ML20195C543
| ML20195C543 | |
| Person / Time | |
|---|---|
| Issue date: | 05/10/1999 |
| From: | Bellamy R, Todd Jackson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20195C532 | List: |
| References | |
| REF-PROJ-M-32 M-32-99-01, M-32-99-1, NUDOCS 9906080213 | |
| Download: ML20195C543 (8) | |
Text
.
m-l U.S. NUCLEAR REGULATORY COMMISSION REGION I i MONITORING REPORT Report No. 99-01 1
! Site Visited: U.S. Department of Energy West Valley Demonstration Project Location: 10282 Rock Springs Road West Valley, NY 14171-9799 Visit Dates:. April 19 through April 23,1999 l
[ 7*((At "/[//
Monitor: 1 Todd J.h3titori, CHP qIate Health Physicist i i
Approved By: - MM )0 , lU T .,
Ronald R. Bellamy, Chief d 9date '
Decommissioning and Laboratory Branch Division of Nuclear Materials Safety 1
l
^
9906000213 990519
r 1 e 1 E
EXECUTIVE
SUMMARY
U.S. Department of Energy West Valley Demonstration Project NRC Monitoring Visit Report No. 99-01 A routine monitoring visit was conducted April 19-23,1999, to observe site operations and current project status at the West Valley Demonstration Project. Operational areas reviewed included recent site events, vitrification operations, high level waste tank operations to mobilize remaining tank contents to the vitrification facility, projects related to operation of other site facilities, radioactive waste management, and planning for decommissioning. As a result of this review, the monitor determined that the Department of Energy's contractor has established and maintained controls, processes, and programs, which are adequate to protect public health and safety.
I 1
l l
il Monitoring Visit Report No. 99-01 G:\DNMSOOCWoRK\lNSPRPT\WV9901.WPD
REPORT DETAILS I
- 1. Introduction This report documents the first routine monitoring visit of calendar year 1999 to observe site operations and current project status at the West Valley Demonstration Project (WVDP). The monitor observed activities in progress, held discussions with Department of Energy (DOE) and West Valley Nuclear Services (WVNS) personnel, and reviewed related documentation. DOE and WVNS personnel presented status briefings on site activities, with emphasis on the following:
Recent Site Events (Reportable and Non-Reportable)
Vitrification Operations High Level Waste Tank Operations Facility Closure and Site Operations Projects Radioactive Waste Management Decommissioning Planning IL Recent Site Events Recent site events were reviewed in detail. Events at West Valley are categorized into three groups: occurrence reports (most significar.t), critiques, and " event fact sheets" (least significant). Only occurrence reports are entered into the DOE event reporting system. The other two categories are used at West Valley to assure complete investigations of more minor events or near-misses, and that the events are captured in the WVNS data and trend tracking system. WVNS described information on 11 occurrence reports and 14 critiques, with several reviewed in detail.
Critiaue of a Small Soill of Contaminated Liauid from Tank 8D7 Work The monitor reviewed the details of the WVNS critique of a spill of contaminated water from tank 8D7 at the Waste Tank Farm on September 17,1998. WVNS had completed a thorough review, and identifieni appropriate corrective actions. In fact, the WVNS Facility Manager had escalated the review from the lowest level (" event fact sheet") up to the next level (" critique") to better assure a more formal and complete review.
Two aspects of this event were of special interest and were discussed with DOE and WVNS representatives. One reason for the event was a second work activity performed concurrently with the tank 8D7 work. The second activity caused conditions to change in tank 8D7, which .
contributed to the water spill event. Each activity had separately been planned and reviewed !
per procedures. Work control processes did not identify the need to evaluate the synergistic j interactions possible if both work activities were undertaken simultaneously. Additionally, the i plant equipment involved in the tank 8D7 work could not readily be isolated, as is commonly j accomplished through the lock out/ tag out program. It was not recognized during the work j planning that the unisolable line could have an impact on the work.
1 Monitoring Visit Report No. 99-01 I G:DNMSDoCWoRKMNSPRPTWW9901.WPD I I
High Level Waste Operations is the WVNS organization which was performing the work on Tank 8D7 when this spill occurred. Comprehensive corrective actions were described by personnel in the High Level Waste Operations group, which had changed the way such work is being planned and conducted by that group.
Medate on Leakina Welds on Processina Skid B in the New Low-Level Waste Buildina in the new Low Level Waste Water Treatment Facility (LLW2), one of the two newly-iristalled processing lines had developed leaks in the piping welds. WVNS had completed the investigation into the cause of the weld leaks, and concluded the stainless steel welds had failed due to chloride pitting corrosion. Two identical process skids had been installed in the LLW2 building, one to treat Sr-90 contaminated groundwater from the North Plateau, and the other to treat wastewater from Lagoon 2. Only skid B, processing North Plateau water, had failed.
Investigation identified corrosion pits, and chloride-rich corrosion deposits, in the piping and
. especially associated with the welds. Characterization of the process streams also identified chemistry differences in pH and chloride concentration. WVNS concluded the differences in wastewater chemistry entering skid piping explained the preferential skid B corrosion in welds and heat-sensitized pipe near the welds. . Resolution of the problem was determined to be replacement of skid B and common system stainless steel piping with PVC piping. The piping
. replacement work was underway 'at the time of the monitoring visit.
Severina 'of a Live 480 Volt Electrical Line Durina Snow Remmt A' temporary power cable had been used during winter 1998-99 to power a portable electric
= heater in the waste tank farm. The cable had been run along the ground from the nearest power source to the heater location, and operators at the time of installation had made appropriate log entries for shift tumover to alert oncoming shifts to the presence of the live cable. A subsequent snow storm had covered the cable, and the shift tumover notation about the cable was inadvertently omitted. As a result, the cable location was forgotten and a snow-removal worker was unaware of the cable. While using a front-end loader to remove snow, the worker severed the live cable, which tripped breakers but did not cause any personnel injury. Work was ,
stopped, WVNS investigated, and the event was reported as a near-miss of a serious injury.
Corrective actions included changes in the mechanisms for tracking temporary equipment and in the handling of shift tumover to prevent information from being inadvertently dropped from tumoverlists.
Ill. Vitrification Operations The metter was in idle during this monitoring visit. WVNS efforts continued to focus on removing high level weste (HLW) heels from the HLW storage tanks, which is more difficult and takes longer to accomplish as the tank contents are further reduced. More transfers from the tanks are required to make up each metter feed batch. The tenth canister for fiscal year 1999 had been partially filled as of this visit. ' A total of 238 canisters have been filled and 233 canisters have been transferred to the HLW Interim Storage Facility in the Main Plant. A total of 10.84 million curies "Sr and *Cs have been reported as transferred from the HLW tanks to the concentrator feed makeup tank.
2 . Monitoring Visit Report No. 99-01 G:DNMSDoCWORKUNSPRPTWVV9901.WPD
c l
j
- Planning had begun regarding design and procurement of equipment necessary to reduce the volume of expended materials within the vitrification cell, including contaminated metal components. Materials had accumulated in-cell during vitrification operations, and this project is intended to begin the strategy for efficient removal and disposal of these contaminated '
- E materials.
WVNS was investigating solutions for removing excess sodium in the waste tank heels. Sodium j had concentrated over time as a result of processing, and is becoming a significant interferent to i proper glass formation. Concentrations of sodium are approaching the level at which vitrification l- operations will be constrained, therefore making a sodium removal strategy necessary. The monitor will continue to follow this activity.'
IV.High Level Waste Tank Farm Operations WVNS continued to work on removing residual heels remaining in the HLW tanks. Zeolite used in tank 8D1 to pre-treat HLW in preparation for vitrification had been transferred to tank 8D2, with plans to eventually incorporate it into feed to the metter. A new spray-arm assembly and camera were installed in tank 8D1 to enable inspection and sluicing to mobilize more residual material in the tank. The monitor had observed the spray arm assembly design and operation when it had been installed in a test stand on site during 1998. One mobilization pump had been repaired and another replaced in tank 801. The grinder installed in the transfer line from tank 8D1 and 8D2 was tested at 2/3 speed and determined to be functional (to grind zeolite and other solids as they are transferred).
V. Facility Closure and Site Operations Projects Activity continued in the preparations and planning for decontamination and decommissioning of the Head End Cells (HEC) in the main plant. Refurbishment of cell shield windows had progressed, making more windows useable. The monitor observed the in-progress work on the Process Mechanical Cell (PMC) A shield window, and reviewed an additional recent videotape showing cell contents. Since the last monitoring visit in December 1998, WVNS had collected
- some samples from within the PMC, had made initial personnel entries into the manipulator repair room and the PMC crane room to obtain radiologicalinformation, and had successfully operated the PMC shield door.
WVNS also described ongoing work to address the conditions described by the NRC following review of the Low-Level Weste Processing and Support Activities Safety Analysis Report :
i (WVNS-SAR-002). In 1995', NRC had commented on SAR Section B.8.7.3.3, " Main Plant Criticality Concems", indicating "As such, NRC expects that the complete characterization of l material within the General Purpose Cell (GPC) and a criticality analysis of all proposed I activities within the GPC be completed prior to the onset of those activities." WVNS was !
l
' Letter from G.C. Comfort (NRC) to T.J. Rowland (DOE), "NRC Review of Safety Analysis Report for Low-Level Waste Processing and Support Activities, WVNS-SAR-002, Rev.
3", dated September 13,1995.
3 Monitoring Visit Report No. 99-01 4 G:ONMSOoCWoRKVNSPRPTWW9901.WPD
analyzing the available information regarding the GPC in preparation to discuss this issue with NRC.
Other projects discussed included installation of a new site electrical power substation interconnection, additional roof replacements scheduled for 1999, decommissioning of the old low level waste processing building (O2 plant), and planning for construction of a new radiological sample counting room for the Radiation Protection (RP) Department. The new substation interconnection will provide additional flexibility in power sources for the site, and should make power more reliable. More roof replacement work was being planned, with expectations that the work can be more efficiently performed using the experience gained over the past three years of replacing roofs. Work continued to dismantle the 02 building, with asbestos removal work in progress. The new counting room is expected to be constructed during May to July,1999. This facility will move RP's gamma sim4ivir4y activities into a new facility outside of the main plant and into an area of lower background radiation.
WVNS presented recent self-assessment program results for various projects and operating
. organizations. ' The monitor noted that the scope and depth of self-assessments was much more consistent than they had been when first examined by the Monitor in mid-1997. Self-assessments are focused on increased observations of in-plant activities and conduct of work, and are based on significant pre-planned commitments of personnel resources. Results of self-assessments are consistently of high quality, producing useful results.
VI. Radioactive Waste Management WVNS continued to emphasize the approach of " touch waste once" to increase efficiency of solid waste handling and processing activities. Waste shipments have been made approximately weekly since the December 1998 Monitoring Visit. A major objective of the program is to prepare for anticipated increases in waste generation rates associated with future site activities including HEC work, deactivation and decommissioning of support facilities, processing of expended materials in the vitrification cell, and the construction and operation of a remote-handling waste processing facility. WVNS is continuing to study the design and materials for a permeable treatment wall, to replace the North Plateau pump-and-treat process for "Sr removal from contaminated groundwater.
The fabric covering over the LSA-4 low-level radwaste storage structure is expected to be replaced during 1999 as planned, implementation of contingency plans to address wind-related
- failure of the covering during the past winter had not been necessary.
Vll. Planning for Decommissioning ,
WVNS described the Construction Work Package (CWP) system, and the process for i controlling construction work at the site, as followed-up to discussions from the previous j monitoring visit (Monitoring Visit Report 98-03). Construction work is controlled through a series !
of detailed procedures, which are contained in WVDP-160, ? Construction Projects Procedures !
Manual". Facility managers are aware of the construction work planning process and can . l require that CWPs be subjected to revicw by the Work Review Group (described in Monitoring l l
4 Monitoring Visit Report No. 99 G:ONMStoCWoRKilNSPRPTWW9901.WPC j U
I L, . .
l Report 98-03), thus providing a mechanism for integrating the CWP into the other site work L planning process when necessary. .WVNS personnel noted that the Integrated Safety Management System (ISMS) also assured detailed review of work planning in a consistent manner for all site work. WVNS management expressed confidence that the lessons learned L from past work planning and coordination problems had been incorporated adequately into the construction work planning process, as had been done in the other site work planning and 1 coordination processes.
Construction welding procedures are contained in the construction welding manual (WVDP-250) ' As part of the planning for a more efficient decommissioning work environment, WVNS is examining the value of integrating the operation and construction welding manuals into a single, site-wide welding program.
Vill. Exit Meeting i - The monitor presented the results of this visit to senior DOE management on April 22, and to WVNS management on April 23,1999.
l l
L
)
1 l
l 5 Monitoring Visit Report No. 99-01 G:ONMSOoCWCRKVNSPRPTWVV9901.WPD f
l
__1
. -). , j
. 4 --
PARTIAL LIST OF PERSONS CONTACTED Department of Enerov. Ohio Field Office-West Vallev Demonstration Project Barbara Mazurowski, Director l T.J. Jackson, Acting Deputy Director .
David Cook, Operations and Engineering Team yVest Vallev Nuclear Services c Robert Campbell, President Robert Lawrence, Waste, Fuel, and Environmental Projects Manager 1
! Paul Valenti, High Level Waste Projects Manager Stuart MacVeen, Site Operations and Facility Closure Projects Manager Bob Fussner, High-Level Waste Operations John Garcia, Radiation Protection Manager Joe Jablonski, Main Plant Operations Manager Tom Kocialski, High-Level Waste Systems Engineering Manager Jack Gert>er, Environmental Affairs Manager
- Jim Gramling, Decommissioning Planning Manager
' Ken Schneider, Head End Cells Project Manager
. Robert Keel, Operations Support Manager John Gwynar, Conduct of Operations Team t.eader Craig Repp, Environmental Projects Manager l Bob Steiner, Senior Environmental Engineer L Lettie Chilson, Safety Analysis and integration Manager l Rich Humphrey, Construction and Project Administration Manager Don Sisson, Construction Projects Manager Jackie Jackson, Waste Management Operations Manager Tom Cottrell, Site Operations Projects and Support Manager Tom Whelan, Operations Technical Support Engineer, LLW2 l Bruce Covert, Waste Operations Manager l
l I
o 6 Monitoring Visit Report No. 99-01 I G;ONMSBoCWoRK\lNSPRPTWV9901.WPD 1 L i