded boundary conditions / ratios for batch R
solidification; revised acceptance criteria for structural stability incor-porated wording regarding full scale test solidi-fication; minor text wording changes.
Rev. 9 December 1988 Revised format to reflect actual use of document (program vice procedure);
incorporated new section(s) dealing with bulk disposal of wet radioactive waste; revised solidification formula (s) in-stalled system solidification' based-upon vendor recommendation.
incorporated new section(s) dealing with bulk disposal of wet radioactive waste; revised solidification formula (s) in-stalled system solidification' based-upon vendor recommendation.
                .APA-ZZ-OlOll Rev.. O July 1989           Incorporation of Tech. Spec.-
.APA-ZZ-OlOll Rev.. O July 1989 Incorporation of Tech. Spec.-
Amendment OL #1087. Formal controls on PCP.placed under Administrative Procedure.
Amendment OL #1087.
Formal controls on PCP.placed under Administrative Procedure.
Added Commitment Tracking System Numbers (CTSNs).
Added Commitment Tracking System Numbers (CTSNs).
                                              -v-
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APA-ZZ-01011 Rcv. O CALLAWAY PLANT PROCESS CONTROL PROGRAM MANUAL (PCP) 1.0         PURPOSE AND SCOPE The purpose of the Process Control Program 4166,4700,             (PCP) is to provide reasonable assurance 41638,41885             and documentation that the processing and packaging of solid radioactive wastes based on demonstrated processing of actual or simulated wet solid wastes will be accom-plished in such a way as to assure com-pliance with 10CFR Parts 20, 61 and 71, State regulations, burial ground require-ments, and other requirements governing the disposal of the. radioactive wastes.
APA-ZZ-01011 Rcv. O CALLAWAY PLANT PROCESS CONTROL PROGRAM MANUAL (PCP) 1.0 PURPOSE AND SCOPE The purpose of the Process Control Program 4166,4700, (PCP) is to provide reasonable assurance 41638,41885 and documentation that the processing and packaging of solid radioactive wastes based on demonstrated processing of actual or simulated wet solid wastes will be accom-plished in such a way as to assure com-pliance with 10CFR Parts 20, 61 and 71, State regulations, burial ground require-ments, and other requirements governing the disposal of the. radioactive wastes.
The PCP contains the campling, tests, analyses, determinations and formulations by which waste classification, solidifica-tion and/or dewatering of radioactive vastes fren liquid systems is assured.
The PCP contains the campling, tests, analyses, determinations and formulations by which waste classification, solidifica-tion and/or dewatering of radioactive vastes fren liquid systems is assured.
2.0         DEFINITIONS Solidification   The conversion of wet vastes into a form that meets shipping and burial ground requirements.
2.0 DEFINITIONS Solidification The conversion of wet vastes into a form that meets shipping and burial ground requirements.
1 Waste Classification - The determination of I waste class as outlined in 10CFR61 by radionuclides isotopic analysis and/or cor- 1 relation with measured nuclides.
1 Waste Classification - The determination of I
Dewatering - The process of removing water from a bed of wet solid waste. Dewatering processes may be utilized to prepare wet     j solid waste for shipment without solidifi-   I cation using cement or other chemical agents. Dewatered wastes must meet NRC and   j burial site conditions on maximum drainable liquid content.                             l
waste class as outlined in 10CFR61 by radionuclides isotopic analysis and/or cor-1 relation with measured nuclides.
Dewatering - The process of removing water from a bed of wet solid waste.
Dewatering processes may be utilized to prepare wet j
solid waste for shipment without solidifi-I cation using cement or other chemical agents.
Dewatered wastes must meet NRC and j
burial site conditions on maximum drainable liquid content.


APA-ZZ-01011 Rcv. O Batch - A specified quantity of liquid wastes / sludges requiring solidification or dewatering (ie., the amount of waste con-tent within a tank, or, the amount of waste content within'two or more tanks if the contents of the tanks are to be solidified or dewatered together within a common con-
APA-ZZ-01011 Rcv. O Batch - A specified quantity of liquid wastes / sludges requiring solidification or dewatering (ie., the amount of waste con-tent within a tank, or, the amount of waste content within'two or more tanks if the contents of the tanks are to be solidified or dewatered together within a common con-tainer) any portion of which would have the
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tainer) any portion of which would have the same physical and chemical characteristics as the whole. If new material is added to a tank's contents which is currently being processed, a new batch is created and fur-ther sampling must be performed prior to solidification or dewatering.
same physical and chemical characteristics as the whole.
3.0   10CFR61 COMPLIANCE METHODOLOGY 2713,2720,       All packaged radioactive wastes generated 5865             at the Callaway Plant shall meet the requirements of Title 10 Code of Federal Regulations Part 61 (10CFR61). As a mini-mum, all radioactive waste streeta sources must be sampled and analyzed on an annual basis for development of applicable radion-uclide correlations for detenaining wasts                                     i 1
If new material is added to a tank's contents which is currently being processed, a new batch is created and fur-ther sampling must be performed prior to solidification or dewatering.
classification rend packaging requirements.
3.0 10CFR61 COMPLIANCE METHODOLOGY 2713,2720, All packaged radioactive wastes generated 5865 at the Callaway Plant shall meet the requirements of Title 10 Code of Federal Regulations Part 61 (10CFR61).
Waste Classification (10CFR61.53) require-ments shall be met by the methodology asta-blished in plant operating procedure (s) governing Waste Classification. Haste Characto.rization (10CFR61.56) requirements shall be met by a combination of the metho-dology stated in the Process Control Pro-f' gram and related Callaway Plant Operating Procedures. Stability requirements stated in 10CFR61 56 (b) and by burial site shall be met and ensured prior to shipping pack-aged radioactive waste offsite for burial.                                   -
As a mini-mum, all radioactive waste streeta sources must be sampled and analyzed on an annual basis for development of applicable radion-uclide correlations for detenaining wasts i
      .                                                                  Additionally, the use of NRC-approved topi-cal reports may be utilized in meeting spe-cific requirements of 10CFR61.                                                 ,
1 classification rend packaging requirements.
Waste Classification (10CFR61.53) require-ments shall be met by the methodology asta-blished in plant operating procedure (s) governing Waste Classification.
Haste Characto.rization (10CFR61.56) requirements shall be met by a combination of the metho-dology stated in the Process Control Pro-f' gram and related Callaway Plant Operating Procedures.
Stability requirements stated in 10CFR61 56 (b) and by burial site shall be met and ensured prior to shipping pack-aged radioactive waste offsite for burial.
Additionally, the use of NRC-approved topi-cal reports may be utilized in meeting spe-cific requirements of 10CFR61.
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L APA-ZZ-01011 Rsv. O l
APA-ZZ-01011 Rsv. O l
4.0 ADMINISTRATIVE CONTROLS All samples.must be handled'in accordance with applicable Callaway Plant _ procedures' and in keeping with ALARA principles.
4.0 ADMINISTRATIVE CONTROLS All samples.must be handled'in accordance with applicable Callaway Plant _ procedures' and in keeping with ALARA principles. Test samples containing radioactive waste and contaminated disposable labware utilized in the performance of the methods described in the PCP should be disposed of as radioac-tive waste.
Test samples containing radioactive waste and contaminated disposable labware utilized in the performance of the methods described in the PCP should be disposed of as radioac-tive waste.
Administrative controls governing the use and' disposal of oils, greases and chelating
Administrative controls governing the use and' disposal of oils, greases and chelating
                                            . agents should be utilized as a means to control and/or limit the production of wastes containing these substances.     In the event that chemical analysis'of process vastes for these substances is impractical due to physical restrictions or analtytical constraints, determination of their pre-sence (or absence) may be made utilizing appropriate evaluation techniques.
. agents should be utilized as a means to control and/or limit the production of wastes containing these substances.
41885     With solidification or dewatering not meet-ing disposal site and shipping and trans-portation require:r: ants, shipment of the inadequately processed wastes shall be suspended. Additionally, the Precess Con-r trol Program, its implementing procedures and/or the Solid Waste System shall be cor-rected,uns necessary, to prevent recurrence.
In the event that chemical analysis'of process vastes for these substances is impractical due to physical restrictions or analtytical constraints, determination of their pre-sence (or absence) may be made utilizing appropriate evaluation techniques.
41885 With solidification or dewatering not meet-ing disposal site and shipping and trans-portation require:r: ants, shipment of the inadequately processed wastes shall be suspended.
Additionally, the Precess Con-r trol Program, its implementing procedures and/or the Solid Waste System shall be cor-rected,uns necessary, to prevent recurrence.
With solidification or devatering not per-formed in accordance with the Process Con-trol Program, the improperly processed waste in each container, as applicable, shall be tested to ensure that it meets burial ground and shipping requirements.
With solidification or devatering not per-formed in accordance with the Process Con-trol Program, the improperly processed waste in each container, as applicable, shall be tested to ensure that it meets burial ground and shipping requirements.
Appropriate administrative actions shall be
Appropriate administrative actions shall be taken to prevent recurrence.
      .                                      taken to prevent recurrence.
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APA-ZZ-010ll Rev. O l
APA-ZZ-010ll Rev. O l
5.0   RADIOACTIVE WASTE PROCESSING USING IN-
5.0 RADIOACTIVE WASTE PROCESSING USING IN-STALLED SOLIDIFICATION SYSTEM 5.1 COLLECTION AND ANALYSIS OF SAMPLES 5.1.1 General Requirements 41886 The PCP shall be used to verify the solid-ification of at least one representative test sample from at least every tenth batch of each type of wet radioactive waste solidified.
  .                  STALLED SOLIDIFICATION SYSTEM 5.1   COLLECTION AND ANALYSIS OF SAMPLES 5.1.1 General Requirements 41886       The PCP shall be used to verify the solid-ification of at least one representative test sample from at least every tenth batch of each type of wet radioactive waste solidified.
If any test sample fails to solidify, solidification of the batch under test shall be suspended until such time as addi-tional test samples can be obtained, alter-native solidification parameters can be determined in accordance with the Process Control Program, and a subsequent test verifies solidification.
If any test sample fails to solidify, solidification of the batch under test shall be suspended until such time as addi-tional test samples can be obtained, alter-native solidification 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 al-ternative solidification parameters determined.
Solidification of the batch may then be resumed using the al-ternative solidification parameters determined.
If the initial test sample from a batch of waste fails to verify solidification, then                           !
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 initial test specimens demonstrate solidification.
representative test samples shall be col-lected from each consecutive batch of the same type of waste until three (3) conse-cutive initial test specimens demonstrate solidification.
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.
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 must 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.
These sam-ples must be as close to the actual waste and chemical properties as possible.
Where practical, all chemicals used to con-dition or solidify waste (or simulated waste) in solidification tests must be identical to the actual chemicals to be used in full scale solidification.
Typi-cal unexpended mixed bead resin may be used to simulate the spent bead resin.
Where practical, all chemicals used to con-dition or solidify waste (or simulated waste) in solidification tests must be identical to the actual chemicals to be used in full scale solidification. _ - - _ _ _ _ _ _ - _ _ _ _


3.,   ...
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APA-ZZ-01011 Rev.'O
APA-ZZ-01011 Rev.'O
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l 5 .1. 2 - ' Collection of samples-5.1.2.1   Sample Analysis' Documentation Pertinent information on the~characte-
l 5.1. 2 -
                              .ristics-of test sample solidification must be-reccrded in order to verify solidifica-tiontof subsequent' batches of similar waste-without retesting. .If waste retreatment is necessary prior.to actual batch solidif-ication, the agent used and amount added must be recorded.
' Collection of samples-5.1.2.1 Sample Analysis' Documentation Pertinent information on the~characte-
                              ~The' test' sample data'for waste must in-clude, but.is not. limited to: the type of wastes solidified; percent. total solids; pH; amount of oil in the sample. Addition-ally, recorded information should include the batch-number, waste type,. waste'clas-sification, total waste received,-total portland cement added, total. sodium meta-                     '
.ristics-of test sample solidification must be-reccrded in order to verify solidifica-tiontof subsequent' batches of similar waste-without retesting..If waste retreatment is necessary prior.to actual batch solidif-ication, the agent used and amount added must be recorded.
silicate added and the date solidified,-
~The' test' sample data'for waste must in-clude, but.is not. limited to:
the type of wastes solidified; percent. total solids; pH; amount of oil in the sample.
Addition-ally, recorded information should include the batch-number, waste type,. waste'clas-sification, total waste received,-total portland cement added, total. sodium meta-silicate added and the date solidified,-
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                                                                      -Rsv. 0 5.1.2.2 Taking Samples A sample (s) of-the wasteLtank's~ contents requiring solidification must be taken in order-to determine the actual process for-L                               mulation for solidification, any pretreat ;
-Rsv. 0 5.1.2.2 Taking Samples A sample (s) of-the wasteLtank's~ contents requiring solidification must be taken in order-to determine the actual process for-L mulation for solidification, any pretreat ;
ment of the waste needed prior to solidifi-a cation, and the-waste classification of the final solidified waste product.
ment of the waste needed prior to solidifi-a cation, and the-waste classification of the final solidified waste product.
Sample sizes, as determined by the Radwaste Department, should be compatible with the standard size samples used for radioactiv-ity and chemical' analysis. .If the radioac-tivity levels are too high to permit full size samples to be taken, then smaller sam-ples should be taken with the results cor-
Sample sizes, as determined by the Radwaste Department, should be compatible with the standard size samples used for radioactiv-ity and chemical' analysis..If the radioac-tivity levels are too high to permit full size samples to be taken, then smaller sam-ples should be taken with the results cor-
                                    -rected accordingly.
-rected accordingly.
Sufficient sampling lead time-should be al-lotted. prior to the planned waste solidifi-cation of a batch to allow adequate time to complete the required testing and verifica-tion of solidification, as applicable. The contents of the waste tanks that are to be-solidified must be recirculated (mixed) prior to sampling to ensure that & repre-sentative sample is obtained.
Sufficient sampling lead time-should be al-lotted. prior to the planned waste solidifi-cation of a batch to allow adequate time to complete the required testing and verifica-tion of solidification, as applicable. The contents of the waste tanks that are to be-solidified must be recirculated (mixed) prior to sampling to ensure that & repre-sentative sample is obtained.
If the contents of more than one tank are     l to be solidified in tha same drum,-then re-preventative samples of each tank should be drawn. These samples should be of a suffi-cient composition that if "X" percent of-the total waste to be solidified is to be-taken from one of the tanks, then the sam-ple taken from that tank should be the same percentage in the composite sample. The samples taken of each should be mixed in the proper proportions to yield a sts dard
If the contents of more than one tank are l
    .                                size sample.
to be solidified in tha same drum,-then re-preventative samples of each tank should be drawn.
These samples should be of a suffi-cient composition that if "X" percent of-the total waste to be solidified is to be-taken from one of the tanks, then the sam-ple taken from that tank should be the same percentage in the composite sample.
The samples taken of each should be mixed in the proper proportions to yield a sts dard size sample. !


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                                                                                                                            'APA-ZZ-010ll Rev. O
'APA-ZZ-010ll Rev. O 5.1.3 Chemical ~ Analysis of Waste Samples Evaporator bottoms.and chemical-wastes must
    ,-                                  5.1.3                 Chemical ~ Analysis of Waste Samples
'be analyzed-for total solids, oil content,
  .                                                            Evaporator bottoms.and chemical-wastes must
' boric' acid concentration and pH.
                                                              'be analyzed-for total solids, oil content,
Spent resin beads and charcoal must be charac '
                                                              ' boric' acid concentration and pH.                               Spent resin beads and charcoal must be charac '
terized by analyzing.the water surrounding
terized by analyzing.the water surrounding
'4 the beads and charcoal'for; oil content and.
'4 the beads and charcoal'for; oil content and.
Line 167: Line 200:
Results of" chemical analysis must'be:
Results of" chemical analysis must'be:
documented.'
documented.'
L5.1.4                 Radiochemical Analysis Of Waste Samples.
L5.1.4 Radiochemical Analysis Of Waste Samples.
A gamma isotopic analysis must be performed on each batch to be solidified. -This analysis is used in determining acceptabil-ity for. solidification as well as waste                     ~
A gamma isotopic analysis must be performed on each batch to be solidified. -This analysis is used in determining acceptabil-ity for. solidification as well as waste classification of the waste to be
classification of the waste to be solidified.
~
solidified.
The results of the gamma isotopic analysis must be recorded on/ attached to the docu-mentation package.
The results of the gamma isotopic analysis must be recorded on/ attached to the docu-mentation package.
5.2                   TEST _ SOLIDIFICATION AlfD ACCEPTANCE CRITERIA i                                       5.2.1                 Waste Conditieniriq Frior to the test sample solidification,                                   i
5.2 TEST _ SOLIDIFICATION AlfD ACCEPTANCE CRITERIA i
: l.                                                             the pH of the *cank must be adjusted to a                                   l o                                                              range ef 7 to 9 pH.                 Should adjustment be                   l necessary, the agent and quantity used must~                               j be recorded.                                                               l L                                                                                                                                         i L                                                             If oil is present in quantities greater than 1% by volume, dilution of the batch to below 1% is required prior to solidification.                   If reduction of the oil L                                                             content is impossible or impractical, solidification of the batch must not be at-tempted using the Stock Solidification Sys-tem, but must be accomplished using a bulk processing method.
5.2.1 Waste Conditieniriq Frior to the test sample solidification, i
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the pH of the *cank must be adjusted to a l
range ef 7 to 9 pH.
Should adjustment be l
o necessary, the agent and quantity used must~
j be recorded.
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If oil is present in quantities greater than 1% by volume, dilution of the batch to below 1% is required prior to solidification.
If reduction of the oil L
content is impossible or impractical, solidification of the batch must not be at-tempted using the Stock Solidification Sys-tem, but must be accomplished using a bulk processing method.
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: 5. 2 . 2. Test solidification Whenever               retreatment of a batch is neces-sary,cthe tank contents must have the
: 5. 2. 2.
            .,              required retreatment accomplished prior to pulling the sample for test solidification
Test solidification Whenever retreatment of a batch is neces-sary,cthe tank contents must have the required retreatment accomplished prior to pulling the sample for test solidification
* analysis.
* analysis.
A test solidification container'should be prepared with a mixing device. This test solidification container could.either be a small sample container, or, in certain'ap-l                           plications, a fullLacale drum when actual
A test solidification container'should be prepared with a mixing device.
                            -full scale testing of a batch may be~-
This test solidification container could.either be a small sample container, or, in certain'ap-l plications, a fullLacale drum when actual
-full scale testing of a batch may be~-
required or desirable.
required or desirable.
The appropriate proportional amount of portland cement and sodium metasilicate, as applicable, determined from.the appropriate solidification formulation nomograms / charts (Attachments 1.through 4) must be added. A known representative volume of the. waste must be transferred to the test solidifica-tion container.
The appropriate proportional amount of portland cement and sodium metasilicate, as applicable, determined from.the appropriate solidification formulation nomograms / charts (Attachments 1.through 4) must be added.
Mixing of the waste, portland cement and sodium metasilicate is then initiated. Af-ter appropriate mixing or when a homogenous mixture is obtained, the cement / waste mix-                                                                       l turo must be allowed to stand for a speci-                                                                         !
A known representative volume of the. waste must be transferred to the test solidifica-tion container.
                            -fied time period. Any free liquid observed                                                                         !
Mixing of the waste, portland cement and sodium metasilicate is then initiated.
on-the top of the test solidification must be decanted into a clear volumetric beaker (cylinder).                 The' amount of liquid decanted                                                       .
Af-ter appropriate mixing or when a homogenous mixture is obtained, the cement / waste mix-l turo must be allowed to stand for a speci-
is used to calculate the percent free liquid.       Results of this analysis must be l1 documented.
-fied time period.
Any free liquid observed on-the top of the test solidification must be decanted into a clear volumetric beaker (cylinder).
The' amount of liquid decanted is used to calculate the percent free l
liquid.
Results of this analysis must be 1
documented.
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b                                                                                                                                           APA-ZZ-010ll L                                                                                                                                           Rev. O
Rev. O
                                                    '5.2.3' Test solidification -Acceptability The test sample solidification shall be l: ,                  2720                                 considered acceptable from a free liquid I
'5.2.3' Test solidification -Acceptability The test sample solidification shall be l:
standpoint if the amount of free liquid is the lessor of either 1% by-volume or burial site limits. The test sample solidifica-l-                                                         tion shall~be considered acceptable from a~
2720 considered acceptable from a free liquid I
solid mass standpoint (i.e., structural L                                                           stability) if the surface of the sample resists penetration when probed with a spatula or comparable firm object.
standpoint if the amount of free liquid is the lessor of either 1% by-volume or burial site limits.
The test sample solidifica-l-
tion shall~be considered acceptable from a solid mass standpoint (i.e., structural
~
L stability) if the surface of the sample resists penetration when probed with a spatula or comparable firm object.
If either or both of the above checks fail to meet the stated criteria, the waste sam-pie analysis and/or the sample.solidifica-tion formula must be verified as being correct. -If this verification shows an.er-ror in waste sample analysis or' sample solidification formula,a corrected solid-ification formula must be obtained and sam-pie solidification performed using this corrected formula.
If either or both of the above checks fail to meet the stated criteria, the waste sam-pie analysis and/or the sample.solidifica-tion formula must be verified as being correct. -If this verification shows an.er-ror in waste sample analysis or' sample solidification formula,a corrected solid-ification formula must be obtained and sam-pie solidification performed using this corrected formula.
In the event that the analysis and formula previously derived and used are correct, alternative solidification parameters must be determined before solidification can proceed.
In the event that the analysis and formula previously derived and used are correct, alternative solidification parameters must be determined before solidification can proceed.
41086                               If the initial test solidification of a batch is unacceptable, then a represents-tive cample shall be test solidified on each subsequent batch of the same type of waste until three consecutive test samples demonstrate solidification.
41086 If the initial test solidification of a batch is unacceptable, then a represents-tive cample shall be test solidified on each subsequent batch of the same type of waste until three consecutive test samples demonstrate solidification.
if a test san.ple fails to providt accepta-ble solidification of waste, equal volur.es of dry cement and water should be mixed to ensure that the problem is not due to a bad batch of cement.
if a test san.ple fails to providt accepta-ble solidification of waste, equal volur.es of dry cement and water should be mixed to ensure that the problem is not due to a bad batch of cement.
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"**      " e .                                                                                                                                         t
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                                                                                    .                                  APA-ZZ-01011 Rsv. 0 5.3   PROCESS FORMULATIONS 5.3.1 General Requirements 4166-Prior to batch solidification ofIthe waate-to be solidified, waste classification and acceptability for near-surface disposal.
APA-ZZ-01011 Rsv. 0 5.3 PROCESS FORMULATIONS 5.3.1 General Requirements 4166-Prior to batch solidification ofIthe waate-to be solidified, waste classification and acceptability for near-surface disposal.
n-"
shall be determined..This wi11' involve n-calculating the activity within-the.
shall be determined. .This wi11' involve calculating the activity within-the.
projected waste _ drums using the. isotopic analysis of the batch.and-the actual solid-ification formulas to be used.
projected waste _ drums using the. isotopic analysis of the batch.and-the actual solid-
Solidification' formulations are based upon use of formulations / nomograms shown as Attachments 1 through 4 dependant upon the chemical analysis and-type of' waste to be solidified.-
                                .                          ification formulas to be used.
Instructions for-use'of these nomograms are' described in plant operating procedures.
Solidification' formulations are based upon use of formulations / nomograms shown as Attachments 1 through 4 dependant upon the chemical analysis and-type of' waste to be solidified.- Instructions for-use'of these nomograms are' described in plant operating procedures.
5.3.2 Spent Resins / Charcoal Spent resins / charcoal must be solidified ~
5.3.2 Spent Resins / Charcoal Spent resins / charcoal must be solidified ~
utilizing the formulations of Attachment 1, Resin Solidification Formulas, and the operating sequences specified in plant operating procedures.
utilizing the formulations of Attachment 1, Resin Solidification Formulas, and the operating sequences specified in plant operating procedures.
3.3.3 Chemical Drain Tank Wastea chemical Drain Tank Wester. requiring solid-ification must be solidified utilizing the forraulation nomogram of Attachment 2, Concentrated Wastas (Non-Borated) Solidifi-cation, and the operating sequences spect-fied in plant operating procedures.
3.3.3 Chemical Drain Tank Wastea chemical Drain Tank Wester. requiring solid-ification must be solidified utilizing the forraulation nomogram of Attachment 2, Concentrated Wastas (Non-Borated) Solidifi-cation, and the operating sequences spect-fied in plant operating procedures.
j In the event the boric acid analysis of the waste sample yields boric acid in excess of                                                                                                 ]
j In the event the boric acid analysis of the
33.33 mg/ml, solidification must be based upon the formulation nomogram of Attachment 3, Concentrated Wastes (Borated)
]
waste sample yields boric acid in excess of 33.33 mg/ml, solidification must be based upon the formulation nomogram of, Concentrated Wastes (Borated)
Solidification, with a corresponding amount of sodium metasilicate per Attachment 4, Sodium Metasilicate Addition, added.
Solidification, with a corresponding amount of sodium metasilicate per Attachment 4, Sodium Metasilicate Addition, added.
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APA-ZZ-01011 R           ,            ,                                                                            .Rev. O h-                                   .5.3.4                           Evaporator Bottoms 1-
+
                                                                      . Evaporntor Bottoms must be solidified util-izing-the formulation nomogram of
APA-ZZ-01011 R
                                                                      ' Attachment 2, Concentrated. Wastes .
.Rev. O h-
.5.3.4 Evaporator Bottoms 1-
. Evaporntor Bottoms must be solidified util-izing-the formulation nomogram of
' Attachment 2, Concentrated. Wastes.
(Non-Borated) Solidification, and the'oper--
(Non-Borated) Solidification, and the'oper--
                                                                      -ating sequences specified'in plant operat-
-ating sequences specified'in plant operat-ing procedures.
* ing procedures.
In theLevent the boric acid analysis.of;the waste sample yields boric acid in excess'of-
In theLevent the boric acid analysis.of;the waste sample yields boric acid in excess'of-
                                                                      ,33.33.mg/ml, solidification must be based ~
,33.33.mg/ml, solidification must be based ~
                                                                      ;upon the formulation nomogram of' 4
;upon the formulation nomogram of' 4
                                                                      ' Attachment 3,' Concentrated-Wastes (Borated).
' Attachment 3,' Concentrated-Wastes (Borated).
Solidification, with a' corresponding amount "of sodium metasil.icate per Attachment 4, Sodium Metasilicate Addition, added.
Solidification, with a' corresponding amount "of sodium metasil.icate per Attachment 4, Sodium Metasilicate Addition, added.
                                      '6.0                             RADIOACTIVE WASTE PROCESSING USING BULK DISPOSAL METHODS.
'6.0 RADIOACTIVE WASTE PROCESSING USING BULK DISPOSAL METHODS.
6.1-                           RADIOACTIVE WASTE PROCESSING USING CON-TRACTED VENDOR-SERVICES 6.1.1                         General Recruirements 41886                                                   Contracted vendor services shall be provided to process _and package radioactive wastes to the required waste form to satisfy the applicable transportation and disposal requirements for those instances when the installed solid radioactive waste     ,
6.1-RADIOACTIVE WASTE PROCESSING USING CON-TRACTED VENDOR-SERVICES 6.1.1 General Recruirements 41886 Contracted vendor services shall be provided to process _and package radioactive wastes to the required waste form to satisfy the applicable transportation and disposal requirements for those instances when the installed solid radioactive waste system is incapable of processing these wastes. - - -
system is incapable of processing these wastes.


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                                                                                                      -l va Contracted vendor services will be'esta-.
-l va Contracted vendor services will be'esta-.
blished for the-packaging of wet;radioac-tive wastes by vendor solidification and/or dewatering. Contracted vendor services may be. exercised when,.in the' opinion of plant management, any of the.following conditions exist:.
blished for the-packaging of wet;radioac-tive wastes by vendor solidification and/or dewatering.
a)         The installed. system is declared out-of-service thereby reducing or eliui-
Contracted vendor services may be. exercised when,.in the' opinion of plant management, any of the.following conditions exist:.
      ,,                                          nating the capability of Callaway~ Plant to efficiently and legally package radioactive wastes in accordance with'all applicable requirements governing the disposal'of the wastes; or, b) '       The. installed system is incapable of pack-i nging these wastes in accordance with'any of theLapplicable requirements (e.g.,
a)
                                                  .10CFR61.) governing the disposal of thera
The installed. system is declared out-of-service thereby reducing or eliui-nating the capability of Callaway~ Plant to efficiently and legally package radioactive wastes in accordance with'all applicable requirements governing the disposal'of the wastes; or, b) '
                                                  . wastes; or, c)         When processing and packaging economics show an increased cost. efficiency of vr7 dor L       ,.                                        processing versus installed system i                                                  processing.
i The. installed system is incapable of pack-nging these wastes in accordance with'any of theLapplicable requirements (e.g.,
1 4618                     Specific programmatic controls for these services will be handled in accordance with the vendor *s Quality Assurance program.
.10CFR61.) governing the disposal of thera
. wastes; or, c)
When processing and packaging economics show an increased cost. efficiency of vr7 dor L
processing versus installed system processing.
i 1
4618 Specific programmatic controls for these services will be handled in accordance with the vendor *s Quality Assurance program.
This program shall be approved by Union Electric Quality Assurance prior to imple-mentation of the contracted services.
This program shall be approved by Union Electric Quality Assurance prior to imple-mentation of the contracted services.
                                                                              --________--_a_. _-          .i
. --________--_a_.
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APA-ZZ-010ll Rev. 0 6.1.2   control Of Vendor Procedures And Documenta-tion 6.1.2.1 Vendor Procedure Control Vendor procedures covering equipment setup, operation, and removal must be reviewed and approved in accordance with plant adminis-
APA-ZZ-010ll Rev. 0 6.1.2 control Of Vendor Procedures And Documenta-tion 6.1.2.1 Vendor Procedure Control Vendor procedures covering equipment setup, operation, and removal must be reviewed and approved in accordance with plant adminis-
                                                .trative procedures prior to implementation.
.trative procedures prior to implementation.
Vendor procedures detailing the vendor's Process Control Program (PCP) in addition to the review and approval nantioned above must also be reviewed and approved by the Onsite Review Committee prior to implementation. The vendor PCP must provide for the sampling, tests, analyses and formulation determination, as required by the Callaway Plant PCP.
Vendor procedures detailing the vendor's Process Control Program (PCP) in addition to the review and approval nantioned above must also be reviewed and approved by the Onsite Review Committee prior to implementation.
4955                       Results of all testing and analyses shall be documented, as necessary, to ensure com-pliance with the vendor PCF and all appli-cable transportation and burial ground requirements governing the disposal of these wastes.
The vendor PCP must provide for the sampling, tests, analyses and formulation determination, as required by the Callaway Plant PCP.
6.1.2.2 Control of Vendor Documentation 4955                       Copies of all documentation attesting to compliance with the requirements of the vendor PCP as well as any plant operating procedures utilized in support of the con-tracted vendor service shall be retained by the plant for inclusion in plant files.
4955 Results of all testing and analyses shall be documented, as necessary, to ensure com-pliance with the vendor PCF and all appli-cable transportation and burial ground requirements governing the disposal of these wastes.
6.1.2.2 Control of Vendor Documentation 4955 Copies of all documentation attesting to compliance with the requirements of the vendor PCP as well as any plant operating procedures utilized in support of the con-tracted vendor service shall be retained by the plant for inclusion in plant files.
Documentation containing proprietary in-formation should be appropriately handled and controlled to ensure the required de-gree of confidentiality is met.
Documentation containing proprietary in-formation should be appropriately handled and controlled to ensure the required de-gree of confidentiality is met.
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APA-ZZ-010ll j
;                                                                      ,-      APA-ZZ-010ll           j Rev. O               -!
Rev. O 6.2 RADIOACTIVE WASTE PROCESSING USING IN-HOUSE BULK DISPOSAL OPTIONS 6.2.1 General Requirements All containers used for solidification or dewatering must be inspected to ensure they are free from defects.
6.2   RADIOACTIVE WASTE PROCESSING USING IN-HOUSE BULK DISPOSAL OPTIONS 6.2.1 General Requirements All containers used for solidification or dewatering must be inspected to ensure they are free from defects. Steel containers used for dewatering must be inspect.ed to ensure that their internals are intact and undamaged. High Integrity Containers (HICs) must be inspected to ensure that they are in compliance with their Certifi-cate of Compliance as well as ensuring that their internals are intact and undamaged.
Steel containers used for dewatering must be inspect.ed to ensure that their internals are intact and undamaged.
All wastes dewatered in steel containers shall be dewatered in accordance with ap-proved procedures for which testing has demonstrated that the one-half of one 2720       percent (0.5%) drainable liquid criteria can be met. All wastes to be dewatered in HICs shall be dewatered in accordance with approved procedures for which testing has demonstrated that the one percent (1%)
High Integrity Containers (HICs) must be inspected to ensure that they are in compliance with their Certifi-cate of Compliance as well as ensuring that their internals are intact and undamaged.
drainable liquid criteria can be met. Test.
All wastes dewatered in steel containers shall be dewatered in accordance with ap-proved procedures for which testing has demonstrated that the one-half of one 2720 percent (0.5%) drainable liquid criteria can be met.
All wastes to be dewatered in HICs shall be dewatered in accordance with approved procedures for which testing has demonstrated that the one percent (1%)
drainable liquid criteria can be met.
Test.
data to ensure compliance may be based upon container supplier testing.
data to ensure compliance may be based upon container supplier testing.
6.2.2 Waste Sampling Representative samples of wastes to be processed by bulk disposal means must be obtained and analyzed for chemical and radiochemical content, as appropriate.
6.2.2 Waste Sampling Representative samples of wastes to be processed by bulk disposal means must be obtained and analyzed for chemical and radiochemical content, as appropriate.
Based upon this analysis, the packaging process as well as the container to be utilized will be determined. Results of all analyses must be documented, as neces-sary, to ensure compliance with all appli-cable packaging, transportation and burial ground requirements governing the disposal of these wastes.
Based upon this analysis, the packaging process as well as the container to be utilized will be determined.
Results of all analyses must be documented, as neces-sary, to ensure compliance with all appli-cable packaging, transportation and burial ground requirements governing the disposal of these wastes. _ _ _ _ - _ _ _ _ _ _ _ _ _


        -y---
-y---
APA-ZZ-01011 R:v. O 6.2.3 Packaging Of Spent Filter Cartridges Packaging of spent filter cartridges will be performed in either steel drums and Low Specific Activity (LSA) boxes or in High Integrity Containers (HICs), dependent upon waste classification of the spent filter cartridge (s) involved.
APA-ZZ-01011 R:v. O 6.2.3 Packaging Of Spent Filter Cartridges Packaging of spent filter cartridges will be performed in either steel drums and Low Specific Activity (LSA) boxes or in High Integrity Containers (HICs), dependent upon waste classification of the spent filter cartridge (s) involved.
Determination of waste classification will be performed based upon dose to curie cor-relations of the spent filter cartridges.
Determination of waste classification will be performed based upon dose to curie cor-relations of the spent filter cartridges.
The methodology involved must be covered in approved plant operating procedures.
The methodology involved must be covered in approved plant operating procedures.
Spent filter cartridges which meet the requirements of Class A waste may be pack-aged in common 17H drums with up to 12 filter cartridges per drum or packaged in 2720       LSA boxes. Absorbent media shall be util-ized to absorb twice the volume any inci-dental liquid within the container. Pack-aging methods governing this process must be covered in approved plant operating procedures.
Spent filter cartridges which meet the requirements of Class A waste may be pack-aged in common 17H drums with up to 12 filter cartridges per drum or packaged in 2720 LSA boxes.
Spent filter cartridges requiring stabili-zation per the requirements of 10CFR61 must be packaged in HICs. Specific radiation       !
Absorbent media shall be util-ized to absorb twice the volume any inci-dental liquid within the container.
and curie content limitations for use of the HIC, as identified on the applicable Certificate of Compliance, must be met and ensured prior to disposal of the waste.
Pack-aging methods governing this process must be covered in approved plant operating procedures.
Spent filter cartridges requiring stabili-zation per the requirements of 10CFR61 must be packaged in HICs.
Specific radiation and curie content limitations for use of the HIC, as identified on the applicable Certificate of Compliance, must be met and ensured prior to disposal of the waste.
Dewatering of the HIC contents must be per-formed and documented using approved procedures.
Dewatering of the HIC contents must be per-formed and documented using approved procedures.
Common packaging of spent filter cartridge and spent ion exchange bead resin may be performed in HICs provided for that pur-
Common packaging of spent filter cartridge and spent ion exchange bead resin may be performed in HICs provided for that pur-pose, with specific instructions for load-ing and dewatering covered in approved plant procedures.
    .                        pose, with specific instructions for load-ing and dewatering covered in approved plant procedures.
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APA-ZZ-01011 R;v. O 6.2.4 Packaging Of Spent Ion Exchange Bead Resin Spent resin to be packaged should be sam-pled prior to sluicing in order to ensure the proper container required for packaging the resin is utilized.
APA-ZZ-01011 R;v. O 6.2.4 Packaging Of Spent Ion Exchange Bead Resin Spent resin to be packaged should be sam-pled prior to sluicing in order to ensure the proper container required for packaging the resin is utilized.
Line 296: Line 363:
Class A Unstable wastes may be dewatered in steel containers, while Stable wastes, regardless of class, must be dewatered in HIC's.
Class A Unstable wastes may be dewatered in steel containers, while Stable wastes, regardless of class, must be dewatered in HIC's.
High Integrity Containers must be used for the disposal of unsolidified spent ion ex-change bead resin when the concentration of radionuclides with half lives greater than 5 years exceeds 1 pCi/cc.
High Integrity Containers must be used for the disposal of unsolidified spent ion ex-change bead resin when the concentration of radionuclides with half lives greater than 5 years exceeds 1 pCi/cc.
Procedures governing the sluicing of spent resins from demineralized beds and/or storage tanks must be written and approved for use prior to commencing sluicing operations. Applicable radiological con-trols (i.e., shielding) should be utilized to ensure the process is ALARA.
Procedures governing the sluicing of spent resins from demineralized beds and/or storage tanks must be written and approved for use prior to commencing sluicing operations.
Dewatering processes utilized must be per-formed and documented using approved plant procedures. Appropriate methods should be employed to ensure the applicable drainable liquid criteria is met prior to final seal-ing of the container for disposal.
Applicable radiological con-trols (i.e.,
shielding) should be utilized to ensure the process is ALARA.
Dewatering processes utilized must be per-formed and documented using approved plant procedures.
Appropriate methods should be employed to ensure the applicable drainable liquid criteria is met prior to final seal-ing of the container for disposal.


==7.0   REFERENCES==
==7.0 REFERENCES==
STOCK EQUIPMENT COMPANY, General Process Control Program (M-135-0457) 10CFR20 10CFR61 10CFR71 Reg. Guide 8.8 _


STOCK EQUIPMENT COMPANY, General Process Control Program (M-135-0457) 10CFR20 10CFR61 10CFR71 Reg. Guide 8.8
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"                                                                                Callaway Plant FSAR Chapter 11.4 Technical Specification 6.13.1'{CTSN #2814)
Callaway Plant FSAR Chapter 11.4 Technical Specification 6.13.1'{CTSN #2814)
Technical Specification'6.13.2' (CTSN #20174) h i
Technical Specification'6.13.2' (CTSN #20174) h i
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_ - - _ _ _ . _ _ = _ _ _ - _   __    _ _ -  __ _ - _ _ = _ _ _
__ _ - _ _ = _ _ _


APA-ZZ-01011 Rtv. 0 RESIN SOLIDIFICATION FORMULAS Class A, Unstable Type II           Gallons             Anhydrous Cement       Waste Stream     Sodium Metasilicate 10% F. S. W.         250 lbs.         39.0               48 lbs.
APA-ZZ-01011 Rtv. 0 RESIN SOLIDIFICATION FORMULAS Class A, Unstable Type II Gallons Anhydrous Cement Waste Stream Sodium Metasilicate 10% F. S. W.
15% F. S. W.         260 lbs.         38.0               48 lbs.
250 lbs.
20% F. S. W.         270 lbs.         37.0               48 lbs.
39.0 48 lbs.
15% F. S. W.
260 lbs.
38.0 48 lbs.
20% F. S. W.
270 lbs.
37.0 48 lbs.
NOTE The following formulation may be utilized for Class A waste solidification. Test solidification acceptance criteria must ba 0.0% free standing liquid. Waste solidified using this for-mulation sp il be shipped as " UNSTABLE" waste.
NOTE The following formulation may be utilized for Class A waste solidification. Test solidification acceptance criteria must ba 0.0% free standing liquid. Waste solidified using this for-mulation sp il be shipped as " UNSTABLE" waste.
10% F.S.W. decanted slurry           _
10% F.S.W. decanted slurry 270 lbs Type II Cement 37.0 gallons of resin slurry 48 lbs. Anhydrous Sodium Metasilicate Class B, C, Stable Type II Gallons Anhydrous Cement Waste Stream Sodium Metasilicate Anion Bead Resin 30% FSW 230 lbs.
270 lbs Type II Cement 37.0 gallons of resin slurry 48 lbs. Anhydrous Sodium Metasilicate Class B, C, Stable Type II       Gallons               Anhydrous Cement     Waste Stream       Sodium Metasilicate Anion Bead Resin       30% FSW     230 lbs.       35.0                 48 lbs.
35.0 48 lbs.
Cation Bead Resin       10% FSW   250 lbs.       39.0                 48 lbs.
Cation Bead Resin 10% FSW 250 lbs.
Mixed Bed Bead Resin 66% FSW       350 lbs.       32.0                 48 lbs.
39.0 48 lbs.
Page 1 of 1                             ATTACHMENT 1 1
Mixed Bed Bead Resin 66% FSW 350 lbs.
32.0 48 lbs.
Page 1 of 1 ATTACHMENT 1 1


l APA-ZZ-01011 Rev.     0 CONCENTRATED WASTES (NON-BORATED) SOLIDIFICATION l
l APA-ZZ-01011 Rev.
Percent                                                                                     Percent Total
0 CONCENTRATED WASTES (NON-BORATED) SOLIDIFICATION l
* Type il                                                       Total Sollds                       Cement                           Weste Stream                 Solids o               _
Percent Percent Total
355                                 2s.5                         o to     1                             -    - ns                         -
* Type il Total Sollds Cement Weste Stream Solids o
                                                                                                                                                                    - so.o               -
355 2s.5 o
to 2o    -      -                      -    - 385             -
to 1
                                                                                                                                                              -      -  31.o                         2a
- ns
                                                                                                  . .                          a .                                                            . .
- so.o to
30                                         360-                             - 32 5-                       .30
- 385 31.o 2a 2o a.
                                                                                                                                                                  =
30 360-
                                                                                                                                                                      =.  ..    .    .  . . .          .
- 32 5-
40                           ,
.30
345                         - -
= =.
34.o                         no 50                                             330                               35.5.                     _ 50 Each Small                   Each Small                         Each Small                 Each Small Olvision Equals               Division Equals                     Division Equals           Olvision Equals 2 Percent             -
40 345 34.o no 50 330 35.5.
5 Pounds                           0 5 Gallons                 2 Percent Page 1 of 1                                 ATTACaiENT 2
_ 50 Each Small Each Small Each Small Each Small Olvision Equals Division Equals Division Equals Olvision Equals 2 Percent 5 Pounds 0 5 Gallons 2 Percent Page 1 of 1 ATTACaiENT 2


APA-ZZ-01011 R v.         0 CONCENTRATED WASTES (BORATED) SQLIDITICATION Wetght                                                     Weight Percent             Gallons           Pounds             Percent
APA-ZZ-01011 R v.
,                                        Total               Waste             Type II             Tetal Solids         g    stream             cemet               ** *
0 CONCENTRATED WASTES (BORATED) SQLIDITICATION Wetght Weight Percent Gallons Pounds Percent Total Waste Type II Tetal Solids stream cemet g
* sES                     O 4g           .
sES O
                                                                          ~
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10 30.5 -
                                                                                        - 590     -
- 590
:0 20                   32     ..                          380                   20 25                                           -    .
:0 20 32 380 20 25 29 30 3G 380
29                                           .    .
- 30 4C 30.5
30                   3G                                 380             - 30 4C                 30.5                                 !!G                 40 l
!!G 40 l
                                                '                                                                                              {
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45 ~               31.5                                 110                 45 Each             Each                   Each           Ea-h Division             Small               Small             Division                                   ;
45 ~
Equals 24           Division           Liivision         L:uals 2%                                     l Equals 0.5         Equals 10.0 Gallons           Pounds                                                         f l
31.5 110 45 Each Each Each Ea-h Division Small Small Division Equals 24 Division Liivision L:uals 2%
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SODIUM METASILICATE ADDITION Boric Acid         sodium Metasilicate               Soric Acid
APA-ZZ-01011 Rzv.
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0-SODIUM METASILICATE ADDITION Boric Acid sodium Metasilicate Soric Acid ag/ml Anhydrous asimi sg H-IO t--
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*}}

Latest revision as of 21:06, 1 December 2024

Process Control Program Manual
ML20247D836
Person / Time
Site: Callaway 
Issue date: 07/24/1989
From: Hamilton G
UNION ELECTRIC CO.
To:
Shared Package
ML20247D815 List:
References
APA-ZZ-01011, APA-ZZ-1011, ULNRC-2070, NUDOCS 8909150099
Download: ML20247D836 (28)


Text

. - _ _ - _ _

i ULNRC-20.70 l-l i

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i PROCESS CONTROL PROGRAM MANUAL l

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8909150099 890906 gDR ADOCK 05000483 PDC

APA-ZZ-01011 Revision O i

July 24, 1989 NUCLEAR FUNCTION ADMINISTRATIVE PROCEDURE A.PA-ZZ-01011 PROCESS CONTROL PROGRAM MANUAL (PCP)

Ernisbsf Ed(;jde_

RESPONSIBLE DEPARTMENT f

I PREPARED BY 3.& jn DATE 71 87 APPROVED BY DATE DATE ISSUED This procedure contains the following:

Pages 1

through 17 Attachments 1

through 4

Tables through Figures through Appendices through Checkoff Lists through 4

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APA-ZZ-01011

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1-4 DISCLOSURE STATEMENT The Formulations contained in this document are considered.

proprietary to Union Electric Company and its installed Solid

Radwaste System supplier and shall not be duplicated, used, or disclosed outside the Nuclear' Regulatory. Commission or Union Electric Company'in whole or in part.

l-j;.. ~... __-_-_:__-__:___

. ~,

APA-ZZ-01011 Rsv. O TABLE OF CONTENTS l

p Section:

Page Number Purpose and Scope 1

1.0 2.0 Definitions 1

3.0 10CFR61 Compliance Methodology 2

4.0 Administrative Controls 3

i 5.0 Radioactive Waste Processing Using Installed Solidification System 4

5.1 Collection.and Annlysis of. Samples 4

5.1.1' + General.. Requirements.

4 5.1. 2 '

. Collection of Samples 5

5.1.3 Chemical Analysis of Waste Samples 7

5.1.4 Radiochemical Analysis of Waste Samples 7

5.2 Test Solidification and Acceptance Criteria 7

5.2.1 Waste conditioning 7

5.2.2 Test Solidification 8

5.2.3

. Test Solidification Acceptability 9

5.3 Process Formulations 10 5.3.1 General Requirements 10 5.3.2 Spent Resins / Charcoal 10 5.3.3 Chemical Drain Tank Wastes 10 5.3.4 Evaporator Bottoms 11 6.0 Radioactive Waste Processing Using 11 Bulk Disposal Methods 6.1 Radioactive Waste Processing Using 11 Contracted Vendor Services 6.1.1 General Requirements 11 6.1.2 Control of Vendor Procedures and Documentation 13 6.2 Radioactive Waste Processing Using 14 In-House Bulk Disposal Options 6.2.1 General Requirements 14 6.2.2 Waste Sampling 14 6.2.3 Packaging of Spent Filter Cartridges 15 6.2.4 Packaging of Spent Ion Exchange 16 Bead Resin l

7.0 References 16

s.

l:

l' APA-ZZ-01011 Rcv. O Attachment'l - Resin Solidification Formulations

.(PROPRIETARY) 1 Page - Concentrated Wastes (Non-Borated)'

Solidification (PROPRIETARY) 1 Page.- Concentrated.Wates (Borated) Solidification

'(PROPRIETARY)

'l Page' - Sodium Metasilicate Addition (PROPRIETARY) 1 Page O

h

-111-

APA-ZZ-01011 Rev. O RECORD OF REVISIONS Revision Number Revision Date Reason for Revision Process Control Procram (PCP)

Rev. O October 1983 Initial issue.

Rev. 1 February 1984 Incorporation of NRC review comments.

Rev. 2 December 1984 Revised to generic, non-procedural format; updating of formulations' for solidification of wastes.

Rev. 3 March 1985 Added solidification nomogram for concentrated borated wastes and renumbered attachments; clarified sample analyris documentation requirements.

Rev. 4-August 1985 Incorporated Class A " unstable" resin solidification formulation (based upon in-plant testing).

Rev. 5 March 1986 Update solidification formulation nomegrams; revised covershe'st and

" preface # portion of document; removed section dealing with solidification agents from document; made formulations propietary documents.

Rev. 6 April 1986 Incorporated section dealing with control of vendor services for packaging of solid radioactive wastes; revised purpose to agree more closely with wording shown in Technical Specification definition for

" Process Control Program"

)

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APA-ZZ-OlOll Rsv. O Rev. 7

' June 1987

' Revised'section. dealing with contracted vendor services to clarify type.of. services involved.

Rev. 8 September 1987 Revised recorded boundary conditions / ratios for batch R

solidification; revised acceptance criteria for structural stability incor-porated wording regarding full scale test solidi-fication; minor text wording changes.

Rev. 9 December 1988 Revised format to reflect actual use of document (program vice procedure);

incorporated new section(s) dealing with bulk disposal of wet radioactive waste; revised solidification formula (s) in-stalled system solidification' based-upon vendor recommendation.

.APA-ZZ-OlOll Rev.. O July 1989 Incorporation of Tech. Spec.-

Amendment OL #1087.

Formal controls on PCP.placed under Administrative Procedure.

Added Commitment Tracking System Numbers (CTSNs).

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APA-ZZ-01011 Rcv. O CALLAWAY PLANT PROCESS CONTROL PROGRAM MANUAL (PCP) 1.0 PURPOSE AND SCOPE The purpose of the Process Control Program 4166,4700, (PCP) is to provide reasonable assurance 41638,41885 and documentation that the processing and packaging of solid radioactive wastes based on demonstrated processing of actual or simulated wet solid wastes will be accom-plished in such a way as to assure com-pliance with 10CFR Parts 20, 61 and 71, State regulations, burial ground require-ments, and other requirements governing the disposal of the. radioactive wastes.

The PCP contains the campling, tests, analyses, determinations and formulations by which waste classification, solidifica-tion and/or dewatering of radioactive vastes fren liquid systems is assured.

2.0 DEFINITIONS Solidification The conversion of wet vastes into a form that meets shipping and burial ground requirements.

1 Waste Classification - The determination of I

waste class as outlined in 10CFR61 by radionuclides isotopic analysis and/or cor-1 relation with measured nuclides.

Dewatering - The process of removing water from a bed of wet solid waste.

Dewatering processes may be utilized to prepare wet j

solid waste for shipment without solidifi-I cation using cement or other chemical agents.

Dewatered wastes must meet NRC and j

burial site conditions on maximum drainable liquid content.

APA-ZZ-01011 Rcv. O Batch - A specified quantity of liquid wastes / sludges requiring solidification or dewatering (ie., the amount of waste con-tent within a tank, or, the amount of waste content within'two or more tanks if the contents of the tanks are to be solidified or dewatered together within a common con-tainer) any portion of which would have the

~

same physical and chemical characteristics as the whole.

If new material is added to a tank's contents which is currently being processed, a new batch is created and fur-ther sampling must be performed prior to solidification or dewatering.

3.0 10CFR61 COMPLIANCE METHODOLOGY 2713,2720, All packaged radioactive wastes generated 5865 at the Callaway Plant shall meet the requirements of Title 10 Code of Federal Regulations Part 61 (10CFR61).

As a mini-mum, all radioactive waste streeta sources must be sampled and analyzed on an annual basis for development of applicable radion-uclide correlations for detenaining wasts i

1 classification rend packaging requirements.

Waste Classification (10CFR61.53) require-ments shall be met by the methodology asta-blished in plant operating procedure (s) governing Waste Classification.

Haste Characto.rization (10CFR61.56) requirements shall be met by a combination of the metho-dology stated in the Process Control Pro-f' gram and related Callaway Plant Operating Procedures.

Stability requirements stated in 10CFR61 56 (b) and by burial site shall be met and ensured prior to shipping pack-aged radioactive waste offsite for burial.

Additionally, the use of NRC-approved topi-cal reports may be utilized in meeting spe-cific requirements of 10CFR61.

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L APA-ZZ-01011 Rsv. O l

4.0 ADMINISTRATIVE CONTROLS All samples.must be handled'in accordance with applicable Callaway Plant _ procedures' and in keeping with ALARA principles.

Test samples containing radioactive waste and contaminated disposable labware utilized in the performance of the methods described in the PCP should be disposed of as radioac-tive waste.

Administrative controls governing the use and' disposal of oils, greases and chelating

. agents should be utilized as a means to control and/or limit the production of wastes containing these substances.

In the event that chemical analysis'of process vastes for these substances is impractical due to physical restrictions or analtytical constraints, determination of their pre-sence (or absence) may be made utilizing appropriate evaluation techniques.

41885 With solidification or dewatering not meet-ing disposal site and shipping and trans-portation require:r: ants, shipment of the inadequately processed wastes shall be suspended.

Additionally, the Precess Con-r trol Program, its implementing procedures and/or the Solid Waste System shall be cor-rected,uns necessary, to prevent recurrence.

With solidification or devatering not per-formed in accordance with the Process Con-trol Program, the improperly processed waste in each container, as applicable, shall be tested to ensure that it meets burial ground and shipping requirements.

Appropriate administrative actions shall be taken to prevent recurrence.

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APA-ZZ-010ll Rev. O l

5.0 RADIOACTIVE WASTE PROCESSING USING IN-STALLED SOLIDIFICATION SYSTEM 5.1 COLLECTION AND ANALYSIS OF SAMPLES 5.1.1 General Requirements 41886 The PCP shall be used to verify the solid-ification of at least one representative test sample from at least every tenth batch of each type of wet radioactive waste solidified.

If any test sample fails to solidify, solidification of the batch under test shall be suspended until such time as addi-tional test samples can be obtained, alter-native solidification 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 al-ternative solidification parameters determined.

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 initial test specimens demonstrate solidification.

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 must 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.

Where practical, all chemicals used to con-dition or solidify waste (or simulated waste) in solidification tests must be identical to the actual chemicals to be used in full scale solidification. _ - - _ _ _ _ _ _ - _ _ _ _

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APA-ZZ-01011 Rev.'O

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l 5.1. 2 -

' Collection of samples-5.1.2.1 Sample Analysis' Documentation Pertinent information on the~characte-

.ristics-of test sample solidification must be-reccrded in order to verify solidifica-tiontof subsequent' batches of similar waste-without retesting..If waste retreatment is necessary prior.to actual batch solidif-ication, the agent used and amount added must be recorded.

~The' test' sample data'for waste must in-clude, but.is not. limited to:

the type of wastes solidified; percent. total solids; pH; amount of oil in the sample.

Addition-ally, recorded information should include the batch-number, waste type,. waste'clas-sification, total waste received,-total portland cement added, total. sodium meta-silicate added and the date solidified,-

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1 APA-ZZ-010ll

-Rsv. 0 5.1.2.2 Taking Samples A sample (s) of-the wasteLtank's~ contents requiring solidification must be taken in order-to determine the actual process for-L mulation for solidification, any pretreat ;

ment of the waste needed prior to solidifi-a cation, and the-waste classification of the final solidified waste product.

Sample sizes, as determined by the Radwaste Department, should be compatible with the standard size samples used for radioactiv-ity and chemical' analysis..If the radioac-tivity levels are too high to permit full size samples to be taken, then smaller sam-ples should be taken with the results cor-

-rected accordingly.

Sufficient sampling lead time-should be al-lotted. prior to the planned waste solidifi-cation of a batch to allow adequate time to complete the required testing and verifica-tion of solidification, as applicable. The contents of the waste tanks that are to be-solidified must be recirculated (mixed) prior to sampling to ensure that & repre-sentative sample is obtained.

If the contents of more than one tank are l

to be solidified in tha same drum,-then re-preventative samples of each tank should be drawn.

These samples should be of a suffi-cient composition that if "X" percent of-the total waste to be solidified is to be-taken from one of the tanks, then the sam-ple taken from that tank should be the same percentage in the composite sample.

The samples taken of each should be mixed in the proper proportions to yield a sts dard size sample. !

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'APA-ZZ-010ll Rev. O 5.1.3 Chemical ~ Analysis of Waste Samples Evaporator bottoms.and chemical-wastes must

'be analyzed-for total solids, oil content,

' boric' acid concentration and pH.

Spent resin beads and charcoal must be charac '

terized by analyzing.the water surrounding

'4 the beads and charcoal'for; oil content and.

pH.

Results of" chemical analysis must'be:

documented.'

L5.1.4 Radiochemical Analysis Of Waste Samples.

A gamma isotopic analysis must be performed on each batch to be solidified. -This analysis is used in determining acceptabil-ity for. solidification as well as waste classification of the waste to be

~

solidified.

The results of the gamma isotopic analysis must be recorded on/ attached to the docu-mentation package.

5.2 TEST _ SOLIDIFICATION AlfD ACCEPTANCE CRITERIA i

5.2.1 Waste Conditieniriq Frior to the test sample solidification, i

l.

the pH of the *cank must be adjusted to a l

range ef 7 to 9 pH.

Should adjustment be l

o necessary, the agent and quantity used must~

j be recorded.

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If oil is present in quantities greater than 1% by volume, dilution of the batch to below 1% is required prior to solidification.

If reduction of the oil L

content is impossible or impractical, solidification of the batch must not be at-tempted using the Stock Solidification Sys-tem, but must be accomplished using a bulk processing method.

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APA-ZZ-OlOll Rav. O

5. 2. 2.

Test solidification Whenever retreatment of a batch is neces-sary,cthe tank contents must have the required retreatment accomplished prior to pulling the sample for test solidification

  • analysis.

A test solidification container'should be prepared with a mixing device.

This test solidification container could.either be a small sample container, or, in certain'ap-l plications, a fullLacale drum when actual

-full scale testing of a batch may be~-

required or desirable.

The appropriate proportional amount of portland cement and sodium metasilicate, as applicable, determined from.the appropriate solidification formulation nomograms / charts (Attachments 1.through 4) must be added.

A known representative volume of the. waste must be transferred to the test solidifica-tion container.

Mixing of the waste, portland cement and sodium metasilicate is then initiated.

Af-ter appropriate mixing or when a homogenous mixture is obtained, the cement / waste mix-l turo must be allowed to stand for a speci-

-fied time period.

Any free liquid observed on-the top of the test solidification must be decanted into a clear volumetric beaker (cylinder).

The' amount of liquid decanted is used to calculate the percent free l

liquid.

Results of this analysis must be 1

documented.

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b APA-ZZ-010ll L

Rev. O

'5.2.3' Test solidification -Acceptability The test sample solidification shall be l:

2720 considered acceptable from a free liquid I

standpoint if the amount of free liquid is the lessor of either 1% by-volume or burial site limits.

The test sample solidifica-l-

tion shall~be considered acceptable from a solid mass standpoint (i.e., structural

~

L stability) if the surface of the sample resists penetration when probed with a spatula or comparable firm object.

If either or both of the above checks fail to meet the stated criteria, the waste sam-pie analysis and/or the sample.solidifica-tion formula must be verified as being correct. -If this verification shows an.er-ror in waste sample analysis or' sample solidification formula,a corrected solid-ification formula must be obtained and sam-pie solidification performed using this corrected formula.

In the event that the analysis and formula previously derived and used are correct, alternative solidification parameters must be determined before solidification can proceed.

41086 If the initial test solidification of a batch is unacceptable, then a represents-tive cample shall be test solidified on each subsequent batch of the same type of waste until three consecutive test samples demonstrate solidification.

if a test san.ple fails to providt accepta-ble solidification of waste, equal volur.es of dry cement and water should be mixed to ensure that the problem is not due to a bad batch of cement.

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APA-ZZ-01011 Rsv. 0 5.3 PROCESS FORMULATIONS 5.3.1 General Requirements 4166-Prior to batch solidification ofIthe waate-to be solidified, waste classification and acceptability for near-surface disposal.

shall be determined..This wi11' involve n-calculating the activity within-the.

projected waste _ drums using the. isotopic analysis of the batch.and-the actual solid-ification formulas to be used.

Solidification' formulations are based upon use of formulations / nomograms shown as Attachments 1 through 4 dependant upon the chemical analysis and-type of' waste to be solidified.-

Instructions for-use'of these nomograms are' described in plant operating procedures.

5.3.2 Spent Resins / Charcoal Spent resins / charcoal must be solidified ~

utilizing the formulations of Attachment 1, Resin Solidification Formulas, and the operating sequences specified in plant operating procedures.

3.3.3 Chemical Drain Tank Wastea chemical Drain Tank Wester. requiring solid-ification must be solidified utilizing the forraulation nomogram of Attachment 2, Concentrated Wastas (Non-Borated) Solidifi-cation, and the operating sequences spect-fied in plant operating procedures.

j In the event the boric acid analysis of the

]

waste sample yields boric acid in excess of 33.33 mg/ml, solidification must be based upon the formulation nomogram of, Concentrated Wastes (Borated)

Solidification, with a corresponding amount of sodium metasilicate per Attachment 4, Sodium Metasilicate Addition, added.

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APA-ZZ-01011 R

.Rev. O h-

.5.3.4 Evaporator Bottoms 1-

. Evaporntor Bottoms must be solidified util-izing-the formulation nomogram of

' Attachment 2, Concentrated. Wastes.

(Non-Borated) Solidification, and the'oper--

-ating sequences specified'in plant operat-ing procedures.

In theLevent the boric acid analysis.of;the waste sample yields boric acid in excess'of-

,33.33.mg/ml, solidification must be based ~

upon the formulation nomogram of' 4

' Attachment 3,' Concentrated-Wastes (Borated).

Solidification, with a' corresponding amount "of sodium metasil.icate per Attachment 4, Sodium Metasilicate Addition, added.

'6.0 RADIOACTIVE WASTE PROCESSING USING BULK DISPOSAL METHODS.

6.1-RADIOACTIVE WASTE PROCESSING USING CON-TRACTED VENDOR-SERVICES 6.1.1 General Recruirements 41886 Contracted vendor services shall be provided to process _and package radioactive wastes to the required waste form to satisfy the applicable transportation and disposal requirements for those instances when the installed solid radioactive waste system is incapable of processing these wastes. - - -

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APA-Z" OlOll-

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Rav. C

-l va Contracted vendor services will be'esta-.

blished for the-packaging of wet;radioac-tive wastes by vendor solidification and/or dewatering.

Contracted vendor services may be. exercised when,.in the' opinion of plant management, any of the.following conditions exist:.

a)

The installed. system is declared out-of-service thereby reducing or eliui-nating the capability of Callaway~ Plant to efficiently and legally package radioactive wastes in accordance with'all applicable requirements governing the disposal'of the wastes; or, b) '

i The. installed system is incapable of pack-nging these wastes in accordance with'any of theLapplicable requirements (e.g.,

.10CFR61.) governing the disposal of thera

. wastes; or, c)

When processing and packaging economics show an increased cost. efficiency of vr7 dor L

processing versus installed system processing.

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4618 Specific programmatic controls for these services will be handled in accordance with the vendor *s Quality Assurance program.

This program shall be approved by Union Electric Quality Assurance prior to imple-mentation of the contracted services.

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APA-ZZ-010ll Rev. 0 6.1.2 control Of Vendor Procedures And Documenta-tion 6.1.2.1 Vendor Procedure Control Vendor procedures covering equipment setup, operation, and removal must be reviewed and approved in accordance with plant adminis-

.trative procedures prior to implementation.

Vendor procedures detailing the vendor's Process Control Program (PCP) in addition to the review and approval nantioned above must also be reviewed and approved by the Onsite Review Committee prior to implementation.

The vendor PCP must provide for the sampling, tests, analyses and formulation determination, as required by the Callaway Plant PCP.

4955 Results of all testing and analyses shall be documented, as necessary, to ensure com-pliance with the vendor PCF and all appli-cable transportation and burial ground requirements governing the disposal of these wastes.

6.1.2.2 Control of Vendor Documentation 4955 Copies of all documentation attesting to compliance with the requirements of the vendor PCP as well as any plant operating procedures utilized in support of the con-tracted vendor service shall be retained by the plant for inclusion in plant files.

Documentation containing proprietary in-formation should be appropriately handled and controlled to ensure the required de-gree of confidentiality is met.

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APA-ZZ-010ll j

Rev. O 6.2 RADIOACTIVE WASTE PROCESSING USING IN-HOUSE BULK DISPOSAL OPTIONS 6.2.1 General Requirements All containers used for solidification or dewatering must be inspected to ensure they are free from defects.

Steel containers used for dewatering must be inspect.ed to ensure that their internals are intact and undamaged.

High Integrity Containers (HICs) must be inspected to ensure that they are in compliance with their Certifi-cate of Compliance as well as ensuring that their internals are intact and undamaged.

All wastes dewatered in steel containers shall be dewatered in accordance with ap-proved procedures for which testing has demonstrated that the one-half of one 2720 percent (0.5%) drainable liquid criteria can be met.

All wastes to be dewatered in HICs shall be dewatered in accordance with approved procedures for which testing has demonstrated that the one percent (1%)

drainable liquid criteria can be met.

Test.

data to ensure compliance may be based upon container supplier testing.

6.2.2 Waste Sampling Representative samples of wastes to be processed by bulk disposal means must be obtained and analyzed for chemical and radiochemical content, as appropriate.

Based upon this analysis, the packaging process as well as the container to be utilized will be determined.

Results of all analyses must be documented, as neces-sary, to ensure compliance with all appli-cable packaging, transportation and burial ground requirements governing the disposal of these wastes. _ _ _ _ - _ _ _ _ _ _ _ _ _

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APA-ZZ-01011 R:v. O 6.2.3 Packaging Of Spent Filter Cartridges Packaging of spent filter cartridges will be performed in either steel drums and Low Specific Activity (LSA) boxes or in High Integrity Containers (HICs), dependent upon waste classification of the spent filter cartridge (s) involved.

Determination of waste classification will be performed based upon dose to curie cor-relations of the spent filter cartridges.

The methodology involved must be covered in approved plant operating procedures.

Spent filter cartridges which meet the requirements of Class A waste may be pack-aged in common 17H drums with up to 12 filter cartridges per drum or packaged in 2720 LSA boxes.

Absorbent media shall be util-ized to absorb twice the volume any inci-dental liquid within the container.

Pack-aging methods governing this process must be covered in approved plant operating procedures.

Spent filter cartridges requiring stabili-zation per the requirements of 10CFR61 must be packaged in HICs.

Specific radiation and curie content limitations for use of the HIC, as identified on the applicable Certificate of Compliance, must be met and ensured prior to disposal of the waste.

Dewatering of the HIC contents must be per-formed and documented using approved procedures.

Common packaging of spent filter cartridge and spent ion exchange bead resin may be performed in HICs provided for that pur-pose, with specific instructions for load-ing and dewatering covered in approved plant procedures.

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APA-ZZ-01011 R;v. O 6.2.4 Packaging Of Spent Ion Exchange Bead Resin Spent resin to be packaged should be sam-pled prior to sluicing in order to ensure the proper container required for packaging the resin is utilized.

Packaging of spent ion exchange bead resin may be performed utilizing dewatering processes in lieu of solidification ~.

Class A Unstable wastes may be dewatered in steel containers, while Stable wastes, regardless of class, must be dewatered in HIC's.

High Integrity Containers must be used for the disposal of unsolidified spent ion ex-change bead resin when the concentration of radionuclides with half lives greater than 5 years exceeds 1 pCi/cc.

Procedures governing the sluicing of spent resins from demineralized beds and/or storage tanks must be written and approved for use prior to commencing sluicing operations.

Applicable radiological con-trols (i.e.,

shielding) should be utilized to ensure the process is ALARA.

Dewatering processes utilized must be per-formed and documented using approved plant procedures.

Appropriate methods should be employed to ensure the applicable drainable liquid criteria is met prior to final seal-ing of the container for disposal.

7.0 REFERENCES

STOCK EQUIPMENT COMPANY, General Process Control Program (M-135-0457) 10CFR20 10CFR61 10CFR71 Reg. Guide 8.8 _

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APA-ZZ-01011 Rsv. 0 1

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Callaway Plant FSAR Chapter 11.4 Technical Specification 6.13.1'{CTSN #2814)

Technical Specification'6.13.2' (CTSN #20174) h i

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APA-ZZ-01011 Rtv. 0 RESIN SOLIDIFICATION FORMULAS Class A, Unstable Type II Gallons Anhydrous Cement Waste Stream Sodium Metasilicate 10% F. S. W.

250 lbs.

39.0 48 lbs.

15% F. S. W.

260 lbs.

38.0 48 lbs.

20% F. S. W.

270 lbs.

37.0 48 lbs.

NOTE The following formulation may be utilized for Class A waste solidification. Test solidification acceptance criteria must ba 0.0% free standing liquid. Waste solidified using this for-mulation sp il be shipped as " UNSTABLE" waste.

10% F.S.W. decanted slurry 270 lbs Type II Cement 37.0 gallons of resin slurry 48 lbs. Anhydrous Sodium Metasilicate Class B, C, Stable Type II Gallons Anhydrous Cement Waste Stream Sodium Metasilicate Anion Bead Resin 30% FSW 230 lbs.

35.0 48 lbs.

Cation Bead Resin 10% FSW 250 lbs.

39.0 48 lbs.

Mixed Bed Bead Resin 66% FSW 350 lbs.

32.0 48 lbs.

Page 1 of 1 ATTACHMENT 1 1

l APA-ZZ-01011 Rev.

0 CONCENTRATED WASTES (NON-BORATED) SOLIDIFICATION l

Percent Percent Total

  • Type il Total Sollds Cement Weste Stream Solids o

355 2s.5 o

to 1

- ns

- so.o to

- 385 31.o 2a 2o a.

30 360-

- 32 5-

.30

= =.

40 345 34.o no 50 330 35.5.

_ 50 Each Small Each Small Each Small Each Small Olvision Equals Division Equals Division Equals Olvision Equals 2 Percent 5 Pounds 0 5 Gallons 2 Percent Page 1 of 1 ATTACaiENT 2

APA-ZZ-01011 R v.

0 CONCENTRATED WASTES (BORATED) SQLIDITICATION Wetght Weight Percent Gallons Pounds Percent Total Waste Type II Tetal Solids stream cemet g

sES O

4g

~

10 30.5 -

- 590

0 20 32 380 20 25 29 30 3G 380

- 30 4C 30.5

!!G 40 l

{

45 ~

31.5 110 45 Each Each Each Ea-h Division Small Small Division Equals 24 Division Liivision L:uals 2%

l Equals 0.5 Equals 10.0 f

Gallons Pounds i

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Page 1 of 1 ATTACHMENT 3 j

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APA-ZZ-01011 Rzv.

0-SODIUM METASILICATE ADDITION Boric Acid sodium Metasilicate Soric Acid ag/ml Anhydrous asimi sg H-IO t--

-p t;O 30 d

10 0 '.

g

~

,. 0

=_==_

i

..M

~

-3 200 50 T

200

{

"T"

""f""

ag a

_a 1

e.5 c,;,, m:.;

46.5 s ;.3 80 1

300 l

1,_

_:=

c.' -~ [

=

_= =

,. 0 0

~0

-00

_==

c0 E

l

-i-

-+-

-+-

30:

as sco Iach Small Each Small Each Small Division Equals Division Equals Division Iquals 10 mg/ml 1.0 lb.

10 mg/ml O

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l Page 1 of 1 ATTACHMENT 4 t

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