specification for the modular grouting system for

A-6007-231 (REV 0)

RPP-SPEC-64252

Revision 00 DRAFT

Specification for the Modular Grouting System for Treatment of EMF Brine (Project OP187)

Prepared by

L.E. Ulbricht Washington River Protection Solutions, LLC

Date Published June JulyAugust 2020

Prepared for the U.S. Department of Energy Office of River Protection

Contract No. DE-AC27-08RV14800

RPP-SPEC-64252, Rev. 00 DRAFT

This page intentionally left blank.


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TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................ I

LIST OF APPENDICES..................................................................................................... VII

LIST OF FIGURES .......................................................................................................... VIII

LIST OF TABLES............................................................................................................ VIII

1.0 SCOPE .................................................................................................................... 1-1 1.1 DESCRIPTION ..............................................................................................1-3 1.2 DOCUMENT OVERVIEW ............................................................................1-4

2.0 APPLICABLE DOCUMENTS ............................................................................... 2-1 2.1 GOVERNMENT DOCUMENTS ....................................................................2-1 2.2 NON-GOVERNMENT DOCUMENTS...........................................................2-1 2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS ................2-6 2.4 HIERARCHY OF CODE ................................................................................2-7

3.0 SYSTEM CHARACTERISTICS AND REQUIREMENTS ................................... 3-1 3.1 SYSTEM FUNCTIONS AND FUNCTIONAL PERFORMANCE

REQUIREMENTS..........................................................................................3-1 3.2 CHARACTERISTICS ....................................................................................3-1

3.2.1 Performance Characteristics ..............................................................3-1 3.2.2 Interface Requirements.................................................................... 3-15

3.3 DESIGN AND CONSTRUCTION REQUIREMENTS .................................. 3-16 3.3.1 Design and Operating Conditions .................................................... 3-16 3.3.2 Physical Requirements .................................................................... 3-17 3.3.3 Environmental Conditions ............................................................... 3-17 3.3.4 Structural Analysis and Design ........................................................ 3-17 3.3.5 General Materials Requirements ...................................................... 3-18 3.3.6 Electromagnetic Radiation............................................................... 3-30 3.3.7 Nameplates and Product Markings................................................... 3-30 3.3.8 Labeling ......................................................................................... 3-31 3.3.9 Spare Capacity and Interchangeability ............................................. 3-38 3.3.10 Safety ............................................................................................. 3-39 3.3.11 Environmental Safety ...................................................................... 3-41 3.3.12 Human Performance and Human Factors Engineering ...................... 3-42 3.3.13 Control System ............................................................................... 3-44 3.3.14 Infrastructure Service Provisions ..................................................... 3-46 3.3.15 System Quality Factors ................................................................... 3-51 3.3.16 Transportability .............................................................................. 3-54 3.3.17 Ventilation ...................................................................................... 3-55

3.4 DOCUMENTATION.................................................................................... 3-56


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3.4.1 Conceptual Design .......................................................................... 3-57 3.4.2 Preliminary Design ......................................................................... 3-57 3.4.3 Final Design ................................................................................... 3-60 3.4.4 Fabrication Documents.................................................................... 3-78

4.0 FABRICATION REQUIREMENTS ...................................................................... 4-1 4.1 GENERAL WELDING REQUIREMENTS .....................................................4-1 4.2 VESSEL FABRICATION REQUIREMENTS .................................................4-1

4.2.1 General Vessel Requirements ............................................................4-1 4.2.2 Vessel Layout Requirements .............................................................4-3 4.2.3 Nozzles.............................................................................................4-3

4.3 PIPING FABRICATION REQUIREMENTS ................................................ 4-10 4.3.1 Pipe Spool and Installation Drawings............................................... 4-11 4.3.2 Pipe Welding .................................................................................. 4-11 4.3.3 Fabrication Tolerance and Alignment .............................................. 4-14 4.3.4 Orifice Flange Assemblies............................................................... 4-15 4.3.5 Branch Connections and Miscellaneous Attachments ....................... 4-15 4.3.6 Pipe Bending and Forming .............................................................. 4-15 4.3.7 Heat Treatment ............................................................................... 4-16 4.3.8 Quality Control ............................................................................... 4-17 4.3.9 Flange Joints................................................................................... 4-19 4.3.10 Valves ............................................................................................ 4-19 4.3.11 Pipe Supports.................................................................................. 4-20 4.3.12 Pressure Testing.............................................................................. 4-20 4.3.13 Instrumentation and Control Fabrication and Quality Control

Requirements .................................................................................. 4-26 4.3.14 Electrical Fabrication and Quality Control Requirements.................. 4-26

4.4 CLEANLINESS ........................................................................................... 4-27

5.0 FACTORY ACCEPTANCE TESTING (FAT) AND INSPECTIONS ................... 5-1

6.0 QUALITY ASSURANCE........................................................................................ 6-1 6.1 NONCONFORMANCE REPORTS ................................................................6-1 6.2 INSPECTION AND EXAMINATION ............................................................6-2 6.3 SUSPECT AND COUNTERFEIT ITEMS .......................................................6-2 6.4 CERTIFICATE OF CONFORMANCE ...........................................................6-2

7.0 PACKAGING, STORAGE, TRANSPORT, AND LOAD HANDLING ................. 7-1 7.1 GENERAL .....................................................................................................7-1 7.2 PRESERVATION AND PACKAGING ..........................................................7-2 7.3 PACKAGING.................................................................................................7-2 7.4 MARKING.....................................................................................................7-2 7.5 HANDLING ...................................................................................................7-3

7.5.1 Lifting and Rigging Plan ...................................................................7-3 7.6 TRANSPORTATION AND STORAGE ..........................................................7-4


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7.6.1 Transport and Tie-Down Instructions.................................................7-4 7.6.2 Unpacking and Assembly Drawing ....................................................7-4 7.6.3 Offloading ........................................................................................7-5

8.0 DESIGN VERIFICATION ..................................................................................... A-I

9.0 NOTES .................................................................................................................. A-II 9.1 ASSUMPTIONS........................................................................................... A-II 9.2 DEFINITIONS ............................................................................................. A-II 9.3 LIST OF ACRONYMS ................................................................................. A-II 9.4 UNITS OF MEASUREMENT ......................................................................A-V 9.5 TRADEMARKS ........................................................................................ A-VII 9.6 REFERENCES ......................................................................................... A-VIII

TABLE OF CONTENTS........................................................................................................ I

LIST OF APPENDICES...................................................................................................... III

LIST OF FIGURES ............................................................................................................. IV

LIST OF TABLES............................................................................................................... IV

1.0 SCOPE .................................................................................................................... 1-1 1.1 DESCRIPTION ..............................................................................................1-3 1.2 DOCUMENT OVERVIEW ............................................................................1-3

2.0 APPLICABLE DOCUMENTS ............................................................................... 2-1 2.1 GOVERNMENT DOCUMENTS ....................................................................2-1 2.2 NON-GOVERNMENT DOCUMENTS...........................................................2-1 2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS ................2-4 2.4 HIERARCHY OF CODE ................................................................................2-5

3.0 SYSTEM CHARACTERISTICS AND REQUIREMENTS ................................... 3-1 3.1 SYSTEM FUNCTIONS AND FUNCTIONAL PERFORMANCE

REQUIREMENTS..........................................................................................3-1 3.2 CHARACTERISTICS ....................................................................................3-1

3.2.1 Performance Characteristics ..............................................................3-1 3.2.2 Interface Requirements......................................................................3-8

3.3 DESIGN AND CONSTRUCTION REQUIREMENTS ....................................3-9 3.3.1 Design and Operating Conditions ......................................................3-9 3.3.2 Physical Requirements .................................................................... 3-10 3.3.3 Environmental Conditions ............................................................... 3-10 3.3.4 Structural Analysis and Design ........................................................ 3-10 3.3.5 General Materials Requirements ...................................................... 3-10 3.3.6 Electromagnetic Radiation............................................................... 3-20 3.3.7 Nameplates and Product Markings................................................... 3-20


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3.3.8 Labeling ......................................................................................... 3-20 3.3.9 Spare Capacity and Interchangeability ............................................. 3-26 3.3.10 Safety ............................................................................................. 3-26 3.3.11 Plant and Equipment Protection ....................................................... 3-28 3.3.12 Environmental Safety ...................................................................... 3-28 3.3.13 Human Performance and Human Factors Engineering ...................... 3-28 3.3.14 Control System ............................................................................... 3-30 3.3.15 Infrastructure Service Provisions ..................................................... 3-31 3.3.16 System Quality Factors ................................................................... 3-34 3.3.17 Transportability .............................................................................. 3-35 3.3.18 Ventilation ...................................................................................... 3-36

3.4 DOCUMENTATION.................................................................................... 3-37 3.4.1 Conceptual Design .......................................................................... 3-37 3.4.2 Preliminary Design ......................................................................... 3-38 3.4.3 Final Design ................................................................................... 3-40 3.4.4 Fabrication Documents.................................................................... 3-53

4.0 FABRICATION REQUIREMENTS ...................................................................... 4-1 4.1 GENERAL WELDING REQUIREMENTS .....................................................4-1 4.2 VESSEL FABRICATION REQUIREMENTS .................................................4-1

4.2.1 General Vessel Requirements ............................................................4-1 4.2.2 Vessel Layout Requirements .............................................................4-2 4.2.3 Nozzles.............................................................................................4-3

4.3 PIPING FABRICATION REQUIREMENTS ..................................................4-8 4.3.1 Pipe Spool and Installation Drawings.................................................4-8 4.3.2 Pipe Welding ....................................................................................4-9 4.3.3 Fabrication Tolerance and Alignment .............................................. 4-11 4.3.4 Orifice Flange Assemblies............................................................... 4-11 4.3.5 Branch Connections and Miscellaneous Attachments ....................... 4-11 4.3.6 Pipe Bending and Forming .............................................................. 4-12 4.3.7 Heat Treatment ............................................................................... 4-12 4.3.8 Quality Control ............................................................................... 4-13 4.3.9 Flange Joints................................................................................... 4-14 4.3.10 Valves ............................................................................................ 4-15 4.3.11 Pipe Supports.................................................................................. 4-15 4.3.12 Pressure Testing.............................................................................. 4-15 4.3.13 Instrumentation and Control Fabrication and Quality Control

Requirements .................................................................................. 4-19 4.3.14 Electrical Fabrication and Quality Control Requirements.................. 4-20

4.4 CLEANLINESS ........................................................................................... 4-20

5.0 FACTORY ACCEPTANCE TESTING (FAT) AND INSPECTIONS ................... 5-1

6.0 QUALITY ASSURANCE........................................................................................ 6-1 6.1 NONCONFORMANCE REPORTS ................................................................6-1


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6.2 INSPECTION AND EXAMINATION ............................................................6-2 6.3 SUSPECT AND COUNTERFEIT ITEMS .......................................................6-2 6.4 CERTIFICATE OF CONFORMANCE ...........................................................6-2

7.0 PACKAGING, STORAGE, TRANSPORT, AND LOAD HANDLING ................. 7-1 7.1 GENERAL .....................................................................................................7-1 7.2 PRESERVATION AND PACKAGING ..........................................................7-1 7.3 PACKAGING.................................................................................................7-1 7.4 MARKING.....................................................................................................7-2 7.5 HANDLING ...................................................................................................7-3

7.5.1 Lifting and Rigging Plan ...................................................................7-3 7.6 TRANSPORTATION AND STORAGE ..........................................................7-3

7.6.1 Transport and Tie-Down Instructions.................................................7-3 7.6.2 Unpacking and Assembly Drawing ....................................................7-3 7.6.3 Offloading ........................................................................................7-4

8.0 DESIGN VERIFICATION ..................................................................................... A-I

9.0 NOTES .................................................................................................................. A-II 9.1 ASSUMPTIONS........................................................................................... A-II 9.2 DEFINITIONS ............................................................................................. A-II 9.3 LIST OF ACRONYMS ................................................................................. A-II 9.4 UNITS OF MEASUREMENT .................................................................... A-IV 9.5 TRADEMARKS ......................................................................................... A-VI 9.6 REFERENCES .......................................................................................... A-VII

LIST OF APPENDICES

A Piping Pressure Test Checklist ....................................................................................A-i

B Piping Pre-Pressure Test Checklist.............................................................................. B-i

C Status of Instruments During Pressure Test ................................................................. C-i


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LIST OF FIGURES

Figure 3-1. Modular Grout System Diagram. .....................................................................3-3

Figure 3-2. River Protection Project Functional Hierarchy..................................................3-6

Figure 3-3. Acceptable Nozzle Connections..................................................................... 3-26

Figure 3-4. Unacceptable Nozzle Connections. ................................................................ 3-26

Figure 3-5. Integral Nozzle Reinforcement Methods. ....................................................... 3-27

Figure 3-6. NF Label Coding. ......................................................................................... 3-33

Figure 3-7. NH Label Coding. ......................................................................................... 3-34

Figure 3-8. NL Label Coding. ......................................................................................... 3-35

Figure 3-1. Modular Grout System Diagram. .....................................................................3-3

Figure 3-2. River Protection Project Functional Hierarchy..................................................3-4

Figure 3-3. Acceptable Nozzle Connections..................................................................... 3-17

Figure 3-4. Unacceptable Nozzle Connections. ................................................................ 3-17

Figure 3-5. Integral Nozzle Reinforcement Methods. ....................................................... 3-17

Figure 3-6. NF Label Coding. ......................................................................................... 3-22

Figure 3-7. NH Label Coding. ......................................................................................... 3-23

Figure 3-8. NL Label Coding. ......................................................................................... 3-24

LIST OF TABLES

Table 2-1. Government Documents. .................................................................................2-1

Table 2-2. Non-Government Documents. (3 Sheets) ........................................................2-3

Table 2-3. Non-Government Non-Code of Record Documents. .........................................2-7

Table 3-1. Struvite Precipitation and Solidification Recipe for Nominal 0.6 w/dm ..................3-2

Table 3-2. Summary of Average Radionuclide Components in Waste Feed for the Modular Grout System ...............................................................................................3-8

Table 3-3. Summary of Chemical Components in Waste Feed for the Modular Grout System .......................................................................................................................3-9

Table 3-4. Waste Feed Physical Characteristics. .................................................................. 3-14

Table 4-1. Vessel Fabrication Traveler Hold Points. .........................................................4-4

Table 4-2. Piping Fabrication Traveler Hold Points. ....................................................... 4-18

Table 5-1. EMF Brine Simulant for Factory Acceptance Testing: Production Test .................5-1


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Table 2-1. Government Documents. .................................................................................2-1

Table 2-2. Non-Government Documents. (3 Sheets) ........................................................2-2

Table 2-3. Non-Government Non-Code of Record Documents. .........................................2-4

Table 3-1. Struvite Precipitation and Solidification Recipe .....................................................3-2

Table 3-2. Summary of Average Radionuclide Components in Waste Feed for the Modular Grout System ...............................................................................................3-6

Table 3-3. Summary of Average Chemical Components in Waste Feed for the Modular Grout System .............................................................................................................3-7

Table 3-4. Waste Feed Physical Characteristics. ....................................................................3-8

Table 4-1. Vessel Fabrication Traveler Hold Points. .........................................................4-3

Table 4-2. Piping Fabrication Traveler Hold Points. ....................................................... 4-13


1-1

1.0 SCOPE

This procurement specification establishes the requirements for design, manufacture, and factory acceptance testing (FAT) of a Modular Grouting System (MGS) for treatment of brine resulting from processing the secondary liquid waste from the Waste Treatment Plant’s (WTP) Effluent Management Facility (EMF) through the Effluent Treatment Facility (ETF). The MGS will be housed within a temperature controlled building that is part of the Effluent Grout Treatment Facility (EGTF) (Project OP187). The EMF bBrine requires treatment by solidification to meet Land Disposal Requirements (LDR) prior to disposal. Due to high ammonium content in the brine, the MGS includes a struvite precipitation process step prior to grouting with sulfur activated slag.

The specific scope of this procurement is summarized as follows:

• Design, fabricate, test, and deliver structures, systems, and components (SSC) in accordance with requirements of this specification and approved drawings.

• Furnish labor, supervision, tools, equipment, and consumable materials required to perform work in accordance with this specification and the statement of work.

• Provide process design; equipment required to treat the waste feed by struvite precipitation and grouting using sulfur activated slag.

• Provide general arrangement design to be used in subsequent site plan (civil) design by others.

• Provide control system.

• Provide process equipment and piping design.

• Provide structural design for skids, equipment supports, and structural other structural components.

• Provide design of the container that will contain the grouted waste.

• Procure materials and SSCs.

• Maintain records and accounting of parts and materials required to complete the work scope.

• Fabricate and assemble the system.

• Perform nondestructive examinations (NDEs) for welds and bends as required by this specification.


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• Provide cleaning and identification of SSCs.

• Provide weld-end prep of piping to be field welded.

• Apply protective coatings to surfaces after fabrication as required by this specification.

• Perform FAT using water a simulant as the feed stream.

• Clean and inspect SSCs, as required, following the FAT.

• Provide and install temporary protective covers.

• Provide packaging, crating, loading, and shipping of SSCs.

• Provide documentation for design, fabrication, test, and delivery.

• Deliver the system to the Hanford Site, to include transportation and lift plans in accordance with Section 7.0

• Provide technical support to the BUYER for process hazards analysis, hazards evaluation, control development, environmental permitting, developing supporting documents, Hanford Site installation, start-up testing, system acceptance, readiness review, training of BUYER’s operations and maintenance personnel, and development of operating and maintenance procedures.

The equipment and features listed below will be sized and refined by the VENDOR during process design. The equipment scope of supply includes the main equipment units as follows:

• Process skids with:

– Waste receipt pumps and sampling system, – Staging tank with mixing/delivery pump, – Treatment system including struvite precipitation and grouting of waste, – Grouted waste sampling and container handling system, – Ventilation systems providing radioactive and nonradioactive material confinement, – Dry grout component handling and dust control, – Chemical/reagent systems, – Process control system, – Support skid connections, – Process instrumentation, and – Leak detection.

• Compressed air skid, as required.


1-3

1.1 DESCRIPTION

The U.S. Department of Energy (DOE), Office of River Protection (ORP) primary mission is to retrieve and treat the Hanford Site tank waste and close the tank farms to protect the Columbia River. Radioactive waste is stored in 177 underground tanks at the Hanford Site as reported in DOE/ORP-2003-02, Environmental Impact Statement for Retrieval, Treatment, and Disposal of Tank Waste and Closure of the Single-Shell Tanks at the Hanford Site, Richland, WA – Inventory and Source Term Data Package. As of March 2014, those 177 underground tanks were estimated to contain about 56 million gallons of waste. A key aspect of implementing the Hanford Site cleanup mission is to construct and operate the WTP (ORP-11242, River Protection Project System Plan). The WTP is a multi-facility plant that will separate and immobilize the tank high-level waste (HLW) and LAW fractions for final dispositions.

The MGS supports production of immobilized low-activity waste (ILAW) by treating and immobilizing the secondary liquid waste that is generated in producing ILAW to meet LDR for disposal in the Integrated Disposal Facility (IDF) on the Hanford Site.

1.2 DOCUMENT OVERVIEW

This procurement specification defines the functional, performance, interface, design, fabrication, and acceptance test requirements for delivery of the MGS.

The use of words “shall”, “must”, “should”, “will”, and “may” within this specification express the following meanings:

• Shall – denotes a requirement.

• Must – denotes a requirement.

• Should – denotes a recommendation. If a “should” recommendation cannot be satisfied, justification of an alternative design shall be submitted to the Project Design Review Team for approval.

• Will – denotes a statement of fact.

• May – denotes a “permissive” for a stated action, or denotes a possible outcome, depending on the context of the verbiage.


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2.0 APPLICABLE DOCUMENTS

This section lists only those documents cited as requirements documents in subsequent sections of this procurement specification. The references include the title and/or revision number or date of revision as applicable.

2.1 GOVERNMENT DOCUMENTS

The following documents, of the exact issue shown in Table 2-1, form a part of this specification to the extent specified herein.

Table 2-12-1. Government Documents.

Document Number Title Code of Federal Regulations (CFR) 29 CFR 1910 “Occupational Safety and Health Standards” U.S. Department of Energy (DOE) DOE/RL-92-36 Hanford Site Hoisting and Rigging Manual Revised Code of Washington (RCW) RCW 49.17 “Washington Industrial Safety and Health Act” Washington Administrative Code (WAC) WAC 173-303-640 “Tank Systems”

Copies of specifications, standards, drawings, and publications required by VENDORs in connection with specified procurement functions should be obtained from the contracting agency or as directed by the contracting agent.

2.2 NON-GOVERNMENT DOCUMENTS

The following documents, of the exact issue shown in Table Error! Reference source not found.2-2Table 2-2Table 2-2Table 2-2Table 2-2, form a part of this specification to the extent specified herein.


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Table 2-22-2. Non-Government Documents. (3 Sheets)

Document Number Title American Institute of Steel Construction (AISC®) AISC 325 (15th Edition) Steel Construction Manual AISC 360 (2016) Specification for Structural Steel Buildings AISC Steel Design Guide 27 (2013) Structural Stainless Steel American Petroleum Institute (API) API STD 598 (2016-Tenth Edition) Valve Inspection and Testing American Society of Civil Engineers (ASCE®) ASCE 7 (2017) Minimum Design Loads and Associated Criteria for Buildings and Other

Structures American Society of Mechanical Engineers (ASME®) ASME BPVC (2019) ASME Boiler & Pressure Vessel Code

Section II “Materials” Section V “Nondestructive Examination” Section VIII-1 “Rules for Construction of Pressure Vessels “ Section IX “Welding and Brazing Qualifications”

ASME B16.34-2017 Valves – Flanged, Threaded, ad Welding End ASME B30.20-2018 Below-the-Hook Lifting Devices ASME BTH-1-2017 Design of Below-the-Hook Lifting Devices ASME B31.1-2018 Power Piping ASME B31.3-2018 Process Piping ASME NQA-1-2008/2009A (Addenda A)

Quality Assurance Requirements for Nuclear Facility Applications

American Society for Nondestructive Testing (ASNT) ASNT SNT-TC-1A-2016 Personnel Qualification and Certification in Nondestructive Testing American Society for Testing and Materials (ASTM)® ASTM A380/A380M-17 Standard Practice for Cleaning, Descaling, and Passivation of Stainless

Steel Parts, Equipment, and Systems ASTM D380 1994(R2020) Standard Test Methods for Rubber Hose American Welding Society (AWS®) ANSI/AWS A2.4:2020 Standard Symbols for Welding Brazing, and Nondestructive Examination AWS D1.1/D1.1M:2020 Structural Welding Code—Steel AWS D1.6/D1.6M:2017 Structural Welding Code—Stainless Steel AWS D9.1M/D9.1:2018 Sheet Metal Welding Code Institute of Electrical and Electronics Engineers, Inc. (IEEE®) IEEE C2-2017 National Electrical Safety Code® (NESC®) IEEE Std 142-2007 IEEE Recommended Practice for Grounding of Industrial and

Commercial Power System


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Document Number Title IEEE Std 242-2001 IEEE Recommended Practice for Protection and Coordination of

Industrial and Commercial Power Systems IEEE Std 841-2009 IEEE Standard for Petroleum and Chemical Industry—Premium-

Efficiency, Severe-Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors—Up to and Including 370 kW (500 hp)

IEEE Std 1100-2005 IEEE Recommended Practice for Powering and Grounding Electronic Equipment

International Society of Automation (ISA) ANSI/ISA-5.1-2009 Instrumentation Symbols and Identification ANSI/ISA-7.0.01-1996 Quality Standard for Instrument Air ANSI/ISA-18.2-2016 Management of Alarm Systems for the Process Industries Manufacturers Standardization Society (MSS) MSS SP-58-2018 Pipe Hangers and Supports – Materials, Design, Manufacture, Selection,

Application, and Installation Military Standard MIL-STD-889C 2016 Dissimilar Metals National Board Inspection Code (NBIC) NBBI NB-23 2019 National Board Inspection Code National Electrical Manufacturers Association (NEMA) NEMA ICS 1-2000( R2015) Industrial Control and Systems: General Requirements NEMA ICS 6-1993( R2016) Industrial Control and Systems: Enclosures NEMA ICS-19, 2016 Diagrams, Device Designations, and Symbols for Industrial Controls and

Systems NEMA MG-1-2016 Motors and Generators National Fire Protection Association (NFPA®) NFPA 70 (2020) National Electrical Code® (NEC®) NFPA 79 (2018) Electrical Standard for Industrial Machinery NFPA 101 (2018) Life Safety Code® (LSC®) Pipe Fabrication Institute (PFI) PFI Standard ES-3 2009(R2016) Fabricating Tolerances PFI Standard ES-24 2015 Pipe Bending Methods, Tolerances, Process and Material Requirements National Electrical Manufacturers Association (NEMA)Underwriter’s Laboratories NEMA MG-1-2016UL 508A, 2018 Motors and GeneratorsUL Standard for Safety Industrial Control Panels Other Publications HNF-27957, Rev. 4 200 Area ETF, Load-in, and LERF Pipe Class Specification RMA-IP-2 2009 Hose Handbook


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Document Number Title RPP-13211, Rev. 1 Electromagnetic Compatibility and Electrical Noise Control for the DOE

Hanford Site TFC-BSM-AD-STD-02, Rev. D-12 “Editorial Standard and Format Guidance for Documents” TFC-ENG-DESIGN-D-71, Rev. A-0 Elementary Diagram Guide TFC-ENG-STD-01, Rev. A-7 “Human Factors in Design” TFC-ENG-STD-02, Rev. B-0 “Environmental/Seasonal Requirements for TOC Systems, Structures, and

Components” TFC-ENG-STD-06, Rev. D-2 “Design Loads for Tank Farm Facilities” TFC-ENG-STD-07, Rev. H-5 “Ventilation System Design Standard” TFC-ENG-STD-08, Rev. B-5 “Post Maintenance Testing” TFC-ENG-STD-10, Rev. A-18 “Drawing Standard” TFC-ENG-STD-12, Rev. E-4 “Tank Farm Equipment Identification Numbering and Labeling Standard” TFC-ENG-STD-14, Rev. C-4 “Setpoint Standard” TFC-ENG-STD-15, Rev. C-7 “Standard for Raceway Systems and Flexible Cords & Cables” TFC-ENG-STD-23, Rev. A-9 “Human-Machine Interface for Process Control Systems” TFC-ENG-STD-40, Rev. B-1 “Alarm Management and Annunciator Panel for Process Control Systems” TFC-ENG-STD-41, Rev. A-11 “Electrical Installations” TFC-ENG-STD-51, Rev. A-1 “Vendor Calculation Standard” TFC-ENG-STD-52, Rev. A-1 “Subcontractor Welding Standard” TFC-ESHQ-ENV-STD-03, Rev. A-11 “Air Quality – Radioactive Emissions” TFC-ESHQ-ENV-STD-04, Rev. C-8 “Air Quality Program – Non Radioactive Emissions” WRC Bulletin 297, 1984 Local Stresses In Cylindrical Shells Due To External Loadings On

Nozzles-Supplement to WRC Bulletin No. 107 (Revision 1); Welding Research Council, Inc. (WRC)

WRC Bulletin 537, 2010 Precision Equations and Enhanced Diagrams for Local Stresses in Spherical and Cylindrical Shells Due to External Loadings for Implementation of WRC Bulletin 107; Welding Research Council, Inc. (WRC)

Technical society and technical association specifications and standards are generally available for reference from libraries or they may be obtained directly from the Technical Society/Association.

2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS

The following documents, of the exact issue shown in Table 2-3, are utilized in or referenced by this document, form a part of this specification to the extent specified herein.


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Table 2-32-3. Non-Government Non-Code of Record Documents.

Document Number Title TFC-BSM-IRM_DC-C-07, Rev. A-13 “Vendor Processes” TFC-ENG-FACSUP-C-23, Rev. G-2 “Equipment Identification and Data Management”

2.4 HIERARCHY OF CODE

Except in those instances where Washington State has been granted regulatory authority by the Federal Government, the hierarchical relationship among requirements specified in Section 3.0 is as follows:

• Federal requirements (e.g., Code of Federal Regulations); • Washington State requirements (e.g., Washington Administrative Code); • Local ordinances; • U.S. Department of Energy Orders and Standards; • National consensus codes and standards; and • Hanford Site-specific codes and standards.

This hierarchy establishes the order of precedence of requirements levied in this specification. In the event of a conflict between two requirements, the VENDOR shall submit a “Request for Information” (RFI) (Site Form A-6003-417) for clarifications prior to use.


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3-1

3.0 SYSTEM CHARACTERISTICS AND REQUIREMENTS

3.1 SYSTEM FUNCTIONS AND FUNCTIONAL PERFORMANCE REQUIREMENTS

The top-level mission functions for the River Protection Project (RPP) are described by RPP-51303, River Protection Project Functions and Requirements. Two top-level functions derived from the RPP mission describe the MGS mission. Figure 3-23-23-23-23-2 identifies the functions and their subordinate functions (highlighted in yellow) from the RPP Functional Hierarchy applicable to the MGS mission.

The MGS is comprised of two functional components:

1. A Manage Secondary Waste component to move, store, treat the brine waste to meet LDR for disposal at IDF.

2. A Close Tanks, Waste Management Areas, and Excess Facilities component to decontaminate and decommission the MGS at the program’s end of life.

3.2 CHARACTERISTICS

This section describes the MGS performance characteristics, system relationships, external interface requirements, physical characteristics, system quality factors, environmental conditions, transportability, flexibility and expansion, and portability.

3.2.1 Performance Characteristics

The MGS performance requirements are as follows:

a) The MGS shall have an average processing capacity of 100,000 gallons of EMF brine per year.

b) The Staging Tank shall be sized for 1 week of operations.

c) The following durations shall be used for the following processes:

1) Time for Struvite Precipitation: 1 hour

2) Tiime for Bleedwater absorption: 48 hours

3) Time for Grout Set: 14 hours

4) Time for grout to attain required compressive strength: 7 days

d) The MGS shall be designed based on the materials and quantities for treatment of the EMF brine at a nominal w/dm ratio of 0.6 per Table 3-1, and for a range of w/dm


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ratios of 0.54 to 0.65, corresponding to a range of dry mix of 1869 to 1438 grams of dry mix per liter of EMF Brine:

Table 3-13-1. Struvite Precipitation and Solidification Recipe for Nominal 0.6 w/dm

Order of Addition

Chemical Quantity (g)*

1 EMF Brine (1 L) 1195.976 2 MgSO4 anhydrous 40.95 3 NaH2PO4*H2O 46.47 4 50% NaOH solution 54.193 5 Dry Mix: 92% Ground Blast Furnace Slag 120 and 8% MgO 18691557.47

* Note: Struvite precipitates are nominally 83.45 g per liter of EMF brine.

e) Routine preventative maintenance will be performed on back shifts.

f) Grouted waste shipment frequency is weekly.

g) The MGS shall produce grouted waste in caped (not necessarily sealed) painted carbon steel containers.

h) Slag will be received in tote bags.


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Figure 3-1. Modular Grout System Diagram.


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Figure 3-2. River Protection Project Functional Hierarchy.

Note: The highlighted functions (yellow) compose the functional components of the Tank-Side Cesium Removal System.

CH-TRU = contact-handled transuranic. SST = single-shell tank.

3.2.1.1 Manage Secondary Waste. The following sections provide requirements for the ‘manage system generated waste” function.

i)a) The MGS shall be capable of receiving, moving, storing, and treating brine from the Brine Lag Storage Tank System.

j) The MGS shall incorporate secondary containment, spill prevention, and leak detection design features in accordance with WAC 173-303-640, Paragraphs (3), (4), (5), (6), and (11).

k)b) The MGS process vessels shall be designed to permit draining and flushing with water to support inspection and maintenance activities. If bottom drains are used, the process vessels shall be designed to allow maintenance and replacement of bottom drains.

l)c) The MGS shall be designed for waste with the estimated radiological, chemical, and physical properties shown in Table 3-2 through Table 3-4.

m)d) The process shall be designed with appropriate capability (e.g., waste temperature control features) to minimize solids precipitation in process equipment that would be adverse to treatment and immobilization of the waste.

Remediate Tank Wastes

Store Waste

Move Waste

Concentrate Waste

Characterize Waste

Monitor Waste

Remove Single - Shell Tank Waste

Remove Potential Contact - Handled Transuranic Tank

Waste

Remove Ancillary Storage System

Waste

Deliver Waste Feed

Pretreat Waste

Immobilize High - Level Waste

Process Potential Contact - Handled Transuranic Tank

Waste

Immobilize Low - Activity Waste

Dispose Immobilized High - Level Waste*

Dispose Potential Contact - Handled Transuranic Tank

Waste*

Dispose Immobilized Low - Activity Waste

Dispose Secondary Waste

Manage Tank Waste

Retrieve Tank Waste

Process Tank Waste

Dispose Tank Waste

Manage System - Generated Waste &

Excess Facilities

Manage Immobilized High - Level Waste

Manage Potential Contact - Handled

Transuranic Waste

Manage Immobilized Low - Activity Waste

Manage Secondary Waste

Close Tanks, Waste Management Areas, and Excess Facilities

Store Waste

Move Waste

*Not an Office of River Protection function. Function to be performed by offsite entity.


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n)e) The ventilation system shall control radioactive airborne emissions in compliance with the requirements of TFC-ESHQ-ENV-STD-03, “Air Quality – Radioactive Emissions;” and TFC-ENG-STD-07.

o)f) The ventilation system shall control nonradioactive airborne emissions in compliance with the requirements of TFC-ESHQ-ENV-STD-04 and TFC-ENG-STD-07.

p)g) The MGS shall have the capability to collect and treat/immobilize the waste resulting from washing down and flushing the MGS.


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Table 3-23-2. Summary of Average Radionuclide Components in Waste Feed for the Modular Grout System

Component pCi/liter Component pCi/liter

Gross Alpha 495894 Cs-137 31214047 Gross Beta/Gamma 66199458 Ce-144 439725 C-14 0 Eu-152 303314 Na-22 0 Eu-154 91476 K-40 0 Eu-155 219862 Mn-54 0 Ra-226 4606 H-3 (Tritium) 378707 Ra-228 0 Co-60 31214 Th-228 0 Ni-63 0 Th-232 0 Zn-65 0 U-233 0 Se-79 0 U-235 0 Sr-90 11314089 U-236 0 Nb-94 29770 U-238 0 Zr-95 0 Np-237 604 Tc-99 228689 Pu-238 278 Ru-106 751063 Pu-239/240 458 Sb-125 358681 Pu-241 0 I-129 96 Am-241 1091 Cs-134 483858 Cm-244 214


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Table 3-33-3. Summary of Average Chemical Components in Waste Feed for the Modular Grout System


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Constituent/Parameter Units Nominal Variability

Aluminum µg/L 1.75E+03 1.75E+03 to 2.54E+03

Calcium µg/L 2.25E+03 2.25E+03 to 3.31E+03

Chlorine µg/L 2.51E+05 2.51E+05 to 3.09E+05

Chromium µg/L 5.48E+01 5.48E+01 to 1.13E+02

Lead µg/L 7.97E+03 7.97E+03 to 2.00E+04

Magnesium µg/L 1.62E+02 1.58E+02 to 1.62E+02

Mercury µg/L 6.14E+02 4.78E+02 to 6.14E+02

Potassium µg/L 2.90E+03 2.90E+03 to 4.27E+03

Selenium µg/L 5.00E+02 5.00E+02 to 1.29E+03

Sodium µg/L 6.15E+07 6.14E+07 to 6.31E+07

Nitrate µg/L 3.10E+06 2.83E+06 to 3.10E+06

Nitrite µg/L 2.33E+04 2.28E+04 to 2.33E+04

Phosphate µg/L 4.11E+04 3.48E+04 to 4.12E+04

Silica µg/L 1.06E+02 1.06E+02 to 1.46E+02

Ammonia µg/L 9.63E+02 9.63E+02 to 1.13E+03

Ammonium µg/L 5.80E+06 5.80E+06 to 6.81E+06

H2CO3 µg/L 2.06E+03 2.05E+03 to 2.11E+03

Bicarbonate µg/L 1.60E+05 1.60E+05 to 1.64E+05

Carbonate µg/L 2.80E+00 2.79E+00 to 2.86E+00

Carbon Dioxide, Dissolved µg/L 8.50E+05 8.46E+05 to 8.69E+05

Water µg/L 9.55E+08 9.53E+08 to 9.55E+08

Hydroxide µg/L 5.37E-02 5.37E-02 to 5.37E-02

Bisulfate µg/L 3.77E+04 3.77E+04 to 3.93E+04

Sulfate µg/L 1.42E+08 1.42E+08 to 1.48E+08

2-Butoxyethanol µg/L 1.96E+01 1.52E+01 to 1.96E+01

Acetate µg/L 7.18E+04 5.60E+04 to 7.19E+04

Acetone µg/L 1.34E+02 1.04E+02 to 1.89E+02

Acetonitrile µg/L 6.35E+06 4.95E+06 to 6.82E+06

Acrylonitrile µg/L 8.67E+03 6.75E+03 to 1.21E+04

Formate µg/L 4.52E+04 3.53E+04 to 4.53E+04

N-Nitrosodimethylamine µg/L 1.36E+02 1.06E+02 to 1.36E+02

m-Cresol µg/L 5.11E+02 3.98E+02 to 5.11E+02

N-Nitrosomorpholine µg/L 1.48E+04 1.15E+04 to 1.48E+04

TOC µg/L 3.77E+06 2.94E+06 to 4.05E+06

Constituent Units Nominal Variability


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Constituent/Parameter Units Nominal Variability

Flowrate gpm 0.62 0.526 to 0.701

Aluminum µg/L 1.75E+03 1.75E+03 to 2.54E+03

Calcium µg/L 2.25E+03 2.25E+03 to 3.31E+03

Chlorine µg/L 2.51E+05 2.51E+05 to 3.09E+05

Magnesium µg/L 1.62E+02 1.58E+02 to 1.62E+02

Potassium µg/L 2.90E+03 2.90E+03 to 4.27E+03

Sodium µg/L 6.15E+07 6.14E+07 to 6.31E+07

Nitrate µg/L 3.10E+06 2.83E+06 to 3.10E+06

Nitrite µg/L 2.33E+04 2.28E+04 to 2.33E+04

Phosphate µg/L 4.12E+04 3.49E+04 to 4.13E+04

Silica µg/L 1.06E+02 1.06E+02 to 1.46E+02

Ammonia µg/L 9.63E+02 9.63E+02 to 1.13E+03

Ammonium µg/L 5.80E+06 5.80E+06 to 6.81E+06

H2CO3 µg/L 2.06E+03 2.06E+03 to 2.11E+03

Bicarbonate µg/L 1.61E+05 1.60E+05 to 1.64E+05

Carbonate µg/L 2.80E+00 2.79E+00 to 2.86E+00

Carbon Dioxide, Dissolved µg/L 8.50E+05 8.46E+05 to 8.69E+05

Water µg/L 9.55E+08 9.53E+08 to 9.55E+08

Hydroxide µg/L 5.37E-02 5.37E-02 to 5.37E-02

Bisulfate µg/L 3.77E+04 3.77E+04 to 3.93E+04

Sulfate µg/L 1.42E+08 1.42E+08 to 1.48E+08

2-Butoxyethanol µg/L 1.52E+01 1.19E+01 to 1.52E+01

Acetate µg/L 7.18E+04 5.60E+04 to 7.19E+04

Acetone µg/L 1.34E+02 1.05E+02 to 1.90E+02

Acetonitrile µg/L 6.35E+06 4.94E+06 to 6.82E+06

Acrylonitrile µg/L 8.67E+03 6.75E+03 to 1.21E+04

Formate µg/L 4.52E+04 3.53E+04 to 4.53E+04

N-Nitrosodimethylamine µg/L 1.36E+02 1.06E+02 to 1.36E+02

m-Cresol µg/L 1.56E+02 1.22E+02 to 1.56E+02

N-Nitrosomorpholine µg/L 1.48E+04 1.15E+04 to 1.48E+04

Source: Draft RPP-RPT-62590, 6/22/2020 Rev. 0


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Table 3-43-4. Waste Feed Physical Characteristics.

Parameter Unit Nominal Value Range Density(a) g/mL 1.18 1.06 – 1.21 Viscosity(b) cP TBD1.0 TBDN/A Solids Concentrationn(c)(d) ppm TBD TBD Solids Particle Size(d) μm TBD TBD Waste Temperature(e) °C 35 30 – 40 Precipitation Temperature °C 27 -- Surface Tension(f) dynes/cm TBD TBD pH -- 5.5 5.4 – 5.6

3.2.1.2 Close Facilities.

a) The MGS shall include design features which simplify decontamination and facilitate decommissioning at equipment or facility end-of-life, including:

1) Transitioning the MGS to decommissioning and 2) Safely and efficiently decontaminate and decommission the MGS when no longer

needed to support the RPP mission.

b) The design of the MGS and the selection of materials shall include features that facilitate operations, maintenance, decontamination, and decommissioning, including:

1) Incorporate measures into equipment designs to simplify decontamination of areas that may become contaminated with radioactive materials;

2) Arrange equipment to facilitate decontamination; 3) Minimize the potential for spilled radioactive liquid to migrate into cracks or

crevices;

3.2.2 Interface Requirements

This section describes the external interface requirements for the MGS, including Hanford Site utilities and infrastructure.


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3.2.2.1 Hanford Site Utilities and Infrastructure. The MGS shall interface with existing Hanford Site utilities and infrastructure to support construction and operation of the system. Design and construction of infrastructure to support the MGS shall be performed by others.

3.2.2.1.1 Interface with Existing Electrical Power Grid. The MGS shall interface with the existing Hanford Site electrical distribution system:

a) Design analysis shall be performed to determine the MGS power requirements (e.g., Load List) and submitted to the BUYER at the earliest stage in the design to allow for an evaluation to determine sufficient capacity evaluation.

3.2.2.1.2 Interface with Existing Raw Water Supply System. The MGS shall interface with the existing Hanford Site raw water distribution system:

b)a) Design analysis shall be performed to determine the MGS raw water requirements and submitted to the BUYER at the earliest stage in the design to allow for an evaluation to determine sufficient capacity evaluation.

3.2.2.1.3 Interface with Existing Chilled Water Supply System. The MGS shall interface with the existing Hanford Site chilled water distribution system:

c)a) Design analysis shall be performed to determine the MGS chilled water requirements and submitted to the BUYER at the earliest stage in the design to allow for an evaluation to determine sufficient capacity evaluation.

3.2.2.1.4 Interface with Facilities. The MGS shall interface with the building that will house the MGS.

a) VENDOR shall provide submit the building interface requirements, including equipment layout, equipment anchorage requirements, material handling plans, and required maintenance spaces.

3.2.2.1.5 Interface with Control System. The MGS shall interface with the BUYER’s control system.

a) The MGS control system shall interface with the following BUYER specified, VENDOR supplied ABB PLC processor and network switch.

1) Processor Unit: ABB-PM8S6AKO1; Part Number: 3BSEO6649DRI 24MHZ, 16 MB

2) Network Switch: N-TRON Part number: 7DBFX2 E2-Sr-I5

b) The VENDOR shall provide the process control narrative to the BUYER for the purpose of developing the control software program.

c) Control software and programming will be provided by the BUYER, which will be installed and tested as part of the factory acceptance test.


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d) The MGS control system will interface with the BUYER’s remote control room via Buyer provided fiber optic cable.

d)

3.2.2.2 Secondary Solid Waste Disposition Facilities. The MGS shall interface with Hanford Site disposal facilities for disposition of hazardous and radioactive secondary solid wastes generated within the MGS. The VENDOR shall submit a waste forecast including quantities, form, and constituents of concern to BUYER for evaluation and approval.

3.3 DESIGN AND CONSTRUCTION REQUIREMENTS

This section specifies minimum MGS design and construction standards.

3.3.1 Design and Operating Conditions

The MGS design shall be based on operating 8 hrs per day, 5 days per week, and 250 operating days per year.

3.3.2 Physical Requirements

The MGS should be designed to fit and must be serviceable with contact maintenance within the preliminary footprint constraints of 2800 square feet.

3.3.3 Environmental Conditions

This section provides design requirements relevant to natural and induced environmental conditions and specifies the environmental conditions the MGS must withstand during operation.

3.3.3.1 Temperature. The MGS shall be designed for operations within an enclosed facility with temperature controlled between 50 61 and 90 F. The MGS shall be designed for non-operating conditions in an enclosed facility with no temperature control; temperature range in accordance with Hanford Site climatological condition defined in TFC-ENG-STD-02. The design of structures shall include the effects of stresses and movements resulting from variations in temperature.

3.3.3.2 Induced Environments. The specification, design, installation, and maintenance of SSCs associated with the MGS shall ensure compatibility with the induced environment in their installed locations. Examples of induced environments in the MGS include vibration, temperature variations, electromagnetic fields, and elevated noise. Installed equipment shall be designed to avoid resonance resulting from the harmony between the natural frequency of the


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structure and the operating frequency of reciprocating or rotating equipment supported on the structure.

3.3.4 Structural Analysis and Design

The MGS SSCs shall satisfy consensus standard requirements for design. The MGS SSCs shall be sufficiently designed to satisfy stress, serviceability, displacement, and functional requirements. Constructability shall be considered in the design process. Structural stability shall satisfy overturning, sliding, and P-delta analyses, where required. Anchorage design shall be performed in accordance with TFC-ENG-STD-06.

3.3.4.1 Seismic Analysis and Design. Seismic design for the MGS SSCs will follow ASCE 7-10 with response modification coefficients (R factor) modified per TFC-ENG-STD-06, Table 5, based on seismic design category (SDC) -2, limit state C. Seismic design requirements for the MGS nonstructural (i.e., mechanical, electrical, and architectural) components shall follow ASCE 7-10, Chapter 13. Material specific seismic design and detailing requirements are contained in ASCE 7-10, Chapter 14. Seismic design and detailing requirements for the MGS non-building structures (i.e., freestanding [resists overturning] pipe and ventilation skid structures) shall follow ASCE 7-10, Chapter 1513 with importance factor of 1.0 and skid anchorage shall be designed to NDC-2 requirements with importance factor of 1.5.

3.3.5 General Materials Requirements

This section specifies system requirements for use of material, parts, and processes in the design of the MGS and equipment.

e)a) Equipment, components, and assemblies that may come into contact with waste or waste treatment materials shall be compatible with their physical, chemical, and radioactive properties.

f)b) Materials used shall be noncombustible and corrosion resistant in the environment in which they will be used, including chemical, galvanic, or other reactions that can occur between materials.

g)c) Equipment providing a confinement function shall be fabricated of materials compatible with the material to be stored to minimize corrosion.

h)d) Construction material, coatings, and welding techniques will be selected to minimize the accumulation of radioactive materials in piping, vessels, ventilation systems and other equipment.

i)e) Metallic surfaces, which will routinely contact tank waste, shall be fabricated from 300 series stainless steel.

j)f) Components, including elastomeric seals, shall be selected to withstand a lifetime total integrated radiation dose consistent with dose and shielding calculations.


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k)g) Components that must be periodically replaced shall be identified in the maintenance manual, including service interval.

l)h) Certified Material Test Reports (CMTRs) in accordance with the requirements QA-AVS B49 shall be submitted to the BUYER for all pressure boundary, supports, weld filler material, weld attachments, and fasteners. All other materials used in construction shall be provided with a Certificate of Conformance conforming to the requirements of QA-AVS B79, unless the concurrence is received from the Buyer exempting an item where a certificate of conformance is unavailable.

m)i) A nonconformance report (NCR) shall be initiated by the VENDOR and submitted to the BUYER when chemical composition detected varies from those listed in ASME BPVC, Section II. VENDOR shall not use the nonconforming material unless approved by the BUYER.

n)j) Control shall be established and implemented, with objective evidence through VENDOR’s records, to ensure that only correct and accepted items and materials are used. Consumed filler material lot or heat numbers shall be documented on one or more of the following records: weld map, shop travelers. When the material is subdivided, VENDOR shall transfer the heat number to the part and remnants.

o)k) Small parts may be kept in boxes that are labeled with heat numbers.

p)l) The VENDOR shall submit to the BUYER, for review, all high-strength materials to be incorporated and applicable heat treatments before procuring the material.

q)m) Materials shall be furnished new, free from any defects or imperfections that may affect performance as verified through qualification and production inspection tests.

r)n) Material standard editions, dated within the previous 10 years from the date of Subcontract award, are permissible as long as the VENDOR verifies that physical and chemical properties of material meet the requirements of the cited standard editions.

s)o) Material substitutions shall not be made without BUYER approval. Unless otherwise stated by the VENDOR in the RFI (Site Form A-6003-417), a substitution request constitutes a representation that the VENDOR:

1) Has investigated the proposed product or material and determined that it meets or exceeds the form, fit, function, and quality level of the specified product; and

2) Will provide the same warranty for the substitution as for the specified product.

t)p) Attachment point of spiders, braces, or other temporary attachments shall match the material of the item it is contacting.

u)q) Contact materials shall be controlled and documented in accordance with VENDOR’s inspection and test plan as approved by the BUYER.


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v)r) Contact materials including marking materials, temperature indicating crayons, adhesive backed and pressure sensitive tape, and barrier and wrap materials may be used only under the following limits:

1) The total halogen content shall not exceed 200 ppm; 2) The total sulfur content shall not exceed 400 ppm; 3) No intentionally added low-melting point metals such as lead, zinc, copper, tin,

antimony, and mercury; 4) Anti-spatter compounds shall not contain chlorine, fluorine, sulfur, mercury, or

other low-melting point metals; 5) Materials and residue shall be completely removed when no longer required; 6) Cleaning materials may be non-halogenated solvents or potable water containing

no more than 50-ppm chloride, and 7) Marking materials and liquid penetrant materials used on austenitic stainless

steels and nickel-based alloys shall not cause corrosive or other harmful effects. A certification in accordance with QA-AVS B46 for penetrant materials shall be submitted for BUYER approval prior to fabrication.

w)s) Surfaces exposed to the waste fluid shall be free of pits, scratches, gouges, and sharp weld ripples that could entrap solids. Based on the location and quantity, scratches or gouges greater than 0.020 in. deep shall be repaired by one of the following:

1) Mechanically repair to the adjacent surface contour to eliminate areas that could potentially hold and/or trap contamination and

2) Weld repair (if required) using an appropriately qualified procedure and welder, and mechanically finish to the adjacent contour. Associated nondestructive examination shall be in accordance with either the base material specification or the applicable welding code.

3.3.5.1 Castings. Where the need for castings is identified, VENDOR shall submit RFI (Site Form A-6003-417) identifying the application, cast material, and standards/criteria for acceptance of casting.

3.3.5.2 Structural Steel.

a) All structural-steel shapes and carbon-steel materials shall comply with AISC 325-11.

b) Structural welding and welder qualification shall meet the requirements of AWS D1.1/D1.1M. Stainless-steel structural welding shall comply with the requirements of AWS D1.6/D1.6M. Structural sheet/strip steels shall comply with the requirements of with the requirements of AWS D9.1M/D9.1.

c) All NDC-1 and NDC-2 related steel structures shall comply with AISC 360-10, Specification for Structural Steel Buildings.

d) Stainless-steel structures shall comply with AISC Steel Design Guide 27.


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3.3.5.3 Structural Steel Bolts.

a) A minimum of two bolts in each joint shall be used for permanent installation.

b) Washers shall be used for all bolts. Beveled washers shall be used for flange attachments to S-shapes and channels.

c) Bolts required for erection shall be in clearly marked containers and included with the first shipment of fabricated steel for each unit or structure unless alternate shipping methods are authorized in writing by the BUYER. Common bolt assemblies shall not be in the same container as high-strength bolt assemblies.

d) Quantities of both common and high-strength bolts, including nuts and washers, shall include 5% extra per size and length, to cover requirements for fit-up erection.

e) Bolting materials shall be certified unless noted otherwise. See QA-AVS B73 for control of high strength graded fasteners.

3.3.5.4 Hoisting and Rigging Requirements.

a) All hoisting and rigging equipment shall comply with the requirements of DOE/RL-92-36.

b) Design of lifted items, lift points, and items moved onsite shall follow applicable criteria contained in RPP-8360.

c) The design shall consider equipment orientation (i.e., horizontal to vertical).

d) Recommended Not-To-Exceed Lifting Pull: Provide a “Recommended Not-To-Exceed Lifting Pull” (for each lifting point and for the entire item). This is a safety limit, and is not based on the capacity of either the item or the lifting points. The Recommended Not-To-Exceed Lifting Pull is normally 1.25 times the estimated weight.

e) Recommended Not-To-Exceed Lifting Pull may be as high as, but should never exceed, the maximum allowable rated capacity.

f) Recommended Not-To-Exceed Lifting Pull may be as low as the resulted weight.

g) Recommended Not-To-Exceed Lifting Pull is primarily for items that may be stuck in place and, therefore, is not required for installing new items or for items that are not expected to be stuck.

h) Lift points for packages and individual components shall be clearly identified.

i) All critical welds shall be identified in the design media. For purpose of this requirement, critical welds are defined as those welds whose failure could result in loss of load or loss of load control.


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j) Full-penetration welds are preferred for critical welds on lifting devices.

k) Critical welds shall be verified by nondestructive examination (NDE).

l) Any special handling devices needed for assembly or installation shall be identified and supplied with the equipment. The design of below-the-hook (BTH) devices shall conform to the requirements of ASME BTH-1. The VENDOR shall submit calculations required for the design of all BTH devices and associated lifting points. BTH devices shall be load tested in accordance with ASME B30.20. All lifting devices shall be rated for outdoor service.

m) The lifting attachment(s) on the equipment (lifting eyes, lugs, ears, etc.) and the lifted item shall be designed in accordance with RPP-8360 except ASME BTH-1 should be used to verify lifting lug hole diameter compared to the shackle pin diameter (the D to d ratio).

n) BTH devices shall be load tested in accordance with ASME B30.20. The VENDOR shall submit BTH device load test plans procedures for BUYER approval before performing load testing. All custom designed lifting devices for use on the Hanford Site shall be rated for cold-weather temperature of at least 10 °F.

o) BTH lifting devices shall be provided with markings in accordance with ASME B30.20 and tags in accordance with DOE-RL-92-36. In addition to the requirements of ASME B30.20 and DOE-RL-92-36, the marking shall include Hanford drawing number (if applicable), special lifting instructions, and clearly indicate lifting attachments. The marking shall be in the form of a nametag, nameplate, or other permanent marker.

3.3.5.5 Vessels/ Tanks. MGS vessels and tanks shall comply with the following requirements.

a) Vessels and tanks containing dangerous waste shall comply with requirements set forth in WAC 173-303-640.

b) MGS waste tanks and process vessels that operate above 15 psig shall be designed and constructed in compliance with the requirements of ASME BPVC, Section VIII, Division 1.

c) Pressure vessels shall be U-stamped and registered in accordance with the National Board Inspection Code (NBIC) (NBBI NB-23). The VENDOR shall provide a U-1 Form as a deliverable.

d) The VENDOR shall provide submit design calculations and drawings and that specify applicable materials, dimensions, and thicknesses as required to meet code requirements.


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e) The VENDOR shall provide submit a fatigue evaluation for pressure vessels subject to fatigue loading conditions in accordance with ASME BPVC, Section VIII, Division 1, Part UG-22.

f) The VENDOR shall design the vessels to support process liquid filled to the top of the overflow. If no overflow is identified, the vessel shall be assumed completely full. The VENDOR shall use the process liquid density listed in Table Table 3-43-, or a higher fluid density based on the process design.

g) For lug supported vessels, locally increasing the thickness of the shell or head with an insert plate may be required to comply with loading.

h) Where possible, internal structural component welds shall be full penetration. Fillet welded attachments are subject to approval by the BUYER through the submittal of design and fabrication drawings.

3.3.5.5.1 Nozzles.

a) At a minimum, nozzle wall thickness shall be per ASME BPVC, Section VIII, Division 1.

b) Nozzle wall thickness shall account for nozzle loads.

c) Primary nozzle load combinations to be considered in the design shall be: Weight + Seismic + Operating Pressure + Operating Loads.

d) Secondary nozzle load combinations to be considered in the design shall be: Primary Loads + Thermal.

e) The VENDOR shall design nozzles according to the methods of WRC Bulletin 297, Local Stresses In Cylindrical Shells Due To External Loadings On Nozzles-Supplement to WRC Bulletin No. 107 (Revision 1) and WRC Bulletin 537, Precision Equations and Enhanced Diagrams for Local Stresses in Spherical and Cylindrical Shells Due to External Loadings for Implementation of WRC Bulletin 107, or BUYER-approved analysis as requested in an RFI (Site Form A-6003-417).

f) If a nozzle is loaded internally to the vessel, whether due to operating loads or seismically induced fluid loads, design the nozzle for the sum of the internal and external loads.

g) If the wall thickness of the nozzle neck is greater than that of the connecting piping, the requirements of ASME BPVC, Section VIII, Division 1, Figure UW 13.4 shall be satisfied.

h) Nozzles and their reinforcements located on the head shall be located fully within the crown region of the head. Figures 3-33-33-33-33-3 and 3-43-43-43-43-4 illustrate


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acceptable and unacceptable configurations and welding for pressure vessel shells and heads.

i) Nozzles shall be set-in type or through type with full penetration welds as shown in Figure 3-33-33-33-33-3. All nozzles that are flush with the inside surface of the vessel shall be rounded to 1/8 in. minimum radius as shown.1

Figure 3-3. Acceptable Nozzle Connections.

Figure 3-4. Unacceptable Nozzle Connections.

j) Nozzles for pressure relief devices, vents, and drainage shall be flush with the inside surface of the vessel. Nozzles with internal projection in primary containment shall have an additional fillet weld between the internal projection and the inside surface of the shell or head.

1 Where flat heads that require a large thickness for strength are impractical for set-in type or through type with full penetration welds, nozzle joint configurations j and l from ASME BPVC Section VIII, Division 1, Figure UW-16.1 may be used if approved by the Buyer.


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k) Nozzle reinforcement shall be integral, regardless of Quality Level (Figure 3-53-53-53-53-5). Gusset reinforcement is allowed.

Figure 3-5. Integral Nozzle Reinforcement Methods.

3.3.5.5.2 Vessel Internal Components.

a) Design of support members for vessel internals shall be the responsibility of the VENDOR. Internal supports shall use welded connections exclusively; no bolted connections.

b) The VENDOR shall submit a preliminary layout for review prior to detail design for internal equipment and piping, including proposed support methods.

c) Design of internal components such as wash rings, sparge nozzles, stilling wells, thermowells, etc. shall consider stresses caused by differential thermal expansion, seismic loads, and horizontal transportation of the vessel. The nozzles and internals shall be analyzed for effectiveness of design.

d) The design of support members shall avoid the column of space directly below an ion-exchange media fill/removal nozzle, instrumentation nozzles, equipment nozzles, inspection nozzle, etc. (as applicable).

e) The VENDOR is to determine if internal surface of the head or shell is subjected to direct impingement of process fluid and requires a wear plate or other means of protection. If used, wear plates shall be of a material compatible with the shell or head.

3.3.5.5.3 Vessel External Components.

a) Lifting and tailing lugs shall be designed and installed by the VENDOR.

b) The VENDOR is responsible for determining the necessity of stiffening rings per ASME BVPC, Section VIII, Division 1, Part UG-29. The material shall match the material of the shell and attachment welds shall be continuous on both sides of the ring.

c) The materials welded to the shell shall match the material of the shell.


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3.3.5.5.4 Vessel Seismic Design.

a) The seismic design loads and acceptance criteria for the vessels, anchorage, and internal supports shall be correlated to the requirements in Section 3.3.4.

3.3.5.6 Piping.

The following requirements apply to MGS process piping.

a) Piping materials and specifications for waste feed shall comply with HNF-27957, Pipe Class 163LS

b) Piping materials and specifications for services shall comply with HNF-27957, Pipe Class 151.

c) Flange facings shall be 100% visually examined.

d) Hoses shall meet the following requirements:

Flexible Non-Metallic Hose shall be designed, fabricated, and tested in accordance with the test methods specified in ASTM D380, “Standard Test Methods for Rubber Hose,” and RMA-IP-2, “Hose Handbook”.

Flexible Non-Metallic Hose shall be constructed of (ethylene propylene diene monomer) EPDM with reinforcement materials being fully encapsulated.

Internal surfaces of Flexible Non-Metallic Hose and fittings shall be compatible with the process fluid chemical and physical properties.

e) For both austenitic stainless steel piping and carbon steel piping, the corrosion-erosion allowance used for pressure design of piping components and determining longitudinal stresses in piping systems shall be 0.2 mils per year for the expected service life of the system.

3.3.5.7 Valves.

a) Valve operator closure shall be sufficiently slow to prevent damage from hydraulic transients.

b) Valves shall be accessible with both hands, without crouching, while standing erect without bending, or while seated. For routinely operated valves located in inaccessible areas, consider remote or extended handle operators.

3.3.5.8 Coatings.

a) Stainless steel materials are not to be painted unless noted otherwise on drawings.


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3.3.5.9 Corrosion of Parts.

a) Dissimilar metals, such as those defined by MIL-STD-889B, Chg Notice 3, that have active electrolytic corrosion properties shall not be used in direct contact.

b) Bronze, copper, lead, zinc, tin, antimony, cadmium, or other low-melting point metals, their alloys, or materials containing such metals as their basic constituents or molybdenum and halogens, shall not be used in direct contact with stainless steel, with the exception of oil impregnated bronze bearings. This prohibition applies to use of tools, fixtures, and paints. This requirement does not apply to encapsulated lead shielding identified in Section 3.3.113.3.113.3.113.3.113.3.12.

3.3.5.10 Prohibited Materials. The following materials shall be prohibited in equipment and components:

a) Exposed lead, b) Polychlorinated biphenyls, c) O-zone-depleting refrigerants, d) Asbestos, and e) Beryllium.

3.3.5.11 Toxic Products and Formulations. The MGS design shall minimize the use of products that may become regulated waste.

3.3.6 Electromagnetic Radiation

The MGS system design shall comply with electromagnetic radiation emission requirements set forth in RPP-13211.

3.3.7 Nameplates and Product Markings

a) The MGS components shall be labeled in accordance with TFC-ENG-STD-12 and TFC-ENG-FACSUP-C-23.

b) Equipment or containers that manage dangerous waste shall also comply with labeling requirements set forth in WAC 173-303-640(5)(d).

c) Provide a nameplate for pressure vessels per ASME BPVC, Section VIII. Nameplate should include, as a minimum, the following:

1) Equipment Identification Number (EIN), 2) Manufacturer’s name, 3) Year built, 4) Maximum allowable working pressure (MAWP), 5) Minimum design metal temperature (MDMT), 6) Material of construction, 7) Weight of the vessel and internals, and


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8) U-stamp (as applicable).

d) Vessel lifting points, center of gravity, and the lifting weight shall be clearly marked.

3.3.8 Labeling

The basis for labeling requirements is provided in TFC-ENG-STD-12 and TFC-ENG-FACSUP-C-23.

a) The following components shall be labeled:

1) Piping; 2) Major equipment (e.g., pumps and motors); 3) Instruments; and 4) Vessels and tanks; and 4)5) Electrical enclosures.

b) EINs and the associated Equipment Descriptions shall be provided in the VENDOR’s approved design documentation.

c) If BUYER provided documents do not contain the necessary EINs in accordance with TFC-ENG-STD-12, the VENDOR shall request the missing EINs through the RFI (Site Form A-6003-417) process.

d) Label Materials

Labels shall use a Metalphoto® (anodized photosensitized aluminum) base (www.mpofcinci.com) or stainless steel.

i) Metalphoto labels shall use a black background (foreground color will be bare aluminum).

ii) Stainless-steel labels shall use black text on a stainless-steel (plain/natural) background.

Labels shall be 15 gauge thickness, minimum.

e) Labeling Requirements

Labels excerpted from TFC-ENG-STD-12 are shown in Figures 3-63-63-63-63-6, 3-73-73-73-73-7, and 3-83-83-83-83-8. Application of labels that are inconsistent with this standard, unless addressed by approved deviations, are prohibited.

Font - USE ALL CAPITAL SIMPLE BLOCK TYPE FONT. All labels in a given area shall be of the same font.

Spacing between words shall be at least one full character width.

http://www.mpofcinci.com/


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Spacing between lines on the label shall typically be at least one times the character height of the line being printed.

Power and multi-conductor control cables shall have cable numbers marked at the origination and termination and at junction points in between (i.e., pull boxes and manholes).

Cables shall be identified in accordance with the cable schedule. Internal jumper shall be identified with the wire number of the associated external cable

Figure 3-6. NF Label Coding.

DESIGN ID: NF

LABEL SIZE CODE: B2

WIDTH: 4.00”

BORDER: 0.250”

HEIGHT: 2.50”

LINE

BAR CODE REF DEN

MAX CHAR

ROW HGT

JUST C/L/R

START SIDE TOP

FONT

1 23 0.26 C 2.00 0.40 R-HEL-BOLD 2 32 0.17 C 2.00 0.75 R-HEL-BOLD 3 32 0.17 C 2.00 0.95 R-HEL-BOLD 4 29 0.17 C 2.00 1.35 R-HEL-BOLD 5 18 0.13 R -0.05 1.67 R-HEL-BOLD 6 6 7.1 9 0.16 C 2.00 2.30 R-HEL-BOLD 7 9 0.25 C 2.10 2.15 R-HEL-BOLD

The NF label is applied to large Tiger Tag backing plates. The NF is available in one- or two-sided format and can be hung or adhered with approved adhesives or acrylic adhesive backing pads.


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It is designed for use in harsh environments. The large size is suitable for major components such as tanks, vessels, ventilation skids, breakers, pumps, and motors.

Figure 3-7. NH Label Coding.

DESIGN ID: NH LABEL SIZE CODE: C0 WIDTH: 3.00”

BORDER: 0.188”

HEIGHT: 1.50”

LINE

BAR CODE REF DEN

MAX CHAR

ROW HGT

JUST C/L/R

START SIDE TOP FONT

1 23 0.19 C 1.50 0.36 R-HEL-BOLD 2 32 0.13 C 1.50 0.60 R-HEL-BOLD 3 32 0.13 C 1.50 0.73 R-HEL-BOLD 4 29 0.13 C 1.50 0.99 R-HEL-BOLD 5 18 0.10 R -0.20 1.16 R-HEL-BOLD 6 9 0.11 C 1.50 1.49 R-HEL-BOLD 7 6 7.1 9 0.15 C 1.60 1.39 R-HEL-BOLD

The NH label is applied to small Tiger Tag backing plates. The NH is available in one- or two-sided format and can be hung or adhered with approved adhesives or acrylic adhesive backing pads.

It is designed for use in harsh environments. This is the primary label for use in the tank farms. This label should be specified in all cases except for individual control panel instruments and controls, hand switches, etc., or where size prohibits.


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Figure 3-8. NL Label Coding.

DESIGN ID: NL

LABEL SIZE CODE: CA WIDTH: 2.00” BORDER:

0.125” HEIGHT: 1.00”

LINE BAR CODE REF DEN

MAX CHAR

ROW HGT

JUST C/L/R

START SIDE TOP FONT

1 23 0.13 C 1.00 0.20 R-HEL-BOLD 2 25 0.10 C 1.00 0.40 R-HEL-BOLD 3 25 0.10 C 1.00 0.50 R-HEL-BOLD 4 09 0.10 C 1.00 0.83 R-HEL-BOLD 5 4 7.1 09 0.10 C 1.10 0.73 R-HEL-BOLD

The NL label is a polyester label designed for multiple purposes. It is available in one-sided format with an integral adhesive pad. It is also available in one- or two-sided format attached to a stainless-steel backing plate that can be hung with aircraft cable.

• Description fields limited to 25 characters each. • No provision for old EIN. • No provision for FED FROM data.


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The alphanumeric conductor identifications used shall be the wire numbers shown on the wiring diagrams. Wire numbers shall also be marked on terminal block identification strips in black indelible ink.

Permanently label conduits and cable tray with numbers shown on the drawings, at both ends. For 10 ft maximum length, place on label at the center.

f) Label Information: Equipment labels shall contain:

1) EIN (provided by BUYER per TFC-ENG-STD-12), 2) Equipment Description (provided by BUYER), 3) Bar Code (provided by BUYER), 4) Fed From [insert power supply breaker information] (if applicable), and

g) Additional labelling requirements for Electrical Equipment and Motor Control Centers.

h)g) Electrical Equipment:

The following specific label information is required by code – rated voltage; number of phases; supply power source; type (normal, standby, or emergency); and location;

Control threshold switches are labeled for their function;

Switches are labeled with position (on-off, hand-off-auto, etc.); and

Indication and direction of operation, as necessary.Electrical equipment shall be labeled in accordance with NFPA 79, Section 16.3.

i)h) Attaching Labels:

Labels may be attached to the equipment using permanent stainless-steel fasteners, or hung in a permanent fixed location with stainless-steel aircraft cable, as best suited to the application. Stainless cable shall be 0.063 in. in diameter in a 7 by 7 strand matrix and fastened with stainless-steel wire crimps.

j)i) All pressure boundary material with labels attached using stainless-steel fasteners shall have sufficient wall thickness or reinforcement to address stress concentration and reduced wall due to the fastener holes.

k)j) Label Placement:

Labels shall be placed as follows:

To be readily visible and readable, Horizontal (except hanging labels), To eliminate identity confusion, So they will not be easily damaged or cause hazard to the operator, and


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To avoid obscuring indications or interfering with equipment operation.

Labels are placed on flat surfaces to the extent possible:

On pipes, place the label along the horizontal run versus around the pipe; Horizontal (except hanging labels); and On motors, tanks, and other curved surfaces, locate the flattest portion.

Large equipment (generators, vessels, etc.) shall be labeled in multiple locations.

Wire shall not be used to hang tags inside electrical equipment.

3.3.9 Spare Capacity and Interchangeability

a) The design of the MGS should incorporate interchangeable, standardized, common, and commercially available equipment and parts where practical.

b) The design shall standardize life-function components, to the extent practical, to simplify maintenance and spare parts inventories.

3.3.10 Safety

3.3.10.1 Personnel Safety. Personnel shall be protected around the MGS from work place hazards in accordance with the requirements of this section. The MGS design shall protect workers to as low as reasonably achievable (ALARA) levels of radiation and chemical hazard exposure during waste processing operations and maintenance.

3.3.10.1.1 Occupational Radiological Protection.

a) The MGS shall be designed to protect workers from occupational radiation exposures and maintain radiation exposure ALARA.

b) The MGS design shall preferentially select engineering features over administrative controls to minimize employee exposure to radiation and chemical hazards.

c) Personnel exposure levels from external sources of radiation in areas of continuous rad worker occupancy (2,000 hours per year) shall be maintained below an average of 0.5 mrem/h and ALARA.

d) Exposure rates for potential exposure to a radiological worker, where occupancy differs from the above, shall be ALARA and shall not exceed the external limits below.

Type of Exposure Limit (rem) Whole Body Total Effective Dose 0.5 Lens of Eye 4.5


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Extremity 15 Any Organ (other than eye) or Tissue 15

Source: HNF-5183, Tank Farms Radiological Control Manual, Rev. 5O, Table 2.0

e) The radiological design criteria of shielded structures and penetrations for operation and maintenance are as follows:

1) Continuously Occupied Areas: Exposure Rate ≤ 0.5 mrem/hr @ 30cm (gamma) 2) Intermittently Occupied Areas: Exposure Rate ≤ 5 mrem/hr @ contact (gamma)

Intermittently Occupied Areas accessed during operations with occupancy < 2 hours per week: Exposure Rate <10 mrem/hour @ 30cm

Other Intermittently Occupied Areas accessed during operations <20 hours per year: <50 mrem/hour @ 30cm

3) Continuously Occupied Uncontrolled Areas: Exposure Rate < 0.05 mrem/hr @ contact (gamma)

Note: These exposure rate limits apply to the contribution from the VENDOR-designed MGS SSCs. Contact is defined as less than 1-inch.

f) The system shall be designed so that personnel doses are less than 1 rem/yr per person and ALARA for normal operations and maintenance.

g) The design objective shall be, under normal conditions, to avoid internal radiation exposures:

Engineered features (i.e., confinement and ventilation) shall be used to prevent the release of airborne radioactive material to the work area, and when that is not possible, to control releases to levels that are ALARA. The design or modification of a facility and the selection of materials shall include features that facilitate operations, maintenance, decontamination, and decommissioning.

The design shall not take credit for the use of respiratory protection.

h) Straight-line penetrations of shield walls shall be avoided to the extent necessary to prevent radiation streaming.

i) Consider specialized tools and remote handling equipment, such as remote manipulators, where elevated exposures are anticipated.

3.3.10.1.2 Occupational Safety and Health.

a) The MGS shall be designed for safe installation, operation, and maintenance in accordance with 29 CFR 1910, RCW 49.17, and NFPA 101.

b) The system design shall include features that protect personnel safety, incorporate engineering controls, and minimize the reliance on the use of personnel protective


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equipment during routine functions, thus improving system ergonomics. This includes selection of exhaust vent height, if needed, such that personnel are protected from airborne releases.

c) The MGS equipment containing hazardous energy sources shall have locking features.

3.3.11 Plant and Equipment Protection

a) Control and equipment devices shall comply with NEMA ICS 1, NEMA ICS 6, 29 CFR 1910, NFPA 70, or Factory Mutual (FM) Approval Guide, LLC.

3.3.123.3.11 Environmental Safety

a) The MGS design, construction, and operation shall comply with the requirements specified by applicable sections of WAC 173-303-640.

b) The MGS design shall minimize hazardous and nonhazardous waste generation and the use of hazardous materials during construction, operation, and closure.

c) Where lead or similar hazardous materials must be used for shielding or other purposes, the material shall be encapsulated to prevent radioactive contamination and allow retrieval in an uncontaminated condition. The material will be permanently marked as to contents.

d) The VENDOR shall provide technical support to BUYER’s environmental permitting work, as requested. See Statement of Work for guidance.

3.3.133.3.12 Human Performance and Human Factors Engineering

The MGS design shall comply with the requirements of TFC-ENG-STD-01 and TFC-ENG-STD-23. Apply the following specific aspects for human-machine interface (HMI) during design:

a) Displays, indicators, switches, and actuators:

Arranged and grouped to ensure status and conditions are easily discernable.

Arranged to ensure standard conventions of order (e.g., “A” before or above “B”), direction and rotation (e.g., clockwise or counterclockwise).

Placed at angles and heights that permit comfortable viewing.

Properly illuminated and easily visible in all expected normal lighting conditions.

Clearly and unambiguously labeled as to function.

Easily operated when wearing required personal protective equipment.


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b) Lamp test switches and pushbuttons employed, when appropriate.

c) Color-coding of alarm and status indicators consistent with existing standards.

d) Design appropriately considered the use of “latching” of status and alarm conditions to allow post-event analysis.Alarms shall comply with TFC-ENG-STD-40, ISA-5.1, and ISA-18.2, and shall be latched until reset/acknowledged by the operator.

e) Key-locked or protected switches employed where actuation could result in undesirable or unsafe conditions.

f) Labels and markings:

1) Provided for all items that must be viewed, read, or operated; 2) Clearly viewable and permanently marked.; and 3) Located so that they are correctly associated with the apparatus.

g) Similar names for different controls avoided.

h) Process parameters displayed in commonly used engineering units.

i) Audio warning signals of such intensity so as to not cause discomfort (levels should not exceed 115 dB at the ear of the listener).

j) Communication requirements for operating and maintenance personnel have been considered.

k) Valve positions clearly and unambiguously indicated.

l) Items requiring periodic inspection or replacement are viewable and accessible.

m) Adequate space provided for personnel to perform normal operations and maintenance activities.

n) Assembly clearances are adequate.

o) The design and its parts are easily inspected for conformance to engineering specifications to support in-service inspection.

p) Stairs and platforms provided where necessary for routine work actions.

q) Adequate clearances provided to open all doors including equipment cabinets and enclosures.

r) Captive fasteners used where dropping or losing such items could cause damage to equipment or create a difficult or hazardous removal problem.

s) Captive fasteners used where frequent removal is required.


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t) Operating and surveillance tasks can be performed safely and efficiently and not tax the attention, capabilities, and capacities of personnel.

u) Potential musculoskeletal injury ergonomic-related hazards and risk factors including repetition, awkward posture, force, vibration, sustained exertions, and contact stress have been considered.

v) Potential chemical and radiological exposures considered and design maintains exposures ALARA.

w) Routinely manned work locations protected from releases of hazardous or toxic materials.

3.3.143.3.13 Control System

a) The MGS shall be designed with a standalone monitoring with designed-in expansion capability for future remote monitoring and control operations.

1) Local controls at the location of equipment for maintenance and post maintenance testing, and any required emergency stop controls;

2) Standalone monitoring and control of the MGSstation via vendor supplied PLC/HMI located in the facility with the MGS; and

3) Accommodation for remote monitoring and control via industrial wireless communicationas defined in Section 3.2.2.1.5.

b) The control system shall use latch/unlatch control inputs to activate/de-activate equipment, system, and automation status from different locations and shall use local control selectors to enable/disable other control inputs. a)

b)c) The MGS system shall provide for process control system and process network redundancy as required to meet the availability requirements of Section 3.3.15.43.3.15.43.3.15.43.3.15.43.3.16.4.

c)d) The MGS shall include local station(s) suitable for periodic operating personnel occupancy for MGS process monitoring and control to be used on a non-continuous basis (e.g., for system start-up, maintenance evolutions).

d)e) The control system should be such that automated operations do not typically require operator input or intervention. The degree of automation should consider the complexity in controlling the process, personnel safety, keeping personnel radiological and chemical exposures ALARA; and system reliability, availability, and maintainability.

e)f) System control components, assemblies, and systems shall comply with the requirements of NFPA 70, UL508A, NEMA-ICS-19, TFC-ENG-DESIGN-D-71, and TFC-ENG-STD-41.


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f)g) The MGS setpoints shall be developed in accordance with TFC-ENG-STD-14.

g) Software developed for the basic process control system shall include the following minimum software documentation submitted to the BUYER for review and approval:

1) Software Requirements Specification,

2) Software Design Description,

3) Software Management Plan,

4) Software Verification and Validation Report,

Software Requirements Traceability Matrix,

Input/Output Table

5) Alarm Matrix

6) Software Test Plan,

Software Test Report.

The VENDOR shall provide the controls software and a transfer the control software license to the BUYER.

h) All motor controllers shall be insulated gate bipolar transistor (IGBT) output, variable speed drives (VSDs), except where the starting torque requirement exceeds capacity of available VSDs agreeable to manufacturer in terms of control parameters for oversized variable frequency drives (VFDs).

Manufacturer’s warrantee limitations shall be ignored for electronic equipment, when coinciding with freezing temperatures of water and applicable to warehousing and operations – unless at least one documented instance can be produced by the manufacturer, that their equipment can be damaged by a cargo-hold temperature of minus 40.

i) The VENDOR’s recommended spare parts list shall include electronic equipment that may fail from thermal fatigue due to temperature cycling, temperature controlled or not, because of intentional/operational routine de-energize/energize cycles apart from planned/unplanned maintenance.

7) VENDOR shall design and install on each equipment skid, a distributed PLC Input/Output module for wiring all instruments and actuators, with integral industrial Ethernet switch module with a minimum of two free switch ports for interconnecting skids and PLC/HMI. The I/O module, instruments and actuators shall be limited to 24 VDC using interposing relays for any higher voltage actuators. 24 VDC power


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supply/UPS and any interposing relays or other devices requiring 120 VAC shall be enclosed in a separate enclosure.

3.3.153.3.14 Infrastructure Service Provisions

The MGS shall distribute all utilities and services required to perform its intended functions from a single interface connection for each utility or service. Utilities and services may include, but are not limited to, water and electrical service.

3.3.15.13.3.14.1 Utilities.

3.3.15.1.13.3.14.1.1 Service Air and Instrument Air.

a) The MGS shall provide service and instrumented air to meet all system and operations requirements.

b) The service air system shall have a sufficiently low dew point to prevent condensation in the distribution piping.

c) The instrument air system shall be designed to comply with the requirements of ANSI/ISA-7.0.01-1996.

d) Nonflammable oil shall be used in air compressors.

3.3.15.1.23.3.14.1.2 Electrical.

a) The MGS electrical systems shall be designed in compliance with the requirements of NFPA 70 and TFC-ENG-STD-41.

b) An aAnalyseis shall be prepared and submitted that determines available short circuit currents and normal power requirements for normal operation of the MGS processes.

c) Control system equipment, process network components, instrumentation and equipment should be designed for fail-safe operation in the event of an electrical or process outage.

d) The MGS electrical raceways and flexible cords and cable shall be designed in compliance with the requirements of TFC-ENG-STD-15.

e) Adverse effects of voltage level variations, transients, and frequency variations (i.e., power quality) on equipment operation shall be minimized and sensitive electrical/electronic equipment, such as monitoring and control data-processing equipment, shall be isolated or filtered as needed for power quality protection.Equipment sensitive to electrical power quality shall be prohibited. Control system power supplies shall protect instruments, controls, and electronics from power quality issues including erratic operation, and as needed shall include batteries in the form of 24 VDC uninterruptable power supplies.


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f) Electrical control panels and electrical equipment shall be listed or labeled as recognized by Occupational Safety and Health Administration as a (Nationally Recognized Testing Laboratory) NRTL (see QA-AVS B66 and B65).

g) Electrical equipment for which there is no listing category must be evaluated or tested using a method submitted to and approved by the BUYER prior to delivery of the equipment. A field evaluation performed by an NRTL prior to delivery is the preferred method for BUYER approval.

h) Maximum supply voltage to the MGS is 480VAC ac (3 phase).

f) Identify power load requirements and available short circuit currents using a one-line diagram and/or panelboard schedules.

Identify termination provisions using a one-line diagram. Include interface point(s) for Hanford-provided 120V ac and 480V ac power cables outside of the MGS system.

i) Harmonic suppression or mitigation shall be employed for non-linear loads (variable frequency drives (VFDs), heater controllers, etc.).

j)g) Wiring and/or terminals shall be uniquely labeled to facilitate ease of installation for Hanford Site interface.

k) Equipment, cable, raceway, and wiring shall be capable of performing the intended function when exposed to environmental conditions (radiation, temperature, etc.) in which it is installed.

l) Wire insulation shall be compatible to the voltage and the environment in which it is to be installed.

m)h) Conductor colors:

480/277V ac (3-phase Wye):

Red – Phase A Yellow – Phase B Blue – Phase C White/Gray – Grounded (Neutral) Green – Ground.

208Y/120V ac (3-phase Wye):

Black – Phase A Purple – Phase B Brown – Phase C White/Gray – Grounded (Neutral).


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120/240V ac (Single Phase):

Black – L1 Brown – L2 White – Neutral Green – Ground.

n)i) Each cable shall be permanently identified by cable number. In cases where a cable is composed of noncolor coded conductors or of a number of single cables, apply a permanent wire identification tag showing the assigned wire number and a color tag matching the conductor color described herein.

o)j) For multi-conductor cables, label wiring at both ends of each wire individually.

p)k) Conduit shall be rigid metal conduit (RMC) or intermediate metal conduit (IMC). Steel conduits shall not be used where non-magnet and/or corrosive requirements exist. Non-metallic conduit is prohibited in above grade applications.

Electrical metallic tubing (EMT) is not allowed.

Liquid-tight flexible metal conduit may be used where needed for vibrating equipment isolation.

Steel conduits shall not be used where non-magnet and/or corrosive requirements exist.

l) The BUYER will install and terminate power, control, and instrumentation cables connected between BUYER’s equipment and the VENDOR provided interface control, instrumentation, and power junction boxes.For each electrical circuit extending or originating outside of the VENDOR supplied equipment skid, including circuits interconnecting skids, a raceway shall be brought to the edge of the skid and terminated in a wire pulling condulet turned down to the location matching or informing the BUYER’s equipment pad conduit plan.

q)m) VENDOR shall design and install on each equipment skid, a distributed ProFiBus-DP Input/Output module (ABB compatible) for wiring all instruments and actuators and for interconnecting all skids. The I/O module, instruments, and actuators shall be limited to 24 VDC in as much as possible using interposing relays for any required higher voltage actuators. 24 VDC power supply/UPS and any interposing relays or other devices requiring 120 VAC shall be enclosed in a separate enclosure adjacent to the 24 VDC distributed I/O drop.

r) Provide multiple 120V AC convenience outlets per NFPA 70 for use with test equipment, inside and outside of enclosures.

s)n) Where applicable, pPower cables conductors between VFDs and motors shall comply with the recommendations of the VFD manufacturer.


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t)o) The VENDOR shall submit one copy of electrical drawings and documents required for the electrical installation with the final design for review and approval prior to release of the unit for fabrication.

3.3.15.23.3.14.2 Grounding and Bonding.

a) General equipment shall be grounded per NFPA 70, IEEE Std 142, and IEEE C2.

b) Grounding for computer/control and data processing equipment shall comply with the requirements of NFPA 70 and IEEE Std 1100Auxiliary grounding of electronic equipment shall comply with recommendations of the manufacturer.

c) Where applicable, special grounding between VFDs and motors shall comply with the recommendations of the VFD manufacturer.

d) Skid-mounted packaged systems shall include threaded stud connectors at each end of the skid, diagonally opposite each other, sized appropriately to accept and connect copper ground taps.

3.3.15.33.3.14.3 Electric Motors.

a) Electric motors shall comply with the applicable requirements of NEMA MG-1 and IEEE Std 841.

b) Alternating current motor protection shall comply with NFPA 70 and IEEE Std 242.

c)b) Electrical motors shall be manufactured using class F insulation (minimum), unless approved by the BUYER via RFI (Site Form A 6003 417).

d)c) Electrical motors being operated by a VFD shall be inverter duty rated, meet NEMA MG-1, Part 31, and NFPA 70 (specifically, Section 430.126)the VFD manufacturer’s installation and wiring instructions for the specific class of insulation of the motor.

3.3.15.43.3.14.4 Equipment Drip Pans.

a) Stationary equipment subject to oil leakage shall have containment features to collect oil leakage.

3.3.163.3.15 System Quality Factors

The requirements for reliability, maintainability, and availability quality factors for the MGS are discussed in the following sections.


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3.3.16.13.3.15.1 System Design Life. The MGS shall have a 20-year design life.

3.3.16.23.3.15.2 Reliability. To meet reliability requirements, the following concepts shall be used:

a) To support the MGS 20-year performance lifetime, selection of system components should be based, in part, on component reliability in order to minimize the frequency of component replacements. A graded approach shall be used when specifying equipment useful life taking into consideration human factors (See Section 3.3.123.3.123.3.123.3.123.3.13); however, permanently installed components shall be designed for a useful life of 20 years.

b) Equipment shall be appropriately selected, and when required tested to ensure reliable operation during normal operating conditions and anticipated operational occurrences.

3.3.16.33.3.15.3 Maintainability. This section addresses the MGS maintainability requirements.

a) The MGS shall be designed to facilitate post-maintenance testing to determine whether corrective maintenance, preventive maintenance, or troubleshooting activities have affected the ability of the system to perform its intended function. These requirements are implemented through TFC-ENG-STD-08.

b) Equipment, instrumentation, and items requiring maintenance shall be accessible for ease of inspection, maintenance and removal/replacement in accordance with TFC-ENG-STD-01.

c) Smart instrumentation providing capability to support predictive maintenance practices should be selected where technologically available. Highway Addressable Remote Transducer (HART®) Communications Protocol is acceptable.

d) Instrumentation and control systems shall provide for periodic in-place testing and calibration of instrument channels and interlocks in accordance with TFC-ENG-STD-01.

e) The minimum number of spares needed for like components shall be determined during design and shall be based on the mean time between failures, VENDOR recommendations, procurement lead times, operational strategy, safety classification, operational experience, and the number of like components installed.

f) The VENDOR shall provide submit detailed operations and maintenance manuals and a recommended spare parts list including supply schedule for the MGS design life.

g) The MGS should be designed such that maintenance can be performed with commercially available tools.


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h) Special tools or equipment required for maintenance or inspections shall be provided by the VENDOR and identified in the operations and maintenance manual.

i) Waste containing piping and components should be self-draining with installed water flush capability.

j) The design should use a modular, quick connect/disconnect component maintenance approach where feasible using standard tools to minimize maintenance time.

k) Waste containing piping, vessels, and components that are routinely disconnected for maintenance or replacement should use quick disconnect, dripless fittings, or connector types requiring minimal tool use for ease of assembly and disassembly.

3.3.16.43.3.15.4 Availability. This section addresses MGS availability.

a) The MGS integrated system availability design goal is at least 70%, evaluated on an annual basis.

b) The MGS availability shall be evaluated using standard reliability engineering techniques (failure modes and effects analysis, fault tree analysis, operations research modeling, etc.).

3.3.173.3.16 Transportability

This section specifies requirements for the MGS transportability to allow system deployment and logistical support.

a) Lift points and attachments shall not be used for transportation tie-downs.

b) Equipment shall be packaged, supported, and secured to the transport vehicle in a manner so it can withstand a 0.8 g (forward) hard-braking stop, and rearward or lateral acceleration of 0.5 g, as well as, shock and vibration loads associated with transportation. Vendor shall submit calculations demonstrating compliance with these requirements. Note that this is the minimum requirement; if a VENDOR has more stringent requirements, the VENDOR’s requirements shall be applied. Where equipment is braced internally, it shall be marked to identify removal.

c) The MGS shall be designed for ease of equipment transport, installation in the field, and dismantling.

d) Exterior package type shall provide the level of protection required based on the storage and environmental limits. Containers, crates, and skids shall be used as the methodology for packaging.

e) All equipment shall be shipped in accordance with the applicable U.S. Department of Transportation standards and in an orientation ready for lifting. Additional handling of


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the equipment to orient it for lifting is not acceptable. Load handling instructions shall also be provided with the shipment and made available for the off-loading of the item.

f) All components, unless specified otherwise in this section or related sections, shall be compatible with being transported by public roadway to contract specified destination.

g) Items shall either be self-supporting or provided with packing and dunnage so as to ensure their stability and protection from damage.

3.3.183.3.17 Ventilation

The ventilation system shall be designed in compliance with the applicable sections of TFC-ENG-STD-07 Attachment A-1 for the Radiological or other Hazard Confinement general service process.

3.3.18.13.3.17.1 Ventilation Functional Requirements.

a) The ventilation shall be designed based on the cascading principles from the least to the highest contaminated and hazardous confinement spacesWhen the exhaust vent is on, it shall maintain a vacuum relative to atmosphere to ensure a positive flow of air into the MGS.

a)b) The ventilation exhaust shall be filtered and designed to meet best management practice to comply with the requirements for as low as reasonably achievable control technology (ALARACT) controls for radioactive and nonradioactive emissions.

3.3.18.23.3.17.2 Ventilation Design Criteria. This section discusses the requirements for process ventilation for the MGS.

a) The MGS ventilation design shall prevent the spread of contamination through filters and maintain differential pressures.

b) The MGS ventilation system design shall facilitate ease of maintenance.

c) The MGS ventilation system shall have adequate sampling capabilities to meet standard hand held Industrial Hygiene sampling equipment, method, and detection/measurement technologies for vapor emissions from stacks as specified for the process.installed test ports and measuring devices to facilitate monitoring, maintenance, and periodic inspection and testing. The sampling port(s) and probe(s) shall be compatible with standard hand held Industrial Hygiene sampling equipment and methods.

d) The exhaust vent shall prevent or minimize water intrusion and condensation buildup and have liquid removal capabilitybe self-supported and should not use guy wires.

e) The exhaust vent design shall include features for moisture control, to prevent and/or manage water intrusion, such as drains to remove moisture due to condensation and precipitation, removable vent cap, etc.


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f) Filter housings shall have differential-pressure instrumentation, to monitor loading on all filters.

g) Air stream conditioning (e.g., heating and cooling) and the associated temperature and/or humidity monitoring instrumentation shall be provided, as necessary, to ensure and verify air stream temperatures and humidity levels are maintained within required levels for high-efficiency particulate air (HEPA) filters, instrumentation, personnel, and process requirements.

h)e) The system shall have exhaust flow-rate monitoring equipment and have a means to automatically adjust flow to maintain desired differential pressures in the cascade ventilation systemThe exhaust stack structure design shall meet the requirements of TFC-ENG-STD-06.

3.4 DOCUMENTATION

a) Engineering calculations and drawings shall be developed in accordance with TFC-ENG-STD-51 and TFC-ENG-STD-10.

b) Technical documents shall follow editorial standards in accordance with TFC-BSM-AD-STD-02.

c) As-built drawings shall be required at the completion of fabrication, representing the true configuration of the final MGS.

d) As-built drawing changes may be managed through the VENDOR’S approved redline fabrication change control procedure.

e) BUYER’s review of VENDOR’s drawings, or release of the equipment for shipment by BUYER’s representative, shall in no way relieve VENDOR of the responsibility for complying with all the requirements of this specification and the purchase order.

3.4.1 Conceptual Design

a) A conceptual design shall be provided for in-process design review, performing a process hazards analysis, scoping of hazards analysis and control strategies, and continued environmental permitting work.

b) The VENDOR shall submit a 30% conceptual design review package including the following, as a minimum:

1) Block flow diagram, 2) Process Operations Description, 3) Process flow diagram, 4) Mass and energy balance calculation, 5) Piping and instrument diagrams (P&IDs),


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6) Ventilation and instrument diagrams (V&IDs), 7) Equipment arrangement drawing(s), 8) Process vessel and tank drawings, 9) Structural interfaces and supporting calculations, 10) Electrical load list and one lines diagrams (see Section 3.2.2.1.1), 11) Hydraulic calculations, 12) Ventilation sizing calculations, 13) Radiation shielding calculation for continuously and intermittently occupied

areas. 14) Preliminary interface description and requirements, and 14)15) Preliminary radioactive and criteria/toxic air pollutants emissions

estimates.

c) The VENDOR shall be responsible for managing 30% review comments, dispositioning comments, and tracking comments to closure.

3.4.2 Preliminary Design

a) Calculations for process equipment (e.g., piping, vessels, tanks), skids, and structural supports. Preliminary calculations shall be complete enough to confirm general sizing and operating parameters of vessels and process equipment to ensure that there will be no unforeseen issues moving forward into final design.

b) Preliminary drawings for the process equipment, skids, and structural supports need to provide enough detail to show a layout and interface dimensions.

c) Preliminary datasheets that include VENDOR information and design and operating parameters. Information shall include, but is not limited to: instrumentation, pumps, vessels, and process equipment.

d) The VENDOR shall submit preliminary 60% design review package for in-process design review including the following drawings, diagrams, reports, and calculations in preliminary form with 30% design review comments incorporated:

1) Block flow diagram;

2) Process flow diagram;*

3) Mass and energy balance calculation;*

4) P&IDs;*

5) V&IDs;

6) Instrument schedule and loop diagrams;

6)7) A separate elementary diagram for each control panel;


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7)8) Electrical one-line diagrams and schematics;;

8)9) Electrical load list and calculations identifying power requirements (see Section 3.2.2.1.1);

9)10) Control Narrative;*

10)11) Instrument data sheets;*

11)12) Arrangement drawings;*

12)13) Structural interfaces and supporting calculations to include size, weight, footprint, center of gravity, anchor hole size/layout/spacing, and anchor loads for the equipment being supplied;

13)14) Transportation, load handling, hoisting and rigging;

14)15) General arrangement drawings showing process equipment;, secondary containment, drains, leak detection, ventilation, etc.;*

15)16) Process equipment, connections, piping details, and mechanical layouts, including any equipment specifications and sizing calculations;*

16)17) Leak detection details;*

17)18) Ventilation supporting calculations;

18)19) Ventilation drawings;

19)20) Hydraulic calculations;

20)21) Pressure relief device calculations;

21)22) Utility interface requirements;

22)23) Process vessel and tank drawings, and sizing calculations;*

23)24) Materials of construction evaluations, including material compatibility and National Association of Corrosion Engineers (NACE) corrosion/erosion evaluations;*

24)25) Support skids sizing calculations, drawings, datasheets, etc.;

26) Calculations for below the hook lifting devices and lift points (see Section 3.3.5.4); and

27) Grout container procurement specification.; and


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28) Construction/fabrication/procurement specifications.*

25)

Asterisk (*) denotes minimum design media needed for the initial preliminary Resource Conservation and Recovery Act of 1976 (RCRA) permit application.

e) The VENDOR shall submit the preliminary RCRA design media following incorporation of 60% design review comments.

f) The RCRA design media shall be stamped by a State of Washington licensed Registered Professional Engineer with the caveat “For Permitting Only”.

g) The VENDOR shall be responsible for managing 60% design review comments, dispositioning comments, and tracking comments to closure.

3.4.3 Final Design

The VENDOR shall submit the final design documents listed in Section 3.4.2, and as described in the following sections with previously generated design review comments incorporated. Comments generated during an in-process 90% design review will be provided to the VENDOR. The VENDOR shall manage comments, disposition comments, incorporate comments as agreed upon in comment dispositions, and track comments to closure in the final design submittal.

3.4.3.1 Final RCRA Permit Design Media.

a) Design media identified in Section 3.4.2 shall be updated as required, incorporating any outstanding BUYER comments, and submitted in support of the final RCRA permit application.

b) Design media supporting the RCRA permit shall be stamped by a State of Washington licensed Registered Professional Engineer.

3.4.3.2 Interface Documents. Submit drawings showing interfaces that provide the following information for each processing module and SSC:

a) Identify the coordinates at centerline of each connection;

b) Identify the orientation of each connection that is not normally oriented in plan or elevation view;

c) Identify connection type, size, and schedule for piping and tubing;

d) Identify connection type and size of electrical power conductors and type of monitoring and control network cable and connectors;, instrument, controls, and software cabling.

e) Identify interface parameters such as flow rate, pressure, volatage, amperage, etc.


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3.4.3.3 Document Index. A composite list of the VENDOR documents including, but not limited to: drawings, calculations, reports, studies, manuals, etc., and submitted to the BUYER. Documents listed in the Document Index shall reflect, at a minimum:

a) Document titles,

b) Unique document numbers, and

c) Document revisions.

3.4.3.4 Drawing Legend. Submit a drawing legend defining standard symbology and nomenclature used in P&IDs and V&IDs. Define, use, and adhere consistently throughout the P&IDs and V&IDs with the following:

a) Uniform symbols for each component and

b) Piping and Instrument symbols (Hanford Site-specific templates, cells, flow diagrams, and P&ID legend sheets) will be provided after award of contract and on request.

c) Ventilation and Instrument symbols (Hanford Site-specific templates, cells, flow diagrams, and legend sheets) will be provided after award of contract and on request.

3.4.3.5 Block Flow Diagrams. Submit a block flow diagram representing the flow between associated processing areas (e.g., tanks, columns, treatment filters, unit operations). The block flow diagram should be a high level representation of the process and general operations. Identify equipment and process streams. Include operational information such as process transfer path, equipment boundaries, and process flow rates.

3.4.3.6 Process Flow Diagram. A process flow diagram shall be submitted that schematically represents the following:

a) Display essential equipment and components (e.g., no logic or wiring, only instruments that cause a change in pressure, temperature, flow, and mass/mechanical energy);

b) Numbered or lettered segments between key components, enclosing number or letter in a diamond; and

c) Tabulate pressure, temperature, flow, and volumes corresponding to the numbered or lettered diamond.

3.4.3.7 Piping and Instrument Diagrams and Ventilation and Instrument Diagrams. Submit P&IDs and V&IDs which shall depict processes delineated by the system.

a) Where multiple system interface:

1) Designate system breaks and 2) Locate piping and components of secondary system on connecting P&IDs.


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b) Schematically represent the following on the P&IDs:

1) Mechanical equipment;

2) Valves and dampers (including vent and drain valves);

3) Test connections;

4) Instruments and controls systems in sufficient detail to identify equipment and delineate function and interface with the process (Instrument symbols and EINs shall be in accordance with ANSI/ISA-5.1-2009);

5) Manual switches and push buttons;

6) Piping (define line weights used);

7) Ductwork with delineation of duct levels; and

8) Instrument piping and tubing as a necessary aid in understanding system operation.

c) Display the following types of information on the P&IDs:

1) Piping identification and size;

2) Instrument designations and basic control schemes;

3) Interlocks with explanatory notes (use for complex or critical interlocks only), control narratives and electrical schematics are the main source for this information;

4) Control system interface(s);

5) Boundaries where pipe materials, schedule, diameter, and system changes;

6) Module boundaries;

7) Direction of flow;

8) Piping material;

9) Measuring and restriction orifices;

10) Equipment name;

11) Tanks and wall nozzles with identification;

12) Thermal insulation;


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13) Heat tracing and tracing type with end lights;

14) Special physical arrangement requirements (e.g., minimum slope, relative elevations, no pockets, critical dimensions);

15) Interconnection references to other drawings including grid coordinates;

16) Valve type and actuator type (if applicable);

17) Valve size (if size is different from line);

18) Valve failure state (e.g., fails open, closed);

19) Actuated valves shown in the normal state;

20) Status indicating lights;

21) Annunciator inputs/outputs;

22) VENDOR interface boundary of module-mounted equipment;

23) Piping connection type (i.e., removable spool pieces and flanges at equipment);

24) Use notes to impose requirements, which cannot be shown diagrammatically;

25) Use notes on a limited basis to avoid clutter and excessive revision to P&IDs;

26) Common notes for many P&IDs can be shown on a general notes drawing;

27) Primary and secondary confinement ventilation system boundaries; and

28) Secondary containment boundaries

d) General P&ID flow:

1) Left to right; 2) Top to bottom; and 3) Utility or supporting process lines (enter and exit wherever appropriate to

improve the presentation of the P&IDs).

3.4.3.8 Equipment Location Drawings. Submit the module arrangement within the space available displaying the following minimum information (as applicable):

a) Outlines of equipment drawn to their actual shape with clearance requirements,

b) Equipment pull spaces,

c) Dimensionally locate equipment,


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d) Actual elevation referenced to plant grade, and

e) Interface points with Hanford Site utilities.

3.4.3.9 Assembly Drawings. Submit for each module to include, at a minimum, the following:

a) Equipment, components and instrumentation,

b) Process connections,

c) Bill of materials or parts list,

d) Assembly weight (dry [empty] and wet [maximum]).

e) Center of gravity (dry and wet), and

f) Locations and dimensions.

3.4.3.10 Layout Detail Drawings. Submit drawings for each module displaying the following minimum information, as applicable:

a) Materials;

b) Nominal pipe size(s);

c) Equipment and components;

d) EIN numbers (provided by BUYER per TFC-ENG-STD-12);

e) Ventilation details;

f) Local instrumentation;

g) Conduits and electrical and instrument termination boxes;

h) Pull spaces to support maintenance;

i) Dimensional locations for equipment and components;

j) Electrical panel layout and wiring diagram; and

k)j) Cable and conduit routing and schedule.

3.4.3.11 Vessel and Tank Drawings. Submit drawings for each vessel to include:

a) Details to facilitate fabrication, manufacture, and assembly;


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b) Indicate that the vessel shall be fabricated and tested to the ASME BPVC, Section VIII, Division 1, as applicable;

c) Indicate maximum allowable working pressure and design temperature;

d) Identification of welds and details of welding, including weld type, location, extent, finish, and NDE;

e) Detailed dimensions of vessel envelope and structural supports;

f) Detailed dimensions of parts (e.g., cooling coil, nozzles, piping, and associated supports);

g) Thickness of shell and head material;

h) Material descriptions of assembly components by their ASME and ASTM designation and alloy designation;

i) Tolerances and reference datum planes;

j) Provide units of linear measurement in fractional or decimal inches;

k) Capacity in gallons and tank weight (empty and full);

l) Center of gravity (empty and full);

m) Centerlines and details of the lifting lugs and nozzles;

n) Dimensions and weights of modular frames;

o) Location of nameplates;

p) Parts list; and

q) Insulation installation.

3.4.3.12 Structural Drawings. Submit drawings for each module, including the following, as a minimum:

a) Materials of construction;

b) Plans, sections, elevations, and details;

c) Installation, erection, assembly, and rigging and inspection requirements or restrictions;

d) Bolting and welding requirements;

e) Design loads;


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f) Dimensional locations for equipment and components; and

g) Reference supporting structural calculations.

3.4.3.13 Instrument Location Drawings. Submit location drawings plans and arrrangements for the following items:

a) Instruments,

b) Major instrument racks, and

c) Field panels.

3.4.3.14 Control Logic Narratives.

The control system logic shall be described both visually and in text. It should have only a limited amount of unstructured logic. Where unstructured logic is used, Control Logic Diagrams should be used to show the logic. For structured logic, in addition to the text, other visual methods shall be used. For example, state machines shall use state diagrams, sequences shall use Cause and Effect, Sequential Function Charts, or other graphic representations, etc.

3.4.3.15 Electrical One-Line Drawings. Submit one-line electrical drawings that provide the following minimum information:

a) Electrical schematics,Power source and reference drawings and calculations;

b) Junction boxesDistribution equipment EINs and ratings (i.e., continuous current and interrupt capacity),;

c) Wiring and connection diagrams,Nominal voltage and number of phases;

d) Breaker and fuse size and type,Electrical loads in horsepower or KVA, with EINs;

e) Starter size,Short circuit current at each item of equipment;

f) Cable information and routing,Conductor size, conduit type, and length, and transformer impedances, that were assumed in the short circuit calculations and to be specified on electrical design specifications, plans, and details;

g) OverloadsConductor overload protection sizes and type, and their short circuit interrupt rating;,

h) Electrical equipment size,Conductor/Equipment short circuit protection ratings;

i) Equipment locations,Reference to calculations for short circuit currents; and


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j) Voltage level, andReferenced to calculations or panelboard schedules showing connected loads, NEC required/permitted demand factors, and resulting NEC compliant demand loads.

k) Reference drawings.

3.4.3.16 Schematic Diagrams. Submit schematic electrical drawings that provides the following minimum information:

a) Voltage levels,

b) Controlled transfer information,

c) Breaker and fuse size and type,

d) Cable information,

e) Line reference,

f) Line description,

g) Terminal points, and

h) Reference drawings.

3.4.3.173.4.3.16 Analog Control Logic Documents. Submit analog control logic documents according to the following:

a) “Simple” analog loop logic shall be configured from P&ID depiction.

b) For “complex” analog control logic, submit separate documents labeled with the process unit operation name (i.e., “Analog Control Logic Descriptions”). Each document shall include the analog control logic information required to configure in the Programmable Logic Controller for each of the “complex” analog loops in that process system.

3.4.3.183.4.3.17 Input/Output Summary. Submit input/output summary diagram as follows:

a) Show instrument tag,

b) Input/output type,

c) System designation, and

d) Programmable Logic Controller addressing and input/output point channel and slot numbers.


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3.4.3.193.4.3.18 Instrument Data Sheets. Submit instrument data sheets for each instrument showing the EIN, service description, P&ID number, process data, and salient features of the instrument, including the following:

a) Scope;

b) Specification, codes, and standards (including exceptions);

c) Design requirements; and

3.4.3.203.4.3.19 Calculation Requirements. The VENDOR shall submit the documentation for engineering analysis/design, data analysis/reduction, and engineering/environmental modeling using commercial-off-the-shelf software in accordance with QA-AVS B15.

The VENDOR shall submit the documentation for spreadsheets used to perform mathematical calculations in the performance of work using commercial-off-the-shelf software in accordance with QA-AVS B18.

3.4.3.20.13.4.3.19.1 Structural Calculations.

a) Include, as a minimum, the following information:

1) Analysis and design of each structure; 2) Design of equipment pads and supports; 3) Anchorage design; 4) Provide an electronic copy of the computer model input and output files; and 5) Submit lifting, rigging, and lifting lug calculations (see Section 3.3.5.4).

3.4.3.20.23.4.3.19.2 Heating, Ventilation, and Air Conditioning Calculations.

a) Analysis of heat loads from each process system or area.

b) Analysis of process off-gas during normal operations shall include, at a minimum:

1) Temperature (°F), 2) Flow (standard cubic feet per minute [scfm]), 3) Composition (volume %), 4) Relative humidity (%), 5) Velocity (feet per minute [fpm]), 6) Differential pressure (inches of water column [in. w.c]), 7) Maximum and nominal operating pressures, and

c) Ventilation equipment sizing (ductwork, blowers, re-heater, stack/vent pipe, etc.).


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3.4.3.20.33.4.3.19.3 Piping Calculations.

a) For each system (waste, air, water, etc.), prepare a calculation demonstrating that system will meet the hydraulic requirements. Include basis for line sizing and selection of material.

b) Prepare pressure and stress analysis of waste piping systems and related supports in accordance with ASME B31.3.

c) Prepare pressure and stress analysis of service piping systems and related supports in accordance with ASME B31.1.

3.4.3.20.43.4.3.19.4 Pressure Vessel and Tank Calculations. Submit calculations justifying the vessel design. Calculations shall include, but not be limited to:

a) Code calculations. Design calculations shall include relevant ASME BPVC, Section VIII, Division 1, formulas and source paragraphs, values used in the formulas, the calculated results, and comparison with acceptable values. Where calculations are based on other than the ASME BPVC, Section VIII, Division 1 formulas, the source of the formulas shall be referenced. Where computer program software is used for calculations, each calculation shall include a brief program description of the software, including the name and version of the program software. If the program software is not commercially available to industry, VENDOR shall maintain and provide, upon request, program software documentation.

b) Seismic calculations including base horizontal seismic force and moment inclusive of fluid induced impulsive and convective forces, and loads for anchorage and anchor bolt design

c) Vessel operational stresses limited to less than 50% of the material yield stress.

d) Support calculations including empty weight, operating weight, and location of center of gravity.

e) Calculations associated with lifting and tailing lugs.

f) Nozzle load analysis for local and gross effect, per WRC Bulletin 297 and WRC Bulletin 537.

g) Design of attachments (internal, external, lifting, and hold downs).

h) Thermal and discontinuity stresses, as applicable.

i) Fatigue analysis as applicable for vessels in fatigue services.


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3.4.3.20.53.4.3.19.5 Pressure Relief Device Calculations.

a) Submit design and sizing calculations for each pressure protection device.

b) Include, at a minimum, the following information:

1) Sizing analysis;

2) Stability analysis;

3) Each calculation shall identify credible failure flows (e.g., flow rate as a result of an independent single failure or multiple common mode failures);

4) Manufacturer data for each selected relief device; and

5) Isometric drawings showing configuration.

c) Pressure relief device calculations shall document the set/cracking pressure plus percent overpressure required to relieve the failure flow for over pressurization event(s), and identify manual or automatic reset recovery.

d) Overflow lines shall have calculations documenting each line relieves the failure flow for over pressurization event(s).

3.4.3.20.63.4.3.19.6 Mass and Energy Balance Calculations. Submit mass and energy balance calculations accounting for the materials and energy, demonstrating the conservation of mass and energy. These calculations shall be performed for the bounding ranges of anticipated flow rates and weight percent solids in the feed.

3.4.3.20.73.4.3.19.7 Radiation Shielding Calculations.

a) Submit bounding shielding calculations and thickness estimates for the MGS including:

1) Dose rate and shielding for areas normally accessed by personnel during operation.

b) Include the assumptions and inputs used for source term(s), durations, dimensions, and shielding materials used (including shielding material density and/or ASTM designation).

c) Include shielding thicknesses for lead, steel, and concrete. Document the selection methodology of the bounding condition, including which mode of facility operation is considered bounding (i.e., normal operations, maintenance, shutdown, or anticipated upset conditions).

d) Include an estimate of effective dose equivalent.


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3.4.3.20.83.4.3.19.8 Instrument List. The instrument list should be structured with a header line for the composite instrument tag with sub-entries for each of the instrument equipment components that serve the loop functionality. Submit a composite list of instruments identifying the following:

a) EIN (provided by BUYER per TFC-ENG-STD-12);

b) Service description;

c) Drawing and document references, such as P&ID, V&ID, installation drawing, layout drawing, datasheet reference, calculation reference (setpoints), specification reference, where applicable;

d) Comments field;

e) Functional class;

f) Instrument location (for in-line instruments, the process line reference should be given together with expected radiation level);

g) Instrument type description;

h) Manufacturer;

i) Model number;

j) Instrument accuracy;

k) Calibration range with units;

l) Input/output type;

m) Instrument (span) range with units (manufacturer supplied); and

n) Set point information for control system and hardwired alarms and interlock setpoints to include the following information, as a minimum: (Note: The setpoint information shall be listed with the applicable control record, as applicable.)

1) Setpoints;

2) Setpoint basis (supported by a setpoint determination calculation in accordance with TFC-ENG-STD-14;

3) Setpoint units;

4) Setpoint type (e.g., low, low-low, high, high-high); and

5) Setpoint action (i.e., “A” for alarm, “I” for interlock).


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3.4.3.20.93.4.3.19.9 Line List. Submit a composite piping line list identifying the following:

a) EIN (provided by BUYER per TFC-ENG-STD-12),

b) Material,

c) Schedule,

d) Size,

e) Design pressure,

f) Design temperature,

g) Description (to and from),

h) Test type,

i) Test pressure,

j) Logical boundaries,

k) Material coatings,

l) Cleanliness classification,

m) Run joint types,

n) Maintenance joint types,

o) ASME B31.3 fluid service, and

p) ASME B31.3 code calculation number.

3.4.3.20.103.4.3.19.10 Master Equipment List. Submit a master equipment list including the following:

a) Type of component;

b) Description;

c) Manufacturer;

d) Model number;

e) Operating ranges (temperature, flow, pressure, etc.);

f) Design parameters;


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g) Materials; and

h) Special features (e.g., metal seals instead of elastomeric).

3.4.3.20.113.4.3.19.11 Operations and Maintenance Manuals. Submit detailed operations and maintenance manuals including the following minimum detail:

a) Titles and tables of contents;

b) High resolution color diagrams, figures, and pictures;

c) Cautions and warnings for hazards (stored energy, pinch points, burns, etc.);

d) Recommended maintenance lockout locations;

e) Recommended spare parts;

f) Recommended maintenance and maintenance frequency;

g) Recommended surveillance and surveillance frequency;

h) Identification of calibrated items, instructions for calibrations, and recommended calibration frequency;

i) Identification of parts, tools, equipment, and special tools needed for maintenance evolutions;

j) Identification of rigging equipment, attachments points, weights, and centers of gravity for safe maintenance evolutions;

k) System configuration and prerequisites for initiating safe maintenance and surveillance activities;

l) Detailed step-by-step instructions for maintaining or replacing routinely serviced and limited service life components;

m) Prerequisites for system startup and operation;

n) Detailed step-by-step instructions for startup and operation;

o) Prerequisites and detailed step-by-step instructions for safe shutdown;

p) Detailed instructions for short-term and long-term layup of systems; and

q) References to pertinent engineering and original equipment manufacturer data.


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3.4.4 Fabrication Documents

a) Prior to fabrication, the following documents shall be submitted to the BUYER for approval:

1) The VENDOR shall provide submit a Fabrication Inspection and Test (FIT) Plans, which shall include the shop traveler summaries. Where applicable, the fabrication use and heat treating sequence and methodology for high strength materials shall be addressed.

2) Fabrication schedule

1)3) Redline procedure

2)4) List of fabrication codes and standards.

3)5) Welding related documents identified in TFC-ENG-STD-52, including: certified weld inspector documentation in accordance with QA-AVS B25; welding procedures and qualifications in accordance with QA-AVS B28; and nondestructive examination processes in accordance with QA-AVS B31.

4)6) Design details of each welded joint uniquely identifying the parts joined by the weld. In some cases, the use of AWS welding symbols, properly annotated, and applied to the fabrication drawings will suffice for this requirement.

1)7) A weld map identifying each weld joint by weld number, as applicable.

2)8) Detail drawings shall give a complete dimensional and material definition of every part designed and fabricated. Parts available commercially with standard dimensions (standard forgings, flanges, etc.) shall be identified by manufacturer and part number.

3)9) All submittals and records pertaining to the NDE, base materials, filler materials, fabrication, and inspection shall be traceable to the area and part inspected and be accessible for BUYER’s examination.

5)

b) For each major piece of equipment included in the contract the order shall include delivery of the following documents at conclusion of the fabrication phase:

4) Control software documentation identified in Section 3.3.14. 5)1) The VENDOR shall provide certified copies of the test reports including

ASME BPVC, Section VIII, Division 1, U-1 data reports.


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6)2) The VENDOR shall provide any required fabrication phase inspection and test results.

7)3) Coating procedures, including painting, mixing, and surface preparation procedures compliance matrix.

c) The VENDOR shall submit the following plans and manuals for BUYER’s approval:

1) Software management plan; 2) Software test plan; 3)1) Fabrication, inspection, and test plans; 4)2) Sampling plans; 5)3) Factory acceptance test plan; 6)4) Lifting and rigging plan; 7)5) Packaging, storage, shipping and load handling plan; and 8)6) Detailed operations and maintenance manuals.

d) The VENDOR shall prepare a final data package for each piece of equipment. Final data package submittal items shown on the Material Status Report shall be submitted and approved by the BUYER prior to release for shipment. This package shall include as applicable:

1) VENDOR’s certificate of conformance;

2) Signature verification sheet;

3) Receiving inspection reports;

4) Material and component certificates of conformance;

5) CMTR (including chemical and physical properties test results, heat treat condition, and corrosion test results as defined in the applicable Material Data Sheets per QA-AVS B49.

6) Fabrication, inspection, and test travelers per QA-AVS B13.

7) Weld inspection reports.

8) Weld maps.

9) Weld history reports.

10) NDE reports.

11) Radiograph film and reader sheets.

12) Positive material identification test reports.

13) Liquid penetrant material certification per QA-AVS B46.

14) Calibration certificates and reports per QA-AVS B58 or QA-AVS B61, as applicable.


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15) Dimension verification reports, including critical dimensions.

16) Pipe wall thickness reports.

17) Fastener tightening reports.

18) Factory acceptance and pressure test reports.

19) Flushing records (records verifying acceptable completion of flushing).

20) Lift test records with weight certifications.

21) Identification of age controlled items per QA-AVS B43, where applicable.

22) Inspection and test report per QA-AVS B52.

23) Nonconformance reports (closed).

24) ASME BPVC, Section VIII, data report, if applicable.

25) Verification record for pressure protection devices, if applicable.

26) Manufacture’s and VENDOR’s data (data sheets, material cut sheets, operation and maintenance manuals, etc.) in accordance with QA-AVS B33.

27) Request for Information (pertinent to the fabricated assembly).

28) Approved design changes (design change notices).

29) Calculations of as-built condition.

30) Detailed as-built drawings, including electronic files.

31) Transport tie-down plans.

32) Load handling and lift instructions.

33) Detailed recommended spare parts list for startup and operations in accordance with QA-AVS B82.

34) Detailed operations and maintenance manuals.

35) Electrical inspection and testing reports, records verifying electrical insulation, continuity, and grounding tests.

36) VENDOR data sheets and color charts.

37) Installer’s certificate or training documentation (for decontaminable coatings, as required in contract documents).


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4.0 FABRICATION REQUIREMENTS

4.1 GENERAL WELDING REQUIREMENTS

a) The MGS shall be fabricated in compliance with TFC-ENG-STD-52.

b) All areas from which temporary attachments have been removed shall be examined by the liquid penetrant method after the surface has been restored.

c) Preparation for welds shall be accomplished by nonthermal methods, where practical.

d) Thermally cut surfaces shall be ground to provide slag-free metal and fit-up equivalent to machining.

e) Where welding destroys protective plating on hardware items, the weld and surrounding area shall be thoroughly cleaned, primed, and painted, as appropriate.

f) Where free-iron contamination (shows up as rust streaks on stainless steel) is observed, the surface area shall be cleaned prior to welding.

4.2 VESSEL FABRICATION REQUIREMENTS

The following section discusses vessel fabrication, inspection, and testing requirements. Where a requirement conflicts with a code, standard, or another section within this specification, submit an RFI (Site Form A-6003-417) for clarification.

4.2.1 General Vessel Requirements

a) The VENDOR shall, if necessary, provide temporary stiffening and jigging to prevent shell distortion during fabrication, welding processes, heat treatment, hydrostatic testing, and shipping. Temporary stiffening and jigging not required for shipping shall be removed before shipping. For stiffening and jigging that is welded in place, remove by grinding and perform NDE in accordance with fabrication NDE requirements.

b) Fabrication tolerances shall be in accordance with ASME BPVC, Section VIII, Division 1, and VENDOR’s approved fabrication drawings.

c) The sequence of fabrication shall be planned to permit maximum access to the internal surfaces to enable examination of all welds.

d) Plates and pipes shall be cut to size and shape by machining, grinding, shearing, plasma, laser, or water-jet cutting. Plates, 3/8 in. thick and above, cut by shearing, shall either be liquid penetrant tested on the sheared edge or have 3/8 in. allowance left on the edges, which shall be removed by machining or grinding. All thickness of plate or pipe cut by air plasma cutting shall have the edges dressed to a smooth, bright finish.


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Material cut by the inert gas shielded plasma, laser, or water-jet process will not require further dressing other than de-burring. All lubricants, burrs, and debris shall be removed after cutting.

e) If a butt welded seam is required between materials of different thickness, the thicker material shall be machined or ground on the side away from the process liquid. Machining shall ensure a smooth finished profile with no sharp corners and shall be in accordance with ASME BPVC, Section VIII, Division 1.

f) When rolling any austenitic stainless plate, care shall be taken to prevent iron pickup or contamination of rolled material. The work area shall be free of carbon-steel grindings and general cleanliness shall be maintained to preclude iron contamination.

g) Only stainless-steel brushes, clean iron-free sand, ceramic or stainless-steel grit shall be used for cleaning stainless steel or nonferrous alloy surfaces. Cleaning tools or materials shall not have been previously used on carbon steel.

h) Pipe bending methods, tolerances, processes, and material requirements shall comply with PFI Standard ES-24 and require BUYER’s approval. These requirements shall apply equally to tube-bending processes. The pipe shall not be terminated or butt-welded within the bend; a straight length of 6 in. is recommended.

i) Temporary attachments shall be removed prior to shop hydrostatic test unless specifically approved by the BUYER.

j) Impact testing shall be performed on base metal and weld joints in accordance with ASME BPVC, Section VIII, as applicable.

4.2.2 Vessel Layout Requirements

a) Plate size shall be chosen to minimize welding.

b) The longitudinal seams of adjacent shell courses shall be staggered by a minimum length (measured from the toe of the welds) of five times the plate thickness or 4 in., whichever is greater. Where it is considered impractical to meet this requirement, the VENDOR shall submit a proposed layout to the BUYER for approval.

c) Plate layouts shall be arranged so that longitudinal and circumferential weld seams clear all nozzles and their limits of reinforcement. Additionally, there must be a clearance of at least eight times the shell plate thickness between the toes of the affected welds. Any exception to this requirement will require BUYER’s approval.

d) Structural attachment welds (such as internal support rings or clips; external stiffening rings; insulation support rings; and ladder, platform, or pipe support clips) shall clear weld seams by a minimum of 2 in. If overlap of pad-type structural attachments and weld seams is unavoidable, the portion of the seam to be covered shall be ground flush and examined by radiography before the attachment is welded. The seam shall be


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radiographed per ASME BPVC, Section VIII, Division 1, Part UW-51 for a minimum distance of 2 in. beyond the edge of the overlapping attachment. Radiographic examination of longitudinal weld seams is not required when single-plate, edge-type attachments (such as tray support rings; stiffening rings; insulation support rings; and ladder, platform, or pipe support clips) cross such weld seams.

4.2.3 Nozzles

a) For forged nozzles connecting to pipe of lesser wall thickness, the VENDOR shall prepare the nozzles per ASME BPVC, Section VIII, Division 1, Figure UW-13.4.

b) For shell openings specified with a welded cover (i.e., inspection nozzles), the cover shall be tack welded to the nozzle neck, prepared for field welding to the nozzle neck, and sealed to prevent dirt and water from entering the vessel using adhesive tape which meets the requirements of Section 3.3.5 (materials compatibility).

c) Nozzles to be butt-welded in the field shall be suitably extended and capped for hydrostatic testing. After testing, the caps shall be removed and the nozzle shall be prepared for field welding.

4.2.3.1 Hold Points. The VENDOR shall provide required notifications of verification points and shall not proceed past required hold points without written authorization from the BUYER’s quality assurance (QA) Representative. Table 4-1 lists the minimum hold points to be incorporated into the fabrication traveler. QA-AVS B13 for fabrication/inspection/test plans is invoked for hold points. Before starting fabrication work, the fabrication/inspection/test plan shall be submitted to the BUYER for review and approval with BUYER designated inspection/witness/notification points inserted.

Table 4-14-1. Vessel Fabrication Traveler Hold Points.

Verification Point Description Type of Verification Prior to the first production weld for each weld procedure Hold Prior to nondestructive examination inspection Witness Prior to hydrostatic/leak test Witness Prior to final inspection Hold Prior to shipping Hold

4.2.3.2 Shop Inspection General.

a) The shell and head sections which are subjected to concentrated or large loads through welded attachments (such as lifting and tailing lugs) shall be ultrasonically examined over 100% of the area prior to welding, in accordance with the following:


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1) For connections or attachments directly welded to the shell or head, the area tested shall extend 3 in. beyond the extremity of the proposed weldment and

2) For connections or attachments welded via a reinforcement or doubler plate, the shell area tested shall extend 5 in. beyond each side of the perimeter of the proposed fillet weld attaching the reinforcing or doubler plate to the shell or head.

b) All full penetration welds attaching internal or external structural components to the heads or shell shall be volumetrically tested. If fillet welds are permitted by the BUYER, they shall be dye-penetrant tested. Welds used to attach nameplates do not require NDE.

c) All full penetration welds forming part of the jacket shall be ultrasonically or radiography tested. Records of the NDE and other tests shall be submitted to the BUYER.

d) All welds joining the nozzle neck to the shell or heads, that are not radiographed or ultrasonically tested shall be liquid penetrant tested on the root pass and the cap pass.

4.2.3.3 Shop Inspection for Quality Level-2 and Quality Level-3 Vessels. In addition to the general inspection requirements, quality level (QL) -2 and QL-3 vessels shall be inspected as follows:

a) Volumetric examination using either radiographic testing or ultrasonic testing shall be specified, where possible.

b) The determination of whether a volumetric inspection is possible shall be made by the BUYER’s welding subject-matter expert or BUYER’s NDE subject-matter expert, and shall be approved by the BUYER on a weld-for-weld basis. BUYER’s approval shall be obtained on the fabrication work control document.

c) The following welds shall be subject to NDE as specified:

1) All welds forming part of the primary containment (including weldments, joining nozzles to the vessel shell, or head) shall be 100% inspected using radiography or ultrasonic testing;

2) Where a main seam butt-weld is located, such that only part of its length lies within the primary containment, the complete length of that particular seam shall be inspected;

3) For multi-chambered vessels, where an adjacent chamber is categorized other than QL-2 or QL-3, all interconnecting butt-welds which provide primary containment between the two chambers shall be inspected to QL-2 and QL-3 requirements; and


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4) For vessels fitted with a shell-type jacket, all Primary containment welds in the main shell enclosed by the jacket shall be inspected and found satisfactory prior to fitting the jacket and associated rings.

d) Butt-welds in internal piping shall be 100% volumetrically inspected in accordance with ASME BPVC, Section VIII, Division 1. Where volumetric examination is not practical, liquid penetrant testing of the root and cap may be substituted if approved by the BUYER’s welding subject-matter expert or BUYER’s NDE subject-matter expert on a weld-for-weld basis. BUYER’s approval shall be obtained on the fabrication work control document.

e) Where components attach to any part of the vessel by full or partial penetration tee weld (including a corner weld), the parent plate in the vicinity of the weld shall be ultrasonically tested prior to welding, to ensure that no defects are present that could result in laminar-type tearing during welding.

f) The following component welds shall be subject to NDE as follows:

1) Liquid penetrant test the supports for vessel internals. 2) Ultrasonic test vessel supports, where a small local area of the vessel takes the

support load (ultrasonic inspection is not required for skirt or ring supported vessels).

4.2.3.4 Vessel Nondestructive Examinations .

a) Radiography, ultrasonic testing, and liquid penetrant examination, where specified or required, shall be performed in accordance with ASME BPVC, Section VIII, Division 1 and Section V.

b) All mandatory NDE (visual, surface flaw, and volumetric) of the vessel shall be carried out after the completion of fabrication, including any heat treatment.

c) Visual weld inspections shall be performed by weld inspectors certified in accordance with ASNT SNT-TC-1A to Level II or an AWS Certified-Welding Inspection.

d) Ultrasonic testing, where specified by the BUYER or proposed by the VENDOR, shall be in accordance with Appendix 12 of ASME BPVC, Section VIII, Division 1.

e) Radiographic acceptance criteria shall be in accordance with ASME BPVC, Section VIII, Division 1, Paragraph UW-51 where full radiography is required or UW-52 where spot radiography is required.

4.2.3.5 Hardness Testing for Austenitic Stainless Steel.

a) Hardness testing is required when austenitic stainless-steel plate is cold formed to make sections such as angles and channels. This requirement is not applicable to the cold


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forming of dished heads, which is covered by the relevant section of ASME BPVC, Section VIII, Division 1.

b) Hardness testing is required when austenitic stainless-steel pipe is cold formed for bends with a centerline radius less than three times the nominal pipe diameter.

c) Any cold forming process, which may significantly increase hardness, shall be in accordance with an approved procedure, which contains hardness testing. The procedure shall be submitted for BUYER’s approval.

d) Hardness testing shall be performed on areas subject to the greatest deformation after cold working or any rework or rectification; the maximum permitted hardness shall not exceed that allowed by the applicable material standard and grade.

e) If the maximum permitted hardness is exceeded, the VENDOR shall perform post-weld heat treatment (PWHT) and document in the fabrication, inspection, and test plan.

4.2.3.6 Vessel Acceptance Testing.

a) Leak Tests:

1) If gas or pneumatic leak testing is specified for the approved design, the VENDOR shall conduct the tests in accordance with ASME BPVC, Section V, Article 10;

2) Reinforcing pad attachment welds and accessible surfaces of inside nozzle to vessel wall welds shall be tested for leaks with 15-psig dry air or nitrogen and bubble forming solution; and

3) The leak test shall be performed prior to the final hydrostatic test.

b) Hydrostatic Test:

1) The hydrostatic test shall be performed after any specified leak tests;

2) The vessel hydrostatic test shall be performed in accordance with ASME BPVC, Section VIII, Division 1, Part UG-99, as specified for the approved design;

3) All welds shall be sufficiently cleaned and free of scale or paint prior to hydrostatic testing;

4) Testing of vessels or components made of austenitic stainless-steel materials shall be conducted with potable water containing no more than 50 ppm chloride;

5) The final hydrostatic test pressure shall be held for a minimum of 1 hour;


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6) Test water shall not be in contact with austenitic stainless steel for more than 72 hours, unless treated with a BUYER-approved biocide; and

7) After completion of the hydrostatic test, the vessel and internal piping shall be drained; dried; cleaned thoroughly inside and outside to remove grease, loose scale, rust, and dirt; and closed as quickly as practicable.

c) Obstruction Inspection:

1) The VENDOR shall ensure and document that all internals, internal piping, and jacketing are free from obstructions and

2) If visual inspection cannot confirm lack of obstructions, a flow test shall be performed on internal piping and jackets.

d) Final inspection:

1) Final inspection is a required hold point, and the BUYER shall have 10 days notice;

2) Final inspection of the completed vessel shall be the sole responsibility of the VENDOR;

3) The finished dimensions and cleanliness of the vessels shall be inspected to confirm compliance with the relevant drawings and specifications after completion of all tests;

4) Overall visual inspection shall be performed to confirm items to include, but not limited to, small bore piping and seals, etc. are free from damage;

5) Inspection shall be performed to confirm equipment and nozzle orientations match design documents;

6) Inspection shall be performed to confirm that all structural and equipment bolt tightening has been completed to manufacturer requirements and design documents;

7) Inspection shall be performed to confirm that surface finish matches design documents;

8) Inspection shall be performed to confirm marking and labeling includes the correct item identification and marking in compliance with Sections 3.3.7 and 3.3.8;

9) Inspection documentation shall be complete with all inspection signatures; and


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10) The final inspection shall be documented in a final inspection report for each contract item.

4.2.3.7 Source Quality Control.

a) Orders shall be subject to random fabrication-site inspections by the BUYER or designee.

b) All records pertaining to base materials, filler materials, fabrication, and inspection including welder’s qualification record shall be accessible for BUYER’s examination.

c) The VENDOR shall make a complete set of BUYER-approved drawings and other documents available to the BUYER’s Representative at the time the quality surveillance activities are being conducted.

d) BUYER’s review of VENDOR’s drawings, or release of the vessel for shipment by BUYER’s Representative shall in no way relieve the VENDOR of the responsibility for complying with all the requirements of this specification and purchase order.

4.3 PIPING FABRICATION REQUIREMENTS

The following section discusses piping fabrication, inspection, and testing requirements. Where a requirement conflicts with a code, standard, or another section within this specification, submit an RFI (Site Form A-6003-417) for clarification.

4.3.1 Pipe Spool and Installation Drawings

Submit shop pipe spool and installation drawings that show the following, as a minimum:

a) Flag the locations of all field welds.

b) Location and identification number of all shop welds, including weld symbols in accordance with AWS A2.4.

c) Line Number and Shop Weld Number. Shop welds examined by NDE shall be added to the drawing after completion of NDE.

d) Piece numbers, line numbers, and flow direction arrows as identified on piping drawings.

e) Weld-end preparation details.

f) Heat and lot number or some type of approved code number that provides traceability for materials requiring CMTRs.

g) Location of hanger lug attachments, etc.


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h) Bill of materials.

i) Pipe spool dimensions, assembly weight, and pressure testing pressure.

j) Applicable code and preheat, and PWHT procedures.

k) Reference notes, specifications, and drawings.

l) Spool drawing example.

4.3.2 Pipe Welding

a) The extent of examination for waste contacting piping shall be as follows:

1) Volumetric examination by radiographic testing (RT) or ultrasonic testing (UT) of welds in accordance with ASME B31.3 shall be performed where possible (i.e., in-process examination shall not be specified). In those cases where volumetric examination is not possible (e.g., orientation of the weld), the subject welds shall have documented in-process examination in accordance with ASME B31.3, Paragraph 344.7 with liquid penetrant or magnetic particle examination specified for the root pass [see Paragraph 344.7.1(e)] and shall be identified as such on the fabrication drawings. The determination of whether a volumetric inspection is possible shall be made by the BUYER’s welding subject-matter expert or BUYER’s NDE subject-matter expert, and shall be approved by the BUYER on a weld-for-weld basis. BUYER’s approval shall be obtained on the fabrication work control document. Individual items described in Paragraph 344.7.1 shall be documented (e.g., checklist format) for each in-process examination. The in-process examinations shall not be used to meet the required representation of the Welder’s or the welding Operator’s work unless necessary to meet the required representation of work.

2) The method of ultrasonic examination shall be in accordance with ASME BPVC, Section V, Article 4.

3) The liquid penetrant method or magnetic particle method shall be applied to 100% of all fillets and attachment welds.

b) The final closure welds connecting piping systems or equipment which has been successfully pressure tested shall be in-process examined per ASME B31.3, Paragraph 345.2.3(c), applying the visual examination method per ASME BPVC, Section V.

c) The installation and removal of inflatable balloons shall be tracked on weld maps to ensure their removal.

d) Sufficiency of purge shall be verified by measuring oxygen concentration prior to welding.


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4.3.2.1 Preheat and Post-Weld Heat Treatment.

a) Preheat and PWHT requirements shall be addressed in detail on the welding procedure specification (WPS).

b) Electric or gas heat sources, which provide a uniform application of heat over the weld area, shall be used.

c) Branch connections and other attachments shall be welded to the lines before commencement of heat treatment.

d) Time-temperature cycle records for the furnace, induction, or resistance method shall be prepared and kept on file by the VENDOR. These records shall identify the piece numbers involved and show a continuous recording of the time-temperature cycle. Thermocouple placement shall be recorded.

4.3.2.2 Weld Repairs.

a) The BUYER reserves the right to have the VENDOR cut out and test any and all welds, irrespective of defects. The VENDOR shall furnish equipment and personnel to cut out welds designated by the BUYER for testing. Entire welds shall be cut from the line by cutting the pipe 2 in. back from each side of the weld. Coupons will be cut from pipe, per ASME BPVC, Section IX, Paragraph QW-462, so that the weld may be tested for tensile strength, ductility, and foreign inclusions.

b) The cost of replacing sound welds ordered removed by the BUYER will be borne by the BUYER. The cost of replacing or repairing defective welds including additional examinations or tests resulting from those defects shall be borne by the VENDOR.

c) Defects in welds shall be removed by flame or arc-gouging, chipping, machining, or grinding, but preferably by mechanical means. If removed by a thermal process, an additional 1/16 in. shall be removed by mechanical grinding. Excavated areas shall be magnetic particle tested (ferrous material) or liquid-penetrant tested (nonferrous material) to ensure defect removal. Inspection reports shall be generated. Repair welds shall be made in accordance with welding procedures which have been previously approved for the original weld, unless an alternate procedure is approved by the BUYER.

d) Should laminations or split ends be discovered in the pipe, the joints containing such defects shall be cut back to a point where these defects no longer exist.

e) Examination and/or inspection of the completed weld repair shall be the same as the original weld or by a BUYER-approved alternate method.

f) No more than two repairs will be permitted on any one weld.

g) Cutting out and rebeveling then rewelding is considered a weld repair.


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h) No further attempts to repair shall be carried out without the written authorization of the BUYER using the nonconformance report process.

i) Weld repairs subsequent to the first two repair attempts shall be made only after receiving written approval of VENDOR’s repair procedures. Weld repairs shall be documented in the fabrication traveler and/or weld map.

j) The metal wall thickness shall not be reduced less than that permitted in the applicable ASTM standard, without BUYER’s approval.

4.3.3 Fabrication Tolerance and Alignment

a) Unless otherwise specified, dimensions of all shop fabricated piping shall be within the tolerances specified in PFI Standard ES-3 and approved design drawings.

b) All piping shall be plumb and square. Unless otherwise specified, the internal misalignment of ends to be joined shall not exceed the lesser of 1/16 in.

c) Templates, pantographs, or other suitable methods shall be used in laying out stub-ons, laterals, and other irregular details to ensure accurate cutting and proper fit-up. Caution shall be used in fitting up pipe and components for tack welding, to ensure a proper gap for full-penetration welds.

d) Unless otherwise specified, bolt holes of fixed flanges shall be oriented as follows:

1) Vertical flange faces: A pair of bolt holes shall straddle the vertical centerline.

2) Horizontal flange faces: A pair of bolt holes shall straddle the plant north/south centerline.

3) Sloping flange faces: A pair of bolt holes shall straddle the plane defined by the centerline of the pipe and a vertical line.

4.3.4 Orifice Flange Assemblies

The internal surface of welds between the orifice flanges and the connecting pipe shall be ground smooth.

4.3.5 Branch Connections and Miscellaneous Attachments

a) All connections for branches, vents, drains, and instruments are specified in each pipe material class.

b) The VENDOR shall install thermowells per detail drawings in each applicable pipe material class.


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c) Reinforcing pads and saddles, when used, shall be provided with tapped vent holes that are suitable for pneumatic testing.

d) Reinforcement pads and saddles specified in the pipe material classes or shown on the drawings shall be fabricated to meet the requirements of ASME B31.3.

e) Miscellaneous attachments for hangers, supports, or guides shall be of material similar to the pipe and be suitable for the operating temperature.

4.3.6 Pipe Bending and Forming

a) Pipe bending and forming shall conform to the requirements of PFI Standard ES-24 and ASME B31.3.

b) Submit pipe bending procedure which includes forming temperatures, procedures for heat treatment after bending, and inspection procedures.

c) Bends identified on the drawings shall be formed with the radii specified.

d) Piping bends are preferred over the use of elbows, where practical, to reduce the number of weld joints.

e) The VENDOR shall submit a procedure for BUYER approval, for verifying the post-bending wall thickness in the extrados of the bend meets the minimum wall thickness per ASME B31.3. Wall thickness verification can be performed by qualification of the bending process or measurement of the wall thickness post bending.

f) Shop bends shall be placed on hold and a bending procedure be submitted and approved by the BUYER prior to commencement of fabrication. The VENDOR shall submit a bending procedure, which includes forming temperatures, procedures for heat treatment after bending, and inspection procedures.

g) Tolerances for dimensions of pipe bends shall be in accordance with PFI Standard ES-24.

h) Bends shall be induction bent per ASME B31.3, Paragraph 332. Where induction bends are not practical cold bends shall be used per ASME B31.3, Paragraphs 332 and 304.2.1. No alternates or substitutions will be allowed without prior written approval of the BUYER via the fabrication work control document. Use methods and equipment that produce bends free of wrinkles, bulges, or kinks.

i) See Section Section Error! Reference source not found.4.3.8 4.3.8 for Quality Control examination requirements.

4.3.7 Heat Treatment

a) Spools and fabricated modules shall be checked for dimensions and alignment after heat treatment and a gauge check shall be made on the threads of couplings,


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threadolets, and nipples in the spools. Pipe shall also be checked for straightness. Deviation from a straight line shall not exceed 0.2% of the length. Piping shall be replaced if threads are out of tolerance or pipe is not straight.

b) After all hot bending, welding, grinding, and heat-treating operations have been completed, the threads shall be “chased” with the appropriate size pipe tap to remove scale and weld spatter, and to ensure full engagement of threads and a tight joint.

4.3.8 Quality Control

a) Wall thickness measurement procedures and reports shall be provided for pipe bends.

b) Material hardness measurement procedures and reports shall be provided for pipe bends and other cold formed austenitic stainless steel components.

1) Surfaces shall be free from protruding foreign material and be free of surface defects as determined by visual examination.

2) Dimensional tolerances shall be compliant as specified in manufacturer’s data and as identified by the specified dimensional standard.

3) The VENDOR shall be responsible for ensuring that all requirements set forth in this specification have been satisfied.

4) Nonconforming material shall be physically segregated from acceptable items, when possible, and shall be in strict accordance to Section 6.0 of this specification.

5) Nameplates shall be fully visible when the equipment is in an operating condition.

4.3.8.1 Hold Points.

a) The following verification points in Table 4-2 are required by this section, at a minimum, the following witness and hold points shall apply.

Table 4-24-2. Piping Fabrication Traveler Hold Points.

Verification Point Description Type of Verification Prior to fabrication Hold Prior to initial production welding (first weld*) Hold Prior to shop bends Hold Prior to testing Witness Prior to valve restoration Witness Prior to inspections Witness Prior to acceptance testing Hold Prior to shipping Hold


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Table 4-24-2. Piping Fabrication Traveler Hold Points.

Verification Point Description Type of Verification *First weld strike for each weld process.

b) The VENDOR shall provide required notifications of verification points and shall not proceed past required hold points without written authorization from the BUYER’s QA Representative. QA-AVS B13 for fabrication/inspection/test plans is invoked for hold points. Before starting fabrication work, the fabrication/inspection/test plan shall be submitted to the BUYER for review and approval with BUYER designated inspection/witness/notification points inserted.

c) The BUYER’s Inspector shall be notified 10 days in advance of shipment. The shipment shall be placed on hold until BUYER’s Inspector:

1) Performs a walk-down to verify that the work is in accordance with the P&IDs, V&IDs, drawings, and this specification;

2) Verifies marking and identification is in accordance with marking and identification requirements;

3) Visually examines items that are accessible without disassembly for general workmanship, cleanliness, and quality;

4) Verifies design and manufacturing documentation is complete in accordance with this specification;

5) Verifies packaging and shipping preparation to ensure compliance to this specification; and

6) Verifies that each component of the packing list is included in the shipment.

4.3.8.2 Pre-installation Inspection. Each pipe spool, valve, threaded opening, and gasket surface shall be closely inspected for damage and internal cleanliness immediately before installation of piping.

4.3.9 Flange Joints

a) Gaskets and flange faces shall be protected from damage until installation is complete.

b) When temporary makeup at flanged joints is required in systems using special gaskets (e.g., GPT Industries LineBacker®, spiral wound, etc.), the joints may be made up with less expensive sheet gaskets and the special gaskets saved for the final installation.


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c) Protective grease, paint, and other foreign material shall be cleaned from flange gasket faces prior to positioning the pipe spool for bolt up. Re-facing or repair of damaged flange facing shall not be permitted.

d) Bolt threads shall be coated with a Teflon® lubricant. Flanges shall be made up by tightening diametrically opposite bolts in succession to load the gasket evenly or as directed by the manufacturer.

e) When a flanged joint has been made up and subsequently loosened, a new gasket shall be installed prior to retightening the joint.

f) Bolt tension/torque requirements for flange connections shall be in accordance with the gasket manufacturer’s recommended torque requirements necessary to seat the gasket without overstressing the bolts.

4.3.10 Valves

a) All valves shall be installed in strict accordance with the manufacturer's recommendations.

b) The resilient seats or sleeve of valves are very susceptible to damage from heat during welding. The manufacturer’s recommendations shall be followed when installing such valves in order to prevent seat or sleeve damage.

4.3.11 Pipe Supports

a) Support components in contact with the pipe shall be of a material similar to the pipe and suitable for the operating temperature of the pipe.

b) Other hangers and supports shall be the type and model numbers called out on the piping drawing and meet additional requirements and installation details stated on the standard support details.

c) Welding of pipe supports to structural steel framing shall be performed according to structural specifications, and the quality of welding shall be at least equivalent to that provided by the applicable AWS welding codes. All welds shall run parallel to the axis of the beam span and all welding shall be staggered with cooling allowed between subsequent deposits.

d) Hangers shall be fabricated and installed in accordance with MSS SP-58-2009.

e) Supports which are located on approved drawings shall not be relocated or reoriented without the BUYER’s approval.


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4.3.12 Pressure Testing

a) Piping shall be pressure tested in accordance with the requirements of ASME B31.3 (normal fluid service) and this specification. All tests shall be documented by the VENDOR (see Appendix A).

b) The VENDOR shall repair or replace any piping assembly that does not perform satisfactorily during BUYER’s hydrostatic or pneumatic pressure tests as a result of defective workmanship by the VENDOR, or as a result of faulty materials supplied by the VENDOR.

c) A seat closure test shall be performed on all valves that have been welded in place. Testing is to be performed after all welding activities are complete. Seat closure tests shall be in accordance with ASME B16.34 for test pressure (gas not less than 80 psi) and test time using the test methods in API STD 598. This shall be verified by hold point or source verification.

d) Each valve and actuator assembly shall be cycled from full open to full closed and back to full open for verification of limit and torque switch function and setting, and the ability of the actuator to open and close the valve after the seat leakage test has been performed. Cycling of valve shall be done at maximum shut off pressure differential and design temperature. Valve travel stop settings shall be verified. BUYER shall witness test.

4.3.12.1 Pretest Inspection.

a) Lines shall be thoroughly flushed before pressure testing, and before any automated valves being installed or pressure tested to prevent/minimize weld slag or other foreign material from damaging the valve trim. Other in-line instruments should also be removed or valved off prior to flushing.

b) The VENDOR shall notify the BUYER 10 days in advance of when a piping system will be ready for a pretest inspection. The pretest inspection shall verify that all components in a piping system conform to the appropriate pipe material specification (e.g., material, wall thickness, valve numbers, valve ratings, flange ratings, etc.) and the latest revision of the appropriate P&IDs and V&IDs, and is ready for pressurization.

c) The BUYER’s Inspector will inspect each piping system using a copy of Appendix B and subsequently notify the VENDOR of any problems that need to be corrected prior to pressure testing.

d) Joints shall be inspected by the BUYER’s Inspector to ensure they have been assembled in accordance with the applicable code and this specification. All joints shall be left uninsulated until testing has been completed.

e) Supports, shoes, guides, and anchors shall be inspected by the BUYER’s Inspector for proper type, installation, and location. Spring supports shall also be inspected for


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correct cold setting, with the hot and cold settings permanently marked, and for freedom of spring movement. All springs shall be blocked in the cold location for pressure testing.

f) Pressure vessels, heat exchangers, prefabricated skid-mounted process units, pumps, compressors, and the miscellaneous items listed on Appendix C shall be isolated from piping systems that will be pressure tested unless approved for testing within the system by the BUYER. All control valves shall be installed and included in the pressure test with valves in the open position.

g) If a block valve is used for isolating test sections, the differential pressure across the valve seat shall not exceed the rated seat pressure.

h) Plugs and caps shall be inspected by the BUYER’s Inspector to ensure that they comply with the appropriate pipe material specification.

4.3.12.2 Testing.

a) Pressure testing shall be done hydrostatically unless otherwise specified, or as approved by the BUYER.

b) Shop pressure tests shall be documented with a test report.

c) An initial service leak test is not permitted unless approved by the BUYER.

d) Vent and drain piping which is downstream of the last block valve and open to the atmosphere shall be pressure tested where possible.

e) If there are in-line items (valves, sensors, relief valves, etc.) that are not designed for the test pressure, replace items with a spool and test the whole pipeline. Replaced items shall be identified in the fabrication and test work control documents and approved by the BUYER before testing.

f) The quality of a test fluid shall not be detrimental to the equipment or the pipe system materials. Approval by the BUYER in the fabrication and test work control documents shall be obtained before using any test fluid.

g) Water for testing equipment and piping containing austenitic stainless-steel materials shall contain less than 50-ppm chloride ion.

h) Pneumatic testing shall be done with compressed air or nitrogen when pneumatic testing is approved by the BUYER. Unless otherwise approved by the BUYER in the fabrication and test work control documents, pneumatic testing shall not be performed when any of the following conditions exist:

1) When the temperature of the piping system is less than 21 ºC (70 ºF). 2) The test pressure exceeds 110 psig.


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3) The product of pressure (psig) times volume (cubic feet) exceeds 50,000.

i) Pressure gauges and recorders shall be calibrated before tests. Pressure gauges shall have a range within 40 to 80% of the full scale and be calibrated within 2% at the full-scale reading.

j) Unless otherwise approved by the BUYER in the fabrication and test work control documents, pressure testing shall not be performed when the temperature of test fluid is less than 4 ºC (40 ºF).

k) Filter elements and strainers that may have been installed shall be removed from the system prior to pressure testing.

l) Equipment appurtenances (such as level bridles, etc.) shall be tested separately when the equipment is excluded from pressure testing.

m) The VENDOR shall verify that the status of all pressure relieving devices is as specified per Appendix C, and that all components included in the test can withstand the test pressure.

n) Each pipe system shall be observed to ensure that all supports, including spring supports, are not overloaded due to weight of the test medium. All spring supports shall have factory-installed travel stops installed during pressure testing.

o) If insulation is required, the VENDOR shall immediately remove or dry out any insulation that becomes wet during pressure testing. Re-installation of previously wet insulation is subject to BUYER approval in the fabrication and test work control documents.

p) Piping that is free of leakage for the duration of the specified tests shall be accepted.

q) Test diagrams or isometric drawings shall identify the test parameters. The drawing shall show actual configuration of piping, valves, etc. of the test.

r) The VENDOR shall be responsible for repairing all leaks and the additional examination and tests required as a result of those leaks.

4.3.12.3 Post-Test Restoration.

a) After successful completion of pressure testing, all lines shall be flushed and completely drained.

b) Piping which has been either flushed or hydrostatically tested shall be thoroughly purged with air or nitrogen and dried.


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c) Valves that were closed during pressure testing shall be opened to ensure proper drainage of the bonnet cavity. Valves shall be partially opened and closed during the flushing operation to flush foreign material out of the system.

d) Care shall be exercised in draining vessels and piping so as not to create a vacuum. Vents within a system shall be opened prior to draining. After piping systems and vessels are completely drained, vents and drains, and all other internals which were opened prior to testing shall be closed.

e) Temporary blanks and blinds shall be removed, and valves, orifice plates, expansion joints, instrumentation, and short pieces of piping, which have been removed, shall be reinstalled with proper gaskets in place.

f) The VENDOR shall restore, if required, all valves after successful pressure testing. Restoration of valves shall include the removal of any jacks; re-installation of flappers, balls, plugs, pistons and sleeves, etc.; and the replacing of bonnet gaskets on valves that were disassembled. Restoration of valves shall be a BUYER witness point. The BUYER will sign the tag that was previously placed on the valve and indicate that the valve is ready for operation.

g) After lines have been drained, temporary piping supports shall be removed. Restraining parts that were supplied with hangers and expansion joints for their protection when carrying the test loads shall be removed upon completion of the system test.

h) Special length flange bolting and temporary gaskets shall be removed and replaced with line class bolts and gaskets.

i) Each system shall be connected to equipment, where applicable, and be ready for inspection. The terminal points of piping systems, which are left for future connections, shall be sealed with blinds or plugs.

4.3.12.4 Post-Test Inspection.

a) The VENDOR shall notify the BUYER at least 10 days in advance of when a piping system will be ready for post-test inspection.

b) The BUYER will inspect each piping system using Appendix A and subsequently notify the VENDOR of any problems that need to be corrected.

c) The post-test inspection shall verify that a piping system has been flushed, dried, restored, and connected to the satisfaction of the BUYER, and is ready for operation.

d) Pressure relief valves, spring hangers, and expansion joints shall be inspected by the BUYER’s Inspector to see that all shipping spacers and shipping ties have been applied.


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4.3.13 Instrumentation and Control Fabrication and Quality Control Requirements

a) Valves shall be supplied with actuators and accessories that are tested, operational, packaged, and labeled to allow for correct reassembly.

b) Thermowells shall be located and installed as specified on the BUYER-approved drawing.

c) The VENDOR should take precautions to keep fabrication debris from entering the thermowell. Final inspection shall include boroscope inspection of the thermowell to confirm cleanliness.

d) Pressure measuring devices using capsule seals shall be delivered as complete units with appropriate length of tubing to permit correct installation.

4.3.14 Electrical Fabrication and Quality Control Requirements

a) The VENDOR shall furnish and prewire all components necessary for the complete and proper operation of the packaged equipment.

b) Devices requiring external connections shall be routed to terminals in junction boxes or control panels. Separate terminal boxes shall be provided for:DC circuits shall be provided separate raceways from AC circuits.

b)c) Signal shields shall be grounded in one designated location only, uniformly applied to all shielded circuits, and not otherwise interconnected.

1) Alternate current control circuits; and

2) Direct current analog, resistance temperature detectors, digital signals, or measurement circuits may occupy the same instrument terminal box, but shall be terminated on separate terminal blocks (shields shall be wired to separate terminal points).

c)d) 480-V power and 208/120V power circuits shall be wired to separate terminal boxesraceways.

d)e) Testing and Inspection:

1) The VENDOR shall submit certified electrical inspector documentation in accordance with QA-AVS B17accommodate BUYER’s electrical inspector inspection and remedy all deficiencies prior ot shipping;

2) The VENDOR shall provide submit FATs that shall include, but not be limited to, complete functional test of all electrical components to ensure that the packaged mechanical equipment performs its intended function;

3) The VENDOR shall perform continuity test on all electrical power circuits that are not factory colored/marked to distinguish grounded from ungrounded


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conductorto verify all devices are installed and connected in accordance with drawings and/or specifications;

4) Prior to terminating, test all power and control cable or wire 25 ft or more in length for insulation resistance with megger (500V DC megger for 300V insulation, 1000V DC megger for 600V insulation) (any wire with less than 50 megaohms to ground or other conductors shall be replaced before proceeding with the terminating);

5) Tests shall be performed with calibrated instruments traceable to (National Institute of Standards and Technology) NIST or other nationally recognized standards; and

6) The VENDOR shall supply documented evidence of testing.

4.4 CLEANLINESS

a) Prior to packaging an item, debris and contamination shall be removed using the VENDOR’s documented and approved standard procedure, unless specified otherwise. All items shall meet the ASME NQA-1 cleanness classification of Class B. The surface shall appear clean and free of organic films and contaminants, when examined in accordance with ASTM A380/A380M, and show no deleterious contamination when subjected to a wipe test of ASTM A380/A380M. Wipe tests shall be made prior to the application of any preservative film (if required to maintain Class B level during storage period, prior to installation).

b) All equipment openings shall be capped, plugged, or sealed in accordance with ASME NQA 1 to prevent entry of foreign material and humidity and protected against corrosion and physical damage.


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5.0 FACTORY ACCEPTANCE TESTING (FAT) AND INSPECTIONS

The purpose of the FAT is to demonstrate operation and maintenance of the MGS under standard conditions, and operation, maintenance, and recovery of the MGS under nonstandard conditions defined below. Testing will include the use of water a simulant for demonstrating component and system performance.

a) The VENDOR is responsible for mocking up a fully functional simulated waste feed system to MGS at the VENDOR’s facility. As a minimum, the feed system shall consist of a feed tank with recirculation and sampling loop.

b) The VENDOR is responsible for providing the connected services in accordance with the interface requirements.

c) The VENDOR shall provide all consumables needed for the FAT based on 3600 gallons of grout generated during the FAT.

d) Water used in testing shall be clean and free of chlorides (containing no more than 50 ppm chloride)System production testing shall be performed using a simulant in accordance with Table 5-1.

Table 5-1. EMF Brine Simulant for Factory Acceptance Testing: Production Test

Analyte

Target Reagent Molecular

Weight

Assay

Target

g/L Molar Mass (g) + NH4 6.075 0.3368 (NH4)2SO4 132.14 0.990 22.48

2- SO4 160.014 1.6657 Na2SO4 142.04 0.998 213.11

Cl- 0.265 0.0075 NaCl 58.44 0.990 0.44 - NO3 9.248 0.1491 NaNO3 84.99 0.997 12.72 - HCO3 1.058 0.0173 NaHCO3 84.01 0.990 1.47

H2O - - DI H2O 18.02 1.000 938.21 Total, g/L 1188.43

d)

e) The VENDOR is responsible for disposing materials and consumables used in the performance of the FAT.

f) The VENDOR shall prepare and submit a FAT Plan and test procedures for BUYER approval.

g) The BUYER’s technical and QA representatives will identify any hold, witness, or verification points during review of FAT plans and procedures.


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h) The approved and issued test plans and procedures shall be followed in strict compliance for the testing work.

i) Changes to approved test plans and test procedures shall be performed in accordance with applicable change control procedures under an approved ASME NQA-1 QA program.

j) Test exceptions, such as test article malfunction, test design deficiency, failure to meet test acceptance criteria, shall be documented in a test exceptions log. Approval of the test exception recovery disposition is required by the Test Director before proceeding with the test.

k) After performance of the FAT, systems shall be flushed, cleaned, and dried as prescribed in FAT plans and procedures.

l) The BUYER’s QA and technical personnel will perform oversight of test activities for performance and completeness of testing.

m) Testing shall be performed under the direction of a qualified Test Director and/or Test Engineer whose qualifications are documented and on file.

n) A personnel qualification matrix shall be kept on file at the test facility identifying those designated personnel and their capabilities to perform test activities as required for the conduct of this testing work.

o) Testing shall be conducted in accordance with the VENDOR’s health and safety procedures in accordance with state and federal regulations. Oversight of safety practices related to VENDOR’s testing activities may be performed by BUYER personnel.

p) The FAT plan shall be prepared in accordance with VENDOR’s NQA-1 program and identify the following, as a minimum:

1) Schedule; 2) Test methodology; 3) Test objectives; 4) Acceptance criteria; 5) Recordkeeping; 6) Test exception reporting; 7) Test reporting; 8) Tools, equipment, and supplies; 9) Key staff and responsibilities; 10) Safety; 11) Flushing, cleaning and drying of MGS systems following FAT; and 12) Quality Assurance.


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q) Calibrated measurement and test equipment shall be used and identified in the FAT plan and procedures. Submit measurement and test equipment procedures with the FAT plan and procedures. Calibration records shall be made available upon request of the BUYER.

r) The FAT plan and test procedures shall identify and demonstrate pertinent human factors considerations in Section 3.3.123.3.123.3.123.3.123.3.13.

s) The FAT plan and test procedures shall identify and demonstrate the ability to operate, maintain, or recover under the following nonstandard conditions, unless eliminated through fault analysis:

1) Unplanned system and equipment maintenance, and flushing; 2) Equipment blockage; 3) Malfunction in interfacing system operations; 4) Impacts of conditions on interfacing systems; 5) Power disruptions; and 6) Equipment fault conditions.

t) As a minimum, the FAT test procedures shall include the following:

1) General introduction, purpose and scope;

2) Prerequisites and assurance that all prerequisites have been met;

3) Addresses industrial safety practices and procedures, such as prejob safety brief and personnel protective equipment;

4) Test objectives and acceptance criteria;

5) Procedural steps required in each test;

6) Required instrumentation, calibrations, and records;

7) Measurements/readings or other observable event that are to be recorded as part of that test;

8) Record of simulations or substitutions used in the test;

9) Test Engineer “sign-off” column for all of above; and

10) Independent (quality assurance and quality control) verification.

11) Pre-startup and prerequisites:

i) Mechanical system integrity tests; ii) Instrumentation calibration;


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iii) Leak detection and confinement tests; iv) Electrical wiring verification and continuity; v) System logic and interlock testing; vi) Support systems unit and integrated tests, e.g., air, water, reagents,

ventilation; vii) Valve operation and alignment; and

12) Water run:

i) Ventilation system tests; ii) Normal operations using water including flow tests, hydraulics, and establish the

baseline without solids; iii) Abnormal operations tests such as trips, etc.; iv) Safe shut down demonstration.

13) Production Tests using water with simulated precipitatesthe simulant specified in Table 5-1:

i) Normal production operations, including container and material handling. ii) Washdown/clean-out operations and layup.

14) MGS flushing, cleaning, drying following FAT

u) The VENDOR shall notify the BUYER at least 10 working days in advance of testing.

v) The VENDOR shall submit a FAT report with the results of the FATs for BUYER approval.


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6.0 QUALITY ASSURANCE

a) The VENDOR shall conduct work in accordance with a QA program that meets the QA criteria specified by the BUYER using Site Form A-6006-661, “Quality Assurance Requirements.”

b) Referenced Procurement QA Clauses, provided separately from this specification, shall be followed as required elements of the QA Program. The Procurement QA Clauses are established contractual obligations for quality programs, systems, identification, traceability, document submittals, testing, reporting, qualification, special process controls, inspections, etc.

c) The VENDOR agrees to incorporate the appropriate QA requirements of this section and those requirements specified elsewhere in the contract into their subcontracts and purchase orders for all lower-tier vendors and suppliers used in the performance of this contract, as the QA requirements apply for the services or items being provided. The VENDOR shall communicate these QA requirements to their personnel, suppliers, and lower-tier vendors so that items and work activities provide for safe and reliable construction.

d) The VENDOR shall provide access to its facility, documents, records, applicable to the performance of this contract for BUYER’s review and assessment. The VENDOR shall flow down this “right of access” requirement to its sub-tier vendors and suppliers. The VENDOR shall coordinate the review or assessment of sub-tier vendor and supplier facilities, documents and records with the BUYER.

e) The BUYER will coordinate with the VENDOR to conduct scheduled and periodic oversight of activities or products associated with this scope of work.

6.1 NONCONFORMANCE REPORTS

Nonconformance reports identified at the VENDOR or lower-tier subcontractor’s facility, associated with this specification, with a proposed disposition of “Accept as is” or “Repair,” shall be submitted to and approved by Engineering and QA before the subcontractor takes any corrective action on the nonconformance. Submittals must conform to QA-AVS B22.

During the performance of work, the VENDOR shall provide to the BUYER copies of all documents that constitute reports of deficiencies, weaknesses, nonconformances, or noncompliances with established requirements related to the items or services provided for this contract. Such documents may include:

• Nonconformance reports; • Corrective action reports; • Critique information and reports; • Investigation reports;


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• Internal and external assessment, surveillance, and audit reports; • Employee concerns associated with nuclear safety; and • Any other document associated with a deficiency or noncompliance.

6.2 INSPECTION AND EXAMINATION

The VENDOR shall include the qualifications of the inspectors for all critical items or features identified from the design. Personnel performing weld inspection shall be certified in accordance with QA-AVS B25. Nondestructive weld examination personnel shall be qualified in accordance with QA-AVS B31.

6.3 SUSPECT AND COUNTERFEIT ITEMS

Procurement of genuine, new, and unused parts shall conform to QA-AVS B76.

6.4 CERTIFICATE OF CONFORMANCE

Objective evidence in the form of a written document for all parts procured shall be provided by the VENDOR. Documentation shall be in the form of a certificate of conformance. Certificates of conformance shall be traceable to the material used in the fabrication and shall fulfill the requirements of ASME NQA-1, Requirement 7, Paragraph 503, “Certificate of Conformance.” Documentation shall conform to QA-AVS B79.


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7-1

7.0 PACKAGING, STORAGE, TRANSPORT, AND LOAD HANDLING

The following sections provide requirements for preservation and packaging, package marking, and handling.

7.1 GENERAL

a) Hoisting, rigging, transport, and load handling activities shall comply with DOE/RL-92-36 and RPP-8360.

b) The VENDOR shall receive, clean, package, store, preserve, handle, and ship SSCs to protect against physical damage, or any effect that would affect quality or cause deterioration at all times while items are located on the VENDOR’s premises. Any such activities associated with QA items shall also meet the requirements of ASME NQA-1, Part II, Subpart 2.2. Classification of items and packaging will follow the guidelines of ASME NQA-1.

c) The VENDOR shall follow manufacturer’s recommendations for storage and handling of all purchased items.

d) The VENDOR shall submit a packaging, storage, shipping, and load handling (PSSH) plan. The PSSH plan shall include all plans, procedures, and drawings that address how items will be packaged, stored, shipped, and handled in accordance with the requirements described throughout this specification, with the exception of topics covered by the lift and rigging plan described in Section 7.5.1.

e) Items subject to deleterious corrosion shall be protected in accordance with ASME NQA-1 (e.g., using either contact-preservatives, inert gas blankets, or vapor-proof barriers with desiccants to absorb any moisture inside the container). The VENDOR shall submit for BUYER approval a description of the preservation methodology specific to each package level type.

7.2 PRESERVATION AND PACKAGING

Equipment shall be dry and clean, and openings capped, plugged, or sealed to prevent entry of foreign material and humidity and protected against corrosion and physical damage as defined in Section 4.4.

7.3 PACKAGING

Exterior package type shall provide the level of protection required based on the storage and environmental limits. Containers, crates, and skids shall be used as the methodology for packaging.


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7.4 MARKING

a) Package marking shall follow the requirements of ASME NQA-1, Part II, Subpart 2.2, and at a minimum, shall appear on two sides of a container, preferably on one side and one end. Package markings shall be applied with waterproof ink or paint in characters that are legible.

b) When information relative to handling and special instructions is required, such information shall be preceded by the word “CAUTION” in letters that are at least 1⁄2 in. (12.7 mm), as permitted by package size. Alternatively, if tags or labels are used, they shall be affixed to the container using a waterproof adhesive, tacks where practical, or a corrosion-resistant wire.

c) Clearly mark partial deliveries of component parts of equipment to identify equipment and contents to permit easy accumulation of parts and to facilitate assembly.

d) Prior to shipment, all packages shall be clearly and suitably tagged to identify, at a minimum:

1) BUYER’s name with destination address;

2) VENDOR’s name with return address;

3) Package numbers showing the Purchase Order Number followed by the package number and the total number of packages;

4) Package contents description;

5) Weight of package;

6) Center of gravity;

7) Parts list (for each package);

8) Handling instructions (e.g., Fragile, Center of Gravity, Keep Dry, This Side Up, Sling Here, Do Not Freeze) and stacking limitations, as appropriate;

9) Special instructions (Desiccant Inside, Special Inspection, Storage, Unpacking Restrictions, etc.), as appropriate;

10) Marking of items not within a container shall exhibit the above specified information in a location that is in plain unobstructed view (marking may be applied directly to bare metal surfaces, provided it has been established that the marking material is not deleterious to the item); and

11) If any hazardous chemicals are included with shipments, the transport vehicle shall display the relevant Department of Transportation labels and/or placards.


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7.5 HANDLING

7.5.1 Lifting and Rigging Plan

a) The VENDOR shall provide submit a lift and rigging plan to cover the lifting and handling instructions for each lifted item (entire package as well as individual items that are uncrated). The plan shall describe the lift points, special lifting devices and/or hardware needs, and lift diagrams. Lift diagrams shall be dimensioned drawings for each equipment and assembly indicating all dimensions and tools necessary for support, lift, and shipment of the lifted item. Tolerances for such dimensions shall be noted, either on the specific dimension or in general notes.

b) Weight of the item, lifting points, as well as dimensions locating centers of gravity shall be generated by VENDOR calculation and shall be noted on the drawing, and the calculations shall be submitted with the drawings demonstrating that the requirements of this section have been satisfied. These drawings shall be provided submitted with the PSSH plan.

7.6 TRANSPORTATION AND STORAGE

a) The VENDOR shall be responsible for all equipment damage, which occurs as a result of improper transportation and storage.

b) All components, unless specified otherwise in this section or related sections, shall be compatible with being transported by public roadway to contract-specified destination unless otherwise specified or allowed by equipment-specific design documents. Items shall either be self-supporting or provided with packing and dunnage so as to ensure their stability and protection from damage. See equipment-specific specifications and procurement documents for limits on weight, size, disassembly, protective capability, and long-term storage.

7.6.1 Transport and Tie-Down Instructions

The VENDOR shall provide submit instructions and diagrams for securing all shipping packages. Transportation tie-down points shall be identified on the equipment. Lift points shall not be used for tie-downs.

7.6.2 Unpacking and Assembly Drawing

The VENDOR shall provide a dimensioned drawing that includes receiving instructions, unpacking instructions, and onsite assembly instructions (if equipment is shipped in a disassembled state). These drawings shall be provided submitted with the PSSH plan.


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7.6.3 Offloading

a) Offloading at BUYER-designated delivery site will be performed by the BUYER or a BUYER-designated representative.


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8.0 DESIGN VERIFICATION

Design verification shall be performed by the VENDOR for the MGS design to ensure the design adequately meets design criteria, the design is technically adequate, and the design meets applicable requirements for environmental, quality, safety, and performance. The VENDOR shall have responsibility for the performance and documentation of all design verifications associated with this specification.

a) The MGS design shall be verified in accordance with the VENDOR’s ASME NQA-1 compliant design verification procedures. The BUYER will review and approve the VENDOR’s design in the submittal review process.

b) VENDOR’s developed multiple-use and single use spreadsheets shall be developed and verified in compliance with the VENDORs ASME NQA-1 compliant calculation verification procedures.


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9.0 NOTES

9.1 ASSUMPTIONS

Reserved

9.2 DEFINITIONS

Availability: Availability is the proportion of time a system is in functioning condition. Availability of an individual component is generally calculated by:

Backwash: Typically refers to removing solids from a filter to enable continued process operation.

Design Life: The intended normal and reliable life of SSCs.

Flush: Removal of chemical and radioactive constituents to enable lay-up/shut down, maintenance, replacement, or inspection.

Reliability: The probability of a system or component to perform a required function under stated conditions for a specified period of time.

9.3 LIST OF ACRONYMS

AISC® American Institute of Steel Construction ALARA as low as reasonably achievable ANSI® American National Standards Institute API American Petroleum Institute ASCE® American Society of Civil Engineers ASME® American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing ASTM® American Society for Testing and Materials AVS Acquisition Verification Services AWS® American Welding Society BPVC Boiler and Pressure Vessel Code BTH below-the-hook CFR Code of Federal Regulations CMTR Certified Material Test Report DOE U.S. Department of Energy


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EGTF Effluent Grout Treatment Facility EIN Equipment Identification Number EPDM ethylene propylene diene monomer EMF Effluent Management Facility EMT electrical metallic tubing ETF Effluent Treatment Facility FAT Factory Acceptance Testing FM Factory Mutual HART Highway Addressable Remote Transducer HEPA high-efficiency particulate air HLW high-level waste HMI® human-machine interface ICS Industrial Control Systems IDF Integrated Disposal Facility IEEE® Institute of Electrical and Electronics Engineers, Inc. ILAW immobilized low-activity waste IMC intermediate metal conduit LAW low-activity waste LDR Land Disposal Requirements LSC® Life Safety Code® MAWP maximum allowable working pressure MDMT minimum design metal temperature MGS Modular Grouting System MSS Manufacturers Standardization Society NBBI National Board of Boiler and Pressure Vessel Inspectors NBIC National Board Inspection Code NCR Nonconformance Report NEC® National Electrical Code® NDC NPH Design Category NDE nondestructive examination NEMA National Electrical Manufacturers Association NESC® National Electrical Safety Code® NFPA® National Fire Protection Association NIST National Institute of Standards and Technology NPH Natural Phenomena Hazard NRTL Nationally Recognized Testing Laboratory ORP Office of River Protection P&ID piping and instrument diagram PFI Pipe Fabrication Institute PSSH packaging, storage, shipping, and load handling PWHT post-weld heat treatment


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QA quality assurance QL Quality Level RCRA Resource Conservation and Recovery Act of 1976 RCW Revised Code of Washington RFI Request for Information RMA Rubber Manufacturers Association RMC rigid metal conduit RPP River Protection Project RT radiographic testing SDC Seismic Design Category SSC structures, systems, and components UT ultrasonic testing V&ID ventilation and instrument diagram VFD variable frequency drive WAC Washington Administrative Code WPS Welding Procedure Specification WRC Welding Research Council, Inc. WTP Waste Treatment and Immobilization Plant

9.4 UNITS OF MEASUREMENT

°C degrees Celsius °F degrees Fahrenheit cfm cubic feet per minute Ci curie Ci/L curie per liter Ci/m3 curie per cubic meter Ci/mol curie per mole cP centipoise dB decibel dynes/cm dynes per centimeter fpm feet per minute ft feet or foot g gram g/L grams per liter g/mL grams per milliliter gmole/L gram mole per liter gpm gallons per minute in. inch mm millimeter


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mrem/h one thousandth of a roentgen equivalent man per hour ppm parts per million psia pounds per square inch absolute psig pounds square inch gauge scfm standard cubic feet per minute μm micron V volt V AC volt alternate current V DC volt direct current w.c. water column wt% weight percent


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9.5 TRADEMARKS

AISC is a registered trademark of American Institute of Steel Construction, Inc., Chicago, Illinois.

ANSI is a registered trademark of the American National Standards Institute, Inc., New York, New York.

ASCE is a registered trademark of the American Society of Civil Engineers, Reston, Virginia.

ASME is a registered trademark of the American Society of Mechanical Engineers, New York, New York.

ASTM is a registered trademark of ASTM International, West Conshohocken, Pennsylvania.

AWS is a registered trademark of the American Welding Society, Miami, Florida.

HMI is a registered trademark of Osram Corporation, Wilmington, Delaware.

IEEE is a registered trademark of The Institute of Electrical and Electronics Engineers, Incorporated, New York, New York.

HART is a registered trademark of HART Communication Foundation, Austin, Texas.

LineBacker is a registered trademark of GPT Industries, Houston, Texas.

LSC and Life Safety Code are registered trademarks of the National Fire Protection Association.

Metalphoto is a registered trademark of Metalphoto Corporation, Cleveland, Ohio.

NEC and National Electrical Code are registered trademarks of the National Fire Protection Association, Quincy, Massachusetts.

NESC and National Electrical Safety Code are registered trademarks of The Institute of Electrical and Electronics Engineers, Incorporated, New York, New York.

NFPA is a registered trademark of The National Fire Protection Association, Inc., Quincy, Massachusetts.

Teflon is a registered trademark of The Chemours Company, Wilmington, Delaware.


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9.6 REFERENCES

DOE/ORP-2003-02, 2003, Environmental Impact Statement for Retrieval, Treatment, and Disposal of Tank Waste and Closure of the Single-Shell Tanks at the Hanford Site, Richland, WA – Inventory and Source Term Data Package, U.S. Department of Energy, Office of River Protection, Richland, Washington.

HNF-5183, Tank Farms Radiological Control Manual, Revision 5N, Washington River Protection Solutions, LLC, Richland, Washington.

ORP-11242, 2017, River Protection Project System Plan, Revision 8, U.S. Department of Energy, Office of River Protection, Richland, Washington.

QA-AVS, 2016, “Procurement Quality Clauses,” Acquisition Verification Services, Richland, Washington.

RPP-8360, Lifting Attachment and Lifted Item Evaluation, Rev. 6, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-51303, 2012, River Protection Project Functions and Requirements, Revision 0, Washington River Protection Solutions, LLC, Richland, Washington.


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Appendix A

PIPING PRESSURE TEST CHECKLIST


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B-1

APPENDIX A – PIPING PRESSURE TEST CHECKLISTPIPING PRESSURE TEST CHECKLISTPIPING PRESSURE TEST CHECKLISTPIPING PRESSURE TEST

CHECKLISTPIPING PRESSURE TEST CHECKLIST

INSPECTION DATE

INSPECTED BY

PLANT VENDOR

SYSTEM/LINE NO. DWG REF

TEST MEDIUM (INCLUDING PPM CHLORIDE)

TEST PRESSURE, PSIG TEST TEMP, °F

TEST GAUGE TEST GAUGE PRESSURE, PSIG

CALIBRATION DUE DATE

AMB TEMP/TIME OF DAY/TEST DURATION

BUYER VENDOR (Initials) Date (Initials) Date 1. Pressure test complete and acceptable.

2. Test boundary sketch with identification of

any joints not tested attached. 3. If partial tests were made, define: a. ____________________________ b. ____________________________ c. ____________________________ d. ____________________________ 4. System ready for post-test check. a. Test blinds removed. b. Final line flush complete. c. Vents properly plugged. d. Drains properly valved and plugged. e. Instruments properly installed. f. Expansion joints, relief valves, control

valves, in-line meters, filter elements orifice plates, in-line strainers, and other special items properly installed.

g. Rotating equipment properly in-line. h. Temporary supports removed.

REMARKS


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___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________


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B-i

Appendix B

PIPING PRE-PRESSURE TEST CHECKLIST


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B-1

APPENDIX B – PIPING PRE-PRESSURE TEST CHECKLISTPIPING PRE-PRESSURE TEST CHECKLISTPIPING PRE-PRESSURE TEST CHECKLISTPIPING PRE-PRESSURE

TEST CHECKLISTPIPING PRE-PRESSURE TEST CHECKLIST

INSPECTION DATE

INSPECTED BY

PLANT VENDOR

SYSTEM/LINE NO. DWG REF

BUYER VENDOR (Initials) Date (Initials) Date 1. All material/equipment (valve numbers,

nipple schedules, flange ratings, etc.) complies with specifications and Piping and Instrumentation Diagrams.

2. All threaded connections, flange bolting, gaskets, and socket welds correctly installed.

3. All PWHT completed and acceptable. 4. All NDE (hardness, MT, PT, RT, UT)

acceptable. 5. Instrumentation protected/secure. 6. Rotating equipment internals

protected/secure. 7. Expansion joints, relief valves, orifice

plates, meters, control valves, filter elements, internal refractories, and other special items protected/secured.

8. Vents installed at system high points. 9. Gauges calibrated and installed. 10. Status of check valve internals has been

tagged. 11. Blinds correctly installed. 12. Temporary plugs and caps have been

replaced. 13. Low point drains are installed, as needed. 14. All welded attachments have been

installed and accepted. 15. Instrument status in compliance with

Appendix C.

REMARKS


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___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

PWHT = post-weld heat treatment. MT = magnetic testing. NDE = nondestructive examination.

PT = penetrant testing. RT = radiographic testing. UT = ultrasonic testing.


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Appendix C

STATUS OF INSTRUMENTS DURING PRESSURE TEST


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C-1

APPENDIX C – STATUS OF INSTRUMENTS DURING PRESSURE TESTSTATUS OF INSTRUMENTS DURING PRESSURE TESTSTATUS OF INSTRUMENTS DURING

PRESSURE TESTSTATUS OF INSTRUMENTS DURING PRESSURE TESTSTATUS OF INSTRUMENTS DURING PRESSURE TEST

Block &

Vent Remove Blind

Off Include in Test

Refer to Notes (1,3)

Analyzers -- X -- -- -- Control Valves -- -- -- X -- Flame Arrestors -- X -- -- 2 Flow Indicating Switches-Bellows Types -- X -- -- -- Flow Instruments-D/P Cell & Bellows Type X -- -- -- -- Flow Instruments-Rotameters -- X -- -- 2 Flow Meters-Positive Displacement Type -- -- X -- 2 Flow Meters-Turbine Type -- X -- -- 2 Flow Switches-Vane Type -- X -- -- -- Gauge Glasses X -- -- -- -- Level Instruments-Displacer Type -- X -- -- -- Level Instrument-D/P Cell & Bellows Type X -- -- -- -- Level Switches-Float Type -- X -- -- -- Orifice Plates -- X -- -- 4 Pressure Gauges X -- -- -- -- Pressure Instruments-All Types X -- -- -- -- Pressure Regulators -- X -- -- -- Pressure Switches X -- -- -- -- PSV’s -- X -- -- 2 PSV’s-3/4” and 1” Screwed -- X -- -- 2 Rupture Discs -- X -- -- -- Steam Traps -- X -- -- 2 Thermowells -- -- -- X --

NOTES:

1. Where applicable, instruments shall be protected from damage due to freezing. In preparation for cold weather and during cold weather, all instruments must be drained and process lead lines blown out with air or nitrogen.

2. Fabricate and install temporary spool, if necessary, for test.

3. Where applicable, exercise caution so that instruments are not over pressurized. Check with Instrument Engineer for maximum test pressure allowed by manufacturer.

4. Install after pressure testing and line flushing. D/P = pressure density. PSV = pressure safety valve.


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