ML19344B242

Process Control Program for Cnsi Mobile Solidification Units Using Dow Process. Proprietary Version Withheld (Ref 10CFR2.790)

ML19344B242
Person / Time
Site:	McGuire, Mcguire
Issue date:	08/22/1980
From:	DUKE POWER CO.
To:
Shared Package
ML19268D006	List: ML19344B237 ML19344B241 ML19344B242
References
SD-OP-005, SD-OP-5, NUDOCS 8008250876
Download: ML19344B242 (34)

Text

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L O L DUKE POWER COMPANY MCGUIRE NUCLEAR STATION Units 1 and 2 i 2ROCESS CONTROL PROGRAM FOR CNSI i MOBILE SOLIDIFICATION UNITS USING  !.

THE DOW PROCESS i

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. 3 MCCUIRE NUCLEAR STATION PROCESS CONTROL PROGRAM LIST OF EFFECTIVE PAGES Page Revision Pace Revision LOEP, Page 1 of 1 Original 17 Original 18 Original 2 Rev 1 19 Original 3 Original 20 Original ~

4 Original 21 Rev 1 5 Original 22 Original 6 Original 23 Original 7 Original 24 Original 8 Original 25 Original 9 Original 26 Original 10 Original 27 Original I -11 Original 28 Original 12 Original 29 Original 13 '

Original 30 Original 14 Original 31 Original 15 Original 32 Original 16 Original 33 Original l

Page 1 of 1 Revision 1

TABLE OF CONTENTS Page 1.0 SCOPE 1.1 Purpose 3 1.2 Applicability 3

2.0 REFERENCES

3 3.0 SYSTEM DESCRIPTION 3.1 Chemical Process Description 4 3.2 Mobile Unit Description 6 3.3 System Operation 7 4.0 REQUIREMENTS FOR SAMPLE VERIFICATION 8 4.1 Precautions and Limitations a. 8 4.2 Prerequisites 9 4.3 Sample Acceptance Criteria 12 5.0 SAMPLE VERIFICATION 12 5.1 Initial Conditions 12 5.2 Sample Verification Procedure 14 5.3 Parameter Adjustment 19 6.0 ADMINISTRATIVE PROCEDURES 20 6.1 Maintenance of Records 20 I 7.0 INTERFACE BETWEEN STATION AND MOBIL UNIT 21 7.1 Station. Responsibilities 21 7.2 Vendor Responsibilities 21 APPENDIX A - MOBILE SOLIDIFICATION UNIT (MSU) SUBSYSTEM 23 DESCRIPTION A-1 MSU P&ID l APPENDIX B - REQUIRED EQUIPMENT AND CHEMICALS 30 B-1 Sample Verification Equipment 30 B-2 Chemical Inventory 30

- APPENDIX C - FORMS USED IN PROCESS CONTROL 31 l

l C-1 Sample Verification Form (Form PCP-1) 31 C-2 Batch Solidification Form (Forn PCP-2) 32 Rev.1 Sheet 2 l

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) 1.1 ?urccse The purpose o f :he Process Centrol Progr:m or CMSI M: bile Solidifica:ica Uni:s using the Dow Process is to establish a set of process parame:ers unich provide reasonable assurance of complete solidification of all types of icw-level radio-active liquid waste.

1.2 Aeolicabiliti

.Ihis Process Control Program shall be used by all personnel operating the CNSI Mobile Solidification Unic using the Dow Process.

2.0 REFERE::CES 2.1 CN-AD-003, CMSI Procedure for Document Preparation 2.2 QA-AD-001, CNSI Quality Assurance Program 2.3 CN-AD-019, CNSI ALARA Policy 2.4 EN-AD-002, CNSI Design Control Program 2.5 SD-OP-006, CNSI Operating Procedure for Mobile Solidifica-

-ion Units using the Dew Process 2.6 Dow Topical Report, DNS-RSS-001-P; Topical Repor:: The Dow Systen for Solidification of Low-Level Radioactive Was:e from Nuclaar Power Plants (with Addenda 001 through 003) 2.7 NCREG 0472, RadioYogical Effluent Technical Specifica: ions for PWR 2.8  :~UREG 0473, Radiclogical Effluen: Technical Specifica:1ons for 3WR 2.9 3 ranch Technical Posi:io.n_-E.ST311-3,

.- Design Guidance for Solid Radioac:ive Was:e Management Systems Installed in

'ight-Water-Cooled Nuclear Power Reaccer Plants 2.10 ANSI 199, Licuid Radioac:ive Was:e Processing Sys:ans for l

Pressuri:ed Wa:er Reac:or Plants 2.11 A::S! 197, Liquid Radioactive Was:e Processing Sys: ens for 3ciling Water Reactor Plants l

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s i 3.1 Chemical Process Descristien The CNSI Mcbile Solidification Uni: using :he Cow Process is

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specially designed :o optimize solidificacion of all types of radioactive wastes - evapora:or boctoms, ion-exchange resin slurries, sludges, and decontamination solvents. The Dow solidification process can successfully treat liquids ranging in pH from 2.5 to 11.0 and wastes containing high concentra-tiens of dissolved and undissolved solids.

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The following sections list :he process parameters hat are i i=portant to successful solidificacion.

3.1.1 Secuence o f Chemical Additien The sequence of chemical additien is critical :o successful solidifica:ica and will vary accordin,z :o the type of waste being processed. Fo r' p rece r emulsion fir =acion, 1: is essencial : hat :he radwaste solucion or slurry be added to :he bincer. The

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. See: ion 5 of this procedure and depends on :he che=ical composition of the was:e being created.

Though it will usually not be necessary to pretreat the waste or to add an addi:ional chemical (en: ender),

the sample verification procedure will indica:e if pretreatment or extender 2ddition will be required for optimus solidification.

The volu=es of process agents added will also .be determined according to sa=ple verification procedure.

The amounca of che=1cals to be used and the order of addi: ion of the process agents in full-scale solidifi-ca:1on will be decernined using the results of the

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sa=ple verifica: ion procedure and the conversion 1

for=ulae provided on the Batch Solidifica: ion Form (Form ?CP-2, Appendix C-2) .

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3.2.2 The unit is con:csed of several processin; ab-COCuMENT- R EV. SHEET 3D-C?-005 -

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'N of :he Dov Process. These subEystems include waste and binder transfer, pr:moter injection, extender addition, and catalys: addition s y s t e =s . Control functions for the unit are incorporated into the pneumatic and main control panels. Service supplies are provided by the utility and distributed through the service air, water, and el4c:rical distribution sys:ccs.

3.2.3 Most of the =obile unit compenents are arranged on portable fraceworks (skids) to provide flex 1-bili:y of operations for either indoor or outdcor use. The plant connection stand, pump skid, and hydraulic skid contain =ost of the major elements of the =obile unit.

3.2.4 A closed-circuit television system is an integral part of the =obile unit and allows the operator to :enitor all che steps in the solidification process.

3.2.5 A detailed descriptien of each subsys:em, and a P&ID are provided as Appendix A.

3.3 Svstem Oceretion 3.3.1 3efore beginning any waste processing vi:5 the Mobile Solidification Unit (MSU) using :he Dew

?rocess, the CNS! cpers:or shall c mplete a successful sa=ple verificati:n in ac:crdance wi:h the Sa=ple'Uerift:stion ?recedure of sec: ion 5.2 below.

2.3.2 Parame:ers es:ablished during the sa ple veri-fica: ion are recorded en the Sa=ple Verificacica Form (Form ?C?-1) . These parameters will be transferred to :he Satch Solidification (?:::

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3.3.3 Actual full scale solidifica:icn shall then

. be conducted in accordance with the MSU Cperat-ing Procedure (Reference 2.5) and the para =eters calculated on Forn FCP-2.

4.0 RECUIREMENTS FOR SAMPLE VERIFICATION 4.1 Precautions and Limitaciens NOTE: IF AT .C0f TIME DIFFICULTIES ARE ENCCUNTERED

!.'ITH ANY PART OF THIS PRCCEDURE CR IT THE CHEMICAL REACTICN CCES NOT PRC,CEED AS EXPEC*E3, THE CPERATOR SHALL NOTIFY THE MANAGER, FIELD SERVICES CR HIS DESIGNEE IbtEDIATELY.

Radiological Precautions 4.1.1.1 The CNSI mobile unit operato'r shall be subject to the applicable health physics and safety precautions of the 49A NRC-licensed facility previding w

the radioactive waste.

4.1.1.2 Laboratory gloves, cotton liners, face shield, and an apren (as a mini-

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, =us) shall be worn at all ci=es while collecting, handling, and testing all sa=ples.

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Prior to conducting the sample verifi-l cation procedure, the CMSI opers:::

shall es:ablish radioicgically clean and cen:aminated :enes in the pro-cessing area :a prevent :he possible spread of con:acina:icn.

4.1.2 Chemical Precautiens

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4.1.2.2 The binder is a fla=mable liquid.

For operations involving the binder, strict adherence to the follcwing is required:

1. No smoking at any time.

2. No spark-producing motors or open flames in the vicinity.

3. The binder shall be handled only in well ventilated areas or out-of-doors.

4.1.2.3 If the binder, promoter, or catalyst should contact eyes, premptly flush the eyes with clear water for 15 i, minutes. If skin contact occurs, wash the affected area i=cediately with soap and water.

4.2 Frerecuisites 4.2.1

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requiremen:s needed for use vi:5 :ne ss=ple verifica:ica precedure.

i . 2.2.3 !he C::31 opera:ar shall insure :ha:

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5.0 SA:!PLE YERIFICATION NOTE: IF AT ANY TUE DIFFICULTIES ARE ENCCU:,"IERED '4ITH ANY PART OF THIS PROCEDURE CR IF THE CHE'!! CAL RE-

- ACTION DOES NOT PROCEED AS EXPECTED, THE OPERATOR

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SRALL NOTIFY THE MANAGER, FIELD SERV!CES CR HIS

! DESIGNEE IM:4EDI ATELT.

3.1 ni:ial Condi:icns 5.1.1 verify :ha: all =a:= rial lis:ed in Table I, Equipmen: Lis:, and Table II, Chemical Inven: ry, of Appendix 3 is :vailable and ready for use.

3.1.2 Re'riev sec:icn 4.0 of :his precedure prior to cendue:ing :he Sacple Verifics: ten Procecure.

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/~ 's 5.1.3 A:;endix C :o :his procedure centsins :he Sanple Verifiestion Fcrm (F0r: PCP-1);snd :he 3s:ch Solidification Form (?CP-2). These f:r:s shall be used at all :i=es and shall be =sintained in sccordance with section 6.

5.1.3.1 The Sa=ple Verification Form (Form FCP-1) shall be used to document re-suits of all sample verifiestions conducted. Starting values for sample processing vill be obesined from Table I of section 5.1. Actual values for chemical volumes used and the re-suits of the sample vill also be re-corded on this form.

5.1.3.2 Form FCP-1 is also used to correlate the conversion of sa=ple verifica: ion results to the values used for full

, scale solidification on Form PCP-2.

5.1.3.3 The Batch Solidifiestien Form (Form PCP-2) shall be used to calcula:e the chemical volumes used in full-

.. scale solidification. Values obesined during sample verification shall be -

used as Input Da:s for coepu:ing i-l che=ical addition volumes.

5.1. 3. 4 Liner serisi numbers shs11 be used to i

' 'Frovide association between Form PCP-1 l

t sad For= ?CP-2.

5.1.; Reco rd :' > ecuirad infor:sti:n :n ?sr: : Of :he Sa=ple Ye. ..ics:1:n Ferm (Form PC?-1) o f Appendix C to this erecedure.

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5.2 Sa=cle Verification Procedure CAUTION: IF AT ANY TI!E DIFFICULTIES ARE E::CCII::TERED WIT:t ANY PART OF THIS PROCEDURE OR IF THE CHDIICAL REACTION DOES NOT PROCEED AS EXPECTED, THE OPEPa!OR SHALL :CTIFY THE

!!ASACER, FIELD SERVICES OR HIS DESIC :EE DOEDIATELY.

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5.3.3 5.3.4 5.3.5 5.3.6 6.0 ADMINISTRATIVE PROCEDURES 6.1 Maintenance of Records 6.1.1 The CNSI operator shall forward a copy of all

) completed Form PCP-l's and Form PCP-2's to the Manager, Field Services for review following completion of liner solidification.

6.1.2 Form PCP-1 should be used as a cover sheet when

. . forwarding records. All Form PCP-2's which were ccepleted based on the values cbtair.ed on Form PC?-l shall be attached.

6.1.3 After review by the Manager, Field Services, all forms sh.all be forwarded to the Solidificatien Engineer for final disposition.

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7.0 INTERFACE BETWEEN STATION AND MOBIL UNIT NOTE: Either Duke Power Company or the vendor may determine if pretreatment of waste is needed. Pretreatment must be agreed to by Chem Nuclear, Dow Chemical Company, and Duke Power Company.

Pre t rea tment , if needed is executed by station chemists.

7.1 Station Responsibilities Station personnel shall be responsible for the preparation of procedures which describe in detail the following operation:

a. Preparations for mobile unit use.

(1) Installation of flanges to join mobile unit to external station connections.

(2) Receipt of binder.

b. Sampling requirements prior to solidification.

(1) Recirculation of resin and concentrates to obtain representative sample.

(2) Sample collection using installed samplers.

(3) Analysis of sample for radionuclides present and radioactive content, and perform calculations for solidification.

c. Transfer of waste to vendor unit.

(1) Operation of cranes to move liners into place for solidification.

(2) Operation of pumps and radwaste panels in the station to move waste and binder.*

d. Verification of acceptable product.

(1) Review of process control analysis.

(2) Inspection of final product.

e. Preparations for shipment.

(1) Installation of cask lids.

(2) Inspection of trucks.

(3) Performance of surveys to determine radiatien and contamination levels.

(4) Performance of calculations for shipment based on analytical data; determine shipping requirements.

(5) Coordination of shipments with shipper, appropriate state agencies, and burial facility.

7.2 Vendor Responsibilities The vendor shall be responsible for:

a. Determining the chemical ratios needed to achieve l

solidification based on station analytical data. If station samples are not available, obtain sample using vendor equipment.

b. Running the process control analysis.

c. Submitting the prccess control analysis to station Radwaste Chemistry Supervisor prior to commencement of solidification operations

d. Operating the solidification process equipment.*

e. Specifying and ordering replacement chemicals.

• NOTE: Either station or vendor personnel can terminate the transfer of waste and binder using remete-operation of appropriate station pumps.

Revision 1, Sheet 21 Entire Page Revised l

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