ML19331D159

Process Control Program, Revision 1

ML19331D159
Person / Time
Site:	Three Mile Island
Issue date:	08/21/1980
From:	HITTMAN NUCLEAR & DEVELOPMENT CORP. (SUBS. OF HITTMAN
To:
Shared Package
ML19331D156	List: ML19331D155 ML19331D159
References
PROC-800821, NUDOCS 8008270391
Download: ML19331D159 (13)

Text

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HITTMAN NUCLEAR & DEVELOPMENT CORPORATION PROCESS CONTROL PROGRAM Revision !

Incontainer Solidificati6h' l.0 Purpose 1.1 The purpose of the Process Control Program (PCP) for incontainer solidification is to provide a program which will assure a soli-dified product with no free liquid piror to transportation for disposal.

The program consists of three major steps, which are:

a. Procedures for collecting and analyzing samples;

b. Procedures for solidifying samples;

c. Criteria for process parameters for acceptance or rejection as solidified waste.

2.0 System Description

The systems described herein are designed to handle the solidification of liquids, evaporator bottoms or other concentrated liquids, spent resin, filter sludge and other miscellaneous wastes. Concentrated liquids are processed at elevated temperatures as required to keep the salts in solution. The various operations are as described below.

2.1 Waste Feed System 2.1.1 Concentrated Waste (Evaporator Bottoms)

The waste feed system consists of a progressive cavity positive displacement pump, that is part of the TMI-l urea formaldihyde solidification system, and c waste supply line to convey waste to the fill head. The pump takes suction from the concentrated waste recirculation piping and pumps the waste into the liner. The waste

> pump is manually controlled and flow is discontinued when

! a perdetermined level is reached in the liner.

2.1.2 Bead Resin & Powdered Resin The waste feed system consists of TMI-l resin recir-culation hoses attached to the resin disposal and dewater return connections on the outside wall of the Auxiliary Building. Resin may be directed either to the disposal liner or cack to the resin tank via the 8008270%\ _1_

dewater return connection. The resin flow to the liner is stopped when the re.dn slurry reaches a predetermined level. A dewataring pump operating during the fill cycle dewaters the liner until loss of flow is detected. The dewater pump, a positive displacement air operated diaphram pump, is stopped.

The resin flow is restarted and continued until the predetermined level is reached. The dewater pump is restarted. The fill and dewater procedure is repeated until the dewatering cycle no longer brings the resin level down below the predetermined level. Based on liner size used, a predetermined quantity of water is added back into the liner through the dewatering ele-ment to fluff the bed to relieve any bed packing.

Liners used for powdered resin have special bottom designs to preclude plugging of the dewatering ele-ments.

2.2 Cement Feed Subsystem Cement and chemical additives are batch loaded into the shipping container, where the actual pixing occurs, by means of a screw conveyor. This subsystem consists of:

a. Cement hopper with discharge adaptor I b. Screw feeder and drive motor

c. Container inlet valve As a function of waste volume and container size, the appropriate amount of cement and additives for a single batch are pre-loaded into the cement hopper which, through the discharge adaptor, meters the cement to the screw feeder. Cement is conveyed through the flexible screw feeder to the top of the container, where it passes through the container inlet valve and falls by gravity into the radwaste while the mixing blades are turning.

l Dusting is minimized ,, prr-loading the cement hopper with a known volume of cement, e di :ernined by the Waste Solidification Data Sheet, and by *L. c<a , a dust collector as a feature of the vent air filter su' ay f r: ce 2.4).

The cement contuiner inlet valve and the vent line are an integral part of the container fill head essembly.

2.3 Mixing Each liner is supplied with an internal sixing device designed to provide thorough mixing of the entire linet contents. A mixing motor mounted on the top of the liner prior to the filling operation is started prior to the addition of cement. Mixing continues for approximately twenty minutes or until the motor automatically trips j off due to high resistance to mixing. The mixture will be completely

firm within 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> and be suitable for transport.

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2.4 Vent Air Filter Subsystem The fill-head also includes and elbowed vent line. The vent line is hard piped to the edge of the cask where hoses can be connected to allow the air being vented from the cask to be conveyed to the vent air filter. This unit uses flat. fabric filters to remove particulates from the vent air.

3.0 Collection and Analysis of Samples 3.1 General Requirements 3.1.1 As required by the Radiological Effluent Technical Speci-fications for PWR's and BRW's the PCP'shall be used to verify the solidification of at least one. representative test specimen from at least every tenth batch of each type of wet radioactive waste (e.g. evaporator bottoms, boric acid solution, sodium sulfate solutions, resin and precoat sludge).

3.1.2 For the purpose of the PCP a batch is defined as that quantity of waste required to fill a disposable liner to the waste level indicator.

3.1.3 If any test specimen fails to solidify, the batch under test chall be suspended until such time as additional test specimens can ba obtained, alternative solidification para-meters can be determined in accordance with the Process Control Prograu, and a subsequent test verifies solidifica-tion. Solidification of the batch may then be resumed using the alternate solidification parameters determined.

3.1.4 If the initial test specimen from a batch of waste-fails to verify solidification then representative test specimens shall be collected from each consecutive batch of the same type of waste until three (3) consecutive initial test speci-mens demonstrate solidifications. The Process Control Program-shall be modified as requires to assure solidification of sub-l sequent batches of waste.

3.1.5 For high activity wastes, such as spent resin or used precoat, where handling of samples could result in personnel radiation exposures which are inconsistent with the ALARA principle, re-presentative non-radioactive samples will be tested. These samples should be as close to the actual waste and chemical properties as possible. Typical unexpended mixed bed resin shall be used to simulate the spent bead resin and the appro-priate mix of anion to cation powdered resin shall be used to simulate used precoat.

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3.1.6 All Chemicals used to condition or solidify waste or simulated waste in solidification tests shall be representative of the actual chemicals to be used in full scale solidification. If chemicals of a different type or from a different manufacturer are used, the new material shall be tested to verify it produces a solid product prior to full scale solidification.

3.2 Collection of Samples 3.2.1 Radiological Protection 3.2.1.1 Comply with applicable Radiation Work Permits.

3.2.1.2 Test samples which use actual waste shall be disposed of by solidification in the disposal liner'.

3.2.1.3 A Waste Solidification Data Sheet will be maintained for each test sample solidified. Each Data Sheet will contain pertinent infromation on the test sample and the batch numbers of wastes folidified based on each test sample.

3.2.2 Waste Solidification Data Sheet The Waste Solidification Data Sheet will contain pertinent information on the characteristics of the test sample solidified so as to verify solidification of subsequent batches of similar wastes without re-testing.

3.2.2.1.a The test sample data for concentrated waste will include, but not necessarily be limited to,' the type of waste solidified, major consti-tuents, percent solids, pH, volume of sample, amount ci oil in sample and the ratio of the sample volume to the final volume of the solidi-fied product.

3.2.2.1.b The test sample data for spent resin and used precoat will include, i but not necessarily be limited to,'the type of waste solidified, volume of sample and ratio of sample volume to the final volume of the solidified product.

l 3.2.2.2 The Waste Solidification Data Sheet will include the Batch Number, Batch Volume, and Date Solidified, for each batch solidified based on '

sample described.

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3.2.3 Collection of Samples 3.2.3.1 Evaporator bottoms shall be kept heated or reheated to 130 F. prior j to testing.

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3.2.3.2 Two samples shall be taken for analysis. Sample sizes shall be com-patible with the standard size sample used for the radioactivity analysis and the second for the chemical analysis. If the radio-activity levels are too high to permit full size samples to be taken then smaller samples shall be taken with the results corrected accordingly. Sample sizes shall be determined by the plant Health Physics Staff.

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3.2.3.3 Samples should be drawn at least six* hours prior to the planned waste solidification procedure to allow adequate time to complete the required testing and verification of solidification.

3.2.3.4 The tank containing the waste to be solidified should be mixed by recirculating the tank contents for at least one volume change prior to sampling to assure a representative sample.

3.2.3.5 If the contents of more than one tank are to be solidified in the same liner then representative samples of each tank should be drawn. These samples should be of such size that when mixed together they form samples of standard size as prescribed in Section 3.2.3.2. If the contents of a parti-cular tank represen::s X% of the total waste quantity to be solidified then the sample of that tank should be of such size to represent X% of the composite samples.

3.3 Analysis of Samples for Concentrated Waste (Evaporator Bottoms)

This document only defines the parameters to be analyzed and not the methodology. This is left to the plant staff.

a. pH

b. Boron or Boric Acid

c. Sulfates

d. Detergents

e. Oil

f. Weight % Solids

g. Any other suspected major constituent 4.0 Test Solidification and Acceptance Criteria 4.1 Waste Conditioning 4.1.1 Prior to the test sample solidification the pH of the sample shall be adjusted to a range of 5 to 8 if Metso Beads are used or a range of 8 to 10 if they are not used.

4.1.2 For Boric Acid (including Evaporator Bottoms) wastes it is I recommended that sodium hydroxide be used to adjust the pH.

4.1.3 If large quantities of detergents are presents, the sample l

should be treated with an anti-foaming agent. The quantity of anti-foaming agent required should be recorded.

4.1.4 If oil is present in quantities greater than 1% by volume, j

emulsification agents should be used to break up the oil.

l The quantity of any substance added to the sample for this purpose should be recorded.

4.2 Test Solidification 4.2.1 Any sample to be solidified shall be pretreated as specified in Section 4.1.

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4.2.2 Test solidification should be conducted using a 1000 ml.

disposal beaker or similar size container. Mixing should be accomplished by stirring with a rigid stirrer until a homogeneous mixture is obtained, but in no case for less than five (5) minutes. .

4.2.3 For the test solidification of resin, measure into the mixing vessel 100ml of water and add a sufficient quantity of dewatered resin to yield a 400ml mixture. The degree of compaction cf the resin will determine the volume of resin required.

4.2.4 For the test solidification of precoat sludge, measure into the mixing vessel 400ml of waste at a maximum of 30 w/o solids.

4.2.5 for the test solidification of Concentrated Waste (Evaporator Bottoms), measure into the mixing vessel 400ml of waste.

4.2.6 Measure out the required quantities of cement and Metso Beads as shown below. Volumes are for loose, uncompacted material.

Waste Cement Metso Beads grams ml grams ml Resins 362 240 36 24 Filter Sludge 340 226 34 23 Evaporator Bottoms 583 387 58 39 4.2.7 Mix the cement and Metso Beads together and slowly add this mixture to the test sample while it is being stirred.

4.2.8 Af ter ten (10) ~ minutes of mixing and a homogeneous mixture is obtained allow the waste to stand for a minimum of 30 minutes.

4.3 Solidification Acceptability The following criteria define an acceptable solidification process and process parameters.

4.3.1 The sample solidification is considered acceptable if there is not visual or drainable free water.

4.3.2 The sample solidification.is considered acceptable if upon visual inspection the waste appears that it would hold its shape if~ removed from the beaker and its resists penetration by a rigid stick.

4.4 Solidification Unacceptability 4.4.1 If the waste fails any of the criteria set forth in Section 4.3, the solidification will be termed unacceptable and a new set of solidification parame.:ers will need to be established under the procedures in Section 4.5.

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4.4.2 If the test solidification is unacceptable then the same test procedures must be followed on each subsequent batch of the same type of waste until three consecutive test samples are solidified.

4.5 Alternate Solidification Parameters ~.

4.5.1 If a test sample fails to provide acceptable solidification of waste the following procedures should be followed.

(1) Mix equal volumes of dry cement and water to ensure that the problem is not a bad batch of cenant.

(2) Add additional sodium hydroxide solution to raise pH above 8.

(3) It the waste is only partially solidified, use lower waste to cement and Metso ratios. Using the recommended quantities of cement and Metso Beads, reduce the waste sample volume to 375m1 and continue reducing the sample volume by 25m1 until the acceptability criteria of Section 4.3 are met.

Batch No:

Samole No:

Date:

WASTE SOLIDIFICATION DATA SHEET FOR ~.

(Type of Waste - Resin, Powdered Resin, Concentrated Waste Evaporated Bottoms)

Batch No: Sample No:

Sample Volume, ml:

2 Weight % Solids ;

pH 2; 1

2 Quantity of Oil' 5 Other Major Constituents:

3 3 Quantity of Cement Added: Cement Ratio (!/ft Waste )

3 3 Quantity of Additive Added: Additiver Ratio (#/ft Waste )

Final Waste to Product Ratio: .

Product Acceptable: Yes No (If no, refer to Section 4.5 and proceed as directed)

Radionuclider Present:

(Isotopes & Concentrations)

Additional batches solidified based on this sample solidification:

2ater. Batch 3atch Batch Satch Bat:n

?!c . Vol.- Date "o. Vol. Date No. Voi. Data 2 5 8 3 5 9 1 7 10

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Notes I If pH adjustment is required, note chemical used, quantity used and pH after adjustment.

2N ot required for spent resin or used precoat. ,_

3 Multiply the grams of cement (Metso) per ml of waste by 62.4 to convert to pounds of cement (Metso) per cubic foot of waste. For the ratio given in Section 4.2.6, cement-to-waste ratios are 56.4 pounds per cubic foot for resin, 53.1 pounds per cubic foot powdered resin and 911 pounds per cubic foot for boric acid. Note that the cement ratio for resin is per cubic foot of waste; i .e. , resin plus water. This is equivalent to 75.3 pounds of cement per cubic foot of dewatered resin.

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SOLIDIFICATION DATA TABLES SU.:'A RY For the three waste types investigated in this calculation, bead resin, powdered resin and 12 w/o boric acid and licensed cask payload is limiting in all cases for the HM-iC0 Series 1, HN-100 Series 2 and HN-100S. '!eight is limiting for the HN-100S and tha MM-200 only for Concentrated Waste (Evaporator Bottems). Weight is not a limiting factor for the Hil-600.

BEAD RESIN HN-100 HN-1005 HN-200 HN-600 Series 1 Series 2 Usable Liner Volume, ft 3 149 149 149 64 72 Max.SolidjfiedWaste 64 72 Volume ft 127.2 122.0 149

' Max. Resin Volume 40.6 Cawatered, ft3 71.7 68.7 84.0 36.1

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Water Added at Max. Resin 102

'!ci, gal 179 172 210 90.3 5399 5173 6325 2178 3057 Cerent Added Pounds 32 1 f-3 bags 57 55 67 29

.Tetsc Added 306 540 517 633 272 Pounds 1 ft3 bags 5.7 5.5 6.7 2.9 3.2 Max. Radiation Level 800 100 12 12 5 R/hr. Contact

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CONCENTRATED WASTE (EVAPORATED BOTTOMS)

HN-100 - HH-100S HN-200 HN-600 Series 1 Series 2 Usable Liner Vclume, ft3 156 156 156' 68 79 Max. Solidified Waste Vol ft3 105.5 101.2 126.9 65.8 79 Max. Waste Vol, ft3 74.5 71.4 89.6 46.a 55.8

. Cement Added at Max. Waste Vol.

Pounds 6783 6501 8158 4225 5080 1 ft 33 bags 72 69 87 45 54 M.B. Added at flax. Waste Vol .

. Pounds 678 650 816 *22 508 1 ft3 bags 7.2 6.9 8.7 4.5 .5.4 Max. Rad. Level R/hr en Contact 12 12 5 800 100 t .tri l

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' SOLIDIFICATION CALCULATION SHEET Liner Capacity: (1)

Waste / Product Ratio: -

(2)

Cement Ration: 3

1. /ft (3)

Additive:

Additive Ratio: 3

1. /ft (4)

Volume of Deitaterad or Concentrated Waste:

(1) x (2) = (5)

Cement Quantity -

(5) x (3) = (6)

Additive Quantity (5) x (4) =  : =- - (7)

Quantity of Water to be added - gallons (Resin only)

(5) x 2.5 = (8)

Divide the Quantity of Water to Be added (8) by the supply flowrate (9) to determine hcw long water should be pumned to the disposal liner.

(8) + gal / min (9) = minutes (10) l 12 -

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. POWDERED RESINS

~~HH-100 -

HN-100S HN-200 HN-600 Series 1 Series 2 __

3 72 Usable Liner Volume, ft 149 119 149 64 Max.SolidjfiedWaste 126.8 149 64 72 Vol. ft 1 21.6 Max. Waste Vol. ft 3 98.5 94.5 115.8 49.7 55.9

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Cement Added at Max. .

Waste Vol.

5230 5018 6150 2539 2968 Poungs 28 31 1 ft bags 56 53 65 M.B. Added at Max. Waste Vol.

523 502 615 264 297 Poungs 2.8 3.1 1 ft bags 5.6 5.3 6.5 Max. Rad Level 12 12 5 800 100 R/hr Contact 3

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