3. us9 (mark [xi - unt digital libraryreference copies of mki tool drawings. - added appendices b...

ENGINEERING C H A N G E NOTICE Paps I o f 2

I.ECN 605796 . . . . . . . . . . . . . . . . . . . . . . . ......... . . . . .. Flk

5. Date

8/23/96

8. Approval Designator

SQ

11. Related PO No.

-- L- . - ----- 1

14a. J u s t i f i c a t i o n (mark one)

C r i t e r i a Change [ ] Design Improvement [XI Environmentat [ ] F a c i l i t y Deact iva t ion [ ] As-Found [ ] F a c i l i t a t e Const [ ] Const. Error/Omission [ ] Design Error/Omission [ ] 14b. J u s t i f i c a t i o n D e t a i l s

A r e v i s i o n t o t h e system des ign d e s c r i p t i o n was r e q u i r e d because o f changes i n t h e des ign o f t h e MkI l i d removal t o o l s .

2. ECN Category 3. O r i g i n a t o r ' s Name, Organizat ion. MSIN, (mark one) and Telephone NO.

supplemental G. A. R i t t e r 8M720 HO-32 D i r e c t Revis ion [XI 376-4669 Change ECN Temporary Standby [I Spent Nuclear Fue ls supersedure Cancel/Void

6. Pro jec t Title/No./Work Order No.

[I [I C h a r a c t e r i z a t i o n , LBO24

9. Document Numbers Changed by t h i s ECN ( inc ludes sheet no. and rev.)

WHC-SD-SNF-SDD-005 Rev. 0

15. D i s t r i b u t i o n ( inc lude name, MSIN, and no. o f copies)

R . B. Baker HO-40 N. R. Roe 0. W . Bergmann R3-86 G. A. R i t t e r A. E . Br idges HO-40 M. J. Langevin P . J . MacFarlan HO-40 J . A. T i t t l e R. P . Omberg HO-40 D. 0. Hess S . L . Hecht HO-40 SNFE F i l e s C . D . K i r k X3-72 SNF P r o j e c t F i l e s KG%l)(3-85

e n t r a l F i l e s 88

4 . US9 Required?

[I Yes [XI N O

7. Bldg./Sys./Fac. NO.

105-KE/105-KW

I O . Related ECN No(s) .

N/A

A-7900-013-2 (05/96) GEF095

12a. Mod i f i ca t ion Work 12b. Work Package NO.

[ ] Yes ( f i l l out B lk . N/A 12b)

1

12c. Mod i f i ca t ion Work Complete 12d. Rest0 t i o n (Temp.

N/A

[ X I No (NA Blks. 12b. 12c. 12d)

I Design Authority/Cog. Engineer Design Author i tyfcog. Engineer

Signature & Date Signature & Date

o f 2 ENGINEERING CHANGE NOTICE 1. ECN (use no. from pg. 1)

605796

Functional Design Criteria

opermng Speclflcatlo"

Clltlcallty Speclflcatlon

Conceptual Design Report

Equipment Spec

CO"Sf spec

Procurement spec

Vendor Information

OM Manual

FSARISAR

Safety Equipment List

Radiation Work Permit

Environmental Impact Statement

Environmental Report

Enwanmental Permit

V e r i f i c a t i o n Required

[ X I Yes

[ I No

StresslDesign RspoA

Interface Control Drawing

Calibration Procedure

Installation Procedure

Maintenance Procedure

Engineering Procedure

Operating Instruction

Operating Procedure

Operational Safety Requirsment

IEFD Drawing

Cell Arrangement Drawing

Essential Material Specification

Fac. Proc. Samp. Schedule

Inspection Plan

Inventory Adjustment Request

ENGINEERING CONSTRUCTION

Add i t iona l [ ] $ N/A Add i t iona l [ ] $ Improvement [ ] N/A Savings [I Delay 11 $ savings [ I $

Tank Calibration Manual

Health Physics Procedure

Spares Multiple Unit Listing

Test ProcedureslSpecificati~~

Component Index

ASME Coded Item

Human Factor consideration

Computer Software

Electric Circuit Schedule

ICRS Procedure

Process Control MsnualiPlan

Process Flow Chart

Purchase Requisition

Tickler File

NIA

L J [I [I 20. Other Affected Documents: (NOTE: Documents l i s t e d below w i l l not be rev ised by t h i s ECN.) Signatures below

i n d i c a t e t h a t the s ign ing organ iza t ion has been n o t i f i e d o f other a f fec ted documents L is ted below. Document Number/Revision Document NumberlRevisian Document Number Revis ion

none.

Cog. Eng. G. A. R i t t e r 1.L.

21. Approvals

Cog. Mgr. R . P . 0 erg 2 FC?&

Safety 0. 0. Hess

Envi ran.

Other

Informal Review N. R . Roe

R . B. Baker

M. J. Langevln

C. D. K i r k

Signature Design Agent A. E. Bridge&

PE

PA

Safety

Design

Environ.

Other

DEPARTMENT OF ENERGY

Signature or a Control Number tha t t racks the Approval s ignature

ADDIT IONAL

A-7900-013-3 (05196) GEF096

WHC-SD-SNF-SDD-005, Rev. L

System Design Description for Sampling Fuel in K Basins

Glenn A. R i t t e r Westinghouse Hanford Company, Richland, WA 99352 U.S. Department of Energy Contract DE-AC06-87RL10930

EDT/ECN: 604988 UC: 2070 Org Code: EM720 Charge Code: LBO24 8&R Code: EW3135040 Total Pages: 40

Key Words: K Basins, Sampling Equipment, Fuel Characterization, System Design Description, Spent Nuclear Fuel Project

Abstract: This System Design Description provides: (1) statements of the Spent Nuclear Fuel Project's needs for sampling o f fuel in the K East and K West Basins, (2) the sampling equipment functions and requirements, (3) a general work plan and the design logic followed to develop the equipment, and (4) a summary description o f the design for the sampling equipment. This report summarizes the integrated application o f both the subject equipment and the canister sludge sampling system in the characterization campaigns at K Basins.

TRADEMARK DISCLAIMER. t rade name, trademark, manufacturer, o r otherwise, does no t necessar i l y c o n s t i t u t e o r imply i t s endorsement, recornendation, or favor ing by the United States Government o r any agency thereof o r i t s con t rac tors or subcontractors.

P r i n t e d i n the United States o f America. TO obta in copies of t h i s document, contact: WHCIBCS Document Control Services, P.O. Box 1970, MaiLstop H6-08, Richland WA 99352, Phone (509) 372-2420; Fax (509) 376-4989,

Reference here in t o any s p e c i f i c cornerc ia l product, process, o r serv ice by

9 - i ~ - Y6 R ease Approval' Date Release Stamp / - '

Approved for Public Release

A-6400-073 (10/95) GEF321

( 1 ) Document Nunber

WHC-SD-SNF-SDD-005 RECORD OF REVISION

Page 1

f o i l o w i n g pr imary changes: - updated s e c t i o n s 4 .0 and 5.0 t o r e f l e c t I I chanqes i n t h e design o f t h e MkI l i d

(3 ) Revision ( 4 ) Description of Change - Replace, Add, and Delete Pages

0 (7) I n i t i a l Revis ion, Approval EDT 610195 dated February 9, 1996.

1 be Suoerseded r e v . 0 Der ECN 605796 w i t h t h e

removal t o o l s . - added drawing l i s t and support equipment sketches t o Appendix A and d e l e t e d r e f e r e n c e copies o f MkI t o o l drawings. - added Appendices B and C t o p r o v i d e a l i s t o f suppor t ing documentation and o p e r a t i n g procedures assoc ia ted w i t h t h e sampl ing equipment.

I

Authorized for Release ( 5 ) Cog. Engr. ( 6 ) Cog. Mgr. Date

R. B. Baker R. P . Omberg

G . A. R i t t e r R. P . Ombera

I I I I

I I I I

A-7320-00s (08/91) UEF168

WHC-SD-SNF-SDD-005 Rev . 1

CONTENTS

1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 PROJECT BASIS OF NEED FOR SAMPLING SYSTEM . . . . . . . . . . 1

2 .0 FUNCTIONS AND REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . 2 2 . 1 FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.2 REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.0 GENERAL WORK PLAN AND K BASIN PLANT INTERFACES . . . . . . . . . . . 3

4 .0 SYSTEM DESIGN DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 4

5.0 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.0 SYSTEM LIMITATIONS, CASUALTY EVENTS, AND RESPONSE TO OFF-NORMAL EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6 . 1 MINOR OFF-NORMAL EVENTS . . . . . . . . . . . . . . . . . . . 10 6.2 SIGNIFICANT OFF-NORMAL EVENTS . . . . . . . . . . . . . . . . 11

7.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8.0 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

APPENDIX A - DRAWING LIST AND SUPPORT EQUIPMENT SKETCHES . . . . . . . . A-1

APPENDIX B - SUPPORTING DOCUMENTS . . . . . . . . . . . . . . . . . . . . 6-1

APPENDIX C - OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . C-1

ii


LIST OF FIGURES

1 . Overview o f K Basin SNF C a n i s t e r Contents and Path Forward . . . . . 17 2 .

Development and A p p l i c a t i o n . . . . . . . . . . . . . . . . . . . . 18 3 .

K Bas in Fuel Sampling System . . . . . . . . . . . . . . . . . . . 19 4 . K East Bas in Process Flow . . . . . . . . . . . . . . . . . . . . . . 20 5 . K West Bas in Process Flow . . . . . . . . . . . . . . . . . . . . . . 21

Proposed K Basin P l a n t Review o f Fuel Sampling System

Work Breakdown f o r Development and A p p l i c a t i o n o f

iii


LIST OF TABLES

1 . K Basin Fuel Sampling System . . . . . . . . . . . . . . . . . . . 13

2 . L i s t o f Primary Responsibilities . . . . . . . . . . . . . . . . . . 14 3 . Equipment and Functions . . . . . . . . . . . . . . . . . . . . . . . 15 4 . Sequence o f Operation . . . . . . . . . . . . . . . . . . . . . . . . 16

Documents Supporting Design and Application o f

iv


ALARA CNS DQO DOE-Rl HPT P I C POC SAP SAR SDD SFEC SEP SNF SNFE SNFP USQ WHC

LIST OF TERMS

As Low As Reasonably Achievable Chem Nuclear Svstems Data Q u a l i t y Objective Department o f Energy R ich land F i e l d O f f i c e H e a l t h Physics Technic ian Person I n Charge P o i n t o f Contact Sample A n a l y s i s P1 an S a f e t y A n a l y s i s Report System Design D e s c r i p t i o n s i n g l e f u e l element c o n t a i n e r S a f e t y E v a l u a t i o n f o r Packaging Spent Nuc lear Fuel Spent Nuc lear Fuel Eva lua t ions Spent Nuc lear Fuels P r o j e c t Unreviewed Safe ty Quest ion Westinghouse Hanford Company

V

WHC-SD-SNF-SDD-005 Rev. I

SYSTEM DESIGN DESCRIPTION FOR SAMPLING FUEL I N K BASINS

1.0 INTRODUCTION

A number o f key a c t i v i t i e s underway as p a r t o f t h e Spent Nuc lear Fuels P r o j e c t (SNFP) are r e l a t e d t o t h e process ing and d ispos ing o f spent n u c l e a r f u e l (SNF) f rom t h e 105-K Basins (K Bas ins) . The proposed "Path Forward" ( C u l l e y 1995) d i s p o s i t i o n o f SNF i s summarized i n F igure 1 a long w i t h es t imates o f t h e q u a n t i t i e s invo lved. Development o f SNF recovery equipment, p rocess ing equipment, t r a n s p o r t methods, and d isposa l o p t i o n s a l l r e q u i r e s p e c i f i c SNF c h a r a c t e r i z a t i o n da ta .

i s l e s s da ta than needed f o r p r o j e c t dec is ions and equipment des ign bases. A d d i t i o n a l q u a l i t y da ta a re r e q u i r e d and w i l l be d e f i n e d th rough t h e process o f deve lop ing Data Q u a l i t y Ob jec t ives (DQO) and Sample A n a l y s i s Plans (SAP). Because o f t h e requirements f o r c h a r a c t e r i z i n g SNF i n bo th K East and K West Basins, t h e SNF sampling system was developed t o be used as a r o u t i n e process r u n by Basin Operat ions. cognizance o f t h e Spent Nuclear Fuel Eva lua t ions group who i s tasked t o p r o v i d e c h a r a c t e r i z a t i o n da ta f o r t h e SNFP.

Taking SNF samples i s a compara t ive ly s imple t a s k by Basin Opera t ions standards and i s b a s i c a l l y considered an a c t i v i t y r a t h e r than a p r o j e c t . Based on d iscuss ions w i t h Operat ions s t a f f , a graded approach i s be ing used f o r t h e requirements f o r K Basin reviews as d e f i n e d i n t h e "K Basin P l a n t P r o j e c t Review Guide l ines" (WHC 1996). Responding t o t h i s , t h i s system des ign d e s c r i p t i o n (SDD) document addresses several documentation needs i n c l u d i n g : (1 ) statements o f t h e SNFP needs r e q u i r i n g t h i s sampling, ( 2 ) system f u n c t i o n s and requirements, (3 ) a general work p l a n and des ign l o g i c be ing fo l lowed, and ( 4 ) a summary design d e s c r i p t i o n o f t h e pr imary system i n c l u d i n g process f l o w . T h i s SDD prov ides an i n t e g r a t e d package f o r use w i t h K Basin s t a f f and f o r i n t e r f a c i n g w i t h t h e design and support team.

Whi le some data on SNF have been obtained, r e c e n t s t u d i e s conclude t h e r e

A p p l i c a t i o n o f t h e system w i l l be under t h e

1.1 DEFINITIONS

Fuel samples Selec ted f u e l elements and p a r t s t h a t w i l l be shipped t o t h e 327 B u i l d i n g (ho t c e l l s ) f o r examinat ion.

1 . 2 PROJECT BASIS OF NEED FOR SAMPLING SYSTEM

The system and equipment t h a t i s t h e s u b j e c t o f t h i s SDD w i l l be used t o

Th is a c t i v i t y i s an i n t e g r a l p a r t sample and s h i p spent nuc lear f u e l elements, broken f u e l p a r t s , and c a n i s t e r s ludge t o t h e 327 B u i l d i n g f o r examinat ion. o f t h e c u r r e n t SNFP c h a r a c t e r i z a t i o n program p l a n (Siddoway 1995), which responded t o t h e acce le ra ted Path Forward Memorandum o f Agreement (WHC 1995).

1


2.0 FUNCTIONS AND REQUIREMENTS

2 . 1 FUNCTIONS

The system w i l l p r o v i d e t h e c a p a b i l i t y t o s a f e l y and e f f i c i e n t l y sample SNF from open and c losed c a n i s t e r s l o c a t e d i n t h e K Basins. Inc luded i n t h e system are t h e t o o l s t o decap se lec ted c losed c a n i s t e r s i n KW bas in , remove s e l e c t e d f u e l and sludge samples f rom open KE and KW c a n i s t e r s , t o l o a d t h e samples i n t o an a p p r o p r i a t e cask f o r d e l i v e r y t o t h e 327 B u i l d i n g f o r r e q u i r e d a n a l y s i s and c h a r a c t e r i z a t i o n , and t o recap c a n i s t e r s i n KW bas in . A lso i n c l u d e d i n t h e system are t o o l s t o draw gas and l i q u i d samples f rom c losed c a n i s t e r s i n t h e KW Basin w i t h o u t decapping.

The system w i l l r e l i a b l y p r o v i d e f u e l samples c o n s i s t e n t w i t h t h e DQO and SAP, w i l l m a i n t a i n t r a c e a b i l i t y , and w i l l m in imize p o t e n t i a l con taminat ion i n t h e K Basins and t r a n s p o r t a t i o n pa th t o t h e 327 B u i l d i n g .

f rom pas t f u e l and sludge sampling exper ience and w i l l i n c o r p o r a t e f e a t u r e s t o e l i m i n a t e o r reduce p r e v i o u s l y encountered problems.

The system w i l l i n c o r p o r a t e as many proven des ign f e a t u r e s as p o s s i b l e

2 . 2 REQUIREMENTS

The f o l l o w i n g summarize t h e system requirements:

A . The system s h a l l p r o v i d e t h e c a p a b i l i t y t o d e l i v e r batches o f f u e l and c a n i s t e r s ludge samples t o t h e 327 B u i l d i n g i n batches o f up t o s i x f u e l assemblies.

The system s h a l l opera te w i t h p resent u t i l i t i e s a v a i l a b l e i n t h e K East and K West Basin areas, and be ab le t o opera te w i t h t h e e x i s t i n g p h y s i c a l environment (e.g., f rom e x i s t i n g g r a t i n g , w i t h i n overhead o b s t r u c t i o n s , weight r e s t r i c t i o n s , a i r q u a l i t y , e t c . ) and t h e K Basin Safe ty A n a l y s i s Report (SAR).

t r a n s p o r t a t i o n (e.g. , PAS-1 cask, CNS 1-136 cask) , and l a b o r a t o r y h a n d l i n g (e.g., 222S, 327 B u i l d i n g ) s h a l l be f u l l y d e f i n e d and i n t e g r a t e d i n t h e system p lann ing . I n t e r f a c e l i m i t s (e .g . , dose r a t e , s ize , e t c . ) i n each case s h a l l be f u l l y i n t e g r a t e d . [ T h i s SDD does n o t cover t h e cask system. designed t o i n t e r f a c e w i t h t h e acceptance c r i t e r i a o f t h e l a b o r a t o r y f a c i l i t i e s chosen.]

B.

C . I n t e r f a c e s o f support serv ices (e .g . , mob i le l a b o r a t o r y ) ,

The cask system w i l l be

D. The system s h a l l be designed f o r r o u t i n e use by K Basin Operat ions s t a f f . System c o n t r o l s and hand l ing w i l l account f o r t h e encumbrances on t h e opera tors wear ing t h e l e v e l s o f p r o t e c t i v e c l o t h i n g needed i n t h e K East and K West Basins.

E . The system and i t s o p e r a t i o n w i l l minimize waste and c o n s i d e r ease o f d isposa l o f waste throughout i t s l i f e c y c l e ( i . e . , f a b r i c a t i o n , opera t ion , s to rage and f i n a l d isposa l o f equipment) .

2


F . The system s h a l l l i m i t t h e amount o f water added t o e i t h e r t h e KE o r KW Basin d u r i n g Phase I1 f u e l sampling t o 2000 g a l l o n s .

G . The system s h a l l l i m i t personnel exposure t o f i v e (5) person-rems f o r t h e e n t i r e g a s / l i q u i d , c a n i s t e r sludge, and f u e l sampl ing campaign.

H. The system s h a l l n o t r e q u i r e more than t h r e e (3) opera tors a t any one t i m e d u r i n g f u e l sampling and w h i l e p r e p a r i n g i t f o r shipment

I . Hydrogen genera t ion f rom f u e l and sludge samples s h a l l n o t exceed l i m i t s d e f i n e d i n WHC-SD-TP-SEP-028, N Reactor and S i n g l e Pass Reactor F u e l C h a r a c t e r i z a t i o n Shipments S a f e t y E v a l u a t i o n f o r Packaging, f o r t h e CNS cask (Crow 1996).

3.0 GENERAL WORK PLAN AND K BASIN PLANT INTERFACES

F i g u r e 2 descr ibes t h e general design sequence t h a t was used f o r t h e SNF sampling system equipment. B a s i c a l l y , equipment development f o l l o w e d from t h e f u n c t i o n s and requirements descr ibed i n t h e prev ious s e c t i o n s . b a s i n i n t h e Hanford 305 B u i l d i n g was used as a key f o r assur ing performance o f t h e equipment (as much as p o s s i b l e through c o l d t e s t i n g ) and m i n i m i z i n g dose t o opera tors and developers. t e s t i n g (e .g . , independent t e s t i n g o f design f e a t u r e s ) , design re f inement , acceptance t e s t i n g ( i . e . , f i n a l c o l d t e s t i n g o f t h e i n t e g r a t e d system des ign w i t h s i m u l a t i o n ) , and c o l d t r a i n i n g t h e K Basin opera tors . F u r t h e r v a l i d a t i o n o f t h e opera tors f o l l o w e d i n t h e K West Basin t o min imize dose (versus a d r y r u n i n K East) w h i l e a l l o w i n g f i n a l v a l i d a t i o n o f t h e design i n t h e a c t u a l environment o f t h e Basin f a c i l i t i e s .

The development o f t h e readiness process was performed p a r a l l e l t o t h e development o f t h e equipment us ing a graded approach f o r read iness as p e r DOE- RL d i r e c t i v e 5480.31. Readiness documents ( i . e . , read iness c h e c k l i s t , work p lan , procedures, e t c . ,) and s a f e t y reviews ( i . e . , hazards ca tegory , unreviewed s a f e t y ques t ions , eva lua t ions , e t c . ) f o r t h e sampl ing r u n were devel oped.

and t h e K Basin Operat ions P l a n t s t a f f i s summarized i n Table 2 . T h i s approach was based d i r e c t l y on recommendations g iven i n A d m i n i s t r a t i v e procedure 7-003-00 (WHC 1996), assuming a graded approach--combining r e 1 a ted steps where f e a s i b l e t o s i m p l i f y t h e e f f o r t f o r a r e l a t i v e l y s imp le system. An example o f t h i s i s t h e use o f t h i s SDD t o p r o v i d e f o u r o f t h e pr imary documents (e.g. , documenting t h e SNFP need, f u n c t i o n s and requirements, general work p lan , and design d e s c r i p t i o n summary). T h i s i n t e r f a c e approach was reviewed w i t h key K Basin s t a f f and should p r o v i d e s u f f i c i e n t depth f o r t h e t a s k i n v o l v e d . The P o i n t o f Contact (POC) w i l l be c o n t i n u a l l y advised on t h e des ign development steps as they occur.

The c o l d t e s t

The c o l d t e s t f a c i l i t y was used f o r f e a t u r e

The i n t e r f a c e and reviews between t h e design process o f t h e equipment

F i g u r e 3 shows t h e present work breakdown f o r development and f i r s t a p p l i c a t i o n o f t h e SNF sampling system.

3

Table 1 prov ides t h e pr imary


documents, authors, and approving o r g a n i z a t i o n s . A d e t a i l e d l i s t o f these documents i s g iven i n Appendix B. design areas and r e s p o n s i b i l i t i e s . h i g h p r i o r i t y f o r i n p u t t o process equipment design, t h e schedule f o r t h i s sampl ing equipment made use o f as many p a r a l l e l a c t i v i t i e s and p a s t des ign work as was reasonable. However, sound eng ineer ing , s a f e t y , ALARA, da ta q u a l i t y , and K Basin Operat ion requirements r e q u i r e d a s e t o f steps t h a t c o u l d n o t be s h o r t c u t f o r t h e sampling t o be success fu l .

opera tors was an impor tan t i n g r e d i e n t t o success. th rough (1 ) i n i t i a l i n t e r f a c e meetings on t h e equipment as i t was designed and developed, ( 2 ) c o l d t r a i n i n g i n t h e Hanford 305 B u i l d i n g w i t h t h e opera tors u s i n g t h e f i n a l equipment, and (3) a d r y r u n made i n t h e K West Basin. S i g n i f i c a n t p e r i o d s were a l l o t t e d t o these tasks t o h e l p assure t h e f i n a l a p p l i c a t i o n i s success fu l w i t h minimum dose.

WHC-SD-SNF-SDD-004, System Design D e s c r i p t i o n f o r Sampling Sludge i n K Basins Fuel Storage Can is te rs (Baker 1996). descr ibed i n t h i s SDD t o t h e e x t e n t necessary t o i n t e g r a t e and show t h e r e l a t i o n s h i p s and i n t e r f a c e s between f u e l sampling and c a n i s t e r s ludge sampl ing.

Table 2 p rov ides a summary o f p r imary Because t h e f i r s t sampling was viewed as a

Since t h e sampling systems are t o be r u n by Operat ions, t r a i n i n g o f t h e T r a i n i n g was accomplished

The system and equipment f o r sampling c a n i s t e r s ludge i s descr ibed i n

The process and equipment a re a l s o

4.0 SYSTEM DESIGN DESCRIPTION

The des ign o f t h e sampling system i s based i n l a r g e p a r t on concepts and equipment used i n t h e 1994-95 f u e l and sludge sampling campaigns. T h i s system i s designed t o process SNF s t o r e d a t KE Basin i n open c a n i s t e r s and SNF s t o r e d a t KW Basin i n c losed MkI and M k I I c a n i s t e r s w i t h t h e f o l l o w i n g f e a t u r e s .

The KE c a n i s t e r s a re open a t t h e top , a l l o w i n g f u e l t o be removed o u t o f t h e t o p o f t h e c a n i s t e r .

The KW MkI c a n i s t e r s a re encapsulated us ing a piston-shaped l i d w i t h a G r a f o i l ' compression r i n g i n s e r t e d i n t o t h e t o p o f t h e c a n i s t e r d u r i n g i n i t i a l encapsu la t ion . The c a n i s t e r needs t o be i n t e r n a l l y p r e s s u r i z e d t o d r i v e o u t t h e l i d and t o a l l o w fue l and sludge samples t o be ob ta ined from t h e t o p o f t h e c a n i s t e r .

The KW M k I I c a n i s t e r s a re encapsulated us ing an e x t e r n a l cover secured w i t h a l o c k i n g bar . a l l o w removal o f f u e l and sludge samples f rom t h e t o p o f t h e c a n i s t e r .

The l o c k i n g bar i s tu rned t o remove t h e can and

The c losed MkI and M k I I c a n i s t e r s a re p rov ided w i t h two e x t e r n a l vent va lves : one l o c a t e d i n t h e c e n t e r o f t h e l i d , t h e o t h e r on t h e o u t e r p e r i p h e r y o f t h e l i d . v e r t i c a l l y down i n t o t h e c a n i s t e r . i s f l u s h w i t h t h e i n s i d e o f t h e l i d .

The c e n t e r va lve has a tube t h a t extends 5.0 cm ( 2 i n . ) The o u t e r va lve opening i n t o t h e c a n i s t e r

These two va lves p r o v i d e t h e c a p a b i l i t y

' G r a f o i l i s a trademark o f SEPCO Inc .

4


t o purge and f i l l t h e t o p two inches o f t h e b a r r e l w i t h an i n e r t gas when i n i t i a l l y capping o r recapping a c a n i s t e r , i s o l a t i n g a c a n i s t e r f rom t h e b a s i n water. c a n i s t e r w i t h water and t o t a k e gas and l i q u i d samples.

v a r i e s w i t h t y p e o f c a n i s t e r . summarized i n Table 3 and are descr ibed i n d e t a i l below. Minimum h a n d l i n g t i m e i s d e s i r e d t o m a i n t a i n low worker dose r a t e s . M a t e r i a l s used f o r c o n s t r u c t i o n o f t h e equipment a re compat ib le w i t h t h e b a s i n water and t h e r a d i o a c t i v e gas, l i q u i d , and f u e l i n t h e c a n i s t e r s . Unless o therw ise noted, t h e equipment f u n c t i o n s a t t h e c a n i s t e r i n t e r f a c e b u t i s manual ly operated from l o c a t i o n s above t h e bas in g r a t i n g . The heav ie r t o o l s a re equipped w i t h l i f t i n g b a i l s so t h a t they can be moved u s i n g t h e b a s i n monora i l h o i s t system.

These two va lves are a l s o u t i l i z e d t o vent and comple te ly f i l l t h e

As a r e s u l t o f t h e above d i f f e r e n c e s , t h e equipment needed t o sample SNF The equipment and t h e i r f u n c t i o n s are

Gas and L i q u i d Samoler sample t h e gas and/or l i q u i d conten t o f a c losed MkI o r M k I I c a n i s t e r b a r r e l . Access t o t h e l i q u i d conten ts i n s i d e t h e c a n i s t e r i s th rough t h e c e n t e r vent va lve . v a l v e .

The f u n c t i o n o f t h e gas and l i q u i d sampler i s t o

Access t o t h e gas conten ts i n s i d e t h e c a n i s t e r i s th rough t h e s i d e

The sampler was designed t o draw 20 m l o f gas o r l i q u i d samples f rom a c a n i s t e r . sample, and c l o s i n g t h e vent va lve . excessive sample d i l u t i o n by bas in water o r c ross contaminat ion o f samples. The f i r s t g e n e r a t i o n sampler system i s shown i n drawings H-1-80392 and H- l - 80398. The h o l d e r r a c k used w i t h t h i s f i r s t sampler system i s shown i n drawing H-1-80405. The second/current genera t ion sampler system i s shown i n drawings H-1-80399 and H-1-82347. The f u e l c a n i s t e r r a c k t h a t i s used w i t h t h e c u r r e n t system i s shown i n drawing H-1-80406.

Valve Stem Hand l inq Tool The f u n c t i o n o f t h i s t o o l i s t o open a vent v a l v e f rom a MkI c a n i s t e r l i d by loosen ing t h e v a l v e stem. For t h e l i d removal process, t h e t o o l i s used t o loosen t h e c e n t e r va lve stem o f a MkI l i d so t h a t i t can be removed from t h e v a l v e u s i n g t h e a i r g r i p t o o l ( s u p p l i e d i n t h e b a s i n s ) . The v a l v e stem must be removed so t h a t t h e pressure system t o o l can be threaded i n t o t h e c e n t e r va lve t o p r e s s u r i z e t h e c a n i s t e r . t h i s t o o l i s shown i n Drawing H-1-81198. An a l t e r n a t e v a l v e stem removal t o o l was designed t o p revent loosen ing t h e e n t i r e va lve body i n case t h e v a l v e stem has been over t igh tened. Th is a l t e r n a t e t o o l f e a t u r e s a socket t h a t f i t s over t h e v a l v e body t o h o l d i t i n p lace w h i l e an i n t e r n a l r o d assembly loosens t h e va lve stem. T h i s t o o l i s shown i n Drawing H-1-82348.

Tube Crimoinq Tool tube connect ing t h e MkI c a n i s t e r b a r r e l gas space t o t h e gas t r a p . does n o t have t o comple te ly c l o s e t h e f l o w path . should n o t c o n t r i b u t e s i g n i f i c a n t l y t o water a d d i t i o n t o t h e b a s i n . I n a d d i t i o n , r e s t r i c t i n g t h e volume o f f l o w i n t o t h e c a n i s t e r w i l l h e l p p revent d i s t u r b i n g t h e sludge i n s i d e t h e c a n i s t e r s , which w i l l improve t h e da ta q u a l i t y o f t h e s ludge samples. H-1-81202. advantage, i . e . , 90 N (20 l b f ) a p p l i e d t o t h e handle w i l l p r o v i d e 6200 N (1400 l b f ) o f c r i m p i n g f o r c e .

The sampler equipment i s capable o f opening a vent va lve , drawing a The equipment was designed t o p revent

The des ign o f

The f u n c t i o n o f t h i s t o o l i s t o e f f e c t i v e l y c l o s e o f f t h e The t o o l

However, t h e l e a k p a t h

The design o f t h i s t o o l i s shown i n Drawing The t o o l was designed t o p r o v i d e r o u g h l y a 7 0 : l mechanical

5


Nut Hand l inq Tool The f u n c t i o n o f t h i s t o o l i s t o loosen MkI l i d n u t s d u r i n g l i d removal (if necessary) and t o t i g h t e n t h e n u t s d u r i n g l i d replacement. The t o o l was designed t o a l l o w t i g h t e n i n g t o a to rque o f 40 N-m (30 f t - l b f ) . The t o o l a l s o fea tures a u n i v e r s a l j o i n t assembly t h a t a l l o w s a misal ignment o f about + 5 " . The design o f t h i s equipment i s shown i n Drawing H-1-81199.

Pressure System i n s i d e of MkI c a n i s t e r s v i a t h e c e n t e r vent va lve t o g r a d u a l l y push t h e l i d o u t of t h e c a n i s t e r . The system u t i l i z e s a boos ter pump t h a t inc reases t h e i n l e t p ressure by up t o 830 kPa (120 p s i g ) . The pump d ischarge f l o w , which v a r i e s w i t h p ressure boost, i s approximately 25 L/min (6.7 gpm) a t 690 kPa (100 p s i g ) boost. deminera l i zed water supply i s n o t capable o f supp ly ing s u f f i c i e n t p ressure t o remove a l i d . Two pressure gauges are prov ided w i t h t h e system: one pressure gauge mon i to rs t h e pump d ischarge pressure, t h e second gauge mon i to rs t h e approximate c a n i s t e r i n t e r n a l pressure ( t h e pressure downstream o f t h e c o n t r o l v a l v e ) . The pump system connects t o a p r e s s u r i z a t i o n t o o l v i a a hose and q u i c k d isconnect f i t t i n g s . 1-81200, H-1-81204, and H-1-82089. The p r e s s u r i z a t i o n t o o l shown i n Drawing H-1-81200 i s a p rev ious design and w i l l be used as a spare. p r e s s u r i z a t i o n t o o l shown i n H-1-82089 was designed t o reduce t h e f l o w r e s t r i c t i o n s (and subsequent pressure losses) through t h e t o o l such t h a t a l i d cou ld be removed w i t h o u t c r imp ing ( i f necessary). The pump c o n f i g u r a t i o n i s shown i n drawing H-1-81204.

L i d Hand l inq Tool The pr imary f u n c t i o n o f t h i s t o o l i s t o i n s t a l l new MkI l i d s i n t o t h e c a n i s t e r d u r i n g recapping opera t ions . The t o o l c o u l d a l s o be used t o p i c k up a MkI l i d d u r i n g removal, b u t normal ly t h e p r e s s u r i z a t i o n t o o l (H-1-82089) w i l l be used t o p i c k up and move t h e l i d s i n c e i t w i l l a l r e a d y be connected f o r t h e l i d removal process. The t o o l was designed t o seat t h e l i d such t h a t t h e t o p o f t h e l i d i s f l u s h w i t h t h e t o p o f t h e c a n i s t e r c y l i n d e r a f t e r t h e l i d n u t s a re t i g h t e n e d . The design o f t h e MkI l i d h a n d l i n g t o o l i s shown i n Drawing H-1-81197.

ScraDer Tool The f u n c t i o n o f t h i s t o o l i s t o remove excess G r a f o i l seal m a t e r i a l f rom t h e i n s i d e o f t h e c a n i s t e r , i f necessary. I f no s i g n i f i c a n t amount o f seal m a t e r i a l remains i n s i d e a c a n i s t e r b a r r e l a f t e r removing a l i d , t h e scraper t o o l may n o t be r e q u i r e d . Th is t o o l i s shown i n Drawing H-1-81201. The scraper t o o l i s e s s e n t i a l l y a m o d i f i e d MkI l i d ( w i t h sharpened edges f o r sc rap ing) adapted t o t h e end o f a T-handled p o l e .

Fuel Removal Tools T h i s equipment i s used t o g rapp le and remove s e l e c t e d i n n e r and o u t e r f u e l elements f rom c a n i s t e r s and p lace them i n sample c o n t a i n e r s . The equipment p revents f u e l f rom be ing l i f t e d t o w i t h i n 2.4 m ( 8 ft) o f t h e sur face o f t h e bas in water. The f u e l removal t o o l s are shown i n Drawings H-1-80543 and H-1-80544.

Fuel C a n i s t e r Manual Valve Operators (Purse T o o l s 1 These t o o l s a re used w i t h MkI and M k I I c a n i s t e r s t o (1) open and c l o s e t h e c e n t e r and o u t e r vent va lves , ( 2 ) add water and c o r r o s i o n i n h i b i t o r t o recapped c a n i s t e r s , and (3 ) r e e s t a b l i s h an i n e r t gas space i n t h e t o p o f t h e c a n i s t e r s (purge t h e c a n i s t e r s ) . M k I I and Mkl c a n i s t e r s , r e s p e c t i v e l y .

The f u n c t i o n o f t h i s t o o l i s t o app ly water p ressure t o t h e

The pump i s o n l y needed i f t h e standard K Basin

The design o f t h i s system i s shown i n Drawings H-

The pr imary

These t o o l s are shown i n Drawings H-1-51845 and H-1-82344 f o r

6


S i n q l e Fuel Element Containers (SFECI Th is equipment i s used t o c o n t a i n i n d i v i d u a l fue l samples taken o u t o f t h e s to rage c a n i s t e r s . The c o n t a i n e r s are c y l i n d r i c a l and o f s u f f i c i e n t d iameter and l e n g t h t o h o l d an assembled i n n e r and o u t e r f u e l element. One end i s c losed, and t h e o t h e r end i s equipped w i t h a removable, l e a k t i g h t l i d . h a n d l i n g an i n t e r n a l pressure o f 350 kPa (50 p s i g ) . The l i d i s p rov ided w i t h a smal l v a l v e connect ion t o p e r m i t hydrogen t e s t i n g . T h i s equipment i s shown i n Drawing H-1-80394.

Hydroqen Tes ter Th is equipment w i l l be used t o measure t h e r a t e o f hydrogen g e n e r a t i o n by measuring t h e r a t e o f gas genera t ion i n t h e SFEC w h i l e it i s s t o r e d near t h e bottom o f t h e bas in . Measurement o f hydrogen g e n e r a t i o n i s a necessary p recursor t o cask l o a d i n g and sh ipp ing because i t e s t a b l i s h e s t h e s h i p p i n g window.

Cask I n s e r t T h i s equipment i s a c y l i n d e r w i t h an i n t e r n a l s t r u c t u r e designed t o h o l d up t o s i x SFECs o r s ludge c a n i s t e r s i n a v e r t i c a l p o s i t i o n d u r i n g t r a n s p o r t a t i o n i n t h e cask.

Fuel /Sludqe T r a n s p o r t a t i o n Cask (CNS 1-136, o r e q u i v a l e n t ) The cask w i l l be used t o t r a n s p o r t f u e l and sludge samples h e l d i n t h e cask i n s e r t f rom t h e KE and KW Basins t o t h e 327 B u i l d i n g . It i s capable o f be ing decontaminated b e f o r e l e a v i n g t h e K Basin. The support frame used f o r h a n d l i n g t h e cask l i d i n t h e bas in i s shown i n Drawing H-1-80404. D e t a i l e d i n f o r m a t i o n on t h e t r a n s p o r t a t i o n cask i s g iven i n WHC-SD-TP-SEP-028.

Gas/L iqu id SamDle TransDort Systems g a s / l i q u i d samples t o t h e 222s o r 325 B u i l d i n g f o r i s o t o p e a n a l y s i s . P A S - I cask may be used t o t r a n s p o r t these samples. on t h e PAS-1 cask i s g i v e n i n WHC-SD-TP-SEP-033, S a f e t y E v a l u a t i o n f o r Packaging f o r t h e Transport o f K West Bas in C a n i s t e r Samples i n t h e PAS-1 Cask. However, a l e s s r o b u s t sh ipp ing system may be used depending on sample dose r a t e s .

C a n i s t e r Sludqe Samplinq System T h i s equipment i s used t o sample s ludge from open MkI o r M k I I f u e l s to rage c a n i s t e r s . A s ludge sample c o n t a i n e r i s used t o c o n t a i n i n d i v i d u a l s ludge samples and i s t r a n s p o r t e d u s i n g t h e same cask system as f o r SFECs. i n WHC-SD-SNF-SDD-004.

Misce l laneous Tools and S u m o r t EauiDment Several t o o l s a re r e q u i r e d t o support sampl ing opera t ions . L i d l o w e r i n g dev ices are used t o l o w e r a MkI o r M k I I l i d f rom t h e bas in g r a t i n g l e v e l t o a c a n i s t e r o r l i d s tand on t h e b a s i n f l o o r . A l i d s tand was designed t o h o l d a MkI o r M k I I l i d so t h a t i t can be e a s i l y p icked up w i t h t h e l i d h a n d l i n g t o o l s . equipment a re g iven i n Appendix A .

The c o n t a i n e r s are capable o f

Th is equipment i s shown i n Drawing H-1-81563.

Th is equipment i s shown i n Drawing H-1-81460.

These systems w i l l be used t o t r a n s p o r t

More d e t a i l e d i n f o r m a t i o n The

[ T h i s SDD does n o t cover t h e cask t r a n s p o r t a t i o n process . ]

A more d e t a i l e d d e s c r i p t i o n o f t h i s system i s p rov ided

Sketches o f t h e suppor t

7


5.0 SYSTEM OPERATION

The KE Basin s t o r e s spent nuc lear f u e l i n open c a n i s t e r s . The KW Basin s t o r e s f u e l i n c a n i s t e r s t h a t a re sealed by l i d s . The c h a r a c t e r i z a t i o n process w i l l i n c l u d e sampling f u e l and sludge from c a n i s t e r s i n bo th bas ins , b u t n o t n e c e s s a r i l y bo th f u e l and sludge from t h e same c a n i s t e r . and 5 are process f l o w diagrams f o r KE Basin and KW Basin, r e s p e c t i v e l y .

The sequence o f o p e r a t i o n f o r f u e l and c a n i s t e r sampl ing depends on t h e design o f t h e s to rage c a n i s t e r being sampled. The most complex procedure i s assoc ia ted w i t h t h e MkI sealed c a n i s t e r which has a p i s t o n l i d t h a t r e q u i r e s i n t e r n a l p r e s s u r i z a t i o n t o remove. O f l e s s e r complex i ty i s t h e M k I I c a n i s t e r which has an e x t e r n a l l i d secured w i t h a l o c k i n g bar . The l e a s t complex are t h e open c a n i s t e r s i n t h e KE Basin which do n o t r e q u i r e gas and l i q u i d sampl ing o r need t o be decapped. The pr imary steps i n t h e b a s i n sequence o f o p e r a t i o n are summarized i n Table 4 and descr ibed below.

Samole Storaqe C a n i s t e r Gas and L i a u i d conten t o f capped storage c a n i s t e r s i s needed t o meet DQO requirements and as a screen ing techn ique f o r s e l e c t i n g c a n i s t e r s t o be opened f o r f u e l and/or s ludge sampling.

F igures 4

Sampling o f t h e gas and l i q u i d

The MkI and M k I I c a n i s t e r s a re p rov ided w i t h two vent va lves on t h e t o p

These va lves were used t o

o f t h e l i d ; one i s i n t h e c e n t e r o f t h e l i d , t h e o t h e r i s a t t h e o u t e r c i rcumference o f t h e l i d . approx imate ly 5 cm ( 2 i n . ) down i n t o t h e c a n i s t e r . add c o r r o s i o n i n h i b i t o r t o t h e c a n i s t e r water and t o e s t a b l i s h an i n e r t gas space above t h e c a n i s t e r water and f u e l when t h e f u e l was encapsulated. These va lves p r o v i d e a means t o sample t h e gas and l i q u i d i n t h e c a n i s t e r .

Pressur ize MkI Storaae Can is te r t h a t i s i n s e r t e d i n t o and f i t s f l u s h w i t h t h e t o p o f t h e c a n i s t e r c y l i n d e r . The l i d i s sealed w i t h a r i n g o f G r a f o i l ' t h a t i s compressed. As a r e s u l t o f acceptance t e s t i n g , t h e n u t s used t o compress t h e r i n g w i l l t y p i c a l l y n o t need t o be loosened b e f o r e t h e l i d can be removed from i t s p o s i t i o n i n t h e c a n i s t e r c y l i n d e r (Roe 1996). I f a l i d i s t o be reused, t h e n u t s should be loosened p r i o r t o p r e s s u r i z i n g t h e c a n i s t e r so t h a t t h e l i d can be e a s i l y r e i n s t a l l e d . Even w i t h t h e n u t s loosened, t h e l i d w i l l n o t s l i d e o u t w i t h o u t a p p l y i n g f o r c e , and t h e r e f o r e t h e i n s i d e o f t h e c a n i s t e r i s p r e s s u r i z e d d u r i n g decapping opera t ions .

The c e n t e r va lve has an ex tens ion p r o t r u d i n g

The MkI c a n i s t e r l i d i s b a s i c a l l y a p i s t o n

P r e s s u r i z a t i o n w i l l be done by f i r s t opening t h e vent va lves t o vent gas from t h e c a n i s t e r , and then i n j e c t i n g p r e s s u r i z e d water i n t o t h e c a n i s t e r through t h e c e n t e r vent va lve . l i m i t a t i o n s , t h e i n j e c t i o n pressure w i l l be minimized, and i s n o t expected t o exceed 830 kPa (120 p s i g ) . The MkI c a n i s t e r has a vent l i n e connect ing t h e t o p o f t h e l i d t o t h e gas t r a p . o f f t h e p a t h f o r leakage o f p ressur ized water i n t o t h e b a s i n and t o l i m i t t h e f l o w o f water i n t o t h e c a n i s t e r t o which cou ld d i s t u r b t h e s ludge i n s i d e t h e c a n i s t e r .

Because o f c a n i s t e r des ign pressure

Th is l i n e w i l l be crimped t o e f f e c t i v e l y shut

' G r a f o i l is a trademark o f SEPCO Inc.

a


Remove Storaqe C a n i s t e r L i d The design o f t h e MkI and M k I I l i d s a re d i f f e r e n t and r e q u i r e somewhat d i f f e r e n t procedures. A f t e r t h e MkI l i d i s pushed o u t o f t h e c a n i s t e r c y l i n d e r by h y d r a u l i c pressure, t h e l i d w i l l be r e s t i n g on t o p of t h e c y l i n d e r . from t h e work area around t h e c a n i s t e r . ) The M k I I l i d r e s t s on t o p o f t h e c y l i n d e r and i s secured by a l o c k i n g bar . The l i d must be unlocked by loosen ing t h e n u t and r e l e a s i n g t h e l a t c h i n g bar . I t i s then l i f t e d and moved away from t h e work area. I f a c a n i s t e r l i d i s n o t damaged, i t may be reused. Otherwise, a new l i d w i l l be i n s t a l l e d i n t h e c a n i s t e r . Damaged l i d s w i l l be p laced i n c o n t a i n e r s and disposed o f l a t e r u s i n g r o u t i n e K Basin housekeeping procedures and equipment.

Remove Fuel SamDle from Storaqe Can is te r The f u e l s t o r e d i n t h e K Basin and t h e s u b j e c t o f c h a r a c t e r i z a t i o n i s N Reactor f u e l c o n s i s t i n g o f two c o n c e n t r i c f u e l c y l i n d e r s , i . e . , an o u t e r f u e l element, and an i n n e r f u e l element. Two d i f f e r e n t s i z e d mandrel c o l l e t systems, one t o f i t i n s i d e , expand and l i f t o u t e r elements, t h e o t h e r t o do t h e same w i t h i n n e r elements, w i l l be used t o l i f t f u e l samples o u t o f t h e c a n i s t e r s and p lace them i n t o s i n g l e element c a n i s t e r s o r t o per fo rm v i s u a l examinat ions.

Recap Storaqe Can is te r recapped depending on t h e c o n d i t i o n o f t h e e x i s t i n g l i d . c a n i s t e r s w i t h new l i d s i s n o t r e q u i r e d . c a n i s t e r s w i l l be used d u r i n g recapping opera t ions . on a MkI c a n i s t e r , t h e l i d w i t h G r a f o i l r i n g s w i l l be lowered i n t o t h e b a s i n u s i n g t h e l i d l o w e r i n g dev ice (shown i n Appendix A ) . p icked up u s i n g t h e l i d hand l ing t o o l and i n s e r t e d i n t o t h e c y l i n d e r u n t i l t h e stops on t h e l i d h a n d l i n g t o o l c o n t a c t t h e t o p o f t h e c a n i s t e r b a r r e l . The t h r e e n u t s w i l l then be t i g h t e n e d t o push t h e l i d f l u s h w i t h t h e t o p o f t h e c a n i s t e r and compress t h e G r a f o i l r i n g aga ins t t h e c y l i n d e r t o seal t h e c a n i s t e r . I n t h e case o f t h e M k I I c a n i s t e r s , t h e l i d w i l l be lowered i n t o t h e bas in , cen tered on t o p o f t h e c a n i s t e r , and secured w i t h t h e l o c k i n g mechanism t o seal t h e c a n i s t e r .

It w i l l then be l i f t e d and s e t as ide (away

New c a n i s t e r l i d s may be used when c a n i s t e r s a re Recapping t h e

For i n s t a l l i n g a new l i d Much o f t h e t o o l i n g t o decap t h e

The l i d w i l l t hen be

A f t e r t h e c a n i s t e r s are sealed, t h e vent va lves may be used t o add l i q u i d c o r r o s i o n i n h i b i t o r and e s t a b l i s h an i n i t i a l 5 cm ( 2 i n . ) i n e r t gas space i n t h e t o p o f t h e c a n i s t e r . Note t h a t t h i s purg ing o f t h e c a n i s t e r s i s no l o n g e r r e q u i r e d by t h e c u r r e n t K Basin o p e r a t i o n a l s a f e t y requirements document, WHC-SD-WM-OSR-006, and t h e r e f o r e i s o p t i o n a l .

I f necessary, t h e scraper t o o l w i l l be u t i l i z e d t o remove excess G r a f o i l f rom t h e MkI c a n i s t e r s e a l i n g sur face .

Load S i n l e Fuel Element Containers and Test f o r H Fuel elements and f u e l p a r t s r e i o v e d from storage c a n i s t e r s w i l l be load& i n t o SFECs i n p r e p a r a t i o n f o r l o a d i n g i n t o a sh ipp ing cask. g e n e r a t i o n w h i l e i t i s i n t h e bas in .

The SFEC w i l l be mon i to red f o r gas

Load SFECs i n t o T r a n s p o r t a t i o n Cask The t r a n s p o r t a t i o n cask w i l l be lowered i n t o t h e b a s i n and prepared f o r i n s e r t i o n o f t h e SFECs. A cask i n s e r t w i l l be used t o h o l d t h e SFECs i n u p r i g h t and approximately equal ly-spaced p o s i t i o n s . Adequate steps w i l l be taken t o reduce contaminat ion o f t h e t r a n s p o r t a t i o n cask (e.g. , s t r i p p a b l e p a i n t ) .

9


Prepare Cask for Shipment to the 327 Building The cask will be lifted out of the main basin and the strippable paint removed. overpack and shielding will then be installed. The cask will be installed and secured on a vehicle suitable for transporting heavy loads on Hanford Reservation roads.

Any required protective

Procedures and requirements for transportation of the cask to the 327 Building are described in WHC-SD-TP-SEP-028.

6.0 SYSTEM LIMITATIONS, CASUALTY EVENTS, AND RESPONSE TO OFF-NORMAL EVENTS

6 . 1 MINOR OFF-NORMAL EVENTS

The following events may occur during the course of fuel sampling and are considered to have minor consequences.

Basin Loss of Electric Power Response: This event could affect basin ventilation, basin hoists, and operation of electrically powered equipment associated with fuel sampling. If there is a loss of ventilation, further sampling steps will be stopped and personnel will respond in accordance with established K Basin procedures for this type of event.

Events Involvinq the Gas/Liauid Sampler There are several possible minor events involving this equipment:

- Failed sampler Response: Pull out of basin and repair.

- Vent valve used for sampling fails to open Response: Use a separate vent valve tool (such as the tool shown in Drawing H-1-82348 for MkI lids) to loosen vent valve stem. If valve still fails to open, abandon attempts to obtain sample from the canister.

the canister may continue to vent into the basin. - Vent valve fails to close after sampling Response: Remaining gas in

Events Involvinq the MkI Tools

- Crimping tool fails t o adequately crimp Response: Attempt to

Notify the HPT.

pressurize the canister to remove the lid. affect the capability of the pressure system to push the lid out of the canister cylinder.

system for damage and repair as required, otherwise abandon attempts to sample from the canister.

the basins) to retrieve lid.

An uncrimped tube should not

- Pressure system fails t o remove lid Response: Inspect the pressure

- Lid lowering device drops lid Response: Use the air grips (supplied in

Failure of Other Spent Fuel Svstem Samplinq Svstem Equipment Response: Most of the equipment is designed to be operated from the grating level of the basin and can be taken up for repair. Plans for such repair will be made

10


between Operations and SNFE staff to optimize the process and mitigate ALARA concerns.

Local Electrical Power Loss Response: Put equipment in "standby" mode (i.e., power switches off, power disconnected, etc.) and under direction of PIC and Test Engineer leave area until power is restored.

Radiation Monitorinq Instrumentation Failure Response: Sampling should be stopped and not resumed until PIC and Test Engineer and HPT supervisor are satisfied that adequate monitoring can be performed.

Evacuation of Facility Response: Sampling or preparations for sampling must be stopped as soon as the evacuation alarm sounds and the area evacuated. Equipment should be left with power disconnected. Any off-normal condition of the equipment must be communicated by the PIC to the shift or facility managers or other responsible staff, so the condition is clear to staff restarting the activity after the evacuation.

Spills and Leakaqe of Gas/Liquid Sample be evaluated by PIC and HPT and handled consistent with normal Basin practices (as appropriate, the shift and facility managers will be involved in the evaluation).

Response: Any spills or leaks will

6 . 2 SIGNIFICANT OFF-NORMAL EVENTS

Overdilution of Gas/Liauid Sample Response: The sampler will be periodically tested using a reference source. samples is significant, the sampler will be repaired and samples repeated as requi red.

If duration of overdiluted

7.0 MAINTENANCE

Most of the tools were designed to last the entire sampling campaign and therefore no maintenance is planned or scheduled. If a tool or other piece of sampling equipment fails or is damaged, plans will be made between Operations and SNFE staff to repair or replace equipment as required.

For the gas and liquid sampler, reference samples will be taken to ensure that the equipment is functioning satisfactorily. The concern is overdilution of samples caused by excessive leakage around the seals. reference sample indicates equipment malfunction, then plans will be made between Operations and SNFE staff to perform maintenance on the sampler equipment.

If a

11


8.0 REFERENCES

Baker, R . B., 1996, System Design D e s c r i p t i o n f o r Sampl ing Sludge i n K Bas ins F u e l Storage Can is te rs , WHC-SD-SNF-SDD-004, Rev. 1, Westinghouse Hanford Company, Richland, Washington, January 1996.

Crow, S. R., 1996, N Reactor and S i n g l e Pass Reactor F u e l C h a r a c t e r i z a t i o n Shipments S a f e t y E v a l u a t i o n f o r Packaging, WHC-SD-TP-SEP-028, Rev. 1, Westinghouse Hanford Company, Richland, Washington.

C u l l e y , G. E . , 1995, K Bas in Sludge D i s p o s i t i o n St ra tegy , ( l e t t e r , WHC- 9552284, t o C . A . Hansen (RL), A p r i l 24, 1995), Westinghouse Hanford Company, Richland, Washington.

Roe, N . R., 1996, Acceptance Test Report f o r K B a s i n Mark I L i d Removal System, WHC-SD-SNF-TRP-017, Rev. 0, Westinghouse Hanford Company, Richland, Washington.

Siddoway, D. W . , 1995, K Bas in Path Forward A c t i o n I tems, ( l e t t e r , WHC- 9551459, t o C . A. Hansen (RL), March 15, 1995), Westinghouse Hanford Company, Richland, Washington.

Stevens, P . F . , 1995, S a f e t y E v a l u a t i o n f o r Packaging f o r t h e Transpor t o f K West Bas in C a n i s t e r Samples i n t h e PAS-1 Cask, WHC-SD-TP-SEP-033, Rev. 0, Westinghouse Hanford Company, Richland, Washington.

WHC, 1995, Memorandum o f Agreement on Path Forward f o r K B a s i n SNF, dated

WHC, 1996, A d m i n i s t r a t i v e Procedure 7-003-00, K Bas in P r o j e c t Review Process,

February 14, 1995, Westinghouse Hanford Company, Richland, Washington.

Westinghouse Hanford Company, Richland, Washington.

12


Tab le 1. Documents S u p p o r t i n g Design and A p p l i c a t i o n o f K Bas in Fuel Sampl ing System.

Function and Requirements

LIST OF TERMS

SNFE: SNFP: KR-0, KR-I, KR-2, KR-3: K Basin: Pak: QA: ALARA: USQ: SEP:

NOTE:

Characterization Group Spent Nuclear Fuel Evaluations Spent Nuclear Fuel Project K Basin Review Bodies K Basin Operations Staff Packaging and Transport Group K Basin Quality Assurance Group As Low As Reasonably Achievable Unreviewed Safety Question Safety Evaluation for Packaging

Detailed lists of drawings, supporting documents, and operating procednres associated with the fuel sampling systeni are provided in Appendices A, B, and C.

13


Training QuAity Assurance Air Permit

Table 2. List o f Primary Responsibilities.

K Basin L L Blehm SNFQA D W Smith K Basin R G Gant

SNFE: SNFP: ES: POC: Pak:

Spent Nuclear Fuel Evaluations Group Spent Nuclear Fuel Project Engineering Support Group K Basin Point of Contact Packaging and Transportation Group

14

WHC-SD-SNF-SLID-005 Rev. 1

Tab le 3 . Equipment and F u n c t i o n s

NOTES:

( I )

( 2 )

Two different tools are used depending on canister type, MM or MMI.

Two different tools are used depending on type of fuel, inner or outer element

15


(WHC-SD-SNF-SDD-004) ReCdp Storage Canister Move Canister Back to Storage Location Load SFECs and/or Sludge Sample Containers into Tranaportdtion Cask Prepae Cask for Shipment to 327 Building

T a b l e 4. Sequence o f Operation.

X X

X X X

X X X

X X X

16

WHC-SO-SNF-SDD-005 Rev. 1

Figure 1. Overview o f K Basin SNF Canister Contents and Path Forward.

Fuel Starngc Canistcr Sludge -Lirrlc Clixactcriration h n c .Likely IoContain Iligli Conccnlralions of

Fucl M:ilcd in Some Cascr

I , I K Basin Canistcrcontcnu

Spcnt Nuclcar Fucl -Some ~I~arilc~criia~ion is donc -Most burnup is about 2500 MwlYron

I .May lmprct Sclcction nf Spciil Pucl Proccssinp, Options

-Canisters not scalcd. no lid.; -Edmated half 3,666 fuclcd cmirtcrs hmc

brcaclid fucl cladding

K Wcst -Sludgcvolumc -TDD -Could havc similar sludgc volume as K h t

dcpcnding on fucl behavior -Cmistcn sealed including lids

l- -Pucl mass - I 145 Mtu -Btimaled hallof fucl Itas damagcd cladding -Somc residual sludgc on fucl

K Wcsl -Rcl mass -950 MIU -blcnl of clad brcaching is uncertain -Some midual sludgc on fuel

- I

I . . Disposal Patlis

MCOEucl PaUi (Storage. ctc..) [Rrridual sludgcon lucl clcmcnts]

17


F igure 2 . Proposed K Basin P l a n t Review o f Fuel Sampling System Development and A p p l i c a t i o n .

1 '

I , I I

18

w W

I Dasin Tucl Sampling SysLem

m 0 I m z 77

I m 0 0 I

0 0 ul

W

C

ru 0

K-EAST PROCESS FLOW

Move Canister

Location + to Staging Oblain

Sludge Sarnplc ’ Select Canislcr

t

No

Move Container lo Slaging

Yes

Load Obtained? I Store Container 1

Return Canister to Storage

+ Flush Cask (?)

- 1 Ship Cask

I 1/1 7T 0

W vl z m

VI ‘II I vl rt

W 0 VI 0 m

d. 0 0 (n

7 W V

rn < VI VI w

a

n

3 s

N I

1 K-WEST PROCESS FLOW

Return Canister

Location b To Storage Sample

Select Move Canister lo Weasel Pit Canister

- Visual Exams

Seal Purge Select New* Return Canister

Location -

Canister to Storage 4 Canister - 3 r' I I Select Canister 1 (' G/L sampled)

Seal & Purge Canister

.--I-

* Return Canister

to Storage

(Sludge Container ->)

/i 4 Marked for All , -

Testing Obtained?

t Hydrogen Testing

IJ Ship Cask

n

-n


APPENDIX A

DRAWING LIST AND SUPPORT EQUIPNENT SKETCHES

A- 1


The f o l l o w i n g i s a l i s t o f drawings f o r t h e sampl ing equipment d e s c r i b e d i n t h i s SDD. p r o v i d e d i n t h i s Appendix.

Sketches o f suppor t equipment i d e n t i f i e d i n t h i s SDD a r e a l s o

DRAWING NUMBER

H-1-80392

H- 1-80394

H-1-80396

H-1-80398

H-1-80399

H-1-81402

H-1-81404

H-1-81405

H-1-81406

H-1-80543

H-1-80544

H-1-81197

H-1-81198

H-1-81199

H-1-81200

H-1-81201

H-1-81202

H-1-81203

H-1-81204

H-1-81460

H-1-81563

H-1-81566

H-1-82089

TITLE Fuel C a n i s t e r Sampler - 1

S i n g l e Fuel Element C a n i s t e r (SFEC)

Support Rack - S i n g l e Fuel Element C a n i s t e r Arrangement

Sampler B a i l

Fuel C a n i s t e r Sampler - 2

Sampler Ho lder

CNS 1-136 Cask L i d Support Frame

105K Bas in Fuel C a n i s t e r H o l d i n g Rack

Fuel C a n i s t e r Rack Assembly

Fuel Handl i n g Tool I n n e r Element

Fuel Handl i n g Tool Outer Element

MK-1 L i d Hand l ing Tool Assembly

Valve Stem Hand l ing Tool Assembly

Nut Hand l ing Tool Assembly & D e t a i l s

L i d Removal Tool Pressure System Assembly

M K - I Scraper /C leaner Assembly & D e t a i l s

M K - I Tube Cr imp ing Tool Assembly

MK-1 C a n i s t e r Gas Trap Assembly & D e t a i l s

M K - I L i d Removal Pressure System C a r t C o n f i g u r a t i o n

CNS 1-136 Cask L i n e r Assembly and D e t a i l s

Gas Sampler Assembly

Fuel Hand l ing Tool I n n e r Element

MK-1 L i d Removal Tool Pressure System Assembly

A-2

WHC-SO-SNF-SDD-005 Rev. 1

MkI/II L i d Storage Stand C o n f i g u r a t i o n

I LID

I I t

A-4

DRAWING NUMBER

H-1-82344

H-1-82347

H-1-82348

H-1-82349


TITLE MK-1 C a n i s t e r Purge Tool Assembly

K Bas in Fuel C a n i s t e r Sampler General Arrangement

Valve Stem Removal Tool Assembly

K Bas in Tool S to rage Rack

A-3

r w


MkI/II L i d Storage Stand Assembly & Details

A- 5

L I D LOWERING

MK I


MkI L i d Lowering Device Conf igurat ion

A- 6

WHC-SD-SNF-SOD-005 Rev. 1

MkI Lid Lowering Device Assembly & Details

A-7


APPENDIX B

SUPPORTING DOCUMENTS

B- 1


The f o l l o w i n g l i s t p r o v i d e s t h e p r i m a r y s u p p o r t i n g documents i d e n t i f i e d i n Tab le 1 o f t h i s SDD.

TEST PLANS AND REPORTS

WHC-SD-TP-TP-006 " T e s t P lan f o r K Bas in P r o t o t y p e Mark I L i d Removal Too ls , " G. A. R i t t e r , June 1996.

WHC-SD-SNF-TRP-017

WHC-SD-SNF-TP-010

WHC-SO-SNF-TRP-003

WHC-SO-SNF-TP-008

WHC-SO-SNF-TRP-002

WHC-SO-SNF-TP-030

WHC-SD-SNF-TRP-016

DRAWINGS

see Appendix A

DESIGN DOCUMENTS

WHC-SD-SNF-AP-001

WHC-SD-SNF-FDC-001

WHC-SD-SNF-DR-001

"Acceptance Tes t Report f o r K Bas in Mark I L i d Removal System," N. R . Roe, August 1996.

" T e s t Plan f o r K Bas in Fuel H a n d l i n g T o o l s , " A. E . Br idges , February, 1995.

" T e s t Report f o r K Bas in V e r t i c a l Fuel H a n d l i n g T o o l s , " T. A. Me l ing , March, 1995.

" G a s / L i q u i d Sampling f o r Closed C o n t a i n e r s i n KW Bas in Tes t P lan , " C . C . P i t k o f f , January 1995.

"Gas/L iqu id Sampler f o r Closed C o n t a i n e r s i n KW Bas in Tes t Repor t , " C . C . P i t k o f f , February 1995.

" T e s t P lan f o r Sealed C a n i s t e r Gas and L i q u i d Sampl ing Equipment," D. J . Tr imb le , 1996.

"Tes t Report f o r Sealed C a n i s t e r Gas and L i q u i d Sampling Equipment," D. J . T r i m b l e , J u l y 1996.

"Sealed C a n i s t e r L i q u i d Sampling f o r Fuel C h a r a c t e r i z a t i o n Shipments," D. J. T r i m b l e , January 1995.

"Gas and L i q u i d Sampling f o r Closed C a n i s t e r s i n K- West Bas in F u n c t i o n a l Design C r i t e r i a , " C . C . P i t k o f f , December 1994.

"Design Suppor t Document f o r t h e K Bas ins V e r t i c a l Fuel H a n d l i n g Too ls , " A . E . Br idges , February 1995.

TRAINING PLAN

MWP-95-005 Appendix 1 "Fuel C h a r a c t e r i z a t i o n Phase 11, T r a i n i n g Plan," J . A . S e r l e s , March 1996.

K B A S I N OPERATING PROCEDURES

see Appendix C

B-2


MASTER WORK PLAN AND OTHER WORK PLANS

MWP-95-005 "Fuel C h a r a c t e r i z a t i o n Phase I 1 K-East & K-West

WHC-EP-0830 "Han fo rd Spent Nuc lea r Fuel P r o j e c t Recommended Path

WHC-SO-SNF-WP-012 "Gas and L i q u i d Sampling f o r Closed C a n i s t e r s i n KW

WHC-SD-SNF-WP-011 "Work P lan f o r Development o f K Bas in Fuel H a n d l i n g

WHC-SD-SNF-PLP-010

Bas ins , " J. A. S e r l e s , A p r i l 1996.

Forward," J. C . F u l t o n , October , 1994.

Bas in Work Plan," C . C . P i t k o f f , Feb rua ry 1995.

Tools , " A. E. B r idges , November 1994.

" C h a r a c t e r i z a t i o n Program Management P lan f o r Han fo rd K Bas ins , " October 1995.

DATA QUALITY OBJECTIVES

WHC-SD-SNF-DQO-001

WHC-SD-SNF-DQO-003

WHC-SO-SNF-DQO-006

WHC-SD-SNF-DQO-009

WHC-SD-SNF-DQO-010

SAMPLE ANALYSIS PLANS

WHC-SD-SNF-PLN-004

WHC-SD-SNF-PLN-007

WHC-SD-WNF-SM-001

WHC-SD-SNF-SM-002

"Data Q u a l i t y O b j e c t i v e s f o r t h e I n i t i a l K West Fuel Examinat ions," L . A. Lawrence, Februa ry 1995.

"Data Q u a l i t y O b j e c t i v e s f o r Gas and L i q u i d Samples f rom Sealed K Basins C a n i s t e r s , " 8. J. Makenas, March 1995.

"Data Q u a l i t y O b j e c t i v e s f o r Gas and L i q u i d Samples f rom Sealed K West Bas in C a n i s t e r s (Second Campaign)," B. J. Makenas, J u l y 1996.

"Data Q u a l i t y O b j e c t i v e s f o r t h e K Eas t Fuel Examinat ions," L. A. Lawrence, Februa ry 1996.

"Choices o f C a n i s t e r s and Elements f o r t h e Second Fuel Shipment and Gas /L iqu id Sampl ing f rom K West Basin, " B . J. Makenas, 1996.

"Sampl ing and A n a l y s i s P lan f o r C a n i s t e r L i q u i d and Gas Sampl ing a t 105-KW Fuel S to rage Basin, " D. J. T r imb le , August 1996.

"P lan f o r C h a r a c t e r i z a t i o n o f K B a s i n Spent N u c l e a r Fuel and Sludge," L. A. Lawrence, Oc tober 1995.

"Spent Nuc lea r Fuel Sampl ing S t r a t e g y , " D. W. Bergmann, February 1995.

"Choices o f C a n i s t e r s and Elements f o r t h e F i r s t Fuel Shipment f rom K West Bas in , " B. J. Makenas, March 1995.

8-3


WHC-SD-SNF-SM-003 "Choices o f C a n i s t e r s and Elements f o r t h e F i r s t Fuel and C a n i s t e r Sludge Shipment f r o m K Eas t Basin, " B. J. Makenas, March 1996.

WHC-N-1340 ( l ogbook ) "Fuel and C a n i s t e r S ludge C h a r a c t e r i z a t i o n Phase I 1 K East & K West Basins," E n g i n e e r i n g Da ta Record, J. A. Se r les , A p r i l 1996.

CIA PLAN

WHC-SD-SNF-QAPP-006 "Fuel C h a r a c t e r i z a t i o n - Phase I 1 Q u a l i t y Assurance A c t i v i t y P lan , " G. M. Dav is , Feb rua ry 1996.

WASTE MANAGEMENT PLAN

WMP-07-96 "Fuel and Sludge C h a r a c t e r i z a t i o n f o r KW and KE,"

WHC-SD-SNF-PLN-001

R. M. Jochen, Februa ry 1996.

"Waste Management P lan f o r Han fo rd Spent N u c l e a r Fuel C h a r a c t e r i z a t i o n , " S . A. Chas ta in , Oc tober 1994.

ALARA ASSESSMENT

8M730-RLS-96-002 (memo) "ALARA Assessment f o r K Bas ins C h a r a c t e r i z a t i o n Sampl ing and Sh ipp ing , " R. L . Simons, March 1996 (appendix t o t h e mas te r work p l a n ) .

USCI/HAZARD CATEGORIZATION

WHC-SD-SNF-HC-011 "Hazard C a t e g o r i z a t i o n o f K-Basin Fuel C h a r a c t e r i z a t i o n Phase 11," R. G. Gant, January 1996.

USQ# 1K-96-0015 "Phase I 1 C h a r a c t e r i z a t i o n f o r KE and KW Basins," R. G. Gant, January 1996.

WHC-SD-SNF-TA-002 "Unreviewed S a f e t y Q u e s t i o n E v a l u a t i o n o f IOOK East and lOOK West In -Bas in Fuel C h a r a c t e r i z a t i o n Program A c t i v i t i e s , " L . D. A lward t , January 1995.

Fuel C a n i s t e r Gas and L i q u i d Sampling," L. D. A l w a r d t , January 1995.

WHC-SD-SNF-TA-003 "Unreviewed S a f e t y Q u e s t i o n E v a l u a t i o n o f lOOK West

JOB HAZARD ANALYSIS

s u p p l i e d w i t h t h e Mas te r Work Plan, MWP-95-005

CASK SAFETY EVALUATION FOR PACKAGING

WHC-SD-TP-SEP-028 "N Reac to r and S i n g l e Pass Reac to r Fuel C h a r a c t e r i z a t i o n Shipments S a f e t y E v a l u a t i o n f o r Packaging," S . R. Crow, March 1996.

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APPENDIX C

OPERATING PROCEDURES

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The f o l l o w i n g i s a l i s t o f K Basin o p e r a t i n g procedures used w i t h t h e sampl ing equipment descr ibed i n t h i s SDD.

PROCEDURE NUMBER

OP-07-100E "Obta in Fuel Elements f rom 105-KE f o r C h a r a c t e r i z a t i o n , " March 1996.

"Perform V isua l E;amination o f KE Fuel i n Support o f C h a r a c t e r i z a t i o n , June 1996.

OP-07-107E

OP-07-102E "Load Fuel and/or Sludge Containers i n t o Chem Nuc lear Shipping Cask," March 1996.

OP-07-109W "Obtain Gas/Liquid Samples f rom MkI and M k I I Can is te rs , " August 1996.

OP-07-108W "Obta in Fuel and Sludge Samples f rom MkI and M k I I Can is te rs , " August 1996.

OP-07-lllW "Load Fuel and/or Sludge Conta iners i n t o Chem Nuclear Shipping Cask," August 1996.

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