A-6002-767 (REV 2)

RPP-RPT-57252, Rev. 0

241-A Farm Riser Utilization Evaluation

JP Robocker Washington River Protection Solutions, LLC Richland, WA 99352 U.S. Department of Energy Contract DE-AC27-08RV14800 EDT/ECN: EDT-825699 UC: N/A Cost Center: N/A Charge Code: N/A B&R Code: N/A Total Pages: Key Words: Riser, A-101, A-102, A-103, A-104, A-105, A-106, WRS, 241-A, Retrieval, Riser Utilization

Abstract: This report evaluates the current configuration for the various 241-A Tank Farm waste retrieval systems and associated components to determine the tank risers needed to support installation of modified sluicing style waste retrieval systems in 241-A-101, 241-A-102, 241-A-103, and 241-A-106 and MARS-V style retrieval systems in 241-A-104 and 241-A-105.

TRADEMARK DISCLAIMER. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof or its contractors or subcontractors.

Release Approval Date Release Stamp

Approved For Public Release

20

By Julia Raymer at 12:51 pm, May 05, 2014

May 05, 2014DATE:

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TABLE OF CONTENTS 1.0 INTRODUCTION ..................................................................................................................2

2.0 BACKGROUND ....................................................................................................................2

3.0 ASSUMPTIONS .....................................................................................................................2

4.0 RISER EVALUATION ..........................................................................................................3 4.1 A Farm Tanks Utilizing Sluicing Retrieval Technology ...............................................3

4.1.1 241-A-101 RISERS ...........................................................................................4 4.1.2 241-A-102 RISERS ...........................................................................................6 4.1.3 241-A-103 RISERS ...........................................................................................8 4.1.4 241-A-106 RISERS .........................................................................................10

4.2 A Farm Tanks MARS-V Technology ..........................................................................12 4.2.1 241-A-104 RISERS .........................................................................................13 4.2.2 241-A-105 RISERS .........................................................................................15

5.0 BIBLIOGRAPHY .................................................................................................................17

LIST OF FIGURES

Figure 4-1 – 241-A-101 Riser Configuration ................................................................................ 4

Figure 4-2 – 241-A-102 Riser Configuration ................................................................................ 6

Figure 4-3 – 241-A-103 Riser Configuration ................................................................................ 8

Figure 4-4 – 241-A-106 Riser Configuration .............................................................................. 10

Figure 4-5 – 241-A-104 Riser Configuration .............................................................................. 13

Figure 4-6 – 241-A-105 Riser Configuration .............................................................................. 15

LIST OF TABLES

Table 4-1. 241-A-101 Riser Information. ...................................................................................... 5

Table 4-2. 241-A-102 Riser Information. ...................................................................................... 7

Table 4-3. 241-A-103 Riser Information. ...................................................................................... 9

Table 4-4. 241-A-106 Riser Information. .................................................................................... 11

Table 4-5. 241-A-104 Riser Information. .................................................................................... 14

Table 4-6. 241-A-105 Riser Information. .................................................................................... 16

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1.0 INTRODUCTION

The Tank Operations Contractor, Washington River Protection Solutions, LLC, plans to retrieve the waste in the six single-shell tanks in A Farm: A-101, A-102, A-103, A-104, A-105, and A-106. This riser utilization evaluation provides design input and recommends where to locate retrieval equipment in each of these tanks.

2.0 BACKGROUND

This document provides guidance for the installation of retrieval equipment into the A tank farm. Riser assignments are provided with consideration to reducing or eliminating pit entries and minimizing removal of legacy equipment.

3.0 ASSUMPTIONS

For the purpose of this evaluation, it is assumed that A farm tanks will use the following equipment for waste retrieval:

A-101, A-102, A-103, and A-106:

2 Extended Reach Sluicers 1 Slurry Pump 1 Sample Sleeve 1 Chemical Addition Port 1 ENRAF®

Cameras where possible Ventilation A-104 and A-105 are assumed leakers requiring a more conservative approach to retrievals using the Vacuum Mobile Arm Retrieval System (MARS-V):

1 MARS-V 1 Sample Riser 1 Chemical Addition Port 1 ENRAF

Cameras where possible Ventilation It is also assumed that the most current Waste Storage Tank Riser Data drawings for A Farm accurately reflect legacy equipment currently installed in the waste tanks.

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4.0 RISER EVALUATION

A number of drawings were reviewed to identify existing equipment and its current location. A complete list of the drawings reviewed is included as Section 5.0. The information gathered during the review is summarized in the sections below.

Several risers are located in small instrument houses on top of the tanks in A-Farm. Risers inside the instrument housing would be useful for supporting retrieval. It would be more cost and schedule effective to remove the housing than to exhume below grade risers for retrieval installations. Long length equipment could not be installed in these risers as they are currently located. These houses also take up a large footprint of the top of the tanks. To keep the conduit routing, hose routing, equipment location and other retrieval activities as structured as possible, it is recommended that these housings be removed.

Suggested equipment installation locations are preliminary pending riser inspections to ensure that no obstructions exist which would impede the planned installation.

4.1 A Farm Tanks Utilizing Sluicing Retrieval Technology

Four of the six A Farm Tanks are planned for modified sluicing technology. This requires two Extended Reach Sluicing Systems (ERSSs) and a slurry pump to transfer the waste. Current design of pumps and ERSSs require a minimum of 12” risers.

For the most effective retrievals, sluicers should be located on opposite sides of the tank with the slurry pump in the middle. In this way, sluicers can effectively reach the maximum amount of tank space and waste can be sluiced to the center of the tank where the pump is located.

If possible, retrieval equipment should be located in the same spot on each tank to avoid human error and keep consistent operating procedures. This riser evaluation makes an attempt to locate each piece of equipment on the same spot of each of the tanks. Some risers are numbered differently on each tank, but located, designed and installed the same way. For example, center riser on all the A Farm tanks is 42” in diameter and located inside the center pump pit, however the riser equipment identification numbers (EINs) vary from tank to tank. Even if the risers’ EINs differ, all slurry pumps for retrieval are recommended for install in the center of the tanks. This is true of several other risers on the A-Farm tanks as well.

The center riser on the A Farm tanks is 42” in diameter. Existing slurry pump design interfaces with a 12” flange. An adaptor would be required for all tanks utilizing slurry pumps.

The existing design for the slurry pump was used on 530 Kgal tanks. A farm tanks are one million gallon tanks and much deeper than the 530 Kgal tanks requiring a longer mast on the pumps.

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4.1.1 241-A-101 RISERS

Tank 241-A-101 has three riser pits. There is the distributor pit (241-A-01H), a pump pit (241-A-01B), and two sluice pits (241-A-01C and 241-A-01E).

Figure 4-1 shows in blue the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-1 – 241-A-101 Riser Configuration

Utilizing two ERSSs is most effective when the ERSSs can be located directly across from each other inside the tank. The smallest diameter riser capable of accommodating an ERSS is twelve inches. In order to space the ERSSs out as evenly as possible, it is recommended that ERSSs be installed in A-101 RISER-021 and RISER-022 which are both 12 inches in diameter.

The current ERSS as of this evaluation was designed to accommodate C-Farm waste tanks with shorter risers than those of A Farm. According to construction drawings of the A tanks, the

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length of risers 21 and 22 from pit bottom to the bottom of the riser is approximately 20 feet. The ERSS has a hydraulic function for a moment arm. This moment arm makes the ERSS a very effective tool at retrieving entire waste tanks as it can reach more of the tank bottom. The pivot for this moment arm is located approximately 18 feet from the flange. This dimension would have the pivot of the ERSS moment arm inside the riser on tank A-101 rendering the moment arm ineffective. In order to accommodate the deeper risers in A farm, a modified design of the ERSS is recommended. The mast of the ERSS should be lengthened to locate the pivot below the riser for full functionality.

It should also be noted that both the pump pit and sluice pit at the ERSS recommended locations have very narrow clearances between the risers and the pit walls (approximately 1-2” with the ERSS installed). If construction drawings are accurate and the ERSS design is within tolerance, the ERSS should be able to fit in the pit. If the as-built dimensions are narrower even slightly from construction drawings, a redesign of the ERSS head or a riser adaptor to bring the head of the ERSS up out of the pit for clearance may be required.

Table 4-1. 241-A-101 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A101-WST-RISER-002 8 Thermocouple Air Inlet/ Vac Breaker/Camera A101-WST-RISER-004 12 Saltwell Pump Exhauster Port A101-WST-RISER-005 4 Tank Level Indicator Sample Sleeve A101-WST-RISER-006 4 ENRAF ENRAF A101-WST-RISER-007 4 Crust Breaker Chemical Addition Port A101-WST-RISER-010 6 Spare Camera A101-WST-RISER-012 4 Thermocouple Probe Camera A101-WST-RISER-013 42 Spare Slurry Pump A101-WST-RISER-015 4 Breather Filter Camera A101-WST-RISER-021 12 Pump Pit Riser ERSS A101-WST-RISER-022 12 Sluice Pit Riser ERSS A101-WST-RISER-024 4 Liquid Level Well ‘B’ Camera

Table 4-1 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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4.1.2 241-A-102 RISERS

Tank 241-A-102 contains several of the same characteristics as tank A-101. There is the distributor pit (241-A-02D) and two pump pits (241-A-02A and 241-A-02B).

Figure 4-2 shows in blue the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-2 – 241-A-102 Riser Configuration

Recommended riser locations for the two ERSSs in A-102 are RISER-021 and RISER-022. Risers 021 and 022 are both 12” in diameter and approximately 20’ long. Use of these risers for ERSSs would require a redesign of the ERSS mast as discussed in section 4.1.1.

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Table 4-2. 241-A-102 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A102-WST-RISER-002 8 Spare/Pit Drain Lines Air Inlet/ Vac Breaker/Camera A102-WST-RISER-004 12 Slurry Distributor Exhauster Port A102-WST-RISER-005 4 Spare Sample Sleeve A102-WST-RISER-006 4 ENRAF ENRAF A102-WST-RISER-007 4 Thermocouple Chemical Addition Port A102-WST-RISER-013 42 Pump Slurry Pump A102-WST-RISER-018 4 Breather Filter Camera A102-WST-RISER-019 12 Observation Port Camera A102-WST-RISER-021 12 Pump Pit Riser ERSS A102-WST-RISER-022 12 Receiving Pit Riser ERSS Table 4-2 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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4.1.3 241-A-103 RISERS

Tank 241-A-103 contains a distributor pit (241-A-03D) and three pump pits (241-A-02A, 241-A-02B, and 241-A-02C).

Figure 4-2 shows in blue the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-3 – 241-A-103 Riser Configuration

Recommended riser locations for two ERSSs in A-103 are RISER-020 and RISER-012.

Riser 020 is 12” in diameter and approximately 20’ long and would require a redesign to the ERSS as discussed in section 4.1.1. This riser is also located in a pit of similar design to that of A-101 and potentially has clearance issues with the ERSS. This pit may also require an extension of the riser to locate the head of the ERSS above the walls of the pit.

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Riser 12 is a 12” diameter riser currently used as an observation port. Initial review of construction drawings did not determine the length of this riser. Riser 12 provides the optimum position for the second ERSS on tank A-103. It is recommended that preliminary investigation be done on this riser to determine its length and if a redesign of the current ERSS would be required to locate it at this position.

Table 4-3. 241-A-103 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A103-WST-RISER-002 8 Thermocouple Air Inlet/ Vac Breaker/Camera A103-WST-RISER-004 12 Saltwell Pump Exhauster Port A103-WST-RISER-005 4 Spare Sample Sleeve A103-WST-RISER-006 4 ENRAF ENRAF A103-WST-RISER-007 4 Crust Breaker Chemical Addition Port A103-WST-RISER-012 12 Observation Port ERSS A103-WST-RISER-013 42 Spare Slurry Pump A103-WST-RISER-015 4 Thermocouple Probe Camera A103-WST-RISER-017 4 Breather Filter/Vapor Probe Camera A103-WST-RISER-019 4 Liquid Observation Well Camera A103-WST-RISER-020 12 Pump Pit Riser ERSS Table 4-3 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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4.1.4 241-A-106 RISERS

Tank 241-A-106 contains a distributor pit (241-A-06D), a sluice pit (241-A-06B) and two pump pits (241-A-06A and 241-A-06C).

Figure 4-4 shows in blue the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-4 – 241-A-106 Riser Configuration

Recommended riser locations for two ERSSs in A-106 are RISER-021 and RISER-022. Both of these risers are 12” in diameter and approximately 20’ long requiring a redesign of the ERSS as discussed in section 4.1.1. They are both located in pits with potential clearance issues and may require a riser extension, also discussed in section 4.1.1.

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Table 4-4. 241-A-106 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A106-WST-RISER-002 8 Thermocouple Air Inlet/Vac Breaker/Camera A106-WST-RISER-004 12 Pump Pit Riser Exhauster Port A106-WST-RISER-005 4 Crust Breaker Sample Sleeve A106-WST-RISER-006 4 ENRAF ENRAF A106-WST-RISER-007 4 Spare Chemical Addition Port A106-WST-RISER-016 42 Pump Slurry Pump A106-WST-RISER-017 12 Observation Port Camera A106-WST-RISER-018 4 Radial Breather Filter Camera A106-WST-RISER-021 12 Pump ERSS A106-WST-RISER-022 12 Pump ERSS Table 4-4 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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4.2 A Farm Tanks MARS-V Technology

Two A Farm tanks are assumed leakers not suited for modified sluicing retrieval technology (A-104 and A-105). An alternative sluicing technology called the Vacuum Mobile Arm Retrieval System (MARS-V) is planned for installation into these two tanks for retrieval. MARS-V uses a vacuum system to retrieve the tank utilizing minimal water and supernate in an effort to keep the tank from leaking further fluid.

MARS-V is an all in one system. The slurry pump and slicing technology are located on one piece of equipment. This technology also requires a 47” diameter riser, a larger riser than currently available on either of the tanks. To be fully effective, MARS-V should be installed at the center of the tank. Currently, both tanks A-104 and A-105 have a 42” diameter 27’ long riser located inside pump pits at the center of their tanks, RISER-020 and RISER-013, respectively. A 55” core would need to be cut from these tanks around the existing risers for installation of the 47” diameter riser to support MARS-V. This would require removal of the entire riser and surrounding concrete.

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4.2.1 241-A-104 RISERS

Tank 241-A-104 has four riser pits. There are two pump pits (241-A-04A and 241-A-04B) and a sluice pit (241-A-04C).

Figure 4-5 shows in red the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-5 – 241-A-104 Riser Configuration

Table 4-1 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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Table 4-5. 241-A-104 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A104-WST-RISER-002 8 Thermocouple Air Inlet/ Vac Breaker/Camera A104-WST-RISER-004 12 Observation Port Exhauster Port A104-WST-RISER-005 4 Crust Breaker Sample Riser/Camera A104-WST-RISER-006 4 ENRAF ENRAF A104-WST-RISER-007 4 Spare Chemical Addition Port A104-WST-RISER-008 4 Thermocouple Camera A104-WST-RISER-020 42 Pump MARS-V A104-WST-RISER-021 12 Sluice Pit Pump Camera A104-WST-RISER-022 12 Sluice Pit Pump Camera

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4.2.2 241-A-105 RISERS

Tank 241-A-105 has four riser pits. There are two pump pits (241-A-05A and 241-A-05C) and two sluice pits (241-A-05B and 241-A-05D).

Figure 4-6 shows in blue the recommended locations for retrieval equipment. These locations were selected based on their availability, consistency in layout with other A tanks, ability to accommodate equipment, and optimization of the retrieval system.

Figure 4-6 – 241-A-105 Riser Configuration

Table 4-6 shows the recommended risers for the waste retrieval equipment, their diameters, and what equipment is currently installed in them. Use of these risers would require removal of legacy equipment.

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Table 4-6. 241-A-105 Riser Information.

Riser Number Size (Inches) Current Equipment / Function Equipment / Function During WRS Operation

A105-WST-RISER-002 8 Spare Air Inlet/ Vac Breaker/Camera A105-WST-RISER-004 12 Observation Port Exhauster Port A105-WST-RISER-005 4 ENRAF ENRAF A105-WST-RISER-006 4 Spare Sample Riser/Camera A105-WST-RISER-007 4 Thermocouple Chemical Addition Port A105-WST-RISER-008 4 Tank Pressure Indicator Camera A105-WST-RISER-013 42 Pump MARS-V A105-WST-RISER-018 4 Spare Camera A105-WST-RISER-024 12 Sluice Pit Riser Camera A105-WST-RISER-025 12 Pump Pit Riser Camera

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5.0 BIBLIOGRAPHY

H-14-010608-001, Waste Storage Tank (WST) Riser Data, Revision 5, U.S. Department of Energy, Richland, Washington.

H-14-010608-002, Waste Storage Tank (WST) Riser Data, Revision 6, U.S. Department of

Energy, Richland, Washington. H-2-55910-001, Waste Storage Tanks Dome Plan and Fixture Layout Purex Waste Disposal

Facility, Revision 6, U.S. Department of Energy, Richland, Washington. H-2-55911-001, Waste Storage Tanks Composite Section , Revision 1, U.S. Department of

Energy, Richland, Washington. H-2-55917-001, Waste Storage Tanks Dome Riser Details, Revision 1, U.S. Department of

Energy, Richland, Washington. H-2-55917-002, Waste Storage Tanks Dome Riser Details, Revision 1, U.S. Department of

Energy, Richland, Washington. H-2-55948-001, Ventilation System 241-A-431 Vapor Header Layout & Waste Transfer Line,

Revision 2, U.S. Department of Energy, Richland, Washington. H-2-61985-001, Structural Sluice Pits 241-A Tank Farm Plans & Dets, Revision 1, U.S.

Department of Energy, Richland, Washington. H-2-37850-001, Riser Elevations & Drawing List, Revision 1, U.S. Department of Energy,

Richland, Washington. H-2-69191-001, Piping arrangement Pump Pits 241-A-01B, -03C & -06C, Revision 2, U.S.

Department of Energy, Richland, Washington. H-2-69193-001, Piping Arrangement Distributor Pits 241-A-01H, 02D, 03D, & 06D, Revision 3,

U.S. Department of Energy, Richland, Washington. H-2-62975-001, Structural Jet Sluice Pit Details, Revision 1, U.S. Department of Energy,

Richland, Washington. H-2-69184-001, Piping Plan 241-A Tank Farm, Revision 5, U.S. Department of Energy,

Richland, Washington. H-2-69185-001, Piping Sections and Details, Revision 1, U.S. Department of Energy, Richland,

Washington. H-2-69186-001, Piping Details, Revision 2, U.S. Department of Energy, Richland, Washington.

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H-2-44780-001, Miscellaneous Details & Process Piping, Revision 3, U.S. Department of Energy, Richland, Washington.

H-2-55919-001, Waste Storage Tanks Pump Pit Details, Revision 2, U.S. Department of Energy,

Richland, Washington. H-2-73388-001, Piping Waste Tank Isolation TK 241-A-101, Revision 5, U.S. Department of

Energy, Richland, Washington. H-2-73388-002, Piping Waste Tank Isolation TK 241-A-101, Revision 0, U.S. Department of

Energy, Richland, Washington. H-2-63100-001, 101-A TK. ARRGT. As Built, Revision 3, U.S. Department of Energy, Richland,

Washington. H-2-63107-001, Special 18” Risers 241-A-101 Plot Plan, Revision 1, U.S. Department of

Energy, Richland, Washington. H-2-73390-001, Piping Waste Tank Isolation 241-A-102, Revision 3, U.S. Department of

Energy, Richland, Washington. H-2-36065-001, 102-A TK. ARRGT. As Built, Revision 1, U.S. Department of Energy, Richland,

Washington. H-2-73392-001, Piping Waste Tank Isolation TK 241-A-103, Revision 5, U.S. Department of

Energy, Richland, Washington. H-2-36066-001, 103-A TK ARRGT. As Built, Revision 1, U.S. Department of Energy, Richland,

Washington. H-2-57943-001, Pump Pit Over Waste Tank 241-A-103, Revision 3, U.S. Department of Energy,

Richland, Washington. H-2-73386-001, Piping Waste Tank Isolation 241-A-104, Revision 3, U.S. Department of

Energy, Richland, Washington. H-2-66006-001, 104-A TK. ARRGT As Built, Revision 4, U.S. Department of Energy, Richland,

Washington. H-2-45992-001, Sludge Cooler For Tank 241-SX-107 Arrangement, Revision 2, U.S.

Department of Energy, Richland, Washington. H-2-73387-001, Piping Waste Tank Isolation 241-A-105, Revision 4, U.S. Department of

Energy, Richland, Washington.

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H-2-63099-001, 105-A TK. ARRGT As Built, Revision 2, U.S. Department of Energy, Richland, Washington.

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Washington. H-2-36577-002, Tank 241-A-105 Isolation Details, Revision 1, U.S. Department of Energy,

Richland, Washington. H-2-74691-001, Thermocouple Probes Tank 105A, Revision 1, U.S. Department of Energy,

Richland, Washington. H-2-74691-002, Thermocouple Probes Tank 105A, Revision 1, U.S. Department of Energy,

Richland, Washington. H-2-32537-001, Bottom Detector & Sludge Temp. Probe-105-A TK., Revision 1, U.S.

Department of Energy, Richland, Washington. H-2-32537-002, Bottom Detector & Sludge Temp. Probe-105-A TK., Revision 0, U.S.

Department of Energy, Richland, Washington. H-2-73451-001, Piping Isolation Details Riser Closures, Revision 5, U.S. Department of

Energy, Richland, Washington. H-2-63138-001, Emergency Sluicing Piping Plan & Section Tank 241-A-105, Revision 3, U.S.

Department of Energy, Richland, Washington. H-2-33979-001, Tank 241-A-105 Emergency Sluicing Pits, Revision 2, U.S. Department of

Energy, Richland, Washington. H-2-58658-001, New Pump Pit 105-A TK ARRGT, Revision 4, U.S. Department of Energy,

Richland, Washington. H-2-73394-001, Piping Waste Tank Isolation 241-A-106, Revision 4, U.S. Department of

Energy, Richland, Washington. H-2-66030-001, 106-A TK ARRGT As Built, Revision 1, U.S. Department of Energy, Richland,

Washington. H-2-45998-001, Sludge Cooler for Tank 241-SX-112 Arrangement, Revision 2, U.S. Department

of Energy, Richland, Washington.