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- EQON NUCLEAR COMPANY,1 p cocxErEU o).

2101 Hcrn Raords Road USUSC,

P. O. Rox 130, Richland, Washington 99352Phone- (509) 943-8100 Telex: 32-6353 b, 3 .g]g y -q

Mall. SECTfb ./ June 22, 1979 ]. cocKET cum, - /~

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Mr. William T. Crow 'C' q-

Fuel Reprocessing G Fabrication Branch_._ ] GDivision of Fuel Cycle S Material Safety W

~U. S. Nuclear Regulatory Commission 3CWashington, D. C. 20555 t

License No. SNM-1227Docket No. 70-1257

De2r Mr. Crow: %

Exxon Nuclear Company, Inc. intends to modify and expand its Horn Rapids Fuel Fabri-cation Plant facilities. The bases for these additions, expansions and modificationsare listed below:

1. Increase UO fuel production capacity to 550 metric tonnes uranium (MTU)yper year;

2. Improve the capability to remove uranium from liquid wastes generated inthe UF -UO conmsion facilhy;6 2

3. Improve SNM accountability sampling of liquid wastes discharged to thelagoon system;

4 Improve economics and control of laundering uranium-contaminated protectiveclothing and equipment;

5. Recover uranium from uranium-contaminated solid waste and volume reduction;recover uranium from the lagoons and dispose of solids removed from thelagoons;

6. Eliminate the need for trucks entering the exclusion area to deliver andremove UF cy n

6 rs and to deHm M demicals; and

7. Eliminate the use of trailers for office and storage space.

A summary of the activities involved in the individual parts of this program and ourestimated schedules is enclosed for your information and review. A number of theidentified facilities will not be used to conduct activities licensed by the NRC, andare identified for information only. Detailed environmental impact information andlicense amendment applications, where and when required, will be submitted separately

appropriate future dates.at

Sincerely,

gH. Paul Este;. , ManagerLicensing and Compliance,Richland FacilitiesHPE:gf

EnclosuresAs noted 4 ') 9" ''3"[ 7

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!CC: Mr. W. J. Cooley (USNRCAN AFFILIATE oF EXXON CORPORATION

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ENCLOSURE.

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SU5 NARY.

The items listed and described below are identified by respective numbers on theattached Site Plan.

1. Office Building Complex Addition

Start Schedule: 6/1/79

Size: 12,000 sq.ft., 1 story building

Environmental Impact: Construction activities.

Additional Information to be Submitted: None

2. New Process Chemical Naste Storage Lagoon


Size: 70,000 sq.ft., 6 ft. deep

Environmental Impact: Construction activities; the use of this lagoon willnot increase the environmental impact of the lagoonsystem as it is currently being used.


Contments : Two additional test wells will be drilled into the ground water, andthese will be incorporated into the lagoon leak monitoring program.This expansion project was scoped in Phase III of the overall expansionplans outlined in ENC's letter of June 7, 1973. The construction ofthis lagoon at this time provides the extra storage capacity requiredto allow relining of the other three lagoons this year. However, itwill also provide the additional storage capacity and surface arearequired for the increased fuel fabrication capacity described inItem No. 11.

3. P.I. Tool Examination Facility


Size: 1200 sq.ft., 1 story building

Environmental Impact: Construction activities; the operation to be housed inthis building will be moved out of an existing building.


Ccmments: Inspection tools used by ENC at nuclear power plants (and which arecontaminated with mixed fission products) are examined, maintained,and stored in this facility. The operation of this facility islicensed by the State of Washington.

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4. Materials Warehouse Expansion,


Si:c: 8000 sq.ft., 1 story building addition



5. New UF Cylinder 6 Chemical Storage Facilities


Si:e: 21,600 sq.ft. of ground area



Comments: A fenced area with external and internal gates will be provided sothat deliveries of these materials can be made without trucks enteringthe exclusion area. Existing facilities will be relocated to thisarea.

6. Temporary (Evaluation) Laundry Facility


Si:e: 320 sq.ft., 1 story, pre-fabricated module

Environmental Impact: The only effluent from this facility will be gaseous, whichwill be double HEPA filtered. Uranium-contaminated protectiveclothing will be laundered (dry-cleaned) in this facility.The volume of the gaseous effluent will be s 1000 cu.ft. perminute, and the uranium concentration will be less than2 x 10 12 pCi/al. The exhaust air will be continuouslysampled, and the samples will be analy ed weekly and theresults properly documented.


Comments: This is a commercial facility designed and built by Health PhysicsSystems, Inc. , and offered as a service to nuclear facilities. ExxonNuclear intends to rent this facility for a 6-month period in orderto evaluate the adequacy of the system for cur protective clothinglaundering needs. The facility will be operated as a uranium-contamination controlled area in accordance with established UO,facility radiation protection procedures and controls. Prior t5release from Exxon Nuclear control, the facility will be decontaminatedto acceptable levels specified in " Guidelines for Decontamination ofFacilities & Equipment Prior to Release for Unrestricted Use orTermination of Licenses for Byproduct, Source, or Special NuclearMaterial", USNRC, November 1976.

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7. Permanent Laundry Facility


Information to be Submitted: Following the evaluation described in Item No. 6,_Exxon Nuc lear will submit pertinent informationon its' permanent laundry facility to the USNRCfor review and approval prior to start of installation.

8. Liquid Waste Mixing / Monitoring Facility

Start Schedule: 7/IS/79

Size: 600 sq.ft., 1 story building

Environmental Impact: Construction activities. There will be no additionalliquid nor gaseous effluents.


Com.ments: Presently, all liquid waste streams going to the Process ChemicalWaste Storage Lagoon System are combined prior to discharge into thelagocns. Under the future concept, uranium-bearing liquid wastestreams will be maintained separate from non-uranium-bearing liquidwaste streams until they are discharged into the lagoons. The severaluranium-bearing liquid waste streams will be combined in a surge tankin the new Liquid Waste Mixing / Monitoring Facility. As the combinedflow is discharged frca the surge tank, the volume will be accuratelymeasured, and a continuous sampler will accumulate representativesamples. The flow will then be neutralized in a mixing device anddischarged to the lagoons. The purpose of this facility will be toprovide improved SNM accountability.

9. Ion-Exchange System S Facilities


Si:e: Separate building, 1200 sq.ft., I story, 24 ft. high;200 sq.ft. addition to the UO Building tank gallery

3

Environmental Impact: Construction activities; no additional liquid nor gaseouseffluents; decrease in the uranium content of UF '

6 'conversion liquid wastes. '

Additional Information to be Submitted: Criticality safety demonstration.

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10. Waste Uranium Recovery Facility

Start Schedule: Phase I - 9/1/79Phase II - 7/1/80

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Si:e: Phase I - Two-story building with 2400 sq.ft. on the ground floorPhase II - Two-story building addition with 1600 sq.ft. on the ground floor

Information to be Submitted: Environmental impact information and criticalitysafety demonstration.

11. Increase UO Fuel Production Capacity to 550 SGU/Yr.2

This wiil involve construction of satellite buildings to house non-uraniumoperations, expansion of UO, Building additions, adding additional productionequipment, and rearranging existing production equipment. This project willcover the approximate time period from 7/15/79 to 7/1/82. The major individualsteps of this project are described below.

11.1 Maintenance Building


Si:e: 12,500 sq.ft., 1 story building



Comments: Maintenance equipment currently located in the UO, Building and usedfor "non-contaminated" maintenance activities will be moved to theMaintenance Building. This expansion project was scoped in Phase IIIof the overall expansion plans outlined in ENC's letter of June 7, 1973.Uranium processing equipment will be installed in the space in the UO,Building vacated by equipment moved to the hbintenance Bailding. '

11.2 Component Fabrication Building


Size: 24,000 sq.ft., 1 story building



Comments: Component fabrication and tubing receiving, inspection and cleaningoperations currently 1ccated in the UO, Building will be moved to theComponent Fabrication Building. This expansion project was scoped inPhase III of the overall expansion plans outlined in ENC's letter ofJ un e 7, 1973. Uranium processing equipment will be rearranged andadditional (and similar to existing equipment) equipment will beinstalled in the space in the UO, Building vacated by equipment movedto the Component Fabrication Building.

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11.3 Physical Testing Laboratory Building


Size: Two-story building with 1400 sq.ft. on each floor



Comments: Non-radioactive material physical testing and analytical laboratoryoperations will be moved out of the U0, Building and into the PhysicalTesting Laboratory Building. Uranium analytical laboratory operationswill be expanded in the UO, Building in the space vacated by operationsmoved to the Physical Testing Laboratory Building. This expansionproject was scoped in Phase III of the overall expansion plans outlinedin ENC's letter of June 7, 1973.

11.4 UO, Powder Storage Facility Expansion


Size: 1300 sq.ft., ! story building addition

Environmental Impact: Canstruction activities; there will oc no liquid nor gaseouseffluents from this facility.


Comments: Only closed containers (externally free of significant uraniumcontamination) of UO Powder are allowed in this facility.2

11.5 UO Building Office Expansion3


Size: Two-story addition with 1700 sq.ft. on each floor



11.6 Operating Me::anine Over the Pellet Press Area of the UO, Building


Size: 1700 sq.ft.



Comments: UO, blending with lubricant and green scrap materials and pellet pressfeed operations will be performed on this me::anine.

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11.7 Addition S Rearrangement of UO Building Process Eauipment2

Schedule: 9/1/79 to 7/1/82

Information to be Submitted: Revised floor plans of the U0, Building andenvironmental impact information.

Comments: A third UF - , conversion line and a fourth pelleti:ing and rod6loading line will be added in existing space in the UO, Buildingvacated by relocation of non-uranium operations to sats11itefacilities and rearrangement of process equipment.

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