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‘R OGRAM TITLE

Fuel Decladding Program DE-AC03-86SF16021-.

)cICUMENTTITLE

Annual Report Rockwell International Hot Laboratory Decommissioning - GFY 1993

)OCUMENTTYPE K~y i~~u:t~~

Technical Information Hot Laboratory, Decommissioning,Decontamination .

)RIGINALISSUE DATE REL.OATE APPROVALS 3ATE

q.7?&q5 cd “J.R. RohlfsB*

4. Zo -m”‘REPARED t3Y/DATE DEPT MAILAODR

p HortO~~_- +/~+/~<

K’&A $U- 7 p8 ..~. -R&DPROGRAM? YESa NO%

FYES.ENTERTPA NO.DISTRIBUTION ABSTRACT

++ NAMEMAIL This document presents a summary of the activi-

ADDR ties conducted during GFY 1993 on decontaminationand decommissioning of the Rockwell International

* I Bassat T034 Hot Laboratory (RIHL). This is a multi-year* P. Horton TO09 programe.to decontaminate the RIHL facility to* J. Rohlfs <n> FA66 levels that allow release for unrestricted use.* R. Moore T034 During GFY 1993 the following major tasks were* P. Rutherford TIOO accomplished:

“.1. The remaining hot cell steel linersand decontamination room liners wereremoved;

2. Removal of contaminated concrete fromfloors of cells and decontaminationrooms was completed;

3. -The two remaining-shield doors (80Klb and”90K ’lb) Were removed;

4. 80% of the radioactive drain systemin the cells and decontaminationrooms was removed; and

5. Arevised cost proposal was submittedin response to the new requirements

I for waste shipment to the Nevada TestSite (NTS).

RESERVED FOR PROPRIETARVfLEGAL NOTICES

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OISCUIER

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us< mmld mot lnfrlngc prtwttely J%;::x.d’:\::A,wM2:::”::y :%1;:

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DISCIJUMER

This report was.prepared as an account of work sponsoredby an agency of the United States Government. Neitherthe United States Government nor any agency thereof, norany of their employees, make any warranty, express orimplied, or assumes any legal liability or responsibility forthe accuracy, completeness, or usefulness of anYinformation, apparatus, product, or process disclosed, orrepresents that its use would not infringe privately ownedrights. Reference herein to any specific commercialproduct, process, or service by trade name, trademark,manufacturer, or otherwise does not necessarily constituteor imply its endorsement, recommendation, or favoring bythe United States Government or any agency thereof. Theviews and opinions of authors expressed herein do notnecessarily state or reflect those of the United StatesGovernment or any agency thereof.

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DISCLAIMER

Portions of this document may be illegiblein electronic image products. Images areproduced from the best available originaldocument.

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. .I

ACRONYMS AND

~,fl

2.0

2.1

2.2

3.0

3.1

3.2

3.3

3.4

3.5

3.6

4.0

TABLE OF CONTENTS

Document No. #173’I’1000022Page No. 2 of 49

Page

ABBREVIATIONS ......................................... 4

INTRODUCTION AND

PROGRAM PLANNING

SUMMARY .......................... ....... 5

ACTIVITIES .................................. ~

PROGRAM CHANGES .............................................. 10

EXTERNAL ~ETINGS &REVIEWS. ........... ............-- .....--.-l~

DECONTAMINATION ACTIVITIES .................................. 14

HOT CELL & DECON ROOM

HOT CELL DOOR REMOVAL

LINER REMOVAL ......................... 14

14....................................

CONCRETE FLOOR REMOVAL ...................................... 15

FUiDIOACTIVE EXHAUST SYSTEM REMOVAL .......................... 15 .-

RADIOACTIVE DRAIN SYSTEM REMOVAL ............................. 15

OTHER DECONTAMINATION ACTIVITIES ............................. 16

BUDGET AND SCHJIDULE. ........................................ 18

TABLE 2-1

TABLE 2-2

TABLE 3-1

LIST OF T~LES

CHANGES IN DECOMMISSIONING Pm .......................... 8-

EXTERNAL MEETINGS

LEAD SHIELDING IN

AND REVIEWS ......................----- 13

BLDG 020 ............................... l’7

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Document IJo. /~173TiOOO022Page F:o. 3 Gf 49

LIST OF FIGURES

FIGURJZ 1-1

FIGURE 2-1

FIGURE 3L1

FIGURE 3-2

FIGURE 3-3

FIGURE 3-4

FIGURE 3-!5

FIGURE 3-6

FIGURE 3-7

FIGURE 3-8

FIGURE 3-9

FIGURE 3-10

FIGURE 3-11

FIGURE 3–12FIGUBJ3 3-13FIGURE 3-14FIGURE 3-15

. FIGURE 3-16

FIGURE 3-17

FIGURE 3-18

FIGURE 3-19

FIGURE 3-20

FIGURE 3-21

FIGURE 3-22

FIGURE 3-23

FIGURE 3-24

FIGURE 3-25

FIGURJ3 3-26FIGURE 3-27,.FIGURJ3 3-28FIGURE 3-29

FIGURE 3-30

ROCKWELL INTERNATIONAL HOT LABORATORY, BLDG 020- -------- 6

DOCUMENT CHART FOR HOT LABORATORY D&D ................. 9

CELL IWALL~R LINER REMOVAL ...............--.......19

CELL 2FRONTWZUL AFTER LINER REMOVAL ............--..-.20

LINER PARTIALLY REMOVED FROM CZLL 2 CEILING ............21

CELL FLOOR LINER REMOVAL .............................. 22

EAST DECON ROOM LINER REMOVAL .............-............ 23

CELL DOOR SHOWING CONTAMINATED AREAS ...................24

PASSAGE FOR HOT CELL DOOR REMOVAL ......................25

SAW CUTTING DOORWAY IN CELL WALL .............-..-...--..26

NORTH DOORWAY OPENING FOR SHIELD DOOR REMOVAL .......”..’27

CELL 4NORTH SHIELD DOOR .............................::28

BAGGING THE SHIELD DOOR FOR SHIPMENT .................. 29

PLACING SHIELD DOOR ON THE TRUCK FOR SHIPMENT ...”...... 30CELL 4NORTH SHIELD DOOR AT RMDF ...................... 31CONCRXTE REMOVAL FROM CELL FLOOR UNDER LINER .......... 32CONCRETE RUBBLE FROM CELL FLOORS ...................... 33

CELL EXHAUST DUCT TO BE REMOVED ....................... 34

CELL EXEAUST DUCT REMOVED ............................. 35

EXHAUST DUCTS IN BASEMENT ............................. 36

MINI-TRACK EXCAVATOR .................................. 37

BOBCAT SKIPLOADER FOR CONCRETE REMOVAL ................ 38

R/ADRAINREMOVALINSUPPORT ROOMS .................... 39

DOw’NslzING DRAIN LINES ................................ 40CONCRETE REMOVAL AROUND DRAINS ........................ 41

R/ADRAINLINEUNCOVERED .............................. 42

R/ADRJiINLINEUNDER WALL ............................. 43

R/ADRILtNLINETHROUGH WALL ............................ 44BAGGING DRAIN LINE FOR CUTTING ........................ 45

DOWNSIZE CUT.TING OF DRAIN LINE ........................ 46-

CELL AFTER SURFACE CONCRETE AND DRAIN LINE REMOVAL .:.. 47SUMP PUMPS IN BASEMENT ................................ 48

FIGURE 4-1 SCHEDULE FOR D&D OF HOT LABORATORY .....................49

.-

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.... ,

._,sI-AGA

ASME

CDHS

D&D

DOE

DOE-SAN

DOS

DOT

EPA

GFY’HEPAy,-.

‘ LLW

NRcNTS

OSHAQA

R/A

Rcm

RIHL

RMDF

TRW

ACRONYMS AND ABBREVIATIONS

American National StanLaids Institute - American Gas

Association

American Society of Mechanical Engineers

California Department of Health Se.~i_ces.

Decontamination and Decommissioning

Department of Energy .. -

Department of Energy - San Francisco Field Offi”ce< -

Dioclyl Sebacate---

Department of Transportation- Environmental Protection Agency

Government Fiscal Year

High Efficiency Particulate Air

Low Level WasteNuclear Regulatory Corrunission

Nevada Test SiteOccupational Safety and Health Administration

Quality Assurance

Radioactive.

Resource Coxsexvati.on Recovery Act

Rockwell International Eiot laboratory

Radic...~ve Material Disposal Facility

TRansUranic

_.

Document :!o. #173T1000022?ags No. 5 of 49

ANNUAL REPORT ROCKWELL INTERNATIONAL

HOT LABORATORY DECOMMISSIONING GFY 1993

1.0 INTRODUCTION AND SUMMARY

This document presents a summary of the activities conducted during GFY 1993on decontamination and decommissioning (D&D) of the Rockwell International HotLaboratory (RIHL) . This is a multi-year program to decontaminate the RIHLfaLA&-Ly to levels chat allow release Lor unrescr~~~ed use and subsequentdemolition of the sczucture. The facility consists of four rectangular hotcells, abutted by decontamination rooms. These areas are surrounded by abuilding structure chat provides an opera~ing gallery in front, a servicegallery in the rear, and contiguous operation support, mockup, andadministrative offices. The hot cells and decontamination ,:ooms areconstructed of dense and reinforced concrete, respectively. A1l.stirfaces ofthe hot cells, and the floors and east walls of the decontamination r“ooms areclad with steel. The original layout of the facility is shown in Figure 1-1.In-cell equipment was remotely operated from the operating gallery usingmanipulators and other remote controls. Access into the cells is from theservice gallery, located at the rear of the.hot cells. The decontaminationrooms are located b?cween the cells and service gallery. In these rooms,equipment wzs deconczminated and packaged. The decontamination rooms alsoserve as contamination control areas between the cells and the servicegallery. Ccnnected with the service gallery was a hot manipulator repair roomfor servicing low-leve”l, radioactively contaminated equ~pmenc. The facilityventilation system czuses aiz to flow from the radioactively uncontaminatedareas to~’ard the areas of hiqhest contamination potential, through roughingfilters and high-efficiency particulate air filters (HEPA), and finally out a54-in. outside diameter, 73-ft high stack (above grade). The ventilationducts are installed in the basement directly below the hot cells.

Al 1 areas of the RIHL facility will re ;uire decontamination and/orverification that z~diation levels are be .OW limits for release forunrestricted use. Completion of this efl ort constitutes the primaryactivities.: rf the decotissioning program. The RIHL was last used in GFY1987and all :~~ ial Nuclear Material, tools and equipment were removed prior toGFY 1992. ~‘?Y1992 was the beginning of the major decontamination effort inthe cells. .’-.ebasic approach has been to decontaminate the areas of highestcontamination levels first to minimize personnel exposure and to reduce thebackground rad~ation which will allow detection of lower level contaminationareas.

The following decontamination methods were or are being utilized. Foamcleaning is used in conjunction with localized brushing with detergent toremove surface contamination. The liquids are drained off through thefacility drain system to the facility hold up tank. When the liquids in the

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holdup tank reach 50% full level, the liquids are pumped out and transportedto.an evaporator at the Radioactive Material Disposal Facility (~.DF) . Thesolids are packaged and disposed as R/A waste. Scabbling or grit blasting isused to remove contaminated epoxy paint. The grit blasting material is thencleaned-up and the area is vacuumed. The material is put into 55-gallon drumsand disp,osed as R/A waste. The steel liners are further decontaminated bygrit blasting and hand grinders to remove residual surface contamination and

,paint. The steel liners are cut with oxyacetylene torch and removed assections . Any areas of concrete that have contamination will have the surfacelayer removed by chipping hammers, scabblers, and/or grinders as deemed best.AI-Iydeep penetration of contamination requires scarfing, core drilling, or

jack hammering to reduce the contamination to allowable limits. An expansive

grout is also used to fracture the concrete around components to reduce theconcrete removal effort. For removal of the concrete to expose the R/A drainsin the cell structure a tractor and hydraulic hammer were purcha~d- to help

‘ recover the decommissioning schedule. In general, methods are bei%g”selectedto minimize the quantity of waste generated and personnel radiation exposure.

.,

During GFY1993 the following major tasks were accomplished:

1. The remaining hot cell steel liners and decontamination room liners wereremoved;

2. Removal of contaminated concrete from floors of cells anddecontamination zooms was completed;

}

I3. The two remaining shield doors (80K lb and 90K lb) were removed and

transported to RMDF for final decontamination;

4. 80% of the radioactive drain system in the cells and decontaminationrcoms was removed; and

5. A revised cost proposal was submitted in response to the ~ newrequirements for waste shipment to the Nevada Test Site (NTS) .

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2.0 PROGRAM PLANNING ACTIVITIES

Regulatory requirements that must be met on the program include; NuclearRegulatory Commission (NRC) , Occupational Safety anti Healzh AgencyAdministration (OSHA), Environmental Protection Agency (EPA) (including cleanair and water acts), Department of transportation (DOT), American Society ofMechanical Engineers (ASME) Quality Assurancer and California Department ofHealth Services (CDHS) and local regulations. The hierarchy-of documents which

e been prepared in response to these -equirements is presented in Figure 2-1. Prior to August 1991, RIHL D&D planning assumed the NRC was going to reducetheir criteria on acceptance levels for surface contamination, based on NRCdraft NUREG/CR-5512 “Residual R/A Contamination from Decommissioning”, January1990. NUREG/CR-5512 specified a dose based pathway analysis criteria insteadof a surface contamination criteria, the effect of which would havesignificantly reduced the RIHL decontamination effort. However, NRC’Xn5tructedRockwell to disregard the NUREG/CR-5512 criteria in August 1991. %hYs, alongwith a better knowledge of the extent of contamination in the RIHL and otherregulatory changes, resulted in major changes in the RIHL decontaminationeffort. Table 2-1 lists che subjects of major changes which have occurrec inthe planned decommissioning effort. Substantial effort in GFY 1993 was spenton preparing to meet the requirements of the new waste acceptance criteria forthe Nevada Test Site (NTS).

Table 2-1Changes in Decommissioning Plan

1. New NTS Waste Acceptance Criteria

2. - Removal of Radioactive Dza.in System

3. Removal of Through Tubes ad Storage Tubes by Core D1illing

4. Removal of Shield Doors

5. Removal of Steel Liners

6. Recycling of Lead Shielding

7. . Handling Mixed Wastes ..

8. Hot Laboratory Demolition

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2.1 Program

The effect of

2.1.1 New NTS

Changes

the program changes listed in Table 2-1 are asscribed bel~w.

Waste Acceptance Criteria

Rockwell has been shipping waste to the DOE Nevada Test Site (NTS) for over 30years. The NTS has, however, now issued a new set of requirements forzrcepting radioactive waste from other sites. These new rz<zsria are r?flectedin the Nevada Test Site Defense Waste Acceptance Criteria, Certification, andTransfer Document, NVO-325 Revision 1, dated June 1, 1992. The new criteriarequire that he R/A waste be trezted like a manufactured product whichrequires extensive quality assurance, environmental, health physics oversightand inspection of the process during generation of the product. This requiredactivity is over and beyond that previously required for t~e decommissioningeffort. ~. -

Rockwell submitted Revision A to the Application to Ship Radioactive Wasteto the Nevada Test Site on March 24, 1992.. This application was structured tomeet our interpretation of the NVO-325 Revision 1 document. In response toour submission, DOE-NTS conducted z Pre Audit Visit to the Hot Laboratory onAugust 4-6, 1992. During the pre audit, NTS pointed out numerous defects inour old ‘procedures in meeting the new NVO-325 Revision 1 requirements. NTSrequired that the waste records be easily retrievable and protected fromdamage or loss. The records must be filed by shipment and container number toimprove retrievability and a fireproof vault must be used co store records.Waste must be handled, stored, znd shipped in a manner that ‘will not alter the .certification status, which requires more independent ovezview. Individualwaste bags must be tagged, identified and controlled pricz to loadi~g intoshipping’ containers. Waste bags must be segregated and controlled as toradioactivity, mixed, and non-radioactive/hazardous waste pending chemicalanalysis and/or characterization.

Previously packaged waste containers .do not. meet all of the requirer,ents ofNVO-325 and will probably all have to be opened, resorted, and repackaged tothe new requirements prior to shipment to NTS. . .

Lot followers/travelers must accompany each waste container. All processdocuments must be revised to reflect Resource Conservation Recovery ActEnvironmental Protection Agency (RCRA-EPA) requirements. Current RI shippingcontainers being used do not meet new NTS size requirements. The lotfollowers for each container must contain the volume percent, weight percent,and isotope type in mCi. Each individual shipping container must be trackedfrom the time it is purchased to when it is shipped full of RA waste to NTS bya traveller/lot follower. Log books must be kept for maintaining records ofsamples, “the location of collecting, dater time of collection, personneltaking samples, and sample number.

=1 records produced during waste generation and characterization must betraced and verified.

Cal~bration and quality control procedures for gamma spectrometers must befully implemented. All personnel must be trained in meeting the requirementsof NVO-325.

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In- response to these new requirements Rockwell prepared and submitted a costchange proposal to DOE on March 2, 1993. Cost estimates for ‘rewritingprocedures to meet NVO-325 Xevision 1, for training of personnel, forpackaging of new R/A waste to che new procedures, and for repackaging of R/Awaste already packaged in accordance with pr?vious requirements were includedin the change proposal. The cost change proposal wa> negotiated in May 1993and a contract modification for meeting the NTS shipping requirements wasissued June 2, 1993 by DOE-SAN.

The application for shipment of R/A waste to NTS was revised to reflect DGEcomments and the application was forwarded by DOE to NTS for their review.The NTS review was expected to be completed in September and an NTS audit ofRIHL was scheduled for November 1993. A pre-audit by Rocketdyne QA wasperformed to prepare for the NTS audit. All planned shipments o-~ R/A wastewere re-scheduled into GFY 1994 after formal NTS approval of the ‘application.

2.i.2 Effect of Having to Remove the RA Drains System ~

RIHL D&D .Planning assumed that the ~adioactive (R/A) drains and support drainscould be decontaminated in-situ using mechanical honing followed byelectropolishing. Final survey of the drains was to have been conducted usinga special radiation probe which fits inside che drains. The approach was infinal demonstration when it was concluded that the acid being used foxelectropolishing had been addea to the EPA k,azardous materials list and theprocess would generate mixed hazzrdous waste. Also, thk in-situ R/A surveyresults would not be acceptable because af the inability for 100% verificationas claim ; the person conducting the in-situ R/A survey would not be able toveEify the absence of crzcks or penetrations through the surface beingsurveyed. In order to insur? no contamination rer,ains the drains must beremoved from the concrete (and re-bar structure) and disposed of as R/A wasteat a considerable increase in costs. The drains are buried 3 to 4 feet undert~~ concre: ~::floor as well zs b~ing underneath the 3 1/2 foot thick cellwalls.

2.1.3 Removtil of Through Tubes & Storage Tubes by Core Drilling .-

RIHL D&D Planning assumed that the through tubes that penetrate the thickconcrete structure of the hot cell faces and the storage tubes buried in thecell floors and support pillars could be decontaminated in situ usingelectropolishing similar to that proposed for the drain systems. Since theelectropolishing process would generate mixed waste, an alternate means ofremoving the contamination had to be found. The most cost effectivealternative was to use diamond core drilling to remove the entire tube.

2.1.4.Removal of Heavy Shielding Door

RIHL D&D Planning assumed that the 9 heavy shielding doors to the hot cellsand decontamination rooms could be cleaned in situ. The doors are, however,on tracks which are close to the walls with limited access to door jams,wheels and some portions of “the back of the door. This prevents the doors,jams and wheels from being decontaminated to NRC release requirements and alsorestricts visual access during survey. Therefore, it was decided to removethe heavy doors from the facility and transport them to the RMDF where they

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DOcu==nt NO. \\173T10001222Pags Ito. 12 of 49

i

would have unrestricted zccess for decontamination3.2 for a description of the removal pzocess.

2.1.5. Removal of Steel Liners f~om Hot Cell

and surveying, see Seccian

RIHL D&D Planning assumed that the 1/4 inch thick steel liners in the kotcells could be decontaminated in situ and left for removal during demolition.However, the liners had been breached duxing the hot cells operating life end-significant contamination was found behi?.~.the liners in selected areas duringdecontamination in Cell 1. In order to meet the requirement that any zzeasuspected of being contaminated’ be completely exposed for meter surveyrequires that the steel liner be completely removed from the hot cells. Thecontaminated concrete behind the liners must also be removed and shipped toburial. The steel liners, which were used as the forms for pouring zheconcrete are welded to heavy steel stiffeners which make liner r“~moval verydifficult, see Section 3.1 for a description of this process. ‘.---

2.1.6. Recycling Lead Shielding

RIHL D&D Planning assumed that the radioactive contaminated lead could bedisposed of as normal radioactive waste. The EPA has designated lead zs ahazardous material and when contaminated with radioactive material it becomesa mixed waste which requires special treatment. Over 80,000 pounds of leadwas used in the hot laboratory as shielding. All lead must now be separatedinto R/A contaminated and non-conta~.inated waste strezns. The contaminacsdlead must then be sent to s certified reprocesser to tiecontzminate the leadbefore disposal.

2.1.7. Handling Mixed Waste

The EPA and Californi~ ‘-’i (which has the EPA responsibilities in California)continues to add materials to the iist of designated hazardou? materizls,reduce the concentration levels of compounds specified ss toxic, and modifythe methods that must be used to sample and analyze for hazardous materials.The hazardous waste list h?. been expanded to include pzint, oil:., asbestos,etc. that are found in manj ...’~ercommercial items. These items become mixedwaste when removed from R/: , ,.taminated areas in the RIHL. Special .p;anningmust be established as each .. ;tem is encountered.

2.1.8.Hot Laboratory Demolition

The RIHL will be demolished to assure there is no activity remaining in orunder the building. The RIHL will be demolished by a subcontractor once thebuilding has been decontaminated, all surveys have been completed, and thebuilding has been released for unrestricted use by the NRC. NRC release isscheduled to occur at the end of February, 1995. Prior to facility release,Facilities Engineering and Purchasing will award a subcontract for the actualdemolition and the subcontractor will start mobilization. Demolition isscheduled to begin in March 1995, and to be completed in June. Once thebuilding debris has been removed from the site, a final survey by anindependent source from Oak Ridge will be conducted. When the site has beenreleased the remaining hole will be filled with clean dirt and the site willbe-~raded.

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Tab;

ExteInal Meetings and Reviews

Document :!o. :173TIOO0522Page No. 13 of 49

e 2-2 presents a listing of e:xc~rsal meetings and rev: ews related

activities .

Table 2-2 External Meetings and Reviews

UCC./NOV. 1992 DCAA audit of June 24 and August 27 change proposals

August 5, 1993 Familiarization tour for DOE-SAN and DOE-HQ personnel

August 30, 1993 Facility tour for UAW International Office of Health .and Safety personnel sponsored by DOE grant. .. -

September 22, 1993.. -

Familiarization tour for DOE-SAN personnel :. -

September 1993 RIHL attended “a one week NTS workshop on LLW acceptancecriteria

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3.0 DECONTAMINATION ACTIVITIES

This section presents a summary of the decontamination activitiesperformed during GFY1993. Figure 1-1 shows the relztive location of the cellsand areas within th? RIHL.

3.1 Hot Cell and Decon Room Liner Removal

Entezing GFY 1993 the steel cell lirer had been removed from the walls andc=iling ~f cells 1, 2, and 3, and from part of cell 4. In October 1992 theremaining steel liner was removed from. the walls and ceiling of cell 4. ThelineE removal was a slower than expected process. The liner was used as theforms for pouring the concrete shield wall behind the liner. The liner, whichserved as a gas ba~rier to limit nitrogen leakage during hot cell operation,is welded to horizontal and vertical stiffeners embedded in the .cqgc~ete< seeFigures 3–1 and 3-2. Removal requires the torch cutting of individual piecesthe size of the stiffener spacing, 1’3” x 2’6”, out of the liner. (See Figure3-3. )

A construction specification was prepared for removal of the cell and deconroom floor liners and the deco,n room east wall liners. A liner removalcontract was issued to Lopez Refinery Co. and five subcontractor personnelwere trained in Radiation Safety, Respirator Use, Fire Extinguishers, andFacility Familiarization. In preparation for floor liner removal the openingsin the R/A dxain system in che decon rooms and cells were sealed by welding zcover plate over them and the four storage holes in the cells were also sealwelded. The subcontractors removed the steel liners using oxygen/pfopanetorches in Januazy 1993 (see Figures 3-4 and 3-5). This completeci the linerremoval.

3.2 Hot Cell Door Removal

There were 5 large (64,000 to 90,000 lb.) shield doors within che hot cellcomplex; four doors were between the hot cells and decon rooms and the fifthwas between Cell 4 and the tool and mockup area (see Figure 1-1) . The doors(Figure 3-6), were contaminated and needed to be removed from the cells butthey were too big to pass through any existing doorways. Thereforer the decon .“room door openings were enlarged Figure 3-7, by diamond saw cutting, (Figure3-8) . Shield doors from cells 1, 2, and 3 were removed in GFY 1992. .

In GFY 1993 the west door of decon ~oom 4 was enlarged by removal of a 48[’wide X 41” high section from the wall to provide clearance to remove the cell4 main shield door. The west wall of the service gallery was also opened up.The north doorway of the mockup area was enlarged to provide clearance toremove the cell 4 north shield door (Figure 3-9) . The lead shield plug fromthe cell 4 north shield door was removed and transported to RMDF fordecontamination. Rigging contractors supported by Rockwell personnel removedthe cell 4 main shield door (-80,000 lb) and the north shield door (-90;000lb) and transported them to RMDF for decontamination (See Figures 3-10 to 3-13) .

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Document No. :I73TIOOOO22Page No. 15 of <9

3.3 Concrete Floor Removal

Concrete under the floor liners in the cells and decon rooms was found to be

contaminated. A layer of high density zsncrete 5“-6” deep was removed from thefloors of all 4 cells and all 4 decon zaoms with scabblers and jackhammers andwas packaged as R/A waste (See Figures 3-14 and 3-15) . R/A contamination foundin the e-xpansion joint between the cell 4 wall and the mockup area concretefloor around the north shield dooz-~ay was removed by “chasing” with

‘jackhammers .

3.4 Radioactive Exhaust System RemovaL

Work was started early on the R/A exhzust system to gain access to the R/Adrain system. Reinforced concrete k-as zemoved from around the north cell 1 andthe south cell 2 R/A exhaust ducts and the ducting was removed. %he exhaust.duct elbows were removed from all 4 cells (Figures 3-16 ana---3=17). ‘l’hebasement was set up for exhaust duct size reduction. The exhaust ductpenetration in cell 2 was removed. The exhaust duct valves and ducting in thebasement below all 4 cells was removed, downsized, packaged, and loaded out ofthe basement to complete the exhaust tact removal for this phase of the work(Figure 3-18). The exhaust ducting .a~d air drop system in the decon roomsremained in sezvice for all 4 cells.

3.5 Radioactive Drain System Removal

A Takeuchi mini-track excavator and a Sobcat compact skiploacier equipped witha hydraulic concrete hammer were purchesed and received to support the removalof the R/A drains embedded in the hot cell structure (See Figures 3-19 and 3-20) .

The radioactive support drain systems in Room 141, the Lab; Room 128, the HotRepair Shop; and Room 139, the Glove %x Lab were exposed, removed, and sizereduced (see Figure 3-21 & 3-22) . Tke removed sections were packaged andshipped to RMDF for inspection and remcval of any hazardous waste.

The concrete. was removed from the floors and basement ceilings to expose thedrains in the cells and decon rooms (Figures 3-23 to 3-25). Additionallyconcrete was removed to expose the drain line under the wall between ,cells 1and 2 (Figure 3–26) . Drain piping removed had radiation contact readings fromUp to lR/hr high from cell 2 to 5R/hr high from cell 3. The high readings werecaused by debris inside the piping. After removal of the radioactive debrisinside, the drain piping had contact readinqs of 20-25 mR/hr and could bepackaged as low level radioactive waste, which was shipped to FU4DF (Figures 3-27 and 3-28). The debris, which has gamma radiation readings of up to 20R/hris being put into vented one gallon cans, which are then placed into shieldeddrums with HEPA filter vents. Some of the debris is suspected of containingtransuranic (TRU) material and is being transferred to RMDF for interimstorage.

The weir from the inlet of the R/A Liquid Drain Tank in Bldg 468 was removed,packaged and shipped to RMDF for intezim storage. A special on-site shippingco~-tainer had to be fabricated to accanmodate the as-built modifications tothe weir support flange. The liquid R/.A drain line at the inlet to the draintank was cut just inside the west wall of Bldg .468. Since the drawings did not

indicate any physical connection between the 4“ drain line and zhe la”rge outezcasing, an attempt was made to pull the drain line through its casing into theBldg 020 basement with a come-along. The attempt was unsuccessful and actionwas initiated to prepare to dig down the 10 ft necessary to expose the casingand drain line.

At the end of GFY 1993 all high radiation drain piping had been removed fromthe building except for a section in the northeast corner of cell 3 which isto be removed from the basement (Figure 3-29).

3.6 Other Decontamination Activities

In addition to the major decontamination tasks desczibed above, the followingtasks were also performed:

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1) Approximately 34,000 lb (46%) of the shielding lead from th~~cell/decon.-

room and cell/cell transfer locks was removed (See Table 3-l). About 15,000 lbsurveyed as non-radioactive was tra~sferred to Bldg 055 for use as shieldinqaround a test laser. The radioactive contaminated lead must be handled as zmixed low level hazardous waste.

2) The facility exhaust system was shut down 4 times to allow HEPA filtezreplacement. Following filter replacement the system was reactivated and DOS(Dioclyl Sebacate) tested.

3) Surplus equipment, including 3 shielding windows and 6 manipulators, wa~

packed and shipped to the University of Missouri - Columbia. ~

4) Beginning in GFY 1993 contaminated waste boxes were packaged in zccordanccwith procedures that meet the new NTS requirements. Some prev~ously packagedwaste was overpacked . .L~ NTS qualified containers. During GFY 1993, 1369 Cu.Ft. of packaged solid waste was shipped to RMDF, and 4800 gallons of R/A water‘was transferred to RMDF for processing.

5) The hydraulic oil in the three manlifts was changed to non-hazardous oil.None of the removed oil was R/A contaminated. “ ..

6) The inactive sump pump in R/A Liquid Holdup Tank Bldg 468 was removed andsize reduced to await environmental inspection. An inactive sump pump in RIHLwas removed and disassembled for inspection (Figure 3-30).

7) Required semi-annual breathing air samples verified that the breathing airin RIHL is acceptable per ANSI-AGA G-1 specifications.

8) Removal of the high radiation material from the facility allowed coredrilling of penetrations in the cells and decon rooms to be resumed by thesubcontractor at the end of GFY 1993.

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Document No. =173TIOO0922Page No. 17 0: 49

Table 3-1. Lead Shielding in Bldg 020.

Location Mass of Lead Status

Cell Transfer Locks 11,18’O.lb RemovedDecon Transfer Locks 40,712 lb 7001b removedOMRE Transfer Lock 2311 lb RemovedSRE Transfer Lock 19,873 lb Removed

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4.0 BUDGET AND SCHEDULE

The GE’Y 1993 planning budget for RIi-ILdeccr.z=mination was $3,1OOK. The programended the year slightly under the ?lanned k:ciget with actual costs of $2,965K,not including $1OOK in outstandi~.q commitments. The schedule, shown in Figure4-1 shows the R/A drain system removal and zhe hot cell and decon room cleanupslightly behind, caused mainly by che difficulty in liner removal discussed inSection 3.1. The basement cleanup and R/A’exhaust system removal were startedahead of schedule in order to access rhe R/_% drain system for removal.

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