specification for the tank-side cesium removal

A-6007-231 (REV 0)

RPP-SPEC-61910 Revision C

Specification for the Tank-Side Cesium Removal Demonstration Project (Project TD101)

Prepared by

K. E. Ard Washington River Protection Solutions, LLC

Date Published January 2018

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

Contract No. DE-AC27-08RV14800

RPP-SPEC-61910, Rev. C

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TABLE OF CONTENTS

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 .............................................................. 2-2 2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS ................ 2-8 2.4 HIERARCHY OF CODE .................................................................................. 2-10

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

REQUIREMENTS ............................................................................................... 3-1 3.2 CHARACTERISTICS ......................................................................................... 3-4

3.2.1 Performance Characteristics ................................................................. 3-5 3.2.2 Interface Requirements ....................................................................... 3-16

3.3 DESIGN AND CONSTRUCTION REQUIREMENTS ................................... 3-19 3.3.1 Design and Operating Conditions ....................................................... 3-19 3.3.2 Physical Requirements ........................................................................ 3-19 3.3.3 Environmental Conditions .................................................................. 3-19 3.3.4 Structural Analysis and Design ........................................................... 3-21 3.3.5 General Materials Requirements ......................................................... 3-23 3.3.6 Electromagnetic Radiation .................................................................. 3-38 3.3.7 Nameplates and Product Markings ..................................................... 3-38 3.3.8 Labeling .............................................................................................. 3-39 3.3.9 Spare Capacity and Interchangeability ............................................... 3-44 3.3.10 Safety .................................................................................................. 3-45 3.3.11 Security ............................................................................................... 3-47 3.3.12 Plant and Equipment Protection.......................................................... 3-48 3.3.13 Environmental Safety.......................................................................... 3-48 3.3.14 Fire Protection ..................................................................................... 3-48 3.3.15 Water Supply Protection ..................................................................... 3-49 3.3.16 Human Performance and Human Factors Engineering ...................... 3-49 3.3.17 Control System.................................................................................... 3-51 3.3.18 Infrastructure Service Provisions ........................................................ 3-52 3.3.19 System Quality Factors ....................................................................... 3-57 3.3.20 Transportability ................................................................................... 3-59 3.3.21 System Generated Solid and Liquid Wastes ....................................... 3-60 3.3.22 Heating, Ventilation, and Air Conditioning ........................................ 3-60 3.3.23 Lighting and Illumination ................................................................... 3-63

3.4 DOCUMENTATION ........................................................................................ 3-63 3.4.1 Conceptual Design .............................................................................. 3-64 3.4.2 Preliminary Design ............................................................................. 3-64 3.4.3 Final Design ........................................................................................ 3-67 3.4.4 Fabrication Documents ....................................................................... 3-85


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4.0 FABRICATION REQUIREMENTS ........................................................................... 4-1 4.1 POSITIVE MATERIAL IDENTIFICATION ..................................................... 4-1 4.2 GENERAL WELDING REQUIREMENTS ....................................................... 4-3

4.2.1 Structural Welding ................................................................................ 4-4 4.2.2 Weld Materials ...................................................................................... 4-4 4.2.3 Welding Procedures and Qualifications................................................ 4-4 4.2.4 Weld Inspection Requirements ............................................................. 4-4 4.2.5 Additional Welding Requirements ....................................................... 4-5

4.3 VESSEL FABRICATION REQUIREMENTS ................................................... 4-6 4.3.1 General Vessel Requirements ............................................................... 4-6 4.3.2 Vessel Layout Requirements ................................................................ 4-7 4.3.3 Nozzles .................................................................................................. 4-7 4.3.4 Vessel Welding Requirements .............................................................. 4-8 4.3.5 Vessel Welding Process Limitations .................................................... 4-9 4.3.6 Vessel Preheat and Inter-Pass Temperatures ...................................... 4-11 4.3.7 Vessel Post-Weld Heat Treatment ...................................................... 4-11 4.3.8 Vessel Shop Quality Control .............................................................. 4-11

4.4 PIPING FABRICATION REQUIREMENTS ................................................... 4-16 4.4.1 Pipe Spool and Installation Drawings ................................................. 4-16 4.4.2 Pipe Welding ....................................................................................... 4-17 4.4.3 Piping Erection and Installation .......................................................... 4-19 4.4.4 Fabrication Tolerance and Alignment ................................................ 4-22 4.4.5 Orifice Flange Assemblies .................................................................. 4-22 4.4.6 Branch Connections and Miscellaneous Attachments ........................ 4-22 4.4.7 Pipe Bending and Forming ................................................................. 4-23 4.4.8 Heat Treatment.................................................................................... 4-23 4.4.9 Quality Control ................................................................................... 4-24 4.4.10 Flange Joints ....................................................................................... 4-26 4.4.11 Valves ................................................................................................. 4-27 4.4.12 Pipe Supports ...................................................................................... 4-27 4.4.13 Pressure Testing .................................................................................. 4-27 4.4.14 Instrumentation and Control Fabrication and Quality Control

Requirements ...................................................................................... 4-31 4.4.15 Electrical Fabrication and Quality Control Requirements .................. 4-32

4.5 CLEANLINESS ................................................................................................. 4-33

5.0 FACTORY ACCEPTANCE TESTING 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 6.5 VENDOR PROCUREMENT OF SAFETY-SIGNIFICANT ITEMS AND

MATERIALS ....................................................................................................... 6-2


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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 7.5.2 Lifting Attachments and Equipment Design......................................... 7-3 7.5.3 Lift Point Marking ................................................................................ 7-3 7.5.4 Critical Welds ....................................................................................... 7-4 7.5.5 Special Lifting Devices ......................................................................... 7-4 7.5.6 Below-the-Hook Device Markings ....................................................... 7-4

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

8.0 DESIGN VERIFICATION ........................................................................................... 8-1 8.1 DESIGN REQUIREMENTS COMPLIANCE MATRIX ................................... 8-1

9.0 NOTES ............................................................................................................................ 9-1 9.1 ASSUMPTIONS .................................................................................................. 9-1 9.2 DEFINITIONS ..................................................................................................... 9-1 9.3 LIST OF ACRONYMS ....................................................................................... 9-2 9.4 UNITS OF MEASUREMENT ............................................................................ 9-4 9.5 TRADEMARKS .................................................................................................. 9-5 9.6 REFERENCES .................................................................................................... 9-6

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

3-1. Tank-Side Cesium Removal System Diagram ................................................................ 3-2

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

3-3. AP Tank Farm Footprint Constraints ............................................................................. 3-20

3-4. Acceptable Nozzle Connections .................................................................................... 3-32

3-5. Unacceptable Nozzle Connections ................................................................................ 3-33

3-6. Integral Nozzle Reinforcement Methods ....................................................................... 3-33

3-7. NF Label Coding............................................................................................................ 3-41

3-8. NH Label Coding ........................................................................................................... 3-42

3-9. NL Label Coding ........................................................................................................... 3-43

LIST OF TABLES

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

2-2. Non-Government Documents .......................................................................................... 2-2

2-3. Non-Government Non-Code of Record Documents........................................................ 2-8

3-1. Tank-Side Cesium Removal System Performance Parameters Guidance ....................... 3-4

3-2. Summary of Average Radionuclide Components in Waste Feed for Tank-Side Cesium Removal .............................................................................................................. 3-6

3-3. Summary of Average Chemical Components in Waste Feed for Tank-Side Cesium Removal .............................................................................................................. 3-8

3-4. Double-Shell Tank Feed Physical Characteristics ......................................................... 3-10

3-5. Compositions for Hydrogen Generation Rate................................................................ 3-10

3-6. Maximum Radionuclide Values for Mass and Energy Balance .................................... 3-10

3-7. Compositions for Process Material Selection ................................................................ 3-11

3-8. Radionuclide Concentration Limits for Treated Low-Activity Waste .......................... 3-12

3-9. Design Source Term (Liquid Phase) .............................................................................. 3-13

4-1. Vessel Fabrication Traveler Hold Points ....................................................................... 4-12

4-2. Piping Fabrication Traveler Hold Points ....................................................................... 4-25


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1.0 SCOPE

This procurement specification establishes the requirements for design, manufacture, and factory acceptance testing of a Tank-Side Cesium Removal (TSCR) system. The TSCR system will be deployed as a phased demonstration project in the AP Tank Farm on the Hanford Site. The key project objective is to demonstrate a potentially low-cost, efficient tank-side treatment technology to filter solids and remove cesium from supernatant tank waste using non-elutable cesium ion-exchange media. The resulting treated tank waste will provide low-activity waste (LAW) feed to the Waste Treatment and Immobilization Plant (WTP) in support of hot commissioning and early operations.

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 development and process design, including preparing spent ion-exchange columns for interim storage.

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

• Provide control system and process radiation monitoring.

• Provide process equipment and piping design.

• Provide structural design for skids, enclosures, supports, anchorage, and foundations.

• Provide design for ion-exchange columns supporting SSCs needed for interfacing with the interim storage pad (Section 3.2.2.4).

• Procure materials and SSCs.

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

• Fabricate and assemble the TSCR system.

• Fabricate, install, and connect pipe spools and equipment as shown on the approved drawings including fittings, flanges, orifice flanges, branch connections/reinforcements, thermowells, freeze protection, insulation, pipe supports, pipe hangers, vents, drains, specialty items, and any other structural attachments shown on the drawings.

• 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.

• Prepare waste simulants for use in Factory Acceptance Testing (FAT).

• Perform FAT.

• 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 TSCR system to the Hanford Site at AP Tank Farm (transportation and lift plans will be required).

• Provide technical support to the BUYER for process hazards analysis, hazards evaluation, control development, review of nuclear safety documentation, environmental permitting, safeguards and security, 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.

• Provide an initial set of shielded ion-exchange columns that are fully charged with ion-exchange media ready to remove a minimum of 100,000 curies (Ci) of cesium during the first phase of the demonstration project.

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:

• Enclosed process skid with:

– waste feed solids removal (filtration), – Cesium ion exchange, – Ion-exchange resin trap, – Ion-exchange column dewatering and drying, – Ion-exchange column removal and replacement, – Process and vessel vent connections (for lines to the tank farms double shell tank

[DST] system), – Support skids connections, – Process instrumentation, – Process radiation monitoring, – Cameras,


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– Sump leak detection, and – Sump pump.

• Water supply skid.

• Compressed air skid (instrument air).

• Reagent skid (sodium hydroxide [NaOH]).

• Enclosure heating, ventilation, and air conditioning (HVAC) systems.

• Inert gas skid: A nitrogen gas purge skid may be required to displace flammable gas depending on safety analysis results.

• Control trailer with human-machine interface (HMI®) control system.

• Supporting SSCs for ion-exchange columns placement and storage on the interim storage pad (Section 3.2.2.4).

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 TSCR system provides for the early production of immobilized low-activity waste (ILAW) by preparing LAW that will be fed directly from Tank Farms to WTP’s LAW Facility. Prior to the transfer of feed to the WTP LAW Vitrification Facility, tank supernatant waste will be pretreated within the TSCR system to remove cesium. The TSCR system will be deployed as a two phased demonstration project. The first phase will monitor system performance, and demonstrate the ability to safely operate and maintain the TSCR system in support of WTP hot commissioning and early operations. The second phase will demonstrate the ability to reliably and efficiently treat tank waste for an extended operating period.

1.2 DOCUMENT OVERVIEW

This procurement specification defines the functional, performance, interface, design, fabrication, and acceptance test requirements for delivery of the TSCR system. This specification is developed in accordance to TFC-ENG-DESIGN-C-34, “Technical Requirements for Procurement.”


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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 and establish the Code of Record.

Table 2-1. Government Documents. (2 Sheets)

Document Number Title Code of Federal Regulations (CFR) 10 CFR 830 “Nuclear Safety Management” 10 CFR 835 “Occupational Radiation Protection” 10 CFR 835.1001 “Design and Control” 10 CFR 835.1002 “Occupational Radiation Protection,” Subpart K, “Design and Control,”

Paragraph 835.1002, “Facility Design and Modifications” 10 CFR 850 “Chronic Beryllium Disease Prevention Program” 10 CFR 851 “Worker Safety and Health Program” 10 CFR 1021 “National Environmental Policy Act Implementing Procedures” 29 CFR 1910 “Occupational Safety and Health Standards” 29 CFR 1926 “Safety and Health Regulations for Construction” 40 CFR 61 “National Emission Standards for Hazardous Air Pollutants” 40 CFR 264 “Standards for Owners and Operators of Hazardous Waste Treatment,

Storage, and Disposal Facilities” U.S. Department of Energy (DOE) DOE-0336, Rev. 1A Hanford Site Lockout/Tagout Procedure DOE-0342, Rev. 2A Hanford Site Chronic Beryllium Disease Prevention Program (CBDPP) DOE-0360, Rev. 0A Hanford Site Confined Space Procedure (HSCSP) DOE-HDBK-1169-2003 Nuclear Air Cleaning Handbook DOE M 435.1-1 Chg 2 Radioactive Waste Management Manual DOE O 420.1C Facility Safety DOE O 440.1B Worker Protection Program for DOE (Including the National Nuclear

Security Administration) Federal Employees DOE O 451.1B Chg 1 National Environmental Policy Act Compliance Program DOE O 458.1 Chg 3 Radiation Protection of the Public and the Environment DOE/RL-92-36 Hanford Site Hoisting and Rigging Manual DOE-STD-1020-2016 Natural Phenomena Hazard Analysis and Design Criteria for Department

of Energy Facilities DOE-STD-1066-2012 Fire Protection


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Table 2-1. Government Documents. (2 Sheets)

Document Number Title DOE-STD-1189-2008 Integration of Safety into the Design Process MGT-ENG-IP-05 R3 Fire Protection Program DOE/RL-89-10 Hanford Federal Facility Agreement and Consent Order (Tri-Party

Agreement) Revised Code of Washington (RCW) RCW 49.17 “Washington Industrial Safety and Health Act” Washington Administrative Code (WAC) WAC 173-303 “Dangerous Waste Regulations” WAC 173-303-280 “General Requirements for Dangerous Waste Management Facilities” WAC 173-303-640 “Tank Systems” WAC 173-400 “General Regulations for Air Pollution Sources” WAC 173-460 “Controls for New Sources of Toxic Air Pollutants” WAC 197-11 “SEPA Rules” WAC 246-247 “Radiation Protection – Air Emissions” WAC 246-290 “Group A Public Water Supplies” WAC 246-290-490 “Cross Connection Control” Other Directives/Publications 42 USC §6901 (Public Law 94-580)

Resource Conservation and Recovery Act of 1976 (RCRA)

42 USC §4321-4347 (Public Law 91-190)

National Environmental Policy Act of 1969

MIL-STD-889B, Chg Notice 3 Dissimilar Metals

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 2-2, form a part of this specification to the extent specified herein and establish the Code of Record.

Table 2-2. Non-Government Documents. (7 Sheets)

Document Number Title American Concrete Institute (ACI) ACI 301-10 Specifications for Structural Concrete ACI 318-14 Building Code Requirements for Structural Concrete American Conference of Governmental Industrial Hygienists (ACGIH®) ACGIH (2016-29th Edition) Industrial Ventilation – A Manual of Recommended Practice for Design


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Document Number Title American Institute of Steel Construction (AISC®) AISC (4th Edition) Steel Construction Manual AISC 325-11 (14th Edition) Steel Construction Manual AISC 348-14 Specification for Structural Joints Using High-Strength Bolts AISC 360-10 Specification for Structural Steel Buildings AISC 341-10 (2012) Seismic Provisions for Structural Steel Buildings AISC Steel Design Guide 27 (2013) Structural Stainless Steel Air Movement and Control Association International, Inc. (AMCA) ANSI/AMCA 99-16 Standards Handbook ANSI/AMCA Standard 210-16 Laboratory Methods of Testing Fans for Certified Aerodynamic

Performance Rating AMCA Publication 211-13 (Rev. 09-17)

Certified Ratings Program – Product Rating Manual for Fan Air Performance

American Nuclear Society (ANS) ANSI/ANS-2.26-2004 Categorization of Nuclear Facility Structures, Systems, and Components

for Seismic Design (reaffirmed September 12, 2017 and May 27, 2010) American Petroleum Institute (API) API RP 578 (2010-Second Edition) Material Verification Program for New and Existing Allow Piping

Systems API STD 598 (2016-Tenth Edition) Valve Inspection and Testing American Society of Civil Engineers (ASCE®) ASCE 7-10 (2012) Structural Loads American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE®) ASHRAE 62.1 (2013) Ventilation for Acceptable Indoor Air Quality ANSI/ASHRAE Standard 111-2008 (RA 2017)

Measurement, Testing, Adjusting, and Balancing of Building HVAC Systems

American Society of Mechanical Engineers (ASME®) ASME AG-1-2015 Code on Nuclear Air and Gas Treatment ASME BPVC (2017) ASME Boiler & Pressure Vessel Code

Section II (2017) “Materials” Section V (2017) “Nondestructive Examination” Section VIII-1 (2017) “Rules for Construction of Pressure Vessels “ Section IX (2017) “Welding and Brazing Qualifications”

ASME A13.1-2015 Scheme for the Identification of Piping Systems ASME B1.20.1-2013 Pipe Threads, General Purpose (Inch) ASME B16.5-2017 Pipe Flanges and Flanged Fittings ASME B16.9-2012 Factory-Made Wrought Buttwelding Fittings ASME B16.25-2012 Buttwelding Ends ASME B16.34-2017 Valves – Flanged, Threaded, ad Welding End


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Document Number Title ASME B30.20-2013 Below-the-Hook Lifting Devices ASME BTH-1-2017 Design of Below-the-Hook Lifting Devices ASME B31.1-2016 Power Piping ASME B31.3-2016 Process Piping ASME B36.10M-2015 Welded and Seamless Wrought Steel Pipe ASME B36.19M-2004 Stainless Steel Pipe ASME B46.1-2009 Surface Texture (Surface Roughness, Waviness, and Lay) ASME N509-2002 (R2008) Nuclear Power Plant Air-Cleaning Units and Components ASME N511-2007 (R2013) In-Service Testing of Nuclear Air Treatment, Heating, Ventilating, and

Air-Conditioning Systems ASME NQA-1-2008/2009A (Addenda A)

Quality Assurance Requirements for Nuclear Facility Applications

ASME QME-1-2017 Qualification of Active Mechanical Equipment Used in Nuclear Facilities ASME STS-1-2016 Steel Stacks American Society for Nondestructive Testing (ASNT) ASNT SNT-TC-1A-2016 ASNT Standard Topical Outlines for Qualification of Nondestructive

Testing Personnel American Society for Testing and Materials (ASTM®) ASTM A36/A36M-14 Standard Specification for Carbon Structural Steel

ASTM A53/A53M-12 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A193/A193M-16 Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

ASTM A194/A194M-17 Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or Temperature Service, or Both

ASTM A240/A240M-17 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A262-15 Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels

ASTM A276/A276M-17 Standard Specification for Stainless Steel Bars and Shapes ASTM A312/A312M-17 Standard Specification for Seamless, Welded, and Heavily Cold Worked

Austenitic Stainless Steel Pipes ASTM A325-14 Standard Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength (Withdrawn 2016, Replaced by ASTM F3125/F3125M)

ASTM A380/A380M-17 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A480/A480M-17 Standard Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip


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Document Number Title ASTM A500/A500M-13 Standard Specification for Cold-Formed Welded and Seamless Carbon

Steel Structural Tubing in Rounds and Shapes ASTM A554-16 Standard Specification for Welded Stainless Steel Mechanical Tubing ASTM A563-15 Standard Specification for Carbon and Alloy Steel Nuts ASTM A572/A572M-15 Standard Specification for High-Strength Low-Alloy Columbium-

Vanadium Structural Steel ASTM A992/A992M-11(R2015) Standard Specification for Structural Steel Shapes ASTM A1064/A1064M-14 Standard Specification for Carbon-Steel Wire and Welded Wire

Reinforcement, Plain and Deformed, for Concrete ASTM D4329-13 Standard Practice for Fluorescent Ultraviolet (UV) Lamp Apparatus

Exposure of Plastics ASTM E84-17 Standard Test Method for Surface Burning Characteristics of Building

Materials ASTM F436/F436M-16 Standard Specification for Hardened Steel Washers Inch and Metric

Dimensions ASTM F593-17 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs ASTM F795-88(1993) (Withdrawn 2002)

Standard Practice for Determining the Performance of a Filter Medium Employing a Single-Pass, Constant-Rate, Liquid Test

ASTM F1554-15e2 Standard Specification for Anchor Bolts, Steel, 35, 55, and 105-ksi Yield Strength

ASTM F3125/F3125M-15a Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi, (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

American Welding Society (AWS®) ANSI/AWS A2.4:2012 Standard Symbols for Welding Brazing, and Nondestructive Examination ANSI®/AWS A4.2M/A4.2:1997 Standard Procedures for Calibrating Magnetic Instruments to Measure

the Delta Ferrite Content of Austenitic and Duplex Ferritic-Austenitic Stainless Steel Weld Metal

AWS A5.32/A5.32:2011 Welding Consumables—Gases and Gas Mixtures for Fusion Welding and Allied Processes

AWS B2.1/B2.1M-BMG:2014 Base Metal Grouping for Welding Procedure and Performance Qualification

AWS D1.1/D1.1M:2015 Structural Welding Code—Steel AWS D1.3/D1.3M:2008 Structural Welding Code—Sheet Steel AWS D1.6/D1.6M:2017 Structural Welding Code—Stainless Steel AWS D9.1M/D9.1:2012 Sheet Metal Welding Code AWS QC1:2016 Standard for AWS Certification of Welding Inspectors Health Physics Society (HPS) ANSI/HPS N13.1 (2011) Sampling and Monitoring Releases of Airborne Radioactive Substances

from the Stacks and Ducts of Nuclear Facilities


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Document Number Title International Code Council (ICC) AC156 (2010) Acceptance Criteria for Seismic Certification by Shake-Table Testing of

Nonstructural Components IBC® 2015 International Building Code® (IBC) Institute of Electrical and Electronics Engineers, Inc. (IEEE®) IEEE C2-2017 2017 National Electrical Safety Code® (NESC®) IEEE Std 80-2013 IEEE Guide for Safety in AC Substation Grounding IEEE Std 142-2007 IEEE Recommended Practice for Grounding of Industrial and

Commercial Power System IEEE Std 242-2001 IEEE Recommended Practice for Protection and Coordination of

Industrial and Commercial Power Systems IEEE Std 344™-2013 IEEE Standard for Seismic Qualification of Equipment for Nuclear Power

Generating Stations 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 1050-2004 IEEE Guide for Instrumentation and Control Equipment Grounding in Generating Stations

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

Illuminating Engineering Society (IES) IES HB-10-11 (10th Edition) The Lighting Handbook – Reference and Application International Society of Automation (ISA) ANSI/ISA-5.1-2009 Instrumentation Symbols and Identification ANSI/ISA-5.2-1976 (R1992) Binary Logic Diagrams for Process Operations ANSI/ISA-7.0.01-1996 Quality Standard for Instrumented Air ANSI/ISA 84.00.01-2004 Functional Safety: Safety Instrumented Systems for the Process Industry

Sector Manufacturers Standardization Society (MSS) ANSI/MSS SP-25-2013 Standard Marking System for Valves, Fittings, Flanges, and Unions MSS SP-58-2009 Pipe Hangers and Supports – Materials, Design, Manufacture, Selection,

Application, and Installation National Board Inspection Code (NBIC) NBBI NB-23 2017 National Board Inspection Code National Electrical Manufacturers Association (NEMA) NEMA ICS 1-2000 (R2005, R2008, R2015)

Industrial Control and Systems: General Requirements

NEMA ICS 6-1993 (R2001, R2006, R2011)

Industrial Control and Systems: Enclosures

NEMA MG-1-2016 Motors and Generators


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Document Number Title National Fire Protection Association (NFPA®) NFPA 13 (2016) Standard for Installation of Sprinkler Systems NFPA 70 (2017) National Electrical Code® (NEC®) NFPA 70E® (2018) Standard for Electrical Safety in the Workplace® NFPA 72 (2016) National Fire Alarm and Signaling Code® (NFASC®) NFPA 75 (2013) Standard for the Fire Protection of Information Technology Equipment NFPA 101 (2018) Life Safety Code® (LSC®) NFPA 497 (2017) Recommended Practice for the Classification of Flammable Liquids,

Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas

NFPA 701 (2015) Standard Methods of Fire Tests for Flame Propagation of Textiles and Films

NFPA 780 (2014) Standard for the Installation of Lightning Protection Systems National Institute of Standards and Technology (NIST) Special Publication (SP) NIST SP 800-53A Assessing Security and Privacy Controls in Federal Information Systems

and Organizations NIST SP 800-82 Guide to Industrial Control Systems (ICS) Security Pipe Fabrication Institute (PFI) PFI Standard ES-3 (Revised March 2009)

Fabricating Tolerances

PFI Standard ES-24 (Revised December 2013)

Pipe Bending Methods, Tolerances, Process and Material Requirements

Underwriters Laboratories, Inc. (UL®) UL 508 (2013) Standard for Industrial Control Equipment Other Publications TFC-BSM-AD-STD-02, Rev. D-7 “Editorial Standards and Format Guidance for Documents” TFC-ENG-STD-01, Rev. A-7 “Human Factors in Design” TFC-ENG-STD-02, Rev. A-12 “Environmental/Seasonal Requirements for TOC Systems, Structures, and

Components” TFC-ENG-STD-03, Rev. A-8 “Waste Transfer Confinement Configuration” TFC-ENG-STD-06, Rev. D-0 “Design Loads for Tank Farm Facilities” TFC-ENG-STD-07, Rev. H-3 “Ventilation System Design Standard” TFC-ENG-STD-08, Rev. B-5 “Post Maintenance Testing” TFC-ENG-STD-10, Rev. A-15 “Drawing Standard” TFC-ENG-STD-12, Rev. E-0 “Tank Farm Equipment Identification Numbering and Labeling Standard” TFC-ENG-STD-13, Rev. G “Ignition Source Controls For Work Controls In Potentially Flammable

Atmospheres” TFC-ENG-STD-14, Rev. C-3 “Setpoint Standard” TFC-ENG-STD-15, Rev. C-5 “Standard for Raceway Systems and Flexible Cords & Cables” TFC-ENG-STD-21, Rev. D-11 “Hose-In-Hose Transfer Lines”


2-8


Document Number Title TFC-ENG-STD-22, Rev. G-2 “Piping, Jumpers, and Valves” TFC-ENG-STD-23, Rev. A-8 “Human-Machine Interface for Process Control Systems” TFC-ENG-STD-25, Rev. D-4 “Transfer Pumps” TFC-ENG-STD-26, Rev. C-4 “Waste Transfer, Dilution, and Flushing Requirements” TFC-ENG-STD-34, Rev. A-1 “Standard for the Selection of Non-Metallic Materials in Contact with

Tank Waste” TFC-ENG-STD-41, Rev. A-5 “Electrical Installations” TFC-ENG-STD-45, Rev. B “Design and Installations For Potentially Flammable Atmospheres” TFC-ENG-STD-47, Rev. A-0 “Piping Data Specification Standard” TFC-ESHQ-ENV-STD-03, Rev. A-9 “Air Quality – Radioactive Emissions” TFC-ESHQ-ENV-STD-04, Rev. C-5 “Air Quality Program – Non Radioactive Emissions” (Section 3.3.3.1

only) TFC-ESHQ-ENV-STD-05, Rev. A-7 “Radioactive Airborne Effluent Sampling” TFC-ESHQ-ENV-STD-10, Rev. B-0 “Environmental Requirements Management” TFC-ESHQ-ENV-STD-11, Rev. A-7 “Air Program Plan” TFC-ESHQ-FP-STD-02, Rev. D-0 “Fire Protection Design Criteria” TFC-ESHQ-FP-STD-06, Rev. B-8 “Fire Hazard Analysis and Fire Protection Assessment Requirements” TFC-ESHQ-FP-STD-12, Rev. A-5 “Hanford Fire Department Services” TFC-ESHQ-S_SAF-CD-11, Rev. B “Worker Safety and Health Program Requirements Implementation

Matrix”

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, but are not considered to be Code of Record documents. Washington River Protection Solutions, LLC (WRPS) procedures are provided for reference to ensure consistency and compatibility with Tank Farms processes and SSCs.

Table 2-3. Non-Government Non-Code of Record Documents. (2 Sheets)

Document Number Title 24590-WTP-ICD-MG-01-030, Rev. 1 (draft)

ICD 30 – Interface Control Document for Direct LAW Feed

HNF-4492, Rev. 5 Interface Control Document between Washington River Protection Solutions, LLC (WRPS) and Mission Support Alliance, LLC (MSA) for Electric Utilities Distribution System

HNF-36174, Rev. 4 DOE Fire Protection Handbook - Hanford Chapter


2-9

Table 2-3. Non-Government Non-Code of Record Documents. (2 Sheets)

Document Number Title

HNF-5183, Rev. 5M Tank Farm Radiological Control Manual

HNF-EP-0063, Rev. 16 Hanford Site Solid Waste Acceptance Criteria HNF-SD-WM-OCD-015, Rev. 38 Tank Farms Waste Transfer Compatibility Program RPP-8360, Rev. 6 Lifting Attachment and Lifted Item Evaluation RPP-13211, Rev. 1 Electromagnetic Compatibility and Electrical Noise Control for the DOE

Hanford Site RPP-38172, Rev.0 (Attachment C) Project W-551 Interim Pretreatment System (IPS) Siting Study RPP-50655, Rev. 1 Interface Control Document TFLAN – ICD RPP-51303, Rev. 0 River Protection Project Functions and Requirements RPP-MP-003, Rev. 6d Integrated Environment, Safety, and Health Management System

Description for the Tank Operations Contractor TFC-BSM-IRM_SE-C-01, Rev. A-6 “Computer Security” TFC-BSM-IRM_SE-C-02, Rev. A-9 “Radio and Telecommunications Security” TFC-BSM-IRM-STD-04, Rev. A-6 “Telecommunications and Network Infrastructure Standards” TFC-ENG-DESIGN-C-10, Rev B-12 “Engineering Calculations” TFC-ENG-DESIGN-C-25, Rev. G-1 “Technical Document Control” TFC-ENG-DESIGN-C-34, Rev. C “Technical Requirements for Procurement” TFC-ENG-DESIGN-C-42, Rev. A-7 “Design Requirements Compliance Matrix” TFC-ENG-DESIGN-C-60, Rev. A-3 “Preparation of Piping Analyses for Waste Transfer Systems” TFC-ENG-DESIGN-D-29, Rev. A-1 “Guidance for Inclusion of Human Factors in Design” TFC-ENG-DESIGN-P-07, Rev. D-1 “System Design Descriptions” TFC-ENG-FACSUP-C-23, Rev. G-0 “Equipment Identification and Data Management” TFC-ENG-FACSUP-C-25, Rev. D “Hoisting and Rigging” TFC-ESHQ-EP-C-01, Rev. A-19 “Emergency Management” TFC-ESHQ-IH-STD-08, Rev. C “Lead Control Program” TFC-ESHQ-IH-STD-13, Rev. A-2 “Illumination” TFC-PLN-01, Rev. A-4 “Integrated Safety Management System” TFC-PLN-02, Rev. H-3 “Quality Assurance Program Description” TFC-PLN-05, Rev. F-4 “Conduct of Operations Implementation Plan” TFC-PLN-09, Rev. C-11 “Human Factors Program” TFC-PLN-29, Rev. C-14 “Nuclear Maintenance Management Plan” TFC-PLN-47, Rev C-4 “Worker Safety and Health Program” TFC-PLN-102, Rev. C-3 “TOC Interface Management Plan” TFC-PLN-125, Rev. C “Sustainable Program Plan” TFC-PLN-138, Rev. B “Implementation Plan for ISA 84 (Safety Instrumented Systems)”


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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.


3-1

3.0 SYSTEM CHARACTERISTICS AND REQUIREMENTS

The primary mission of the TSCR system is to demonstrate that the technology can prepare treated tank farm supernatant LAW for delivery to Tank Farm DSTs. The LAW delivered to the DSTs shall meet the requirements for direct feed to the WTP LAW Facility in a safe, economic, and environmentally protective manner. The TSCR system will receive tank supernatant waste from the DST system, filter out undissolved solids, and treat the tank supernatant waste by removing radioactive cesium using an ion-exchange subsystem. The liquid and gaseous effluents from the TSCR system will be returned to the DST system. Treated waste will be sent to a separate DST. The treated waste compliant with WTP waste acceptance criteria will be fed by Tank Farms to the WTP LAW Facility.

A system diagram for TSCR is provided in Figure 3-1. The TSCR system consists of pre-filtration and cesium ion-exchange unit process operations located inside of a process enclosure. Waste feed is delivered from a DST to the process enclosure interface via a transfer pump and hose-in-hose transfer line (HIHTL) provided by others. The pre-filtration subsystem consists of multiple filter units, so that a clean filter is alternated on-line at all times. The solids remain in the offline filter until flushed out with a side stream of filtrate from the online filter. Filter flush is sent back to a DST.

The treated LAW product is sent to a DST via a HIHTL provided by others. When an ion-exchange column is fully loaded, it will be taken out of service and the next ion-exchange column will begin loading. Preparation of the spent ion-exchange column for removal may begin while loading the next ion-exchange column. When all ion-exchange columns within the process enclosure are loaded, the spent ion-exchange columns will be replaced.

Each spent ion-exchange column will be displaced with caustic followed by a water rinse. The caustic and water flush will be sent to a DST. Each spent ion-exchange column will then be air-dried. The drying process is expected to consist of draining an ion-exchange column, and then pushing roughly 30 cfm of dry air through each ion-exchange column in up-flow for approximately one week. Air and liquids will be sent to a DST during the drying process. The spent ion-exchange columns will be moved by others to an interim storage pad provided by others. The newly installed ion-exchange columns will be flushed with caustic solution and water for fines removal and pre-conditioning prior to use. The caustic pre-conditioning solution will be sent to a DST.

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 TSCR mission. Figure 3-2 identifies the functions and their subordinate functions (highlighted in yellow) from the RPP Functional Hierarchy applicable to the TSCR mission.

3-2

RPP-SPEC

-61910, Rev. C

Figure 3-1. Tank-Side Cesium Removal System Diagram.

Solids Filtration

IXC

IXC

IXC

241-AP

TSCR Enclosure Boundary

Solids Return

IX Column Vent

Filtrate

Filter Vent

Treated LAW

Caustic/Water Rinse/Drying Air

Air/Water/Caustic/N2 PurgeWater/Caustic/

N2 Purge

Enclosure Sump

137Cs Removal

241-AP-107

Spen

t IXC Transport dried

IXC to interim storage

241-AP

To DST Headspace

Resin Trap

Enclosure Supply Air

Heat & CoolExhaust

Air ElectricalDrying

AirReagents

Local Control


3-3

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.

The TSCR system is comprised of six functional components:

1. A Move Waste component to provide capability of supernatant transfer within the DST system.

2. A Monitor Waste component to monitor the tank waste during transfer and operations.

3. A Pretreat Waste component to treat tank supernatant.

4. A Dispose Secondary Waste component to discharge and package any secondary solid waste generated from the treatment process.

5. A Manage Secondary Waste component to manage generated solid and liquid secondary waste.

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

Remediate Tank Wastes

Manage Tank Waste

StoreWaste

MoveWaste

Concentrate Waste

Characterize Waste

MonitorWaste

Retrieve Tank Waste

Remove SSTTank Waste

Remove Potential CH-TRU

Tank Waste

Remove Ancillary Storage

System Waste

Deliver Waste Feed

Process Tank Waste

PretreatTank Waste

Immobilize High-Level Waste

Process Potential Contact-Handled

TransuranicTank Waste

Immobilize Low-Activity Waste

Dispose Tank Waste

*Dispose Immobilized

High-Level Waste

*Dispose Potential CH-TRU

Tank Waste

Dispose Immobilized Low-

Activity Waste

Dispose Secondary

Waste

Manage Sys. Gen. Waste

Manage Immobilized

High-Level Waste

Manage Potential CH-TRU

Tank Waste

Manage Immobilized Low-

Activity Waste

Manage Secondary

Waste

Close Tanks, Waste

Management Areas, and Excess

Facilities

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


3-4

3.2 CHARACTERISTICS

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

Table 3-1 provides performance parameter guidance for key TSCR SSCs. These parameters are provided for initial scoping and are assumed to be conservative at this time. These performance parameters may evolve as a result of process hazard analysis and control development.

Table 3-1. Tank-Side Cesium Removal System Performance Parameters Guidance. (2 sheets)

Item Function Safety Quality

Seismic Design

Category (SDC)

Limit State(a) Design Code Basis

Ion-exchange Columns

Pressure Retaining

SS QL-2 SDC-2 C ASME Boiler & Pressure Vessel Code (2017), Section VIII, “Rules for Construction of Pressure Vessels,” Division 1

Safety function: Maintain confinement of radioactive material in a postulated-drop event during removal and preparation of spent ion-exchange columns for transport and storage.

Waste Containing Piping and Components

Pressure Retaining

GS QL-3 SDC-1 A ASME B31.3-2016, Process Piping

Enclosure provides waste spray leak knockdown.

Waste Containing Filter Vessels

Pressure Retaining

GS QL-3 SDC-1 A ASME BPVC, Section VIII


Enclosure for Waste Containing Process Equipment

Confinement Barrier

SS(b) QL-2 SDC-2 C International Building Code (IBC 2015) ASCE 7-10, Structural Loads

Safety function: (1) Prevent damaging interactions with safety-significant SSCs, if present and (2) Provides waste spray leak knockdown.

Compressed Air Pressure Relieve Valve

Overpressure Protection

GS QL-3 SDC-1 A TFC-ENG-STD-22, “Piping, Jumpers, and Valves”


Double Valve Isolation (if used)

Backflow Prevention

SS QL-2 SDC-2 C TFC-ENG-STD-22 Safety function: Prevent backflow of waste to air, water, and reagent systems.

Ventilation System

Confinement, Ventilation, Heating and Cooling

GS QL-3 SDC-1 C TFC-ENG-STD-07, “Ventilation System Design Standard”

Enclosure air space is not in communication with tank waste.

Ion-exchange Column Process Vent

Limit Flammable Gas Accumulation and ion-exchange column pressurization

SS QL-2 SDC-2 C -- Safety Function: ion-exchange column open to DST system during upon loss of flow.


3-5

Table 3-1. Tank-Side Cesium Removal System Performance Parameters Guidance. (2 sheets)

Item Function Safety Quality

Seismic Design

Category (SDC)

Limit State(a) Design Code Basis

Ion-Exchange Column Filtered Vent

Limit Flammable Gas Accumulation and ion-exchange column pressurization

SS QL-2 SDC-2 C -- Safety Function: Spent ion-exchange column open to filtered vent for transport and storage.

Nitrogen Purge System (if used)

Limit Flammable Gas below LFL

SS QL-2 SDC-2 C -- Safety Function: Limits accumulation of flammable gas in ion-exchange columns to below LFL during loss of flow through ion-exchange columns.

(a)See ANSI/ANS 2.26-2004, “Categorization of Nuclear Facility Structures, Systems, and Components for Seismic Design” for definitions. (b)Design Features means the design features of a nuclear facility specified in the Technical Safety Requirements (TSR) that, if altered or modified, would have a significant effect on safe operation. Design Features are normally passive characteristics of the facility not subject to change by operations personnel, and do not require, or infrequently require, maintenance or surveillance. ASCE® = American Society of Civil Engineers. ASME® = American Society of Mechanical Engineers. BPVC = Boiler & Pressure Vessel Code. DST = double-shell tank. GS = general service. IX = ion-exchange.

LFL = lower flammability limit. N/A = not applicable. QL = Quality Level. SDC = seismic design category. SS = safety significant.

3.2.1 Performance Characteristics

The TSCR system performance requirements are as follows:

a) The TSCR system shall have a minimum throughput of 5 gpm.

b) The TSCR system shall treat a minimum of 170,000 gallons of waste from Tank AP-107 during the first phase of the demonstration project. This corresponds to at least 100,000 Ci of cesium.

c) The TSCR system shall be capable of performing a second phase of the demonstration project following the first phase for up to 5,000,000 gallons of additional waste feed processing.

d) The ion-exchange column cesium loading and physical configuration shall provide design margin to prevent ion-exchange column boiling in static and dynamic flow conditions.

e) The TSCR system design shall minimize operational downtime due to ion-exchange column replacement frequency (see availability requirements in Section 3.3.19.4).

f) The TSCR system shall have a cesium removal efficiency or decontamination factor greater than 1,000; and shall be able to determine when an ion-exchange column is no longer meeting the decontamination factor requirement.


3-6

3.2.1.1 Manage Tank Waste. The following sections provide requirements for the “manage tank waste” function. This includes the requirements for the movement and monitoring of tank waste that will be pumped from Tank Farms DST system to the TSCR system by others. The average waste radionuclide content, average chemical composition, and physical characteristics of the waste are tabulated below.

Move Waste.

a) The TSCR system shall be capable of receiving supernatant waste from the DST system, as required, to meet the requirements of Section 3.2.1.

b) The TSCR system 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).

c) The TSCR system process vessels (e.g., filters, strainers, ion-exchange columns) shall be designed to permit draining and flushing to support inspection, maintenance or replacement, and dewatering and drying activities. If bottom drains are used, the process vessels shall be designed to allow maintenance and replacement of bottom drains.

d) The TSCR system shall be designed to receive waste with the estimated radiological, chemical, and physical properties shown in Tables 3-2 through 3-7. NOTE: These tables are the average waste component concentrations in waste feed batches to WTP as calculated in RPP-RPT-59659, Waste Characteristics for Inclusion in RPP-SPEC-56967, Project T5L01 Low Activity Waste Pretreatment System Specification.

Table 3-2. Summary of Average Radionuclide Components in Waste Feed for Tank-Side Cesium Removal.(a,b) (2 sheets)

Component Unit Liquid Solid

Average(a) Minimum(b) Maximum(b) Average(a) Minimum(b) Maximum(b) 106Ru Ci/L 8.48E-12 7.21E-17 3.07E-11 0.00E+00 0.00E+00 1.24E-11 113mCd Ci/L 8.95E-06 1.80E-07 1.12E-05 0.00E+00 0.00E+00 1.07E-04 125Sb Ci/L 4.66E-07 1.45E-09 9.51E-07 0.00E+00 0.00E+00 1.24E-06 126Sn Ci/L 5.02E-07 4.57E-08 3.99E-06 0.00E+00 0.00E+00 2.30E-05 129I Ci/L 1.64E-07 6.04E-08 1.85E-07 0.00E+00 0.00E+00 2.69E-07 134Cs Ci/L 4.37E-08 5.69E-10 1.06E-07 0.00E+00 0.00E+00 2.68E-08 137Cs Ci/L 1.35E-01 6.47E-02 2.76E-01 0.00E+00 0.00E+00 3.10E-01 137mBa Ci/L 1.27E-01 6.11E-02 2.61E-01 0.00E+00 0.00E+00 2.93E-01 14C Ci/L 1.03E-06 3.99E-07 7.86E-06 0.00E+00 0.00E+00 4.42E-08 151Sm Ci/L 3.55E-03 5.25E-05 4.77E-03 0.00E+00 0.00E+00 1.22E-01 152Eu Ci/L 4.47E-07 3.84E-09 5.15E-07 0.00E+00 0.00E+00 7.94E-06 154Eu Ci/L 6.23E-06 5.58E-08 1.38E-05 0.00E+00 0.00E+00 2.78E-04 155Eu Ci/L 1.78E-06 7.13E-09 2.22E-06 0.00E+00 0.00E+00 2.19E-05 226Ra Ci/L 5.25E-11 1.57E-12 7.54E-11 0.00E+00 0.00E+00 4.14E-10


3-7

Table 3-2. Summary of Average Radionuclide Components in Waste Feed for Tank-Side Cesium Removal.(a,b) (2 sheets)


Average(a) Minimum(b) Maximum(b) Average(a) Minimum(b) Maximum(b) 227Ac Ci/L 1.20E-09 3.24E-10 1.74E-08 0.00E+00 0.00E+00 2.83E-07 228Ra Ci/L 1.36E-09 2.24E-11 3.34E-09 0.00E+00 0.00E+00 1.05E-08 229Th Ci/L 1.25E-09 1.34E-11 2.39E-09 0.00E+00 0.00E+00 2.11E-09 231Pa Ci/L 2.09E-09 8.10E-10 2.74E-08 0.00E+00 0.00E+00 4.66E-07 232Th Ci/L 1.36E-09 2.25E-11 3.34E-09 0.00E+00 0.00E+00 1.06E-08 232U Ci/L 1.35E-09 4.08E-11 2.23E-09 0.00E+00 0.00E+00 1.18E-07 233U Ci/L 1.54E-08 1.34E-09 3.95E-08 0.00E+00 0.00E+00 9.43E-06 234U Ci/L 5.44E-09 1.55E-09 4.87E-08 0.00E+00 0.00E+00 2.63E-06 235U Ci/L 1.88E-10 5.97E-11 1.85E-09 0.00E+00 0.00E+00 1.08E-07 236U Ci/L 1.84E-10 5.05E-11 4.31E-09 0.00E+00 0.00E+00 7.04E-08 237Np Ci/L 5.90E-08 6.01E-09 1.35E-07 0.00E+00 0.00E+00 7.59E-06 238Pu Ci/L 4.72E-08 6.82E-09 2.71E-07 0.00E+00 0.00E+00 1.93E-05 238U Ci/L 4.13E-09 1.28E-09 3.39E-08 0.00E+00 0.00E+00 2.44E-06 239Pu Ci/L 3.59E-07 1.63E-07 6.37E-06 0.00E+00 0.00E+00 5.69E-04 240Pu Ci/L 7.71E-08 3.57E-08 1.47E-06 0.00E+00 0.00E+00 1.32E-04 241Am Ci/L 6.69E-07 2.00E-07 1.50E-05 0.00E+00 0.00E+00 1.88E-03 241Pu Ci/L 5.36E-07 9.82E-08 5.11E-06 0.00E+00 0.00E+00 2.87E-04 242Cm Ci/L 3.13E-09 1.79E-09 2.13E-07 0.00E+00 0.00E+00 1.32E-06 242Pu Ci/L 3.32E-10 1.75E-11 2.62E-09 0.00E+00 0.00E+00 1.48E-08 243Am Ci/L 4.33E-11 2.69E-11 3.77E-09 0.00E+00 0.00E+00 1.19E-06 243Cm Ci/L 7.14E-10 1.28E-10 9.16E-09 0.00E+00 0.00E+00 1.07E-07 244Cm Ci/L 1.26E-08 2.00E-09 1.51E-07 0.00E+00 0.00E+00 1.54E-06 3H Ci/L 1.34E-06 3.85E-07 3.42E-06 0.00E+00 0.00E+00 6.61E-09 59Ni Ci/L 4.56E-07 4.56E-08 1.03E-06 0.00E+00 0.00E+00 7.62E-05 60Co Ci/L 4.71E-07 3.58E-09 5.76E-07 0.00E+00 0.00E+00 7.40E-06 63Ni Ci/L 3.40E-05 3.25E-06 7.97E-05 0.00E+00 0.00E+00 5.97E-03 79Se Ci/L 5.10E-07 7.90E-08 9.38E-07 0.00E+00 0.00E+00 1.20E-06 90Sr Ci/L 8.53E-04 3.88E-04 1.36E-03 4.98E-04 0.00E+00 7.54E-01 90Y Ci/L 8.53E-04 3.88E-04 1.36E-03 4.98E-04 0.00E+00 7.54E-01 93mNb Ci/L 6.46E-06 1.89E-06 1.54E-05 0.00E+00 0.00E+00 2.14E-04 93Zr Ci/L 7.40E-06 2.04E-06 1.76E-05 0.00E+00 0.00E+00 2.27E-04 99Tc Ci/L 1.11E-04 5.91E-05 1.43E-04 0.00E+00 0.00E+00 3.92E-04 (a)Average values come from TOPSim Case 3335 (MR-50242). (b)Minimum and maximum values come from TOPSim Cases 1514, 3322, and 3335 (RPP-RPT-60146, TOPSim Data Package for the River Protection Project System Plan, Revision 8, Scenarios; MR-50242).


3-8

Table 3-3. Summary of Average Chemical Components in Waste Feed for Tank-Side Cesium Removal.(a) (2 sheets)


Average(a) Minimum(b) Maximum(b) Average(a) Minimum(b) Maximum(b)

Ag+ g/L 1.39E-03 8.25E-05 4.05E-03 0.00E+00 0.00E+00 3.02E-02 Al(OH)3 g/L 0.00E+00 0.00E+00 0.00E+00 3.00E+03 2.16E+03 3.00E+03 Al(OH)4

- g/L 1.36E+01 3.91E+00 3.28E+01 0.00E+00 0.00E+00 0.00E+00 Al+3 g/L N/A 0.00E+00 0.00E+00 N/A 7.91E-03 2.74E+00 AlOOH g/L N/A 0.00E+00 0.00E+00 N/A 0.00E+00 2.11E+02 As+5 g/L 7.40E-03 1.27E-04 4.04E-02 0.00E+00 0.00E+00 3.87E-02 B+3 g/L 1.43E-02 5.71E-04 3.44E-02 0.00E+00 0.00E+00 1.31E-01 Ba+2 g/L 8.11E-04 3.50E-05 2.44E-03 0.00E+00 0.00E+00 4.73E-02 Be+2 g/L 5.56E-04 7.76E-06 1.31E-03 0.00E+00 0.00E+00 1.86E-03 Bi+3 g/L 1.13E-02 1.88E-03 1.70E-02 0.00E+00 0.00E+00 2.00E-01 C2O4

-2 g/L 5.74E-01 2.92E-01 1.05E+00 0.00E+00 0.00E+00 2.71E+02 Ca+2 g/L 3.95E-02 7.21E-03 8.94E-02 0.00E+00 0.00E+00 3.96E+00 Cd+2 g/L 1.09E-03 2.07E-04 1.07E-02 0.00E+00 0.00E+00 1.61E-02 Ce+3 g/L 1.06E-02 1.26E-04 2.42E-02 0.00E+00 0.00E+00 7.75E-02 Cl- g/L 3.22E+00 7.24E-01 3.80E+00 0.00E+00 0.00E+00 0.00E+00 CN- g/L N/A 5.15E-07 7.99E-04 N/A 0.00E+00 4.61E-04 Co+3 g/L 9.00E-04 3.16E-05 8.08E-03 0.00E+00 0.00E+00 8.36E-03 CO3

-2 g/L 2.86E+01 6.57E+00 3.73E+01 0.00E+00 0.00E+00 0.00E+00 CrO4

-2 g/L 1.10E+00 2.47E-01 1.63E+00 0.00E+00 0.00E+00 0.00E+00 CrOOH g/L 2.20E-05 0.00E+00 2.84E-05 0.00E+00 0.00E+00 5.08E+01 Cs+ g/L 8.37E-03 4.69E-03 1.87E-02 0.00E+00 0.00E+00 2.07E-02 Cu+2 g/L 1.69E-03 4.91E-05 4.04E-03 0.00E+00 0.00E+00 1.64E-02 F- g/L 2.86E-01 1.31E-01 1.02E+00 0.00E+00 0.00E+00 1.44E+01 Fe+3 g/L 1.03E-02 1.76E-03 3.83E-02 0.00E+00 0.00E+00 7.64E+00 H2O g/L 8.86E+02 8.54E+02 9.00E+02 0.00E+00 0.00E+00 2.59E+02 Hg+2 g/L 1.93E-05 6.49E-06 6.84E-03 0.00E+00 0.00E+00 9.68E-03 K+ g/L 4.20E+00 4.70E-01 1.75E+01 0.00E+00 0.00E+00 3.60E+01 La+3 g/L 9.16E-04 1.63E-05 1.45E-03 0.00E+00 0.00E+00 4.89E-02 Li+ g/L 6.01E-04 3.38E-05 3.15E-03 0.00E+00 0.00E+00 1.64E-02 Mg+2 g/L 5.34E-03 3.15E-04 4.04E-02 0.00E+00 0.00E+00 7.00E-02 Mn+4 g/L 9.46E-04 6.69E-04 1.18E-02 0.00E+00 0.00E+00 9.88E-01 MNO4

- g/L N/A 0.00E+00 0.00E+00 N/A 0.00E+00 0.00E+00 Mo+6 g/L 2.86E-02 8.54E-04 4.47E-02 0.00E+00 0.00E+00 4.70E-02 Na+ g/L 1.29E+02 1.29E+02 1.38E+02 0.00E+00 0.00E+00 1.55E+02 Nd+3 g/L 6.23E-03 2.16E-04 1.25E-02 0.00E+00 0.00E+00 8.62E-02 NH3 g/L N/A 0.00E+00 1.08E-03 N/A 0.00E+00 0.00E+00


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Table 3-3. Summary of Average Chemical Components in Waste Feed for Tank-Side Cesium Removal.(a) (2 sheets)


Average(a) Minimum(b) Maximum(b) Average(a) Minimum(b) Maximum(b)

NH4+ g/L N/A 0.00E+00 7.15E-02 N/A 0.00E+00 0.00E+00

Ni+2 g/L 2.12E-02 1.17E-03 2.59E-02 0.00E+00 0.00E+00 7.74E-01 NO2

- g/L 5.32E+01 4.10E+01 6.16E+01 0.00E+00 0.00E+00 0.00E+00 NO3

- g/L 1.24E+02 9.71E+01 2.23E+02 0.00E+00 0.00E+00 0.00E+00 O(BOUND) g/L 1.61E-03 2.23E-05 5.00E-03 0.00E+00 0.00E+00 9.06E+00 OH- g/L 2.22E+01 7.15E+00 5.38E+01 0.00E+00 0.00E+00 0.00E+00 OH(BOUND) g/L 5.48E-02 1.24E-03 8.41E-02 0.00E+00 0.00E+00 1.01E+01 Pb+2 g/L 1.66E-02 7.22E-04 2.85E-02 0.00E+00 0.00E+00 9.48E-01 Pd+2 g/L 7.01E-04 1.69E-05 1.36E-02 0.00E+00 0.00E+00 3.89E-04 PO4

-3 g/L 1.71E+00 8.74E-01 6.40E+00 0.00E+00 0.00E+00 1.44E+02 Pr+3 g/L 1.52E-03 3.03E-05 7.76E-03 0.00E+00 0.00E+00 1.25E-02 Rb+ g/L 3.33E-03 5.05E-05 1.52E-02 0.00E+00 0.00E+00 9.46E-05 Rh+3 g/L 5.26E-04 2.37E-05 6.41E-03 0.00E+00 0.00E+00 9.06E-04 Ru+3 g/L 2.90E-04 3.97E-05 1.18E-02 0.00E+00 0.00E+00 1.84E-02 Sb+5 g/L 6.79E-03 2.31E-04 4.04E-02 0.00E+00 0.00E+00 1.80E-02 Se+6 g/L 1.09E-02 6.29E-04 8.08E-02 0.00E+00 0.00E+00 2.59E-03 Si+4 g/L 3.86E-02 2.80E-02 3.92E-01 0.00E+00 0.00E+00 2.97E+00 S4O-2 g/L 3.72E+00 1.21E+00 8.42E+00 0.00E+00 0.00E+00 0.00E+00 Sr+2 g/L 6.44E-04 1.16E-04 1.84E-03 1.67E-04 0.00E+00 2.19E-01 Ta+5 g/L 2.92E-04 7.93E-06 5.34E-03 0.00E+00 0.00E+00 8.81E-05 Te+6 g/L 4.67E-04 2.20E-05 1.04E-02 0.00E+00 0.00E+00 3.96E-03 Th+4 g/L 4.20E-06 2.09E-07 2.79E-05 0.00E+00 0.00E+00 1.88E-02 Ti+4 g/L 9.41E-04 3.53E-05 4.04E-03 0.00E+00 0.00E+00 9.39E-03 Tl+3 g/L 7.62E-03 7.08E-05 8.08E-02 0.00E+00 0.00E+00 8.23E-03 TOC g/L 2.26E+00 3.06E-01 2.92E+00 0.00E+00 0.00E+00 2.08E+01 V+5 g/L 6.34E-04 9.06E-05 4.04E-03 0.00E+00 0.00E+00 1.86E-02 W+6 g/L 3.41E-03 2.73E-04 3.17E-02 0.00E+00 0.00E+00 0.00E+00 Y+3 g/L 8.59E-04 4.87E-05 4.19E-03 0.00E+00 0.00E+00 4.70E-03 Zn+2 g/L 2.84E-03 8.80E-05 8.91E-03 0.00E+00 0.00E+00 2.62E-02 Zr+4 g/L 3.45E-05 3.80E-06 2.46E-01 0.00E+00 0.00E+00 1.38E-01 (a)Average values come from TOPSim Case 3335 (MR-50242). (b)Minimum and maximum values come from TOPSim Cases 1514, 3322, and 3335 (RPP-RPT-60146, TOPSim Data Package for the River Protection Project System Plan, Revision 8, Scenarios; MR-50242). N/A = not available.


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Table 3-4. Double-Shell Tank Feed Physical Characteristics.

Parameter Unit Nominal Value Range

Density(a) g/mL 1.27 1.0 – 1.35 Viscosity(b) cP 3.7 1 – 8 Temperature(c) °C 25 20 – 35 Solids Concentration(d) ppm 160 0 – 15,000 Solids Particle Size(e) μm < 1 < 1 – 550 Surface Tension(f) dynes/cm 80 70 – 100 (a)The upper bound value originates from TFC-ENG-STD-26, “Waste Transfer, Dilution, and Flushing Requirements,” in which supernatant is defined as having a specific gravity of less than or equal to 1.35 and containing minimal solids. (b)The nominal value is calculated in RPP-RPT-60549, “Supernatant Viscosity Assessment to Support Direct Feed Low Activity Waste Treatment.” (c) WRPS-1705804, “Temperature Ranges for Direct Feed Low-Activity Waste Feed.” (d)Values derived based on One System integrated flow sheet evaluation and engineering judgment. Tank-Side Cesium Removal will be designed to make full throughput at the nominal solids content, but is not required to achieve throughput at the maximum solids content of 15,000 ppm (1.5 wt%). (e)Values derived based on One System integrated flow sheet evaluation and engineering judgment. (f)The surface tension values originate from PNL-10173, Ammonia in Simulated Hanford Double-Shell Tank Wastes: Solubility and Effect on Surface Tension.

Table 3-5. Compositions for Hydrogen Generation Rate.(a,b)

Component Maximum Concentration Unit

Al 9.05E-01 gmole/L TOC(c) 3.11E-01 gmole/L (a)Draft Values. RPP-RPT-60588, Waste Characterization for Low Activity Waste Pretreatment System Utilizing Non-Elutable Ion Exchange. (b)Values reported are for supernatant at 5.61M Na. (c)Total Organic Carbon value includes oxalate (C2O4-2). The oxalate value associated with this maximum is 2.24E-02 gmole/L.

Table 3-6. Maximum Radionuclide Values for Mass and Energy Balance.(a,b) (2 sheets)

Radionuclide Liquid Phase Solid Phase


Ci/L Ci/L Ci/L Ci/L 106Ru 3.94E-11 9.00E-12 236U 5.69E-10 1.27E-10 113mCd 2.89E-05 1.37E-06 237Np 2.58E-07 8.34E-11 125Sb 3.55E-06 3.92E-07 238Pu 3.47E-07 1.00E-06 126Sn 3.18E-06 3.22E-08 238U(d) 2.66E-08 2.23E-09 129I 2.31E-07 2.39E-13 239Pu(d) 2.90E-05 8.64E-06 134Cs 6.55E-07 1.76E-09 240Pu 6.83E-07 2.44E-06 137Cs(c) 3E-01 1.31E-03 241Am 1.05E-05 1.67E-08 137mBa(c) 4.97E-01 1.24E-03 241Pu 5.99E-06 2.79E-05 14C 6.88E-06 9.33E-09 242Cm 1.82E-09 7.69E-08 151Sm 5.94E-03 1.15E-03 242Pu 1.52E-09 3.08E-10


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Table 3-6. Maximum Radionuclide Values for Mass and Energy Balance.(a,b) (2 sheets)



Ci/L Ci/L Ci/L Ci/L 152Eu 7.51E-07 2.74E-07 243Am 5.96E-09 7.97E-12 154Eud 1.70E-05 1.86E-06 243Cm 7.71E-08 4.95E-09 155Eu 2.87E-06 1.03E-06 244Cm 1.40E-06 9.68E-08 226Ra 1.57E-10 5.94E-13 3H 7.51E-06 1.63E-07 227Ac 3.95E-08 1.11E-09 59Ni 2.76E-07 1.64E-07 228Ra 2.42E-08 1.48E-09 60Co(d) 1.00E-06 1.95E-07 229Th 3.49E-09 2.36E-10 63Ni 2.24E-05 1.33E-05 231Pa 3.10E-08 4.75E-10 79Se 1.31E-06 4.11E-09 232Th 6.97E-09 3.93E-10 90Sr 1.20E-03 2.78E-02 232U 1.21E-09 2.87E-10 90Y 1.20E-03 2.78E-02 233U(d) 1.50E-07 3.77E-09 93Zr 7.20E-05 4.89E-06 234U 1.21E-08 2.67E-09 93mNb 2.80E-05 3.99E-06 235U(d) 1.60E-09 1.07E-10 99Tc(d) 4.70E-04 3.92E-07 (a)Table extracted from RPP-RPT-59659, Waste Characteristics for Inclusion in RPP-SPEC-56967, Project T5L01 Low Activity Waste Pretreatment System Specification. (b)Decay date of 1/1/2021. (c)137Cs and 137mBa values set at maximum value used in shielding calculations from Table 3-9, below. (d)Supernatant values reflect maximum allowed by 24590-WTP-ICD-MG-01-030, ICD 30 – Interface Control Document for Direct LAW Feed.

Table 3-7. Compositions for Process Material Selection.

Chemical Components Minimum Concentration Maximum Concentration

ppm ppm

Chloride, Cl- 210 5,900

Fluoride, F- 20 3,900

Nitrite, NO2- 16,000 76,000

Nitrate, NO3- 20,000 128,000

Free Hydroxide, OH- 6,000 49,000

Sulfate, SO4-2 510 17,000

(a)Table extracted from RPP-RPT-59659, Waste Characteristics for Inclusion in RPP-SPEC-56967, Project T5L01 Low Activity Waste Pretreatment System Specification. Analysis of HTWOS modeling indicates above values are an appropriate representation of a nominal feed to LAWPS. System design will be based on a range of values for specific waste parameters important to LAWPS processes. HTWOS = Hanford Tank Waste Operations Simulator. LAWPS = Low-Activity Waste Pretreatment System.


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Monitor Waste Feed Delivery. At a minimum, monitoring of waste transfer operations between the DSTs and the TSCR system shall include the following capabilities:

• TSCR line pressure, • TSCR flow rate, • TSCR waste temperature, and • Transfer pump interlocks.

3.2.1.2 Process Tank Waste. The requirements for the “process tank waste” function are provided below under a pretreat sub-function. The pretreat sub-function includes requirements for filtration of undissolved solids and cesium removal using cesium ion exchange.

Pretreat Waste.

a) The TSCR system shall be capable of removing undissolved solids from tank supernatant waste to protect functionality of the ion-exchange column.

b) Back-flush capability of the prefilter located before the ion-exchange column(s) shall be provided to flush the filter to a nearby DST in accordance with TFC-ENG-STD-26.

c) The prefilter shall be designed to be back-flushed and replaced with minimal system downtime, minimal expense, and limiting radiation dose to workers as low as reasonably achievable (ALARA).

d) The TSCR system shall be capable of selectively removing cesium from filtered waste through the use of a non-elutable ion-exchange resin.

e) The cesium ion-exchange media shall be Crystalline Silicotitanate (CST), or BUYER-approved, non-elutable equivalent to CST. If an ion-exchange resin other than CST is proposed, submit objective evidence that the proposed ion-exchange column and resin design will comply with the requirements of this specification.

f) Ion-exchange columns shall be designed to minimize channeling.

g) The concentration of radioactive constituents in treated LAW shall comply with the requirements of Table 3-8.1

Table 3-8. Radionuclide Concentration Limits for Treated Low-Activity Waste. (2 sheets)

Radionuclide Radionuclide Concentration in Treated LAW to WTP Immobilization(a) 60Co concentration < 1.10E-06 Ci/L 90Sr ratio < 1.19E-03 Ci/mol sodium 99Tc concentration < 4.8E-04 Ci/L 137Cs ratio < 3.18 E-05 Ci/mol sodium

1 The 137Cs concentration in ILAW must be less than 0.3 Ci/m3 to meet DOE M 435.1-1 Chg 2 requirements for near surface disposal.


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Table 3-8. Radionuclide Concentration Limits for Treated Low-Activity Waste. (2 sheets)

Radionuclide Radionuclide Concentration in Treated LAW to WTP Immobilization(a) 154Eu concentration < 1.8E-05 Ci/L 233U concentration < 1.6E-07 Ci/L 235U concentration < 1.7E-09 Ci/L 239Pu concentration < 3.0E-05 Ci/L TRU(b) ratio < 1.30E-05 Ci/mol sodium U fissile to U total < 0.96 wt% (a)24590-WTP-ICD-MG-01-030, ICD 30 – Interface Control Document for Direct LAW Feed, Table 5. (b)Transuranic (TRU) is defined as alpha-emitting radionuclides with an atomic number greater than 92, with half-life greater than 20 years, in HNF-EP-0063, Hanford Site Solid Waste Acceptance Criteria, which has been adopted for this study.

h) The design of the TSCR equipment for removing cesium shall use the values for potassium, cesium, and 137Cs for LAW waste that are shown in Table 3-9; the average values shown in Tables 3-2 and 3-3, above, should be used for all other constituents. Ion-exchange column sizing calculations shall consider downtime due to ion-exchange column replacement.

Table 3-9. Design Source Term (Liquid Phase).

Component Limit Unit Ion-Exchange Sizing Source Term Cesium(a) 1.04E-04 gmole/L 137Cs(a) 2.16E-05 gmole/L 137Cs(a) 2.57E-01 Ci/L 137Cs: Total Cesium Ratio (maximum)(b) 0.24

Potassium (minimum)(b) 0 gmole/L Potassium (maximum) (b) 0.35 gmole/L Shielding Design Source Term 137Cs(b) 3E-01 Ci/L (a)Value based on RPP-RPT-59659, Waste Characterization for Inclusion in RPP-SPEC-56967, Project T5L01 Low Activity Waste Pretreatment System Specification. Decay date of 1/1/2021. (b)Value based on the recommendations of RPP-RPT-58445, Basis for Sodium, Potassium, and Cesium Values Used in the Design of LAWPS Ion Exchange System.


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i) To compensate for the potential of solids precipitation from waste, the TSCR process shall be designed with appropriate capability (e.g., waste temperature control features) to minimize solids precipitation.2

j) The TSCR design shall be based on a range of values for specific parameters considered important to the TSCR process. Variations of parameters that affect TSCR throughput include:

1) Sodium molarity – 5-6 M, 2) Viscosity – see Table 3-4, 3) Density – see Table 3-4, 4) Solids concentration – see Table 3-4, 5) Cesium and 137Cs concentration – see Table 3-9, 6) Potassium concentration – see Table 3-9, and 7) Susceptibility to precipitation.

k) The VENDOR shall provide enough materials and consumables (e.g., ion-exchange resin) during the first phase of the demonstration to remove at least 100,000 Ci of 137Cs from waste feed.

l) Submit the technical data and salient features that are used to purchase the following:

1) Replacement ion-exchange resin, shielded columns, and processing consumables including physical description and chemical compositions, as applicable.

2) Storage systems and equipment that will be sent to interim storage.

Note: The BUYER will use this information for future orders.

m) Spent ion-exchange resin columns filled with ion-exchange resin shall be removable from the TSCR system for transfer to interim storage. See Section 3.2.2.4 for interim storage criteria.

n) Access to the resin inside of spent ion-exchange columns shall be provided should future removal of the spent resin be determined necessary.

3.2.1.3 Dispose Tank Waste.

Dispose Secondary Waste (Treated Gaseous Effluents). Control of airborne emissions are handled primarily through design and operation of a pressure cascade ventilation system. Treating of gaseous effluents by the TSCR system is not anticipated. If treatment of

2 The design basis salts for precipitates downstream of filtration are NaF, with density of 2.78 g/mL and particle size of 7 μm, and Na3PO2•0.25NaOH•12H2O (sodium phosphate dodecahydrate), with density 1.62 g/mL and particle size of 1,200 μm. The references for densities and particle sizes are from PNNL-20646, Hanford Waste Physical and Rheological Properties: Data and Gaps and RPP-RPT-46618, Hanford Waste Mineralogy Reference Report.


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gaseous effluents is determined to be a required function of the TSCR system, the BUYER will provide written direction to the VENDOR implementing the following requirements:

a) The ventilation system shall control radioactive airborne emissions in compliance with the requirements of WAC 246-247; 00-05-006, Hanford Site Air Operating Permit; TFC-ESHQ-ENV-STD-03, “Air Quality – Radioactive Emissions;” TFC-ESHQ-ENV-STD-11; RPP-16922, Environmental Specification Requirements; and TFC-ENG-STD-07.

b) The ventilation system shall control nonradioactive airborne emissions in compliance with the requirements of 40 CFR 61, and WAC 173-400, as implemented by TFC-ESHQ-ENV-STD-04 (Section 3.3.3.1 only), TFC-ESHQ-ENV-STD-11, and TFC-ENG-STD-07.

3.2.1.4 Manage System-Generated Waste and Excess Facilities. The “manage system-generated waste” function includes requirements associated with secondary solid and liquid wastes generated during operation of the TSCR system. This function also includes wastes generated as a result of eventual decontamination and decommissioning activities.

Manage Secondary Waste.

a) The TSCR system shall include design features to move secondary solid waste packages containing spent ion-exchange resin for transfer to a permitted interim storage pad.

b) The TSCR system shall be capable of transferring backwashed filtered solids to the DST system in accordance with TFC-ENG-STD-26.

c) The TSCR system shall be capable of transferring column drain and drying liquids back to the DST system.

d) The TSCR system shall be capable of either collecting for transport or transferring spent pre-conditioning caustic solutions back to the DST system.

e) The TSCR system shall have the capability to flush the transfer lines and valves to the DST system in compliance with the requirements of TFC-ENG-STD-26.

Close Facilities.

a) The TSCR system shall include design features which simplify decontamination and facilitate decommissioning at facility end-of-life in compliance with the requirements of DOE O 420.1C [Chapter 1, 3.b.(4)(a)], including:

1) Transitioning the TSCR system to decommissioning and 2) Safely and efficiently decontaminate and decommission the TSCR system when

no longer needed to support the RPP mission.


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b) The design or modification of the TSCR system and the selection of materials shall include features that facilitate operations, maintenance, decontamination, and decommissioning [10 CFR 835.1002(d)].

c) The design shall include features that facilitate decontamination and decommissioning.

1) The equipment design shall incorporate measures to simplify decontamination of areas that may become contaminated with radioactive materials.

2) Items such as service piping, conduits, and ductwork shall be kept to a minimum in potentially contaminated areas.

3) Equipment shall be arranged to facilitate decontamination.

4) The modules shall be provided with a confinement system to prevent the migration of airborne radioactive materials from confinement enclosures, containment vessels, process equipment, and their associated ventilation systems to occupied and unoccupied work areas.

5) Design shall minimize the potential for spilled radioactive liquid to migrate into cracks or crevices.

6) There shall be no interconnection among storm water systems, the sanitary waste systems, and the radioactive or other hazardous material handling systems or areas.

7) The TSCR system design shall prevent the migration of radioactive material into process utilities.

3.2.2 Interface Requirements

This section describes the external interface requirements for the TSCR system, including Hanford Site utilities and infrastructure, secondary solid waste disposal facilities, and interim storage. Interfaces will be formally controlled through interface control documents or memoranda of understanding, as appropriate. Interfaces between DSTs and the TSCR system will be managed using Tank Operating Contractor management protocols.

All Interface Control Documents (ICDs) will be developed in accordance with TFC-PLN-102, as interfaces are identified between the TSCR system and existing infrastructure, facilities, and ongoing operations. As new requirements are developed through interface definition, the ICDs will be revised to reflect the changes.

3.2.2.1 Double-Shell Tank System and Tank Farms Interface.

The TSCR system shall interface with the DST system:

a) Transfer of tank supernatant waste from the DST system to the TSCR system solids filtration.

b) Transfer of filter backwash to the DST system in accordance with TFC-ENG-STD-26.


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c) Transfer of ion-exchange column flush water to the DST system.

d) System-generated waste (slurry containing separated solids and ion-exchange column flush and rinse) returned to the DST system from the TSCR system shall meet the requirements of HNF-SD-WM-OCD-015.

e) The TSCR system shall be designed to minimize resin and resin fines from entering the DST treated waste tank. Intentional transfer of resin into a DST is not allowed. Unintentional carryover of resin particles shall be less than 80 μm (diameter – nominal).

f) Equipment will be mounted on concrete pads that interface with the AP Tank Farm footprint constraints described in Section 3.3.2.

g) Interfacing fittings with HIHTL shall meet the requirements of RPP-14859, Specification for Hose-in-Hose Transfer Line and Hose Jumpers.

3.2.2.2 Hanford Site Utilities and Infrastructure. The TSCR system shall interface with existing Hanford Site utilities and infrastructure to support construction and operation of the system:

a) Design analysis shall be performed to determine the TSCR system infrastructure and utilities requirements.

b) Design and construction of infrastructure to support the TSCR system shall be performed by others.

Interface with Existing Roadways. The TSCR system shall interface with existing Hanford Site roadways.

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

a) Design analysis shall be performed to determine the TSCR system 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.

b) The interface for the electrical distribution system shall be Mission Support Alliance Hanford Site Operations Infrastructure Services, Electrical Utilities distribution system, in compliance with the requirements of HNF-4492.

3.2.2.3 Secondary Solid Waste Disposition Facilities. The TSCR system shall interface with Hanford Site disposal facilities for disposition of hazardous and radioactive secondary solid wastes generated within the TSCR system.

Interface with Solid Waste Operations Complex.

a) The TSCR system secondary solid wastes shall be transferred by others to the Solid Waste Operations Complex.


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b) Secondary solid waste for onsite disposal shall meet requirements set forth by HNF-EP-0063.

c) Spent ion-exchange resin will be transferred to interim storage by others and will not interface with the Solid Waste Operations Complex.

3.2.2.4 Interim Storage. The following interface requirements allow spent ion-exchange columns to be loaded for transport to interim storage, unloaded at interim storage, and placed within the interim storage site. The interim storage pad and transportation equipment (e.g., cranes, forklifts, trailers, trucks) are provided by others and are outside the scope of this specification.

a) The equipment and methods used for systems shall have the following performance criteria:

1) The spent ion-exchange columns and supporting SSCs needed for interim storage, shall be capable of free standing (resist overturning), passive storage, and prevent releases to the environment.

2) The ion-exchange columns and supporting SSCs shall maintain structural and containment integrity for a minimum design life of 50 years in interim storage.

3) The spent ion-exchange column shall be self-shielded to maintain an outside dose rate less than 5 mrem/h at contact.

4) Spent ion-exchange resin shall meet the following sub-criteria before being sent to interim storage:

i) Remain within the column assembly for the duration of interim storage and ii) Be de-watered or in a non-liquid form. For example, resins shall be

drained completely of free liquid.

5) Gasses generated while at interim storage shall be vented through a high-efficiency particulate air (HEPA) filter.

b) The spent ion-exchange columns and support equipment shall interface with both a forklift and crane for handling.

c) The spent ion-exchange columns shall be transportable using flatbed truck or forklift. Provide ion-exchange column tie-down design in accordance with Section 7.6.1.

d) Submit to BUYER the design of the equipment and the methods used to store the spent ion-exchange columns sent to interim storage. This includes ion-exchange column weights, dimensions, anchorage, and point loads.

3.2.2.5 Hanford Fire Department. The TSCR system shall interface with the Hanford Fire Department for fire protection, incident management, emergency medical response and treatment, and other services as defined in TFC-ESHQ-FP-STD-12 coordinated by others.


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3.2.2.6 Emergency Services. The TSCR system shall interface with Emergency Services as defined in TFC-ESHQ-EP-C-01 and coordinated by others.

3.3 DESIGN AND CONSTRUCTION REQUIREMENTS

This section specifies minimum TSCR system design and construction standards.

3.3.1 Design and Operating Conditions

a) The TSCR system design shall be evaluated to minimize the lift height of spent ion-exchange columns during removal and preparation for transport and storage.

b) The ion-exchange column shall be designed and evaluated to prevent the release of radioactive material from a spent ion-exchange column dropped from the maximum postulated lift height during removal and preparation of spent ion-exchange columns for transport and storage.

c) Size, weight, and geometry of ion-exchange column shall facilitate ease of ion-exchange column replacement, and spent ion-exchange column transport and storage.

d) The TSCR system shall be designed to limit the accumulation of flammable gas concentrations below the lower flammability limit within ion-exchange columns and other process equipment during normal operating conditions, and during off-normal or upset conditions.

3.3.2 Physical Requirements

The TSCR system should be designed to fit and must be serviceable with contact maintenance or remote operations within the preliminary footprint constraints for AP Tank Farm shown in Figure 3-3.

3.3.3 Environmental Conditions

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

3.3.3.1 Natural Environment. The system shall be designed to perform its functions and meet its performance requirements under the natural environmental conditions required by DOE O 420.1C, as implemented by DOE-STD-1020, TFC-ENG-STD-02, and TFC-ENG-STD-06.

3.3.3.2 Temperature. The TSCR system shall be designed 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. Structures shall be designed for movements resulting from the maximum seasonal temperature change. The design shall provide for the lags between air temperatures and the interior temperatures of concrete members or structures. Consideration shall be given to passive soil loading resulting from thermal growth of subgrade structures.

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RPP-SPEC

-61910, Rev. C

Figure 3-3. AP Tank Farm Footprint Constraints.


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3.3.3.3 Induced Environments.

a) The specification, design, installation, and maintenance of SSCs associated with the TSCR system shall ensure compatibility with the induced environment in their installed locations. Examples of induced environments in the TSCR system include vibration, elevated radiation, elevated temperature, low temperature, electromagnetic fields, and elevated noise. Installed equipment shall be designed to avoid resonance resulting from the harmony between the natural frequency of the structure and the operating frequency of reciprocating or rotating equipment supported on the structure.

b) The TSCR system process equipment that contacts radioactive material shall be designed to function in its expected environment dose.

3.3.3.4 Environment Due to Accidents and Unplanned Events.

a) The TSCR system shall be designed and constructed, as specified in DOE O 420.1C [Section I.3b(3), (4)] so in the event of an accident, the potential exposure to hazardous and/or radioactive materials is minimized.

b) The TSCR system enclosure shall be designed to prevent the dispersal of airborne contamination to the environment in the event of an accident, and shall be designed to withstand the maximum fan pressures and vacuums of the ventilation system without structural deformation.

3.3.4 Structural Analysis and Design

The structural design of the TSCR system shall consider it as a permanently installed system. The basis of design for the TSCR system SSCs is DOE-STD-1020 and IBC 2015. Natural Phenomena Hazards (NPHs) design loads are provided in TFC-ENG-STD-06. ASCE 7-10 shall be used to determine applied structural demands such as wind design pressures, seismic response spectra and acceleration coefficients, and roof snow loads.

The TSCR system SSCs shall satisfy consensus standard requirements for design. The TSCR system 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.

3.3.4.1 Natural Phenomenon Hazards. The TSCR system components shall be designed in accordance with NPH requirements provided in TFC-ENG-STD-06 and the applicable seismic design criteria and limit states given in Table 3-1, above. It is anticipated that only NPH Design Category (NDC)-1 or NDC-2 loading will apply to the TSCR system.


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NPH Design Category shall be uniformly applied:

NPH NDC-1 Designation NDC-2 Designation

Wind Design Category WDC-1 WDC-2

Seismic Design Category SDC-1 SDC-2

Precipitation Design Category (Snow) PDC-1 PDC-2

Volcanic Design Category (Ashfall) VDC-1 VDC-2

Interactions between NDC-1 and NDC-2 SSCs shall be considered.

3.3.4.2 Seismic Analysis and Design. Seismic design for the TSCR system SSCs will follow ASCE 7-10 with response modification coefficients (R factor) modified per DOE-STD-1020, Table 3-1, based on limit state. Seismic design requirements for the TSCR building (or occupied) structures shall follow ASCE 7-10, Chapter 12. Seismic design requirements for the TSCR 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 TSCR nonbuilding structures (i.e., freestanding [resists overturning] pipe and ventilation skid structures) shall follow ASCE 7-10, Chapter 15. Seismic detailing requirements for the associated framing systems shall be met.

Ventilation components shall comply with ASME AG-1-2015 Service Level B design (Tables AA-4412 and AA-4231). This has been determined to be equivalent to Limit State C for Seismic Design Category (SDC-1) and SDC-2.

3.3.4.3 Methods of Seismic Qualification. For passive equipment, qualification of SSC for SDC-1 or SDC-2 events is most effectively accomplished by the static equivalent analysis method specified below. However, qualification may be by any (or a combination) of the three methods delineated below. Active safety functions shall be demonstrated through experience data or physical testing.

a) Analysis in accordance with ASME QME-1, IEEE Std 344-2013, or the code applicable to system or component is allowed for any SSC. Any of the following methods are acceptable for quantifying seismic response:

1) Equivalent static method, 2) Response spectrum method, 3) Time history, and 4) Complex frequency response method.

b) Testing in accordance with IEEE Std 344-2013, ASME QME-1, or AC156 may be used.


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c) Equipment may be qualified by experience data/similarity to previously qualified equipment. Qualification by similarity must address:

1) Materials, arrangement/configuration, and dynamic similarity of the components and 2) Seismic input of previously qualified equipment must envelope the seismic design

requirements of new components.

3.3.5 General Materials Requirements

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

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 including those in Table 3-7, above.

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.

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

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

e) The guidance in TFC-ENG-STD-34 shall be used for selection of non-metallic materials.

f) Metallic surfaces, which will routinely contact tank waste, shall be fabricated from stainless steel.

g) Corrosion-erosion allowance used for design shall comply with TFC-ENG-STD-22, Section 3.5.2.1.

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

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

j) Certified Material Test Reports (CMTRs) shall be submitted to the BUYER for all safety-related items, pressure boundary, supports, weld filler material, weld attachments, and fasteners. All other materials used in construction shall be provided with a Certificate of Conformance.


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k) Certificates of Conformance shall be traceable to the material used in the fabrication and conform to the requirements in QA-AVS B79. Material CMTRs are also acceptable and if supplied, shall contain the test results from all testing specified by the referenced material code or standard, be traceable to the material used in the fabrication, and shall also conform to the requirements in QA-AVS B49.

l) When Positive Material Identification (PMI) testing is used, the VENDOR shall provide:

1) Documentation showing qualification of operating technician, techniques used, testing methodology, acceptance criteria, documentation requirements, and how the process is managed and

2) A PMI test data report to include the minimum information identified in Section 4.1.

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

n) When the material is subdivided, VENDOR shall transfer the heat number to the part and remnants. This will ensure that all parts of the original stock piece are traceable.

o) Small parts, such as couplings, flanges, etc., may be kept in boxes that are labeled with heat numbers.

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

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

r) 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) Material substitutions shall not be made without BUYER approval. Unless otherwise stated by the VENDOR in the substitution-related 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) Attachment point of spiders, braces, or other temporary attachments shall match the material of the item it is contacting.


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u) Austenitic stainless-steel (P-No. 8) welding materials for pressure boundary and load bearing welds shall contain a minimum delta ferrite content of 5%. The maximum ferrite content shall not exceed 12% for post-weld heat treatment (PWHT) applications. Compliance with the minimum and maximum ferrite requirements may be based upon the certified chemical analysis and the Welding Research Council, Inc. (WRC) Delta Ferrite Diagram or a ferrite gauge complying with ANSI/AWS A4.2M/A4.2:1997. Alternatively, for shielded metal arc welding (SMAW) electrodes and solid wire filler metal manufactured in the United States of America, a CMTR may be used to confirm acceptability of the ferrite requirements.

v) Austenitic stainless-steel material in contact with process liquids shall exhibit no chromium carbides or detrimental inter-metallic phases as demonstrated by testing and accepting a minimum of one specimen per heat treatment lot in accordance with ASTM A262-15, Practice A.

w) CMTRs are required for all filler materials. CMTRs for gas shielded consumables shall reflect that testing was done with the same gas (gas mixture) as used in production.

x) Welding filler material shall meet the quality standards of and be supplied in accordance with AWS D1.6/D1.6M:2017 (welding of stainless steel) or AWS D1.1/D1.1M:2015 (welding of carbon steel) and the following additional requirements:

1) Control shall be established and implemented, with objective evidence through supplier’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 record: drawings, weld map, shop travelers, inspection reports, etc.

2) The VENDOR shall submit an inspection plan covering the inspections to be performed on weld filler metal for BUYER’s review. The VENDOR shall submit their Material Control Procedure for controlling, issuance, handling, storage, and traceability for welding metals.

y) The storage, baking and drying of all welding consumables (i.e., covered electrodes, flux cored electrodes, and fluxes) shall be as recommended by the manufacturer. Segregation of carbon steel, low alloys, and alloy consumables is required during storage, baking, holding, handling (including portable ovens), and in the fabrication area. Shielding and purging gases shall be welding-grade, having a dew point of less than or equal to (-)40 °F.

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

aa) 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:


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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 nonhalogenated 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.

bb) 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.

cc) Exposed surface finishes of piping, plate, or bar that are exposed to the tank waste shall not exceed 32 μ in. (radium) in accordance with ASME B46.1-2009.

3.3.5.1 Castings.

a) The external surface shall not exceed 125 μ in. (radium) in accordance with ASME B46.1-2009.

b) Castings shall be free of cracks, tears, or other linear defects.

c) Any discontinuity exceeding .06 in. deep after surface finishing shall be excavated and repaired by welding.

d) Any discontinuity exceeding 1/16 in. size, but not exceeding .06 in. deep after surface finishing shall be blended smooth into existing contour at no steeper than 1 in 3 slope.


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e) Randomly dispersed discontinuities of 1/64 in. or less shall be considered nonrelevant and shall not be considered in the overall count. Areas deemed “spongy” are not acceptable and shall be removed by blending (to a depth not exceeding .05 in.) or repaired by welding.

f) Relevant discontinuities shall be randomly dispersed with a minimum spacing of 1/4 in. However, these discontinuities may be removed via blending if the depth does not exceed .05 in.

g) As-cast-surfaces in limited access regions of the hydraulic casing shall be removed, but are not subject to these requirements.

3.3.5.2 Structural Steel Materials.

a) Applicable ASTM specifications for various structural shapes shall follow Tables 2-4 and 2-5 of AISC 325-11.

b) Wide flanges (W shapes): Conform to ASTM A992/A992M-11(R2015).

c) Shapes (M, S, C, MC, L): Conform to ASTM A36/A36M-14.

d) Hollow structural sections (HSS) or “tubes” shall conform to the following:

1) Pipe – ASTM A53/A53M-12, Grade B; 2) Round HSS – ASTM A500/A500M-13, Grade B (42 ksi); and 3) Rectangular (includes square) HSS – ASTM A500/A500M-13, Grade B (46 ksi).

e) Plate – ASTM A36/A36M-14 or ASTM A572/A572M-15, Grade 50.

f) High-strength bolts shall be used in structural connections. ASTM F3125/F3125M-15a, Grade A325.

g) Nuts: Conform to ASTM A563-15.

h) Washers: Conform to ASTM F436/F436M-16.

i) Anchor Bolts: Cast-in-place concrete anchor bolts conforming to ASTM F1554-15e2. Interior or exterior service conditions shall be considered.

3.3.5.3 Structural Stainless Steel Materials.

a) Except for vessels, stainless steel furnished as bulk material or delivered as fabricated assemblies shall be as follows unless otherwise noted on the design drawings:

1) Shapes and Bars: Conform to ASTM A276/A276M-17, Type 304L or 316L.

2) Plates: Conform to ASTM A240/A240M-17, Type 304L or 316L.

3) Pipe: Conform to ASTM A312/A312M-17, Grade TP 304L or 316L.


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4) Tubing: Conform to ASTM A554-16, Grade MT-304L, Tensile Strength 70 ksi minimum, Yield Strength 25 ksi minimum.

5) Bolts: Conform to ASTM A193/A193M-16, Grades B8 or B8M, Class 1 for pressure retaining SSCs. Conform to ASTM F593-17 for structural applications using the same compatible alloys as connecting elements.

6) Remote Studs: ASTM A276/A276M-17 Nitronic 60.

7) Nuts: Conform to ASTM A194/A194M-17, Grade 8 or 8M, heavy hex.

8) Washers: Cut from plate conforming to ASTM A240/A240M-17, Type 304 or 304L, or machined from bar stock that meets ASTM A193/A193M-16, B8 or B8M, Class 1. Dimensions in accordance with ASTM F436/F436M-16.

9) Welding Filler Metal: Conform to AWS D1.6/D1.6M:2017.

3.3.5.4 Pipe Materials.

a) Piping materials and specifications shall comply with TFC-ENG-STD-47.

b) Flange facings shall be 100% visually examined. Flange facings shall meet ASME B16.5-2017, Paragraph 6.5.6.

c) End connections shall be furnished in accordance with the following:

1) Pipe threads shall be taper threads in accordance with ASME B1.20.1-2013 and 2) Butt-weld ends in accordance to ASME B16.25-2012. Flame-cut weld bevels are

not allowed.

d) Each piping system shall be identified in accordance with ASME A13.1-2015.

e) Pipe and piping components shall be marked in accordance with the specification referenced for manufacture (ASTM, ASME, etc.). Flanges, fittings and unions shall be marked in accordance with ANSI/MSS SP-25-2013 if no marking is specified.

3.3.5.5 Concrete. The following requirements shall apply to concrete installed at the TSCR system:

a) Design and construction of concrete structures shall comply with ACI 301-10.

b) All NDC-1 and NDC-2 related concrete structures shall comply with ACI 318-14.

3.3.5.6 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:2015. Stainless-steel structural welding shall comply with the


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requirements of AWS D1.6//D1.6M:2017. Structural sheet/strip steels shall comply with the requirements of AWS D1.3/D1.3 M:2008. Nonstructural sheet metal and components and systems shall comply with the requirements of AWS D9.1M/D9.1:2012.

c) Steel structures shall comply with AISC 360-10. Where required, seismic design of steel structures shall satisfy AISC 341-10. Stainless-steel structures shall comply with AISC Steel Design Guide 27.

3.3.5.7 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. Plate washers shall be provided per AISC 348-14 by Research Council on Structural Connection.

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 (CMTRs for safety designated equipment and Certificate of Compliance for other equipment), unless noted otherwise. See QA-AVS B73 for control of high strength graded fasteners.

3.3.5.8 Hoisting and Rigging Requirements.

a) All hoisting and rigging equipment shall comply with the requirements of DOE/RL-92-36 and TFC-ENG-FACSUP-C-25.

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.


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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.

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. VENDOR-provided structural and mechanical lifting devices, as defined by ASME B30.20-2013, shall also conform to the requirements of ASME B30.20-2013. The design of below-the-hook (BTH) devices shall conform to the requirements of ASME BTH-1-2017. 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 B30.20-2013. All lifting devices shall be rated for outdoor service.

m) BTH lifting devices shall be provided with markings in accordance with ASME B30.20-2013 and tags in accordance with DOE-RL-92-36. In addition to the requirements of ASME B30.20-2013 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.

3.3.5.9 Waste Transfer System Configuration.

a) The TSCR system waste transfer system shall comply with the requirements of TFC-ENG-STD-03.

b) The waste transfer and processing piping systems (piping, valves, instruments, etc.) that come into contact with HLW shall be welded construction, except where remote configurations or periodic rerouting of HLW streams require nonwelded construction [DOE M 435.1-1, Chg 2, Chapter 2, Section P(2)].3

c) The system design shall establish the number, arrangement, and characteristics of confinement barriers based on consideration of the type, quantity, form, and conditions

3 Note that HLW streams can result in a high-dose stream or a low-dose stream, depending on content. For the purposes of this requirement, a low-dose stream is defined as a stream that allows for hands-on maintenance; everything else is classified as a high-dose stream (see Section 9.2 for definitions of low-dose and high-dose configurations).


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for dispersing the radioactive and hazardous material in the confinement system design [DOE O 420.1C, Section I.3.b.(3)(a),(b)].

3.3.5.10 Vessels, Tanks, Piping, Pumps, Jumpers, and Valves. TSCR system vessels, tanks, piping, jumpers, and valves shall comply with the following requirements.

Vessels and Tanks.

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

b) TSCR vessels containing waste shall be designed and constructed in compliance with the requirements of ASME BPVC, Section VIII, Division 1 or 2.

c) As applicable, TSCR 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.

d) 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.

e) Installations in potentially flammable atmospheres shall meet the requirements of TFC-ENG-STD-45.

f) The VENDOR shall provide design and specify applicable materials, dimensions, and thicknesses as required to meet code requirements.

g) The VENDOR shall provide a fatigue evaluation in accordance with ASME BPVC, Section VIII, Division 1, Part UG-22.

h) 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 3-4.

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

j) Where practical, 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.

k) Pulled bends shall be specified in preference to using pipe fittings; piping bends shall have a minimum bend radius of five times the piping diameter, unless specified otherwise. Where 5D pipe bends are not practical, the VENDOR may submit for approval the use of 3D bends or long-radius pipe fittings.

l) Vessel plate materials to have a 2B surface finish per ASTM A480/A480M-17.


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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 3-4 and 3-5 illustrate 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 3-4. All nozzles that are flush with the inside surface of the vessel shall be rounded to 1/8 in. minimum radius as shown.

Figure 3-4. Acceptable Nozzle Connections.


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Figure 3-5. 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.

k) Nozzle reinforcement shall be integral, regardless of Quality Level (Figure 3-6).

Figure 3-6. Integral Nozzle Reinforcement Methods.

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.


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d) The design of support members shall avoid the column of space directly below an ion-exchange resin 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.

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.

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.

b) Vessel nozzles shall be designed for the seismic loads specified in Section 3.3.4.

Piping.

a) The TSCR system piping shall be designed, fabricated, tested, inspected, and installed to the requirements of ASME B31.3-2016 as implemented by TFC-ENG-STD-22 for normal fluid service.

b) Process piping shall be designed for a design pressure of greater than or equal to 400 psig and a design temperature of greater than or equal to 180 °F, which is the maximum limit of the primary HIHTL stated in TFC-ENG-STD-21.

c) Interfacing connection points with HIHTL shall be designed, fabricated, inspected, and examined in accordance with the applicable requirements of ASME B31.1-2016 for normal fluid service as implemented by TFC-ENG-STD-21.

d) The design pressure and temperature rating for the pipe connections that interface with primary HIHTL shall be greater than or equal to 400 psig and greater than or equal to 180 °F.

e) The design pressure for connections that interface with HIHTL encasements shall be greater than or equal to 170 psig.

f) Waste transfer piping within the scope of the TSCR system shall include freeze protection in compliance with TFC-ENG-STD-02 and TFC-ENG-STD-22.


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g) Waste transfer secondary containment piping shall direct the flow of leaked waste from the primary confinement piping to pits or vaults containing a leak detection sump or other capability to detect waste leaks.

h) Waste transfer piping shall be subject to pressure and stress analyses in compliance with TFC-ENG-DESIGN-C-60.

i) The TSCR system potentially pressurized drain lines shall be segregated from any gravity drain lines so as not to pressurize a gravity drain line.

j) The VENDOR’s drawings will be reviewed as requested by the BUYER. The BUYER’s review will not relieve the VENDOR of the responsibility for either the accuracy of the VENDOR’s drawings or compliance with this specification and the referenced drawings.

Sump Pump.

a) The TSCR system shall include a submersible sump pump in accordance with TFC-ENG-STD-25, Section 3.7, for pumping supernatant waste and/or water back to a DST in AP Tank Farm in the event of a leak.

b) Installations in potentially flammable atmospheres shall meet the requirements of TFC-ENG-STD-45.

c) The pump shall meet the requirements of Ignition Source Control Set 1 in TFC-ENG-STD-13 (e.g., Gorman-Rupp SM Series Pump).

d) Wetted parts shall be Type 316/316L stainless steel. Static elastomeric seals shall be ethylene propylene diene monomer (EPDM). Other materials shall be submitted to the BUYER for approval.

e) The pump motor power cord shall be a minimum of 50 ft long, EPDM insulating material.

f) The pump shall have a lifting point or device, and that point or device must be used to install or remove the pump.

g) The pump, adapters, lifting point or device, etc. shall be installed, tested, and delivered with the TSCR system.

h) The pump shall not produce a discharge pressure in excess of the lowest rated component of the transfer system.

i) The pump shall be approved by a Nationally Recognized Testing Laboratory (NRTL).

j) Inspection Reports (bowl thickness, critical dimensions, castings, weld inspections); Test Reports (pressure test and performance curve) shall be provided with the TSCR system.

k) The submersible pump shall be labeled in accordance with Section 3.3.8.


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Jumpers.

a) Jumpers, if used, shall be designed, fabricated, tested, inspected, and installed to the requirements of ASME B31.3-2016, for normal fluid service as implemented by TFC-ENG-STD-22.

b) Jumpers shall be designed for a design pressure of greater than or equal to 400 psig and a design temperature of greater than or equal to 180 °F.

c) A means of breaking the vacuum in the transfer line should be provided as required to allow gravity liquid draining. The drain piping shall be sloped continuously from high point to low point with a minimum slope of 0.25% wherever connecting nozzle locations and interface permit.

d) Jumpers shall be designed and fabricated to minimize dead legs.

e) Transfer valve manifolds and jumpers should be either 2-in. or 3-in. internal diameter as dictated by the connecting transfer line.

f) Jumpers shall be provided with lifting points positioned to be suitable for balanced lifting by crane, if not designed for lifting by slings.

g) Taps for instrumentation and test connections shall be made on the top of the pipe.

h) Nozzle, manifold, and jumper assembly connections installed should be the Plutonium-Uranium Extraction (PUREX)-type design.

i) Pipe elbow and bends should have a bend radius greater than or equal to a long-radius elbow.

j) Jumpers and piping systems used for liquid waste shall be of welded construction to the fullest extent practical. Materials of construction shall be selected to minimize all forms of corrosion.

k) Jumper arrangements shall be such to allow the tightening and loosening of connector heads remotely via an electric impact wrench (Part #C-HEFIG-002).

l) The jumpers shall be designed to accommodate the fabrication specification requirements listed in RPP-14541, Jumper Fabrication and Testing Specification for Tank Farms.

m) When jumper support legs are required to come into contact with the flooring or walls as part of installation and/or operation, the contact surface of the leg shall use materials to minimize risk of damage to floor and wall protective coatings.

Valves.

a) The TSCR system valves shall be designed, installed, and tested in accordance with the requirements of TFC-ENG-STD-22.


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b) Valves which are to be used for double-valve isolation criteria shall use valve body indicator plates identified on Drawing H-14-107606, “Valve Indicator Plate Details,” to allow remote valve positioning and in-service inspections.

c) Valve operator closure shall be sufficiently slow to prevent damage from water hammer.

d) Manual valves in safety-significant jumpers shall meet the double-valve isolation criteria in TFC-ENG-STD-22.

e) Manual valves, which are to be used for double-valve isolation criteria, shall be positioned using gear operated assemblies in accordance with RPP-PLAN-34886, Investigation and Work Plan for the Resolution of Double-Shell Tank Valve Positioning Problems.

f) Valves shall use split-collar valve funnels identified on Drawing H-14-107471, “Valve Funnel Receiver Assemblies,” to allow engagement between the valve stem and the gear actuator drive shaft.

g) For routinely operated valves located in inaccessible areas, consider remote or extended handle operators.

h) Remote (manual or automatic) valves shall have their valve position indicator visible by camera inspection. For extended handle valves, position marking “Open” and “Closed” in a permanent manner outside of any shielding will suffice.

i) The position marking will be used for normal operations. The capability of camera inspection shall enable confirmation of valve position in the case of operational issues.

3.3.5.11 Coatings.

a) The TSCR system interior finish shall be in compliance with the requirements of DOE-STD-1066-2012.

b) Areas that provide secondary confinement of hazardous and radioactive liquids should consider the use of stainless-steel liners for those locations (e.g., sumps) which have a high probability of becoming contaminated.

c) Seams and surfaces that provide secondary containment shall be sealed (free of cracks or gaps) (WAC 173-303-640).

d) If special protective coatings are used to provide secondary confinement of hazardous and radioactive liquids, the special protective coatings shall comply with requirements of WAC 173-303-640(4).

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


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3.3.5.12 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.

3.3.5.13 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.

3.3.5.14 Toxic Products and Formulations. The TSCR system design shall minimize the use of products that may become regulated waste in compliance with the requirements of TFC-PLN-125.

3.3.6 Electromagnetic Radiation

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

3.3.7 Nameplates and Product Markings

a) The TSCR system components shall be labeled in accordance with TFC-PLN-05, 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 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),


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6) Material of construction, 7) Weight of the vessel and internals, and 8) U-stamp (as applicable).

d) The nameplate shall be installed in the location and manner identified on the VENDOR’s approved drawing. Additional manufacture’s nameplate, if any, shall be installed in the same manner and adjacent to the ASME BPVC, Section VIII nameplate. The nameplate shall be constructed of 300-series stainless steel and compatible with the vessel material.

e) 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-PLN-05, 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; 4) Vessels and tanks; and 5) Any named safety SSC item or operator control.

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

1) Labels not located in process pits shall use a Metalphoto® (anodized photosensitized aluminum) base (www.mpofcinci.com).

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

3) Labels located in process pits shall be laser-engraved stainless steel.

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

5) Labels shall be 15 gauge thickness.

6) Materials contacting austenitic stainless steel and nickel-alloy surfaces shall not be compounded from, or treated with chemical compounds containing elements in


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such quantities that harmful concentrations are leachable, or that they could be released by breakdown under expected environmental conditions and could contribute to inter-granular cracking or stress corrosion cracking, such as those containing fluorides, chlorides, sulfur, lead, zinc, copper, and mercury.

7) Weathering: The label shall remain readable after 7,000 hours of exposure in a weathering deck in accordance with ASTM D4329-13 using Ultraviolet A340 lamps.

e) Labeling Requirements

1) Labels excerpted from TFC-ENG-STD-12 are shown in Figures 3-7, 3-8, and 3-9. Application of labels that are inconsistent with this standard, unless addressed by approved deviations, are prohibited.

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

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

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

5) 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).

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

7) 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.

8) 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 5) Additional labelling requirements for Electrical Equipment and Motor Control

Centers.


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Figure 3-7. 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.

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.


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Figure 3-8. NH Label Coding.

DESIGN ID: NH LABEL SIZE CODE: C0 WIDTH: 3.00” BORDER: 0.188” HEIGHT: 1.50”


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 3-9. NL Label Coding.

DESIGN ID: NL LABEL SIZE CODE: CA WIDTH: 2.00” BORDER: 0.125” HEIGHT: 1.00”


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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g) Electrical Equipment:

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

2) Control threshold switches are labeled for their function;

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

4) Indication and direction of operation, as necessary.

h) Attaching Labels:

1) 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.

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.

j) Label Placement:

1) Labels shall be placed as follows:

i) To be readily visible and readable, ii) Horizontal (except hanging labels), iii) To eliminate identity confusion, iv) So they will not be easily damaged or cause hazard to the operator, and v) To avoid obscuring indications or interfering with equipment operation.

2) Labels are placed on flat surfaces to the extent possible:

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

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

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

3.3.9 Spare Capacity and Interchangeability

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


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

c) The ion-exchange columns, filters and other regularly replaced or serviced SSCs shall be interchangeable.

3.3.10 Safety

The environmental and safety management system, which integrates environment, safety, and health requirements into the work planning and execution processes to effectively protect the workers, the public, and the environment, is described in RPP-MP-003 and TFC-PLN-47. Personnel safety, equipment safety, and environmental safety are all part of the integrated safety management system as documented in TFC-PLN-01. Additional safety requirements include:

a) Design, construction, and operations shall adhere to system principles and the requirements of 10 CFR 830 and 10 CFR 851.

b) The confinement systems shall protect against releases of hazardous materials due to natural phenomena hazards.

c) Guidance from TFC-ESHQ-S_SAF-CD-11 shall be used to assist in the implementation of 10 CFR 830 and 10 CFR 851 system principles and requirements.

d) Control devices shall be designed in accordance with 29 CFR 1910.

e) Beryllium protection measures shall be incorporated in accordance with 10 CFR 850 and DOE-0342.

f) The TSCR system shall be incorporated into the Tank Farms Documented Safety Analysis (RPP-13033), or a new Documented Safety Analysis.

g) The TSCR system safety SSCs shall be designed and constructed in accordance with DOE O 420.1C, Attachment 3.

h) The TSCR system design shall comply with national consensus industry standards and the strictest model building codes applicable for the State of Washington and the local region, supplemented in a graded manner with additional safety requirements for the associated hazards in the facility that are not addressed by the codes [DOE O 420.1C Section 4.b and 10 CFR 851, Appendix A, Subpart 4(b)(3)].

3.3.10.1 Personnel Safety. Personnel shall be protected around the TSCR system from work place hazards in accordance with the requirements of this section. The TSCR system design shall protect workers to ALARA levels of radiation and chemical hazard exposure during waste processing operations, surveillance, and maintenance.


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Occupational Radiological Protection.

a) The TSCR system shall be designed to protect workers from occupational radiation exposures and maintain radiation exposure ALARA in accordance with the requirements in 10 CFR 835.1002 and HNF‑5183, Tank Farms Radiological Control Manual, Table 2-0.

b) Process equipment for transferring or processing waste concentrate shall be located in shielded enclosures as required by the ALARA analysis.

Note: Personnel cannot enter the process TSCR system process area if waste is present.

c) The TSCR system design shall preferentially select engineering features over administrative controls to minimize employee exposure to radiation and chemical hazards in compliance with 10 CFR 835.1001.

d) 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.

e) 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 1 Lens of Eye 3 Extremity 10 Any Organ (other than eye) or Tissue 10

f) 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) and 2) Intermittently Occupied Areas: Exposure Rate ≤ 5 mrem/hr @ contact (gamma).

Note: These exposure rate limits apply to the contribution from the Supplier-designed TSCR system SSCs.

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

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

1) 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


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modification of a facility and the selection of materials shall include features that facilitate operations, maintenance, decontamination, and decommissioning.

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

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

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

Occupational Safety and Health.

a) The TSCR system shall be designed for safe installation, operation, and maintenance in accordance with 10 CFR 851, 29 CFR 1910, 29 CFR 1926, 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 equipment during routine functions, thus improving system ergonomics. This includes selection of exhaust stack height, if needed, such that personnel are protected from airborne releases of waste vapors and other hazardous chemicals.

c) The TSCR system equipment containing hazardous energy sources shall have locking features to support compliance with 29 CFR 1910, Subpart J, Section 147 and DOE-0336.

d) The TSCR system shall comply with the environment, safety, and health requirements of DOE O 440.1B and with applicable federal, state, and local laws and regulations to protect the public, worker health and safety, and the environment.

e) Confined spaces shall be identified and designated in compliance with 10 CFR 851, 29 CFR 1910, and DOE-0360.

Personnel Fire Protection. The TSCR system shall protect personnel from fires in accordance with DOE O 420.1C; MGT-ENG-IP-05, NFPA 101, and IBC 2015.

Nuclear Safety. The VENDOR shall provide technical support to the BUYER for process hazards analysis, hazards evaluation, safety design strategy development, development of control decisions, safety analysis, incorporation of safety design strategies and controls into the design, and review of nuclear safety documentation. Further guidance is provided in the Statement of Work.

3.3.11 Security

Safeguard and security measures are designed to prevent malevolent acts such as theft, diversion, terrorist attack, unauthorized access, and radiological and chemical sabotage; and to respond to adverse acts such as emergencies caused by acts of nature. The BUYER will assess the need for


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safeguards and security measures and how measures will be incorporated into the design with assistance from the VENDOR.

3.3.12 Plant and Equipment Protection

a) Control and equipment devices shall comply with NEMA ICS 1-2000, NEMA ICS 6-1993, 29 CFR 1910, NFPA 70, and FM Approval Guide, LLC.

b) Control and equipment devices necessary to carry out a safety function, from sensor(s) to final element(s), shall comply with the requirements of ANSI/ISA 84.00.01-2004, as implemented by TFC-PLN-138.

c) Control and equipment devices to be relied upon for safety functions shall be identified through the process hazard analysis and control decision process.

3.3.13 Environmental Safety

a) The TSCR system shall comply with 42 USC §4321-4347 (National Environmental Policy Act of 1969); environment, safety, and health requirements of DOE O 440.1B, and with applicable federal, state, and local laws and regulations to protect the public, worker health and safety, and the environment.

b) The TSCR system design, construction, and operation shall comply with the requirements in 10 CFR 1021, DOE O 451.1B Chg 1, DOE O458.1 Chg 3, and 42 USC §6901 (RCRA), as specified by applicable sections of implementing regulations 40 CFR 264, WAC 173-303, and WAC 197-11.

c) The TSCR system shall control, reduce, segregate, and minimize generated waste in accordance with the applicable requirements in 40 CFR 264 and WAC 173-303.

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

e) 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. Lead use shall be in compliance with TFC-ESHQ-IH-STD-08.

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

3.3.14 Fire Protection

a) The TSCR system shall meet the requirements of MGT-ENG-IP-05 and TFC-ESHQ-FP-STD-02.

b) Certificates of Completion are required and systems shall pass an acceptance test as approved by the WRPS Fire Protection Engineer (FPE).


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c) The fire suppression systems shall meet the requirements of HNF-36174 and NFPA 13, or appropriate NFPA Code for the chosen alternative type system as approved by the WRPS FPE.

d) The fire suppression and alarm systems shall be approved by the WRPS FPE, and comply with the requirements in HNF-36174 and NFPA 72.

e) Fire protection systems shall be designed such that their inadvertent operation, inactivation, or failure of structural stability will not result in the loss of vital safety functions or inoperability of safety-significant systems as determined by a preliminary fire hazard analysis performed in accordance with TFC-ESHQ-FP-STD-06.

f) Fire and related hazards that are unique to DOE and are not addressed by industry codes and standards shall be protected by isolation, segregation, or use of special fire control systems (e.g., inert gas or explosion suppression) as determined by the fire hazard analysis.

g) The design shall select noncombustible materials. Where noncombustible materials are not practical, fire retardant materials based on ASTM E84-17 and NFPA 701 may be used with approval of the WRPS FPE.

h) Fire protection systems installed in the TSCR system shall meet the requirements of DOE O 420.1C, DOE-STD-1066-2012, and MGT-ENG-IP-05. Design installation of fire protection systems shall be according to the applicable code or standard of the NFPA.

3.3.15 Water Supply Protection

Where applicable for water systems connecting to the Hanford Site water supply, the TSCR system shall comply with requirements of WAC 246-290-490 for water supply protection.

3.3.16 Human Performance and Human Factors Engineering

The TSCR system design shall comply with the requirements of TFC-PLN-09, TFC-ENG-STD-01, TFC-ENG-STD-23, and TFC-ENG-DESIGN-D-29. The following specific aspects for HMI shall be considered during design:

a) Displays, indicators, switches, and actuators:

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

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

3) Placed at angles and heights that permit comfortable viewing.

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

5) Clearly and unambiguously labeled as to function.

6) 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.

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.

t) Lighting adequate for normal operations and maintenance activities.


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

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

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

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

3.3.17 Control System

a) The TSCR system shall be designed with a standalone monitoring and control enclosure located at AP Tank Farm with designed-in expansion capability for future remote monitoring and control operations such that:

1) The TSCR control system network should integrate with the Tank Farm Local Area Network (TFLAN) and

2) The TSCR system process equipment shall be designed for remote operation and maintenance capability.

b) The TSCR control system shall use the wireless Hanford Local Area Network (HLAN) to TFLAN interface to connect with the monitoring and control system in areas such as:

1) Remote locations or remote instrumentation where the infrastructure to support wired connectivity will not be installed or does not exist;

2) Facility locations where installing conduit and wiring are not feasible; and

3) Where there are life cycle, cost, or schedule advantages over the installation and maintenance of a wired infrastructure.

c) The TSCR system shall provide for process control system and process network redundancy as required to meet the availability requirements of Section 3.3.19.4.

d) The control system should be automated such that routine TSCR system operations do not typically require operator input, intervention and control.

e) System control components shall comply with the requirements of NFPA 70 and TFC-ENG-STD-41.

f) Installations in potentially flammable atmospheres shall meet the requirements of TFC-ENG-STD-45.

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


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h) 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, 5) Software Requirements Traceability Matrix, 6) Software Test Plan, and 7) Software Test Report.

i) The control system shall comply with the requirements of RPP-50655.

j) If safety-significant safety instrumented systems (SIS) are used, they shall comply with ANSI/ISA 84.00.01-2004 per direction contained in External Letter 15-NDS-0033, “Contract No. DE-AC27-08RV14800 – Approval of Washington River Protection Solutions LLC Request to Continue to Use the Currently Implemented Industry Standard ANSI/ISA 84.00.01-2004 in Lieu of DOE-STD-1195 for the Low-Activity Waste Pretreatments System Project” (Hader and Smith 2016).

k) The TSCR system SISs (if applicable) shall be designed to operate independently of the TSCR process control system. The TSCR system SIS – TSCR process control interface(s) shall be designed to prevent any interference with the performance of the TSCR SIS safety functions.

l) Monitoring and alarm functions of SISs shall interface with the process control system as needed to provide indications.

m) The TSCR system safety instrumented systems and alarms should consider the wireless HLAN to Tank Farm Safety Programmable System interface in areas such as:

1) Remote locations or remote instrumentation where the infrastructure to support wired connectivity will not be installed or does not exist;

2) Facility locations where installing conduit and wiring are not feasible; and

3) Where there are life cycle, cost, or schedule advantages over the installation and maintenance of a wired infrastructure.

n) The TSCR control system network shall implement security controls identified in NIST SP 800-53A. These controls may be tailored for Industrial Control Systems as outlined in NIST SP 800-82.

3.3.18 Infrastructure Service Provisions

The TSCR system shall distribute all utilities and services required to perform its intended functions. Utilities and services may include, but are not limited to, instrumented air, water, reagent, and electrical service.


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3.3.18.1 Utilities.

Water.

The TSCR system shall provide de-ionized or de-chlorinated potable water to meet all system operations requirements.

Service Air and Instrument Air.

a) The TSCR system 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.

Electrical.

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

b) An analysis shall be prepared and submitted that determines power requirements for normal operation of the TSCR 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 TSCR 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.

f) Installations in potentially flammable atmospheres shall meet the requirements of TFC-ENG-STD-45.

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

h) 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


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equipment. A field evaluation performed by an NRTL prior to delivery is the preferred method for BUYER approval.

i) Maximum supply voltage to the TSCR system is 480V ac (3 phase).

1) Identify power load requirements using a one-line diagram and/or panelboard schedules.

2) 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 TSCR system.

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

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

l) 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.

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

n) Conductor colors:

1) 480/277V ac (3-phase Wye):

i) Red – Phase A ii) Yellow – Phase B iii) Blue – Phase C iv) White/Gray – Grounded (Neutral) v) Green – Ground.

2) 208Y/120V ac (3-phase Wye):

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

3) 120/240V ac (Single Phase):

i) Black – L1 ii) Brown – L2 iii) White – Neutral iv) Green – Ground.


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o) 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.

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

q) Conduit shall be rigid metal conduit (RMC) or intermediate metal conduit (IMC).

1) Conduit run outdoors shall be hot galvanized.

2) Electrical metallic tubing (EMT) is not allowed.

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

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

r) 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.

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

t) Where applicable, power cables between VFDs and motors shall comply with the recommendations of the VFD manufacturer.

u) 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.

3.3.18.2 Grounding and Bonding.

a) General equipment shall be grounded per NFPA 70, IEEE Std 80-2013, IEEE Std 142-2007, and IEEE C2-2017.

b) Lightning protection shall be in accordance with NFPA 70 and NFPA 780.

c) Grounding for computer/control and data processing equipment shall comply with the requirements of NFPA 70 and IEEE Std 1100-2005, NFPA 75, and IEEE Std 1050-2004.

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


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e) 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.

3.3.18.3 Electric Motors.

a) Electric motors shall comply with the applicable requirements of NEMA MG-1-2016 and IEEE Std 841-2009.

b) Alternating current motor protection shall comply with NFPA 70 and IEEE Std 242-2001.

c) Electrical motors subject to radiation exposure shall be manufactured using class H insulation (minimum).

d) Electrical motors being operated by a VFD shall be inverter duty rated, meet NEMA MG-1-2016, Part 31, and NFPA 70 (specifically, Section 430.126).

3.3.18.4 Floor Sumps.

a) Sumps should be provided in process areas to collect waste spills and washdown water.

b) Sump liners shall be compatible with the expected composition of sump waste.

c) The floors of process areas shall be lined or otherwise sealed to prevent waste leakage.

d) Capability should be provided to transfer sump liquid to the DST system.

e) Stationary equipment subject to oil leakage shall have containment features to prevent the flow of oil into the drain or sump systems.

3.3.18.5 Communications. This section describes requirements for the TSCR communication systems.

Telephone System.

a) The TSCR system shall have telephones for internal and external communication.

b) The location of telephones shall be chosen to support efficient operations and the safety of personnel.

Radio System.

a) The TSCR system shall use the Tank Operations Contractor Operator and Maintenance radio system and frequencies.

b) Radio systems shall be designed in compliance with the requirements of TFC-BSM-IRM_SE-C-02 and TFC-BSM-IRM-STD-04.


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Computer Intranet/Internet System.

a) The TSCR system shall provide infrastructure (hardware and software) that is compatible and integrated with the HLAN.

b) The hardware and software should be provided to connect via wireless HLAN (Wi-Fi).

c) Computer and software security shall be considered in the design and be in accordance with TFC-BSM-IRM_SE-C-01 and TFC-BSM-IRM-STD-04.

Control Systems Infrastructure. See Section 3.3.17 for infrastructure related to control systems, and safety instrumented system and alarms.

3.3.19 System Quality Factors

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

3.3.19.1 System Design Life. The TSCR system shall have a 5-year design life, or treat 5,000,000 gallons of tank waste. See interim storage requirements for ion-exchange columns design life in Section 3.2.2.4.

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

a) To support the TSCR system 5-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 3.3.16); however, permanently installed components shall typically be designed for a useful life of 5 years or 5,000,000 gallons of tank waste.

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

3.3.19.3 Maintainability. This section addresses the TSCR system maintainability requirements.

a) The TSCR system shall be designed for maintenance and operations in compliance with the requirements of TFC-PLN-05 and TFC-PLN-29.

b) The TSCR system 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-PLN-29 and TFC-ENG-STD-08.

c) Equipment, instrumentation, and items requiring maintenance shall be accessible for ease of inspection, maintenance and removal/replacement.


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

e) Instrumentation and control systems shall provide for periodic in-place testing and calibration of instrument channels and interlocks.

f) 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.

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

h) The TSCR system should be designed such that maintenance can be performed with commercially available tools.

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

j) Windows and cameras shall be deployed to the extent practical to minimize the need to access controlled areas for routine surveillance and inspection.

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

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

m) 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.

n) Key areas of concern for minimizing the time of maintenance evolutions, and minimizing exposure to radiation and chemical hazards are:

1) Filter service/replacement;

2) Post-filter (resin fines filter) service/replacement;

3) Spent ion-exchange columns de-watering, storage preparation, removal, and replacement; and

4) Routine and nonroutine maintenance of key components (e.g., valves, actuators, instruments) incorporating interchangeable, standardized, common, and commercially available equipment and parts, where practical.


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3.3.19.4 Availability. This section addresses TSCR system availability.

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

b) The TSCR system shall be designed such that failures of individual active components do not compromise the ability of the TSCR system to treat supernatant.

c) The TSCR system availability shall be evaluated using standard reliability engineering techniques (failure modes and effects analysis, fault tree analysis, operations research modeling, etc.). This evaluation shall demonstrate that the TSCR system has sufficient inherent availability to provide LAW to the DST system staging tank.

d) Items that contribute to the overall availability include fabrication quality controls, high quality, robust replaceable equipment items such as valves, instruments, filter back-flush frequency and duration, and ion-exchange column replacement frequency and duration.

e) The VENDOR should design a multiple filter arrangement that allows a filter to be online at all times while backup filtration capacity is serviced.

f) Ion-exchange column replacement frequency and complexity shall be minimized to the extent practical to reduce operational downtime.

g) Evolution efficiency for spent ion-exchange column preparation, removal, and replacement shall be evaluated and optimized by the VENDOR. A design goal of less than or equal to 20 days is assumed.

3.3.20 Transportability

This section specifies requirements for the TSCR system transportability to permit system deployment and logistical support.

a) The SSCs shipped to the Hanford Site shall be evaluated and properly secured to satisfy RPP-8360, Attachment E, Section 1.6. Lift points and attachments shall not be used for transportation tie-downs.

b) The TSCR system shall be designed for ease of equipment transport, installation in the field, and dismantling.

c) The TSCR system shall be designed to be transportable using existing Hanford Site rigging and transport equipment.

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

3.3.21 System Generated Solid and Liquid Wastes

The TSCR system shall be designed to manage hazardous solid and liquid wastes internally generated in compliance with applicable requirements of 40 CFR 264 and WAC 173-303.

3.3.22 Heating, Ventilation, and Air Conditioning

3.3.22.1 General.

a) The TSCR system HVAC system shall be designed in compliance with the requirements of TFC-ENG-STD-07 (Tables A-1 and A-2).

b) The TSCR system HVAC system shall be able to maintain vapor/gas concentrations below 25% of the lower flammability limit in the ion-exchange column vent line.

c) The TSCR system shall provide an interface point (raised-face ASME 150# flanged connection) on the ion-exchange column vessel ventilation line that will use the AP Tank Farm ventilation to provide process ventilation for the ion-exchange columns.

3.3.22.2 Ventilation Functional Requirements.

a) The TSCR cascading ventilation system shall be a once-through containment exhaust filter housing and maintaining a controlled, continuous flow of outdoor air into the system. See DOE-HDBK-1169-2003 for general guidance on cascade ventilation.

b) A means to obtain a sample of air in an airlock and TSCR process areas for habitability must be provided. The sample location shall be accessible from the exterior of the TSCR container.

c) A vacuum relative to atmosphere must be maintained at all times to ensure a positive flow of air into the TSCR process area confinement. See DOE-HDBK-1169-2003 for guidance on confinement zones.

d) The TSCR ventilation system shall maintain the process air temperature between 68 and 105 °F, with the ability to moderate the temperature between 60 and 80 °F for maintenance evolutions.


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3.3.22.3 System Design Criteria. This section discusses the requirements for process, control, and operating zones for the TSCR system.

a) The TSCR system shall include air locks and other barriers (HEPA filtration, backdraft dampers, etc.), as required, to separate ventilation zones, maintain ventilation balance, prevent the spread of contamination between ventilation zones, and maintain differential pressures.

b) Spaces designated for human occupation shall meet the requirements of ASHRAE 62.1.

c) Walls, floors, ceilings, and penetrations (piping, ductwork, electrical trays, conduit, etc.) of confinement barriers require adequate seals to prevent migration of contamination out of the confinement zone and to maintain differential-pressure requirements between the confinement zones.

d) Airlocks between the outside and the secondary confinement shall be provided for personnel access ways.

e) Ventilation for contaminated and potentially contaminated process areas shall include backflow prevention.

f) When part of the supply air to an occupied zone is from air cascaded into the zone, airflow from the supply system shall be sufficient to provide the necessary degree of contaminant control, and heating and cooling.

g) A loss of pressure or airflow in the confinement ventilation exhaust system shall shut off the supply air to the affected zone.

h) The TSCR ventilation system design shall facilitate ease of maintenance.

i) The TSCR system ventilation system shall have 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 Industrial Hygiene sampling equipment and methods.

j) The exhaust stack shall be designed in accordance with ASME STS-1. The exhaust stack shall be self-supported and should not use guy wires.

k) The stack design shall include drains to remove moisture due to condensation and precipitation.

l) Air flow through HEPA filters shall be maintained at a relative humidity of 70% or less during operation by means of air stream conditioning, as required.

m) The minimum stack height shall be evaluated by the BUYER from dispersion modeling results to ensure the maximum exposure limit for components listed in 29 CFR 1910, Subpart Z, is not exceeded.


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n) The design shall have capabilities for flow measurements, testing, and adjusting shall comply with ANSI/ASHRAE Standard 111-2008.

o) A minimum of two air changes per hour during normal operation are required for a secondary confinement ventilation zone. Greater air flow rates may be needed if required to maintain: (1) differential-pressure control of confinement zones and (2) temperature, moisture, and air quality control for personnel, equipment, and filters.

p) The design shall include all necessary test ports, pressure taps, pressure isolation capabilities, and monitoring access points necessary to perform ASME N511-2007. Testing requirements without disassembly of the system or safety guards (e.g., leak testing, vibration monitoring, aerosol testing, flow-rate testing).

q) Housings shall have differential-pressure instrumentation, to monitor loading on all filters.

r) 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 HEPA filters, instrumentation, personnel, and process requirements.

s) Filters shall have instrumentation for differential-pressure monitoring.

t) The system shall have exhaust flow-rate monitoring equipment and have a means to automatically adjust flow to maintain desired differential pressures and in the cascade ventilation system.

High-Efficiency Particulate Air Filter Housing.

a) The HEPA filtration housing shall be designed, fabricated, tested, inspected, packaged and transported in accordance with ASME AG-1-2015 (Division I, Sections AA, HA, and TA) as identified in RPP-SPEC-61096, Filter Housing General Equipment Procurement Specification. ASME AG-1-2015 housing qualification tests shall support all potential pressures and flow rates that may be used for operation.

b) The selected HEPA filters shall meet the requirements of ASME AG-1-2015 (Section FC) as identified in RPP-SPEC-60522, General Procurement Specification for Standard Nuclear Grade High Efficiency Particulate Air (HEPA) Filters (ASME AG-1, Section FC Compliant Filters). Filters shall also have a “gel-seal.”

c) The HEPA filtration systems shall be designed and tested in accordance with ASME AG-1-2015 (Section TA) and ASME N511-2007.

d) The filter housings shall be adequately reinforced to withstand the system structural capability pressure as defined in ASME AG-1-2015.


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Ductwork.

a) Ductwork for confinement ventilation (shall comply with ASME AG-1-2015 [Sections AA, SA, and TA]).

b) Exhaust ducts shall be per ASME AG-1-2015 (Table SA-B-1310) Class I.

Exhaust Fan and Motor.

a) Exhaust fans for confinement ventilation shall be designed, fabricated, tested, inspected, packaged, and transported in accordance with ASME AG-1-2015 (Sections AA, FA, and TA) as identified in RPP-SPEC-61095, General Equipment Procurement Specification for a Fan.

b) Fan assembly design shall provide features to allow for all required periodic maintenance and periodic ASME N511-2007 testing without having to remove safety guards or interrupt system operation.

Control System, Computer, and Telecommunication Rooms. Control system, computer, and telecommunication rooms shall have ventilation designed to maintain equipment within the temperature, humidity, and filtration limits specified by the manufacturers.

3.3.23 Lighting and Illumination

a) Average illumination levels for general exterior and interior lighting shall be based on the recommended values of IES HB-10-11.

b) Emergency lighting shall comply with NFPA 101.

c) Minimum illumination intensities for specific work areas shall be in compliance with TFC-ESHQ-IH-STD-13.

3.4 DOCUMENTATION

a) Engineering documents shall be developed in accordance with TFC-ENG-DESIGN-C-25 and TFC-ENG-STD-10.

b) New or revised engineering drawings to be released into the document control system shall be prepared and entered into the BUYER’s SmartPlant® Foundation in accordance with the TFC-ENG-STD-10.

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

d) The VENDOR shall not place any proprietary legend or stamp on any data produced as a result of this specification. All drawings or other data are the property of DOE.

e) As-built drawings shall be required at the completion of fabrication, representing the true configuration of the final TSCR system.


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f) 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), 6) Ventilation and instrument diagrams (V&IDs), 7) Equipment arrangement drawing(s), 8) Process enclosure general arrangement drawing(s), 9) Ion-exchange column drawing and supporting sizing calculations, 10) Process filter arrangement drawing, 11) Structural interfaces and supporting calculations, 12) Electrical load list and one lines diagrams (see Section 3.2.2.2.2), 13) Hydraulic calculations, 14) HVAC sizing calculations, 15) Radiation shielding calculations for loaded ion-exchange column, and 16) Radiation shielding calculation for continuously an intermittently occupied areas. 17) Preliminary compliance matrix specific to managing industrial safety and health

hazards under 10 CFR 851 (to be combined with Preliminary Design Review Compliance Matrix [DRCM] at 60% design)

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, filters), skids, and enclosures structural supports. Preliminary calculations shall be complete enough to confirm general sizing and operating parameters of vessels, and filters to ensure that there will be no unforeseen issues moving forward into final design.

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


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c) Preliminary datasheets that include VENDOR information and design and operating parameters. Information shall include, but is not limited to: instrumentation, enclosures, and accessories.

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;

7) Electrical one-line diagrams and schematics;

8) Electrical load list and calculations identifying power requirements (see Section 3.2.2.2.2);

9) Hazardous area classification drawings;

10) Control logic diagrams;*

11) Instrument data sheets;

12) Arrangement drawings;

13) Architectural plans;

14) Structural interfaces and supporting calculations;

15) Transportation, load handling, hoisting and rigging;

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

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

18) Leak detection details;*

19) Secondary containment details (liner drawings, coating specifications, volume calculations);*


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20) HVAC supporting calculations;

21) HVAC drawings;

22) Sump and drain details;*

23) Hydraulic calculations;

24) Pressure relief device calculations;

25) Shielding, containment, confinement, and ventilation plan;

26) Utility interface requirements;

27) Ion-exchange column drawing;

28) Ion-exchange column sizing calculations;

29) Radiation shielding calculations for loaded ion-exchange column;

30) Radiation shielding calculation for continuously and intermittently occupied areas;

31) Process Filter drawings;

32) Process Filter sizing calculation;

33) Materials of construction evaluations;

34) Building and foundation, slab, concrete structural and seismic analysis;*

35) Support skids sizing calculations, drawings, datasheets, etc.;

36) Spent ion-exchange column storage interface data (see Section 3.2.2.4);

37) Calculations for below the hook lifting devices and lift points (see Section 3.3.5.8); and

38) Preliminary DRCM.

Asterisk (*) denotes minimum content needed for the preliminary RCRA permit application. The VENDOR shall submit this package following incorporation of 60% design review comments.

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


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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.d) shall be updated as required, incorporating any outstanding BUYER comments, and submitted in support of the final RCRA permit application.

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

3.4.3.2 Interface Document.

Submit an interface document that is a compilation of drawings that provides 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 relevant interface dimensions for each other type of mechanical appendage (e.g., for conveyer attachments, hopper discharge, etc.); and

e) Identify connection type and size of electrical, instrument, controls, and software cabling.

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.


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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 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 block flow diagrams representing the flow between associated processing areas (e.g., tanks, columns, treatment filters, unit operations). Identify equipment and process streams. Include discussions of operational information which may include, but it not limited to the following: process transfer path, process cycle times, equipment, stream compositions (chemical and radioactive), physical properties, process flow rates, and mass and energy balances.

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.

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

1) Mechanical equipment;

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

3) Test connections;


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4) Instruments and control systems in sufficient detail to delineate function and interface with the process (Instrument symbols 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 logic diagrams 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;

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);


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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 (shelf) 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,

d) Actual elevation referenced to plant grade, and

e) Interface points with Hanford Site utilities.


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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) Camera ports, camera port covers, and fastening mechanisms;

f) Maintenance access ways, covers, and fastening mechanisms;

g) Lighting information (layout, intensity, illumination level, power consumption, etc.);

h) HVAC details;

i) Ventilation details;

j) Local instrumentation;

k) Areas for piping with valve reach rod reserve space;

l) Raceways;

m) Conduits and electrical and instrument termination boxes;

n) Pull spaces to support maintenance;

o) Dimensional locations for equipment and components;


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p) Electrical panel layout and wiring diagram; and

q) Cable and conduit routing and schedule.

3.4.3.11 Architectural Drawings.

Submit drawings for each enclosed module including the following:

a) Dimensional locations for major equipment and components;

b) Access and egress paths;

c) Plans, sections, elevations, and details;

d) Penetration locations; and

e) Materials of construction.

3.4.3.12 Vessel and Tank Drawings.

Submit drawings for each vessel to include:

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

b) Indicate that the vessel shall be fabricated and tested to the ASME BPVC, Section VIII, Division 1 (cite year and addenda);

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 end-head material;

h) Material descriptions of assembly components by their ASME and ASTM designation, alloy designation, and Unified Numbering System number;

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;


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

n) Dimensions and weights of modular frames;

o) Location of nameplates; and

p) Parts list.

3.4.3.13 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;

f) Dimensional locations for equipment and components; and

g) Reference supporting structural calculations.

3.4.3.14 Instrument Location Drawings.

Submit location drawings for the following items:

a) Instruments,

b) Major instrument racks, and

c) Field panels.

3.4.3.15 Control Logic Drawings.

Control Logic Drawings (CLDs) shall be prepared per the methodology of ANSI/ISA-5.2-1976, for discrete logic including discrete sequential operations, pre-start conditions, interlocks, etc. for TSCR devices (automatic on/off, valves, pumps, heaters, etc.) and submitted to the BUYER. Include basic system operation in conjunction with P&ID.

a) Drawing Requirements Identify input requirements as follows:

1) Include units for each input and 2) The terminology for setpoints and interlocks shall be in English standard gauge

units, based on 60 °F (15.5 °C) and atmospheric pressure of 14.7 psia for standard units, as appropriate.


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b) Format:

1) CLD shall be arranged such that it is not overcrowded or cluttered, is easily readable, and has some extra space for future alterations. The CLD shall clearly delineate field devices, controller logic, and any hard-wired interlocks which may exist. Operator interface shall also be shown on the drawing.

2) Provide drawings suitable for as produced size image as well as producing readable ANSI B size image (11 in. by 17 in.).

3) Overall logic flow shall be from left to right.

4) Solid right angle lines shall be used to connect the logic symbols. Line connections shall be indicated by dots.

5) Arrowheads shall be used where flow of logic is not in the normal direction, and where increased clarity will result.

6) Notes and references shall be included to clarify the specific and overall system function.

c) Content:

1) Use graphic symbols consistent with BUYER standards.

2) Show only one or two items of equipment per drawing.

3) Instruments, control switches, and equipment shall be identified by EINs.

4) Process inputs shall indicate the condition at which they will function, such as low pressure. Setpoints shall be included, if required, to understand the logic.

5) Show each input circuit or contact as a separate logic input.

6) Show logic for each operating state of the equipment.

7) Output actions shall be clearly defined (i.e., “stop main pump”).

8) Show operator displays, indicating lights, annunciator inputs, and computer inputs along with the location.

9) The following terminology shall be used:

i) “Start” and “Stop” is applied to mechanical equipment, such as pumps or fans;

ii) “On” or “Off” shall be used for equipment, such as heaters;

iii) “Close” and “Trip” shall be used for circuit breakers;


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iv) “Electrical Protection” shall be used to describe process logic inputs that involve any short-circuit current, over-current, torque protection, or motor high-temperature protection for electrical equipment; and

v) “Mechanical Protection” shall be used to describe process logic inputs that protect mechanical equipment, such as loss of suction pressure or high vibration.

3.4.3.16 Electrical One-Line Drawings.

Submit one-line electrical drawings that provide the following minimum information:

a) Electrical schematics,

b) Junction boxes,

c) Wiring and connection diagrams,

d) Breaker and fuse size and type,

e) Starter size,

f) Cable information and routing,

g) Overloads,

h) Electrical equipment size,

i) Equipment locations,

j) Voltage level, and

k) Reference drawings.

3.4.3.17 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,


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g) Terminal points, and

h) Reference drawings.

3.4.3.18 Hazardous Area Classification Report.

The hazardous area classification (HAC) evaluation report shall document the engineering evaluation and basis for the locations that are classified, or unclassified in some cases.

a) Prepare and submit a new, stand-alone HAC evaluation report meeting the requirements of TFC-ENG-STD-45.

b) HAC evaluation reports shall be consistent with NFPA 497.

c) Illustrations in HAC evaluation reports may include process flow diagrams or P&IDs to identify sections of a process system that must be included and further detailed in HAC drawings.

3.4.3.19 Hazardous Area Classification Drawings.

HAC drawings are the medium of communicating to installers and inspectors to the extent and boundaries of the classified location, to support installation and inspection as well as design, operations, and maintenance.

a) Prepare and submit HAC drawings meeting the requirements of TFC-ENG-STD-45.

b) Dedicated HAC drawings shall clearly identifying the boundaries of the classified locations (implements NFPA 70, NEC Article 500.4A).

c) P&IDs and process flow diagrams shall not be used as HAC drawing media.

d) HAC drawing media shall include sufficient detail of physical layout of process system to identify a classified area/region and its boundaries.

e) Area/region details may be “typical of” where geometry of the system, such as a lengthy run of pipe, makes complete coverage both impracticable and excessive, providing that all details relevant to the HAC are illustrated, such as piping penetrations or sections involving instrumentation, valves, and interfaces with other relevant systems, equipment, or structures.

f) Identification of classified region/area and its boundaries shall follow the illustration conventions appearing in NFPA 497 example illustrations of HAC regions/areas.

g) The full classification details shall be identified for each region/area (e.g., Class I, Division 2, Group B, Hydrogen).


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h) A reference to the HAC evaluation report shall be included on each HAC drawing.

i) Electrical and mechanical drawings effected by separate HAC drawings shall include reference to the HAC drawings.

3.4.3.20 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.

3.4.3.21 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.

3.4.3.22 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

d) Critical characteristics for instruments with a safety function.

3.4.3.23 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.


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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.

General.

Submitted calculations shall meet the following requirements:

a) Each calculation shall be prepared and signed by an originator, competent in the relevant engineering field.

b) Each calculation shall be prepared independent of any assistance by the checker.

c) Each calculation shall be checked and signed by a checker.

d) Checker shall possess the following qualifications:

1) Did not participate in the development of the document being checked;

2) Competent in the area of the design or analysis for which they review and capable of performing similar design or analysis activities;

3) Checker shall verify the following calculation attributes:

i) Mathematical correctness, ii) Correctness of technical input and conclusions, and iii) A review of the approach used and reasonableness of the output.

e) Prepare and submit calculations in sufficient detail to ensure that allowable criteria and proper factors of safety have been followed. Provide each calculation with:

1) Sufficient detail to allow an individual competent in that discipline to understand the methodology, inputs, and results;

2) Objective;

3) Statement of its problem;

4) Logical description of calculation methodology;

5) Design inputs and assumptions (including a sensitivity analysis) with explanation of assumption bases;

6) Codes and standards governing its design, including formulas;

7) Calculations and computations, including units;

8) References;

9) Results;


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10) Conclusions; and

11) Attachments (attach inputs relied upon not commonly available in copyrighted print, such as component manufactured data, written correspondence).

Structural Calculations.

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

1) Analysis and design of each structure; 2) Shielding structure design and its anchorage; 3) Design of equipment pads and supports; 4) Design of lift points and yokes; 5) Provide an electronic copy of the computer model input and output files; 6) Submit lifting, rigging, and lifting lug calculations (see Section 1.0); and 7) Ion-exchange column drop analyses (see Section 3.3.1).

Heating, Ventilation, and Air Conditioning Calculations.

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

b) Analysis of process off-gas 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 8) Structural capability pressures.

c) Analyze the above for the following conditions:

1) Normal operations, 2) Maintenance, and 3) Largest credible breach of the primary confinement.

d) HVAC equipment sizing (ductwork, blowers, re-heater, stacks, etc.).

e) Perform stress calculations for ductwork exceeding 150 °F (65.5 °C) and for outdoor ductwork in accordance with ASME AG-1-2015 or ASME B31.3-2016.

Hydraulic 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.


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b) For Hanford Site-provided process utilities, use input values provided at the interface point.

Ion-Exchange Column Sizing Calculations.

Submit calculations justifying ion-exchange column sizing. Calculations shall consider, as a minimum, ion-exchange column static condition cooling, total cesium loading without ion-exchange column boiling during static and dynamic flow conditions, size, and weight for ion-exchange column replacement and transportation loads.

Pressure Vessel 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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ASME B31.3-2016 Code Calculations.

Include, as a minimum, piping specifications that include the following:

a) Minimum Wall Thickness Calculations:

1) Evaluate each pipe and tube used in design;

2) Base minimum wall thickness for each service upon the pressure and temperature at the most severe condition of coincident internal or external pressure and temperature (minimum or maximum) expected during service; and

3) Segregate evaluation by materials, fabrication methodology, pipe diameter, schedule, and service.

b) Piping and System Stress Calculation(s):

1) Address system and piping flexibility due to fatigue loading, thermal loading, and other conditions as required by code and

2) Perform calculation for lines exceeding 150 °F (65.5 °C) and for outdoor lines (however, when using the ASME B31.1-2016 methodology, the allowable stresses from ASME B31.1-2016 shall also be used).

c) Unlisted Component Calculations:

1) For each unlisted component used in the piping system, demonstrate that the component meets or exceeds ASME B31.3-2016 requirements and

2) Present results (pipe schedule, material, etc.) in tabular format.

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.


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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).

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

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.

Radiation Shielding Calculations.

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

1) Spent ion-exchange column dose rate and shielding requirements and 2) 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.

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;


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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 CLD 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).

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),


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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 B31.3-2016 fluid service, and

p) ASME B31.3-2016 code calculation number.

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;

g) Materials; and

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

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;


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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.

System Design Description.

Systems design description shall be submitted in accordance with TFC-ENG-DESIGN-P-07.

3.4.4 Fabrication Documents

a) 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:

1) Control software documentation identified in Section 3.3.17.

2) List of fabrication codes and standards.

3) NDE procedures.

4) 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.


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

6) Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Qualification Records covering each weld in accordance with QA-AVS B28.

7) Welder, visual inspector, and NDE personnel qualification records (including eye tests for inspectors) in accordance with QA-AVS B25 and QA-AVS B31.

8) Liquid penetrant material certifications.

9) A dimensional drawing for the pressure vessel, indicating all dimensions necessary for support, lift, and shipping of the completed vessel. Tolerance held for such dimensions shall be noted, either on the specific dimension or in general notes. Dimensions locating centers of gravity which are generated by calculation shall be so noted on the drawing, and the calculations shall be submitted with the drawings.

10) 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.

11) 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.

12) The VENDOR shall provide certified copies of the test reports including ASME BPVC, Section VIII, Division 1, U-1 data reports as specified in the purchase order.

13) The VENDOR shall provide a Fabrication Inspection and Test Plan, which shall include the shop traveler summaries. Where applicable, the fabrication and heat treating sequence and methodology shall be addressed.

14) The VENDOR shall provide a DRCM in accordance with Section 8.1.

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

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

1) Software management plan; 2) Software test plan; 3) Fabrication, inspection, and test plans; 4) Sampling plans; 5) Commercial-grade item dedication plans 6) Factory acceptance test plan; 7) Lifting and rigging plan;


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8) Packaging, storage, shipping and load handling plan; and 9) Detailed operations and maintenance manuals.

c) 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) Positive material identification test reports.

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

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

14) Dimension verification reports, including critical dimensions.

15) Pipe wall thickness reports.

16) Fastener tightening reports.

17) Factory acceptance and pressure test reports.

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

19) Lift test records with weight certifications.

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


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

22) Nonconformance reports (closed).

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

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

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

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

27) Approved design changes (design change notices).

28) Calculations of as-built condition.

29) Detailed as-built drawings.

30) Transport tie-down plans.

31) Load handling and lift instructions.

32) Design requirements compliance matrix.

33) Final commercial grade dedication data and reports.

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

35) Detailed operations and maintenance manuals.

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

37) Qualification data including seismic qualification for safety-related equipment.

38) Manufacturer’s data and seismic qualification documents for electrical cabinets and enclosures.

39) VENDOR data sheets and color charts.

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

41) Gasket and seal reports (Section 4.4.9).


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4.0 FABRICATION REQUIREMENTS

4.1 POSITIVE MATERIAL IDENTIFICATION

This section prescribes the requirements for PMI for pressure-containing components to verify that the nominal composition of alloy components are of acceptable chemical composition independent of any certificate and marking that may exist, and ensure that correct alloy materials are used at the places where intended.

a) PMI shall be performed as close to the actual final installation as practical and prior to shipment of the completed module to ensure installation of the proper materials.

b) Components shall not be disassembled, and welds shall not be excavated to perform PMI. PMI may not be possible at final installation due to the lack of accessibility of components or welds requiring PMI. Inaccessible items requiring PMI shall be tested at the appropriate time during the fabrication or assembly process.

c) The extent of PMI examination shall be applied to alloy pressure-containing components that make up fabricated module piping identified as Quality Level (QL)-2 or QL-3. All pressure-containing parts shall be 100% verified, with the exception of bolting. PMI examination of bolting samples shall be completed for each heat/lot used for spool fabrication and shall meet the “Normal Sampling Plan” in accordance with Guidance for Sampling in the CGI Acceptance Process (TR-017218, Table 2-1).

d) PMI examination shall consist of a minimum of one test point for each pressure-piping component of module piping. This includes each:

1) Plate; pipe length; pipe fitting (elbows, olets, tees, reducers, etc.); flange; blind; special component; pipe nipple;, solid metal gasket;, bolting; etc.; and

2) Pressure containing weld (welds exceeding 48 in. in length shall include one additional test point for every 48 weld length).

e) PMI, where required, shall be performed by one of the following methods:

1) Portable X-Ray Fluorescence spectrometers with direct reading of alloy grade or percentage of each element present.

2) Optical Emission Spectrometry.

Testing of any material grades not suitable for testing by the above methods shall be tested as agreed upon by the BUYER. Other methods such as chemical spot testing, thermoelectric, mechanical methods etc. are not acceptable.

f) The PMI testing procedure shall be submitted to the BUYER for approval.


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g) PMI testing shall comply with the manufacturer’s recommendations when calibrating and/or verifying the test equipment performance. Calibration shall occur daily, at the start of work, if possible.

h) The BUYER’s Inspector shall be allowed to witness any or all PMI testing.

i) Personnel performing PMI testing shall be certified in the operation of the equipment and the test method used by completing a training course approved by the manufacturer of the PMI test equipment. Personnel qualifications shall include certification and be submitted for review and approval by the BUYER.

j) Qualified personnel using PMI equipment shall calibrate and maintain equipment in accordance with the manufacturer’s specification.

k) Acceptance criteria for PMI testing are as follows:

1) Materials shall meet the chemical composition percentages specified in the relevant ASME BPVC, Section II or ASTM material specifications as defined by the drawings. Alternatively, a match against the relevant reference spectra stored in the instrument (i.e., 316 stainless steel or 16Cr – 12Ni – 2Mo, is acceptable). The testing results shall fall within the chemical range while allowing for the accuracy of the machine.

2) If testing leads to the potential rejection of a component, then the component shall be rejected and replaced or analyzed with a more accurate method for acceptance.

3) Component replacements shall undergo PMI and conform to the acceptance requirements.

4) If a component is rejected, all items within the lot should be considered suspect. A more extensive inspection shall be performed on the lot.

5) All rejected material, items, and welds shall be marked and segregated.

l) PMI test locations shall be marked, preferably with low-stress stamp or semi-permanent paint applied to each item. The marker shall not contain additives such as aluminum, chlorides, sulfur, lead, or zinc, which may be detrimental to the material.

m) PMI test reports shall be submitted to the BUYER for approval and contain the following information, as a minimum:

1) VENDOR name (fabricator);

2) Specific job reference (PO#);

3) PMI procedure(s) and revision used;

4) Testing date and location;


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5) Testing personnel and company performing the tests;

6) Test equipment identification number or serial number;

7) Date of calibration of the alloy analyzer;

8) Recorded results of the tests for each item;

9) Material specification and grade;

10) Traceability (heat number and welding joint number);

11) Inspection batch size;

12) Number of items examined;

13) Documentation as described in API 578, Section 7.5.f and g;

14) Signature and date of the VENDOR’s representative ensuring compliance to the requirements of this specification; and

15) Signature and date by the BUYER’s Inspector verifying the review and acceptance of results.

4.2 GENERAL WELDING REQUIREMENTS

a) Welding qualifications shall be in accordance with applicable fabrication standards. ASME B&PV Section IX may be used in-lieu of these requirements.

b) Weld size and type shall be selected by the manufacturer based on applicable loads and system pressure requirements established within this specification and must meet all applicable codes.

c) Special care shall be taken to limit contamination of stainless-steel components with halides, which are common to adhesive products. If necessary, stainless steel components shall be cleaned with neutral detergent and water. Equipment shall have a name plate permanently attached to the top or side of the case.

d) All weld joints and seams along the pressure boundaries shall be 100% continuously welded. Weld joints and seams shall be wire brushed or buffed after final NDE and inspections as required to remove heat discoloration, oxidation, all burrs, and sharp edges. For stainless-steel material, the wire brush shall not be made of carbon-steel elements.


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4.2.1 Structural Welding

Structural welding shall meet the requirements of the following codes, as applicable, and all welds will be visually inspected per statically loaded AWS criteria:

a) AWS D1.1/D1.1M:2015 for structural carbon steel.

b) AWS D1.3/D1.3M:2008 for sheet steel.

c) AWS D1.6/D1.6M:2017 for structural stainless steel and stainless steel to carbon steel.

4.2.2 Weld Materials

All welding filler metals and fluxes used in the fabrication and repair of components shall be in accordance with the requirements of ASME BPVC, Section II, Part C or AWS B2.1/B2.1M-BMG:2014. Legible CMTRs for all weld materials shall be submitted to the BUYER.

4.2.3 Welding Procedures and Qualifications

a) The VENDOR shall prepare written welding procedures. Welding procedures and performance qualification shall be in accordance with the applicable codes.

b) The VENDOR shall submit copies of all WPSs, PQRs, and Welder PQRs to be employed in the performance of this specification. The VENDOR shall provide records to indicate that the Welder and Operator is qualified.

c) The VENDOR’s quality control procedures shall include the requirement that no welders shall have in their possession more than one type of filler metal at any one time, an exception is that welders may have both bare wire and covered electrodes that deposit weld metal of the same A-number class. VENDOR’s filler metal control procedure shall be submitted and approved.

d) For the ASME AG-1-2015-compliant components, Welding, WPSs, Welder PQRs, and Inspections shall be in accordance with ASME AG-1-2015. All welding performed by the housing manufacturer shall be based on published consensus standards, such as AWS D1.1/D1.1M:2015, AWS D1.3/D1.3M:2008, AWS D1.6//D1.6M:2017, AWS D9.1M/D9.1:2012, and/or ASME BPVC, Section IX, or ASME B31.3-2016.

e) Welder PQRs shall be submitted for all personnel performing welding, including tacking. Welders shall be qualified in accordance with ASME BPVC, Section IX, or applicable fabrication code requirements.

4.2.4 Weld Inspection Requirements

a) Personnel performing visual weld inspections shall be a Certified Welding Inspector (CWI) (Minimum Level II) in accordance with the requirements specified in ASME BPVC, Section IX, and AWS QC1:2016. Documentation shall be submitted prior to the start of fabrication per QA-AVS B25.


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b) Welds for ASME AG-1-2015-compliant components and structures shall meet the visual acceptance criteria of ASME AG-1-2015 (Article AA-6330) and the fabrication code applicable acceptance criteria, whichever is the more stringent.

c) The NDE processes required within this purchase order shall require review and approval of VENDOR submittals:

1) Personnel certification procedure; 2) The NDE operational procedures; and 3) Personnel certifications, including current and valid visual acuity examination

(less than 1 year old). The examination must be performed annually.

d) Per QA-AVS B31, the personnel certification procedure and certification package for NDE personnel shall accurately reflect the requirements embodied in the applicable issue of ASNT SNT-TC-1A-2016, plus any other requirements of the VENDOR.

e) The NDE operational procedures shall contain all applicable requirements of the documentation referenced in the purchase order including:

1) Reference standard or image quality indicator information, 2) Chemical purity requirements per QA-AVS B46, 3) Calibration requirements per QA-AVS B58 and QA-AVS B61, and 4) Report forms, as a minimum, per QA-AVS B52.

f) Data packages and changes, shall be submitted to the BUYER as identified in the purchase order.

g) Personnel performing NDE (Acoustic Emission [AE], Eddy Current Testing (ET), Leak Testing [LT], magnetic testing [MT], penetrant testing [PT], radiographic testing [RT], or ultrasonic testing [UT]) shall be qualified/certified to ASNT SNT-TC-1A (Level II or III), current edition unless otherwise specified. The recommended practices in ASNT SNT-TC-1A are mandatory requirements for this purchase order per QA-AVS B31.

h) The VENDOR will maintain and submit weld history data for each weld per QA-AVS B13.

4.2.5 Additional Welding Requirements

a) All tools used for stainless steel shall be kept separate from any tools previously used or currently being used for cleaning carbon-steel components. Tools for stainless steel shall be used only on stainless-steel surfaces. Similarly, appropriate controls shall be put into place to ensure ferrous and nonferrous material is properly segregated and that tools specifically used on nonferrous material be designated.

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.


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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.

4.3 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.

4.3.1 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, 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. 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) Stamps used for identification reference markings shall be of the low stress type. Stampings shall not be located near discontinuities.

f) 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.


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

h) 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.

i) Pipe bending methods, tolerances, processes, and material requirements shall comply with Pipe Fabrication Institute (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.

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

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

4.3.2 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 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.

4.3.3 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.


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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).

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.

4.3.4 Vessel Welding Requirements

a) Welds, including those for nonpressure parts and attachments, including temporary attachments, welded to pressure boundary components, shall be made by welders, welding operators, and welding procedures qualified under the provisions of ASME BPVC, Section IX. The responsibility for welding to be used in ASME BPVC construction rests with the VENDOR.

b) The VENDOR’s responsibility includes the following documents, which shall be available for use by the Welders and Welding Operators and for reference by the BUYER:

Selecting and preparing the WPSs suitable to the need shall be as follows:

1) Preparing and providing a PQR documenting proof of the weld ability of the variables described in the WPS,

2) Preparing and providing a Welder PQR documenting proof of the Welder’s ability to deposit sound weld metal within the range of WPS parameters being used, and

3) Welder Qualification Continuity Log.

c) Weld joints for pressure retaining applications shall have a minimum of two passes.

d) Where joints are welded from both sides, the first pass shall be back chipped, ground, or arc-gouged to sound metal before welding the second side. This requirement shall be stated on the WPS.

e) Peening shall not be used. The use of pneumatic tools for slag removal is not considered peening.

f) Each layer shall be completed prior to starting the next layer (no block welding).

g) Vertical welding shall be vertical up unless approved otherwise by the BUYER for each specific application.

h) For clad (or weld overlaid) plate, the following limitations apply:

1) The cladding shall be stripped back a minimum of 1/4 in. from the edge of base material bevels by machining or grinding, not by flame or arc-gouging. The


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removal shall not reduce the base material thickness below the design thickness. The method of verifying complete removal from this area shall be submitted for review.

2) Overlay weld metal shall not be used for joining base metals to each other. Local repair cavities in overlay deposits that penetrate into the base material more than 10% of its thickness or 3/16 in., whichever is less, shall have the base material re-welded with welding materials having properties consistent with the base material before completing the overlay repair.

i) All attachments such as lugs, brackets, nozzles, pads, and reinforcements around openings and other members (when permitted) shall follow the contour and shape of the surface to which they will be attached. The gap at all exposed edges to be welded shall not exceed the greater of 1/16 in. or 1/20th of the thickness of the attachment at the point of attachment.

j) Joints shall be assembled and retained in position for welding. The use of manipulators or other devices to permit welding in the flat position should be employed where practical.

k) Temporary welds including tack welds shall be made by qualified welders using qualified weld procedures.

l) All low-alloy, stainless-steel alloy, and nickel-alloy welds shall be back purged with argon. The purge shall be maintained until three layers or 3/16 in of deposit has been welded. Purging applies to vessel shell and all piping butt-welds, fillet welds and temporary attachments. Sufficiency of purge shall be verified by measuring oxygen concentration prior to welding.

m) Misalignment (high-low) in butt joints shall conform to the applicable ASME BPVC requirements. Bridging is prohibited.

n) When welds are overlaid, each layer and the adjacent metal shall be cleaned to remove all surface discoloration prior to deposition of the next bead. The final weld surface may have intermittent, iridescent straw-colored oxides. This requirement also applies to the addition of Stellite alloy to the vessel interior. Overlay and cladding procedures are to be approved per ASME BPVC, Part UCL.

4.3.5 Vessel Welding Process Limitations

a) Root Pass of Single-Side Butt-Welds without Backing (Open Butt). Only the following welding processes may be used and are subject to the limitations listed:

1) Shielded Metal Arc Welding

i) EXX10 or EX11 electrodes are permissible for welding P1 and P3 steels only and

ii) Impact test temperature not less than (-)20 °F.


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2) Gas Tungsten Arc Welding

i) Back purge three layers, minimum, for 2-1/4 Cr -1 Mo alloys and higher and ii) Gas tungsten arc root passes for 2-1/4 Cr-1 Mo alloys and higher.

3) Gas Metal Arc Welding (GMAW)

i) Only pulsed spray or spray transfer may be used and ii) Gas metal arc welding short arc is prohibited.

b) All Welding Except Root Passes (Open Butt). Only the following welding processes may be used and are subject to the limitations listed.

1) Shielded Metal Arc Welding

i) Filler metal number F1 and F2 are not permissible for pressure retaining welds’

ii) Filler metal number F3 is only permitted on P1 metals with 0.30% maximum carbon or 70 ksi maximum specified ultimate tensile strength (not permitted when base material requires impact testing below (-)20 °F); and

iii) Filler metal numbers F4 is permitted for all welds.

2) Gas Tungsten Arc Welding

i) Addition of filler metal is required (dry washing is prohibited).

3) Gas Metal Arc Welding

i) Gas metal arc welding-pulsed axial spray transfer (no Limitations); ii) Continuous spray transfer (no Limitations); and iii) For nominal pipe sizes less than 6 in., wherever possible all shop welding

shall be rotated.

4) Flux Cored Arc Welding

i) Arc shielding gas is required for pressure retaining welds and ii) Self-shielding flux cored arc welding consumables are prohibited.

5) Submerged Arc Welding

i) Neutral flux (no active or alloy constituents) is required; ii) Run on/run off tabs shall be used, where possible; and iii) Unfuzed used fluxes shall not be reused.


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4.3.6 Vessel Preheat and Inter-Pass Temperatures

a) Preheat temperature shall be in accordance with the applicable codes except that code recommended minimum preheat temperatures shall be mandatory. Preheat requirements shall apply to all welding, including tack welding and welding of temporary attachments. Preheat requirements also apply to all thermal gouging and cutting operations. Preheat shall be maintained a minimum of 3 in. on either side of the joint.

b) For welds requiring preheating, the weld joint shall be completed with no intermediate cooling. Cooling under an insulating blanket is permitted provided that at least 30% of the joint depth has been filled and that applicable documents do not specify more stringent requirements.

c) The inter-pass temperature for austenitic stainless-steels and nickel-based alloys shall not exceed 350 °F or lower, if as defined by welding rod manufacturer, except that for the hard facing of low carbon austenitic stainless steels, the inter-pass temperature shall not exceed 800 °F.

d) Preheat shall be determined by temperature indicating crayons, contact pyrometers, or other equally suitable means. Temperature indicating crayons used on austenitic stainless-steel and nickel-based alloys shall not cause corrosive or other harmful effects. It is the VENDOR’s responsibility to determine suitable brands that may be used. This information shall be made available to the BUYER’s representative, if requested.

e) If oxy-fuel torches are used for preheating, the torch tip shall be appropriate for the work (i.e., a “rosebud,” not a cutting or welding tip).

4.3.7 Vessel Post-Weld Heat Treatment

a) Direct impingement by furnace burner flames is not permitted.

b) Only resistance, induction, furnace, or quartz lamp heating methods are permitted. Exothermic-heat treatment shall require prior written authorization by the BUYER.

c) When local PWHT is performed, all attachment areas, including areas from which attachments have been removed, shall be included.

4.3.8 Vessel Shop Quality Control

a) Each layer of welding shall be smooth and free of slag inclusions, porosity, excessive undercut, cracks, and lack of fusion prior to beginning the next layer. In addition, the final weld layer shall be free of coarse ripples, non-uniform bead patterns, high crown, and deep ridges to permit the performance of any required inspection. All arc strikes, starts, and stops shall be confined to the welding groove or shall be removed by grinding. Welds containing cracks shall be locally repaired.


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b) Temporary attachments shall be removed and areas finished smooth with the vessel shell. NDE, in addition to visual examination, shall be performed to ensure no cracks have been generated.

c) Each weld shall be stamped with the welder’s unique symbol or number identification using low-stress stamps. Any alternative method of marking shall be submitted for BUYER approval.

4.3.8.1 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 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 4-1. 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 load test Witness Prior to final inspection Hold Prior to shipping Hold

4.3.8.2 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:

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 ultrasonically tested. If fillet welds are permitted by the BUYER, they may be dye-penetrant tested with approval from the BUYER.

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.


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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.

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

a) Radiography is the preferred method of NDE and shall be specified, where possible. Where it is considered impractical to perform radiographic examination due to joint configuration, the VENDOR may propose ultrasonic examinations for BUYER approval.

b) 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

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.

c) Butt-welds in internal piping shall be 100% volumetrically inspected in accordance with ASME BPVC, Section VIII, Division 1.

d) 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.

e) The following component welds shall be ultrasonically examined:

1) Supports for vessel internals and 2) 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).

4.3.8.4 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. NDE procedures shall be submitted to the BUYER for review and approval prior to fabrication.


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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.

4.3.8.5 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 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 PWHT (Post-Weld Heat Treatment).

4.3.8.6 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.


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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;

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 vulnerable equipment 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;


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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

10) The final inspection shall be documented in a final inspection report for each contract item as identified in the Master Submittal Register.

4.3.8.7 Source Quality Control.

a) Orders for pressure vessels shall be subject to random fabrication-site inspections by the BUYER or his 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.

4.4 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.

4.4.1 Pipe Spool and Installation Drawings

Submit shop pipe spool and installation drawings that show the following, as a minimum:

a) Location of all field welds identified as "FW" (Field Weld).

b) Location and identification number of all shop welds, including weld symbols in accordance with AWS A2.4:2012.

c) Line Number and Shop Weld Number. Shop welds examined by NDE shall be added to the drawing after completion of NDE.


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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.

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.

m) WPSs.

4.4.2 Pipe Welding

This section covers the minimum requirements for the welding, heat treatment, weld examination and inspection, testing, and repair of circumferential welds and branch connections in both the shop and field fabrication of piping. This specification shall be used in conjunction with ASME B31.3-2016 and other codes and standards referenced within.

4.4.2.1 Pipe Welding Materials.

a) Pipe welding filler metals shall meet the requirements of ASME BPVC, Section II, Part C. After opening of hermetically sealed containers, filler metals and fluxes shall be handled, stored, and monitored in accordance with the manufacturer’s recommendations. All filler metals shall be submitted with CMTRs and shall be submitted for approval.

b) Filler metals shall be shown on the WPS and PQR by AWS or ASME classification, except that submerged arc wire and flux combinations shall be shown on the WPS by AWS or ASME classification and manufacturer’s designation.

c) The use of internal purge dams such as inflatable balloons or water-soluble paper may be used where required.

4.4.2.2 Pipe Welding Quality Control.

a) Welding under this specification shall be placed on hold until the WPS, PQRs, and Welder QTRs have been approved by the BUYER.


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b) The VENDOR shall be responsible for qualifying the welding procedures. Welders and welding procedures shall be kept current for the duration of the project. The VENDOR shall maintain a list of all Welders (including their qualifications) used on this project. Records of continuity as described in ASME BPVC, Section IX, QW-322 shall be submitted and subject to BUYER approval.

c) All Welders shall be qualified in accordance with the requirements of ASME B31.3-2016, Paragraph 328.2. Welders performing successful procedure qualification tests are considered qualified to that procedure.

d) Weld symbols shall be displayed on assembly and shop drawings in accordance with ANSI/AWS A2.4:2012. Each qualified Welder shall be assigned a unique and unduplicated identifying symbol or number. Each identifying mark shall be employed exclusively by an individual Welder. In the event a Welder is terminated or leaves before completion of the project, his identifying mark shall be retired and shall not be reassigned to another Welder.

e) All welds shall be examined in accordance with the requirements of ASME B31.3-2016, Chapter VI. The extent of examination shall be as follows:

1) 100% visual examination per ASME B31.3-2016, Paragraphs 341.4.1(A) and 344.2 of materials, components, fabrication, joint assembly, and of alignment and supports during or after erection.

2) 100% volumetric examination (RT or UT) of welds shall be performed in accordance with ASME B31.3-2016 where possible (i.e., in-process examination shall not be specified) for all piping systems. 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 B31.3-2016, 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. Fabrication drawings shall be approved by the BUYER prior to fabrication. 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.

3) Radiographic examination shall be per ASME B31.3-2016, Paragraphs 341 through 344 for circumferential butt- and miter-welds and of branch connections similar to those shown in ASME B31.3-2016, Figure 328.5.4(E). The method of ultrasonic examination shall be in accordance with ASME BPVC, Section V, Article 4.


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4) The liquid penetrant method or magnetic particle method shall be applied to 100% of all fillets and attachment welds. Liquid penetrant examination shall be per ASME B31.3-2016, Paragraph 344.4. Magnetic particle examination shall be per ASME B31.3-2016, Paragraph 344.3.

f) Acceptance criteria shall be in accordance with ASME B31.3-2016, Paragraph 341.3.2. Acceptance criteria stated elsewhere in applicable referenced specifications shall be followed.

g) All welds, as a minimum, require a visual examination. Visual examination is governed by ASME B31.3-2016, and all NDE personnel used shall be certified in accordance with ASNT SNT-TC-1A to Level II or an AWS Certified-Welding Inspection.

h) The VENDOR shall be responsible for providing Records of Annual Vision Tests required by ASME BPVC, Section V, Article 9, T-923 for all ASME B31.3-2016 examination personnel.

i) Records for NDE personnel shall be available for review or inspection upon request of the BUYER.

j) The VENDOR shall submit and maintain weld maps for each weld.

k) Segregation of carbon steel and stainless steel shall be maintained throughout the welding and fabrication process.

l) Nonconforming material shall be physically segregated from acceptable items when possible and shall be in strict accordance to Section 6.0 of this specification.

4.4.3 Piping Erection and Installation

The following section covers piping erection and installation. Sections welding requirements, fabrication tolerances and alignment, orifices, branch connections, pipe bending and forming, heat treatment, and quality control.

4.4.3.1 General Welding Requirements.

a) Pads and other welded attachments shall be welded to the piping before heat treatment. Carbon-steel attachments welded to stainless-steel pipe are not allowed.

b) Butt-weld ends shall be prepared in accordance with ASME B16.25-2012.

c) Backing rings shall not be used and consumable inserts shall not be used without prior written approval of the BUYER. BUYER’s approval shall be obtained on the fabrication work control document.

d) Each qualified Welder shall identify each of their welds with their assigned, unique, and unduplicated identifying symbol or number adjacent to the weld joint. Steel stamping is not allowed; use Vibro Tool or BUYER-approved substitute. For stainless-


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steel and nonferrous alloys, marking materials shall contain less than 50 ppm chlorides and shall not contain any harmful metal or metal salts such as zinc, lead, or copper. Markings shall not be water soluble.

e) Peening of weld deposits and/or base materials is not permitted.

f) Tack welds shall be consumed in the weld, or removed prior to welding.

4.4.3.2 Welding Processes.

a) Welding of piping materials for fabrication or installation shall be per ASME B31.3-2016.

b) The gas tungsten arc welding process shall be used to weld at least the root and hot pass on process piping and process pressure retaining components that are welded from one side.

c) All gas tungsten arc welding welds must be made with the addition of filler metal.

d) The gas metal arc welding, flux core arc welding, shielded metal arc welding, or submerged arc welding processes can be used for welding on process piping and process pressure retaining components subject to proper qualification as allowed by the WPS.

e) The short-circuit gas metal arc welding transfer process shall not be used on any material.

f) The application of heat to correct weld distortion and dimensional deviations is prohibited without BUYER approval using a nonconformance report for a repair condition.

4.4.3.3 Purge Procedures.

a) The shielding and backing gas composition and flow rates shall be as specified in the WPS. Moisture control shall be by specification of shielding gas classification per AWS A5.32/A5.32:2011.

b) The installation and removal of inflatable balloons shall be tracked on weld maps to ensure their removal.

c) Sufficiency of purge shall be verified by measuring oxygen concentration prior to welding.

4.4.3.4 Preheat and Post-Weld Heat Treatment.

a) Preheat and PWHT requirements shall be addressed in detail on the WPS.

b) Electric or gas heat sources, which provide a uniform application of heat over the weld area, shall be used.


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c) Branch connections and other attachments shall be welded to the lines before commencement of heat treatment.

d) Preheat and PWHT shall be in accordance with the requirements of ASME B31.3-2016, Paragraphs 330 and 331. The maximum preheat and inter-pass temperatures for the welding of austenitic stainless steel shall not exceed 350 °F (177 °C).

e) Minimum preheat temperatures specified for welding shall also be used for tack welding, as well as welding.

f) 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.

4.4.3.5 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.

h) No further attempts to repair shall be carried out without the written authorization of the BUYER using the nonconformance report process.


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i) Weld repairs subsequent to the first two repair attempts shall be made only after receiving written approval of VENDOR’s repair procedures.

j) Arc strikes shall be removed and the area ground to a smooth contour. After grinding, the area shall be examined by liquid penetrant or magnetic particle examination, as applicable.

k) The metal wall thickness shall not be reduced less than that permitted in the applicable ASTM standard, without BUYER’s approval.

4.4.4 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. or as permitted by the WPS. Where misalignment exceeds the permitted misalignment, the end of the thicker pipe shall be bored in accordance with ASME B31.3-2016, Paragraph 328.4.3.

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.

4.4.5 Orifice Flange Assemblies

The internal surface of welds between the orifice flanges and the connecting pipe shall be ground smooth.

4.4.6 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 B31.3-2016.

e) Miscellaneous attachments for hangers, supports, or guides shall be of material similar to the pipe and be suitable for the operating temperature.

4.4.7 Pipe Bending and Forming

a) Pipe bending and forming shall conform to the requirements of PFI Standard ES-24 and ASME B31.3-2016.

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 B31.3-2016. 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 B31.3-2016, Paragraph 332. Where induction bends are not practical cold bends shall be used per ASME B31.3-2016, 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 4.3.8 for Vessel Shop Quality Control examination requirements.

4.4.8 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, 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.


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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.

4.4.9 Quality Control

a) Wall thickness measurement procedures and reports shall be provided for piping identified as QL-2 or QL-3. Wall thickness measurements apply to pipe bends, piping, bulk piping, butt-weld flanges, and butt-weld fittings.

b) Wall thickness measurement samples shall be completed for each heat/lot used for spool fabrication and, as a minimum, shall meet the “Normal Sampling Plan” per TR-017218 (Table 2-1). A sampled item is considered defective if the measured wall thickness does not meet the established acceptance criteria. The lot acceptance basis is as follows:

1) The lot shall be accepted if the sample metal wall thickness is within the permitted thickness tolerances in the applicable ASTM standard.

2) For ASME B16.9-2012 tees, the lot shall be accepted if:

i) The sample metal wall thickness is a minimum of 1.00 times the nominal thickness specified in ASME B36.10M-2015 or ASME B36.19M-2004 for straight pipe of the specified schedule and

ii) The tee-side wall and crotch wall thickness is a minimum of 1.15 times the nominal thickness specified in ASME B36.10M-2015 or ASME B36.19M-2004 for straight pipe of the specified schedule.

3) The lot shall be rejected (considered nonconforming) if the sample has one or more metal wall thicknesses not within the permitted thickness tolerances in the applicable ASTM standard.

c) Nonconforming lots shall require metal wall thickness measurements of each component in the lot with the established acceptance criteria above applied.

d) Wall thickness reports are to be submitted for the required components for each heat/lot used for spool fabrication. The report shall contain each heat/lot along with sample results. In addition, the applicable bulk pipe and butt-weld fitting wall thickness report is to be linked to every pipe and fitting on each extended spool sheet or referenced on each extended spool sheet where that heat/lot of pipe or butt-weld fittings has been used. The term “butt-weld fitting” includes elbows, tees, reducers, caps, laterals, crosses, butt-weld reinforced fittings, and swages; however, it excludes socket weld nipples, fittings, and flanges. Additionally, the side wall and crotch thickness of ASME B16.9-2012 tees shall be included in the submitted reports.


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e) Reports are to be submitted for verification of gasket and seal (including O-rings) functionality according to the following acceptance criteria:

1) Part description shall be confirmed per the call out of the applicable pipe material class.

2) Material composition per the applicable pipe material class shall be established via chemical analysis. Where the analysis can only be established by destructive testing, a randomly selected set may be used from the same heat/lot.

3) Durometer hardness shall be (+/-) 5 of the specified value on the Shore A scale. For gaskets whose cross section is too small to perform a Shore A test, an alternative test shall be recommended and conducted by the VENDOR. Where the durometer can only be established by destructive testing, a randomly selected set may be used from the same heat/lot.

4) Surfaces shall be free from protruding foreign material and be free of surface defects as determined by visual examination.

5) Dimensional tolerances shall be compliant as specified in manufacturer’s data and as identified by the specified dimensional standard.

6) The VENDOR shall be responsible for ensuring that all requirements set forth in this specification have been satisfied.

7) Nonconforming material shall be physically segregated from acceptable items, when possible, and shall be in strict accordance to Section 6.0 of this specification.

8) Nameplates shall be fully visible when the equipment is in an operating condition.

4.4.9.1 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 4-2. 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 *First weld strike for each weld process.


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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.

4.4.9.2 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.

4.4.10 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.

c) Where LineBacker gaskets are used, special care shall be taken during the installation to avoid rendering the gasket as ineffective by misalignment and/or overstressing.

d) 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.


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e) 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.

f) When a flanged joint has been made up and subsequently loosened, a new gasket shall be installed prior to retightening the joint.

g) 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.

4.4.11 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.

4.4.12 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.

f) Weldments of supports to piping shall be made prior to PWHT.

4.4.13 Pressure Testing

a) Piping shall be pressure tested in accordance with the requirements of ASME B31.3-2016 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


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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 B16.34-2017 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 delta P and design temperature. Valve travel stop settings shall be verified. BUYER shall witness test.

4.4.13.1 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 if insulation is required.

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 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.


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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.

4.4.13.2 Testing.

a) Pressure testing personnel shall be qualified in accordance with Section 4.3.8 for Vessel Shop Quality Control.

b) Pressure testing shall be done hydrostatically unless otherwise specified, or as approved by the BUYER.

c) Shop pressure tests shall be documented with a test report.

d) An initial service leak test is not permitted unless approved by the BUYER.

e) Vent and drain piping which is downstream of the last block valve and open to the atmosphere does not require pressure testing.

f) 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.

g) 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.

h) Water for testing equipment and piping containing austenitic stainless-steel materials shall contain less than 50-ppm chloride ion.

i) 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. 3) The product of pressure (psig) times volume (cubic feet) exceeds 50,000.

j) Pressure gauges and recorders shall be calibrated before tests. Pressure gauges shall have a dial scale 4-1/2 in. diameter, a range such that the test pressure is within 40 to 80% of the full scale and be calibrated within 2% at the full-scale reading.

k) 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).


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l) Filter elements and strainers that may have been installed shall be removed from the system prior to pressure testing.

m) Equipment appurtenances (such as level bridles, etc.) shall be tested separately when the equipment is excluded from pressure testing.

n) 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.

o) 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.

p) 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.

q) Piping that is free of leakage for the duration of the specified tests shall be accepted.

r) Test diagrams or isometric drawings shall identify the test parameters. The drawing shall show actual configuration of piping, valves, etc. of the test.

s) The VENDOR shall be responsible for repairing all leaks and the additional examination and tests required as a result of those leaks.

t) The final closure welds connecting piping systems or equipment which has been successfully tested shall be in-process examined per ASME B31.3-2016, Paragraph 345.2.3(c), applying the visual examination method per ASME BPVC, Section V. For “safety-significant” closure welds, the root pass shall be PT examined in addition to the in-process examination. Records of individual examinations are required. The weld shall pass with 100% radiographic examination in accordance with ASME B31.3-2016, Paragraph 344.5 or 100% ultrasonic examination in accordance with ASME B31.3, Paragraph 344.6.

4.4.13.3 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.

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.


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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.

4.4.13.4 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.

4.4.14 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.


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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 of the thermowell.

d) Pressure measuring devices using capsule seals shall be delivered as complete units with appropriate length of tubing to permit correct installation.

4.4.15 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:

1) Alternate current control circuits;

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); and

3) HLAN/TFLAN circuits.

c) 480-V power and 208/120V power circuits shall be wired to separate terminal boxes.

d) Testing and Inspection:

1) The VENDOR shall submit certified electrical inspector documentation in accordance with QA-AVS B17;

2) The VENDOR shall provide 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 circuits to 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 NIST or other nationally recognized standards; and

6) The VENDOR shall supply documented evidence of testing.


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4.5 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-1-2008/2009A 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-17, and show no deleterious contamination when subjected to a wipe test of ASTM A380/A380M-17. 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 1-2008/2009A to prevent entry of foreign material and humidity and protected against corrosion and physical damage.


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5-1

5.0 FACTORY ACCEPTANCE TESTING AND INSPECTIONS

a) The VENDOR is responsible for mocking up a fully functional simulant waste feed system to TSCR system at the VENDOR’s facility. As a minimum, the feed system shall consist of a feed tank, receipt tank, feed pump, feed recirculation loop with an automated flow control valve capable of providing a variable 5 to 10 gpm slip feed stream at sufficient pressure to move through the TSCR to a receipt tank. The automated flow control valve shall be compatible with TSCR control system design.

b) Water used in testing shall be clean and free of chlorides.

c) The VENDOR shall supply sufficient physical simulant for hydraulic performance testing, including solids for filter performance testing, that is consistent with the properties of the actual waste and compatible with the ion-exchange media and TSCR system materials of construction.

d) Submit the waste simulant recipe, preparation procedure, and verification acceptance procedure for BUYER approval before manufacturing the simulant.

e) The VENDOR is responsible for disposing materials and consumables used in the performance of the FAT.

f) Submit the certified waste simulant composition for BUYER approval before performing the FAT.

g) Perform test lifts as shown on lift instructions and plans for all equipment prior to shipping.

h) The VENDOR shall prepare and submit a FAT Plan and test procedures for BUYER approval.

i) The BUYER’s technical and QA representatives will identify any hold, witness, or verification points during review of FAT plans and procedures.

j) The approved and issued test plans and procedures shall be followed in strict compliance as the governing documents for the testing work.

k) Changes to approved test plans and test procedures shall be performed in accordance with applicable change control procedures under an approved ASME NQA-1-2008/2009A QA program.

l) Test exceptions, such as test article malfunction, test design deficiency, failure to meet test acceptance criteria, shall be documented.

m) After performance of the FAT, systems shall be flushed, cleaned, and dried.

n) The BUYER’s QA personnel may perform surveillance oversight of test activities.


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o) Testing shall be performed under the direction of a qualified Test Director and/or Test Engineer whose qualifications are documented and on file.

p) 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.

q) 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 WRPS personnel.

r) 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; and 11) Quality Assurance.

s) 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.

t) The FAT plan and test procedures shall identify and demonstrate pertinent human factors considerations in Section 3.3.16.

u) The FAT plan and test procedures shall identify and demonstrate the ability to operate, maintain, or recover under nonstandard conditions. Nonstandard conditions include:

1) Unplanned system and equipment maintenance, flushing, and cleaning; 2) Equipment blockage; 3) Malfunction in interfacing system operations; 4) Impacts of conditions on interfacing systems; 5) Power disruptions; and 6) Equipment fault conditions.


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v) As a minimum, the FAT test procedures shall include the following:

1) General:

2) Prerequisites and insurance 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; iii) Leak detection and confinement tests; iv) Electrical wiring verification and continuity; v) System logic and interlock testing; vi) Valve operation and alignment; and vii) Pre-startup testing may include the use of clean, chloride free water.

12) Waste simulant run:

i) Confinement ventilation system tests; ii) Normal operations using simulant including flow tests, hydraulics, and calibration; iii) Filter performance; iv) Ion-exchange column hydraulic performance; v) Verification of bed integrity through ion-exchange column life; vi) Abnormal operations tests such as trips, etc.; vii) Infrequent operations, such as flushing; and viii) Safe shut down demonstration.


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13) Prefilter cleaning or flushing capability:

i) Maintenance; ii) Pre-filter removal or replacement demonstration; iii) Resin fines filter service and replacement; iv) Disconnect, removal, and replacement of the ion-exchange columns; v) De-watering of ion-exchange column; vi) Prepare ion-exchange column for interim storage; and vii) Ability to successfully replace or repair a key component (e.g., valve,

actuator, instrument).

14) Ion-exchange column testing – demonstrate and record the following:

i) Ion-exchange column differential pressure and flow rate and ii) Absence of channeling through the ion-exchange column resin bed.

15) Perform test lifts – demonstrating lift instructions and plans:

i) Lifts during construction and installation evolutions, ii) Lifts during operations and maintenance evolutions; and iii) Other lifts as determined by BUYER during review of FAT plans and

procedures.

w) A suitable surrogate ion-exchange resin exhibiting similar physical and hydraulic characteristics to the proposed non-elutible resin may be used for the FAT. Submit proposed ion-exchange resin substitute for BUYER approval with data demonstrating suitability as a substitute and compatibility with the proposed waste simulant.

x) The VENDOR shall notify the BUYER at least 10 working days in advance of testing.

y) 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 NQA-1, Requirement 7, Paragraph 503, “Certificate of Conformance.” Documentation shall conform to QA-AVS B79.

6.5 VENDOR PROCUREMENT OF SAFETY-SIGNIFICANT ITEMS AND MATERIALS

a) Items designated by the BUYER as safety significant shall be procured by the VENDOR when contractually indicated to do so in the Statement of Work.

b) Safety-significant items shall be procured from an evaluated supplier on the VENDOR’s Evaluated Suppliers List (ESL).

c) The safety-significant item or material must be within the scope of provision of the ESL supplier, as indicated on the ESL (e.g., pipe is provided by pipe suppliers, not by structural steel suppliers).

d) When the safety-significant item or material is not available from a supplier on the VENDOR’s ESL, the safety-significant item or material must undergo a commercial grade item dedication. The provisions of ASME NQA-1 2008/2009A, Part II, Subpart 2.14, requirements for commercial grade items (CGI) shall not apply to the VENDOR unless the VENDOR’s QA program is approved by the BUYER to perform commercial grade dedication in accordance with their approved QA program.

e) To facilitate the procurement of items or materials that are intended to be dedicated, the VENDOR must submit their proposed procurement document (part of the commercial


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grade dedication [CGD]) to the BUYER for approval before ordering, in accordance with the following:

1) The BUYER identifies the safety function for the item or material. Critical characteristics for CGI shall be formally identified on a VENDOR-provided CGD form. A CGI dedication plan shall be prepared by the VENDOR and approved by the BUYER prior to the VENDOR ordering items or material to be dedicated.

2) The VENDOR submits for BUYER approval a proposed procurement document specifying the CGI item or material, the VENDOR’s CGI dedication plan number, the intended supplier, the QA requirements, the procurement quality clauses to be invoked, and acceptance criteria at receipt.

Note: The acceptance criteria for receipt may relate to one or more critical characteristics for the item or material identified by the VENDOR. VENDOR receipt inspection activities may be witnessed by the BUYER at the BUYER’s discretion. See QA-AVS B70 for requirements for providing objective evidence that items were provided by the original manufacturer.

3) The VENDOR shall order the safety-significant item or material upon receipt of written authorization from the BUYER.

4) The VENDOR’s personnel, equipment, and facilities may be required to conduct CGI dedication. Inspections or tests called for by the CGI dedication plan shall be performed only by qualified personnel.

5) The dedication reports shall be submitted to the BUYER for approval. The approved CGD reports shall be part of the quality documentation packaged delivered with the item.


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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, RPP-8360, and TFC-ENG-STD-06.

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-1-2008/2009A, Part II, Subpart 2.2. Classification of items and packaging will follow the guidelines of ASME NQA-1/2008/2009A.

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-1-2008/2009A (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 4.5.

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-1-2008/2009A, 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 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 with the PSSH plan.

7.5.2 Lifting Attachments and Equipment Design

The VENDOR may use these specifications for design, or provide lifting instructions proprietary to the manufacturer. Lift instructions shall provide the same information required above including lifting attachment locations and how to lift the item. Calculations on the lifting attachments may be required for custom made equipment and must be provided for special or critical lifts.

The objective of the process is to ensure all items to be lifted and their lifting attachments, can withstand the loads imposed by lifting operations with acceptable margins of safety. Equipment designs, tests, and reports shall be submitted for evaluation and approval during design review. Design shall include load conditions for lifting the load and rotation of the load from horizontal to vertical, if appropriate. The suspended assembly shall hang true vertical end to end. This process shall also ensure the design includes the ability to safely remove the item from a facility at the end of its design life. Long-length equipment must provide an area free of sharp edges or corners at the lower end of the equipment such that a choke hitch using a synthetic sling may be used during equipment removal.

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-1-2017 should be used to verify lifting lugs hole diameter compared to the shackle pin diameter (the D to d ratio). The analysis shall follow TFC-ENG-DESIGN-C-10, Attachment A and the analysis method described in RPP-8360.

7.5.3 Lift Point Marking

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


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7.5.4 Critical Welds

a) Critical welds shall be identified in the VENDOR’s design media.

b) For the purpose of this requirement, critical welds are defined as those welds whose failure could result in loss of load or loss of load control.

c) Critical welds on lifting devices shall be full-penetration welds, if possible.

d) Critical welds shall be verified by an NDE.

7.5.5 Special Lifting Devices

Special handling devices needed for assembly or installation shall be identified and supplied with the equipment. This includes the lifting devices, slings, shackles, and other hardware necessary to lift the equipment. All lifting equipment shall be in accordance with DOE/RL-92-36 requirements. All slings must be tested and certified to 200% of the working load limit. Identify pinch points and sling-cut protection requirements. VENDOR-provided structural and mechanical lifting devices, as defined by ASME B30.20-2013, shall conform to the requirements of ASME B30.20-2013 and ASME BTH-1-2017. BTH devices shall be load tested in accordance with ASME B30.20-2013. All custom designed lifting devices for use on the Hanford Site shall be rated for cold-weather temperature of at least 10 °F.

7.5.6 Below-the-Hook Device Markings

BTH lifting devices shall be provided with markings in accordance with ASME B30.20-2013 and tags in accordance with DOE/RL-92-36. In addition to the requirements of ASME B30.20-2013 and DOE/RL-92-36, the marking shall include Hanford Site drawing number (if applicable), special lifting instructions, and clearly indicate lifting attachments. The marking shall be in the form of a name tag, name plate, or other permanent marker.

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.

c) 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. Calculations demonstrating compliance with these requirements shall


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be included in the PSSH plan, described in Section 7.1. 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.

7.6.1 Transport and Tie-Down Instructions

The VENDOR shall provide 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. Calculations are required for the design of all transport tie-down attachment points.

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 with the PSSH plan.

7.6.3 Offloading

a) Equipment shall be shipped in accordance with the applicable Department of Transportation standards and in an orientation ready for lifting. Additional handling of the equipment to orientate 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.

b) Offloading at BUYER-designated delivery site will be performed by the BUYER or a BUYER-designated representative.


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8-1

8.0 DESIGN VERIFICATION

Design verification shall be performed by the VENDOR for the TSCR 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 TSCR design shall be verified in accordance with the VENDOR’s ASME NQA-1-2008/2009A-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-1-2008/2009A-compliant calculation verification procedures.

8.1 DESIGN REQUIREMENTS COMPLIANCE MATRIX

a) The VENDOR shall submit a DRCM demonstrating compliance with the requirements of this specification prepared in accordance with TFC-ENG-DESIGN-C-42. Full completion of the DRCM will include engineering design, fabrication, and testing to confirm functionality of the system.

b) The DRCM should be prepared during the preliminary design phase and used for engineering, testing, inspection, and procurement activities planning, as needed, to verify the completed design.

1) An example format will be provided by the BUYER upon request.

2) For each requirement, identify the method or methods that will be used to confirm verification of the design to meet the requirement.

3) For each requirement’s verification method, identify acceptance criteria and document them in the DRCM.

c) A preliminary copy of the DRCM shall be submitted with the 60% design package for review by the BUYER.

d) Design verification and the DRCM shall address required elements defined in TFC-ENG-STD-45.

e) A final DRCM shall be submitted for BUYER approval following FAT, but before BUYER final acceptance of the TSCR system.

f) The DRCM is allocated as described in the following items, which represent the columns of the matrix (table); however the table may include additional fields and information, as needed, to assist in organization and tracking of requirements.

1) Requirement ID: Provides a unique identification tag for each requirement.


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2) Requirement Source: Provides the specific reference to the requirement in a source document.

3) Requirement Text: Provides the specific text of the requirement as extracted from the source. When the requirement text is not suitable for extraction, a summary may be made, or reference made, as necessary, to figures or tables in the source document. This section should include any design assumptions made regarding the requirement.

4) Category: To assist in review and planning for project activities needed to verify requirements are met, each requirement should be organized into one of the following categories:

i) Structural systems; ii) Piping systems and components; iii) Instrumentation and controls; iv) Electrical systems; v) Heating, cooling, ventilation, and control; vi) Chemical processes; vii) Radiation protection; viii) Emergency planning; ix) Environmental compliance; and x) Safety and health.

5) Inspections, Tests, and Analyses (verification method): Identification of the proposed method (inspection, testing, analysis, or some combination of all three) by which the design commitment will be verified. If the analysis method is a design review or calculation include in the table, include the organization(s) which will perform the work.

6) Verification Status: Indicates if the verification has been completed.

7) Acceptance Criteria: Identify the specific acceptance criteria and basis for the inspections, tests, or analyses used for each requirement that when met will confirm the design requirement and commitment has been demonstrably satisfied.

8) Requirement Flow Down: This field is used to document how requirements from upper tier documents are passed down into lower tier requirements document, as well as to subcontractor documents when applicable.

9) Verification Documents: This field references the documents and evaluations that contain the information demonstrating the requirements were satisfied; these documents may be items such as test reports, inspection reports, engineering calculations, design reviews, etc. This field should also include the confirmation or closure of design assumptions made for the requirement.


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9.0 NOTES

9.1 ASSUMPTIONS

The TSCR system will be designed for continuous (i.e., 24 hour per day/7 day per week) operation.

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:

𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑜𝑜𝑜𝑜 𝐴𝐴𝑎𝑎𝐴𝐴𝑎𝑎𝑖𝑖𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝑖𝑖𝐴𝐴𝐴𝐴 𝑐𝑐𝑜𝑜𝑐𝑐𝑐𝑐𝑜𝑜𝑎𝑎𝑐𝑐𝑎𝑎𝐴𝐴 =

𝑀𝑀𝑐𝑐𝐴𝐴𝑎𝑎 𝑇𝑇𝐴𝐴𝑐𝑐𝑐𝑐 𝐵𝐵𝑐𝑐𝐴𝐴𝐵𝐵𝑐𝑐𝑐𝑐𝑎𝑎 𝐹𝐹𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝐹𝐹𝑐𝑐𝐹𝐹𝑀𝑀𝑐𝑐𝐴𝐴𝑎𝑎 𝑇𝑇𝐴𝐴𝑐𝑐𝑐𝑐 𝐵𝐵𝑐𝑐𝐴𝐴𝐵𝐵𝑐𝑐𝑐𝑐𝑎𝑎 𝐹𝐹𝐴𝐴𝐴𝐴𝐴𝐴𝑖𝑖𝐹𝐹𝑐𝑐𝐹𝐹 + 𝑀𝑀𝑐𝑐𝐴𝐴𝑎𝑎 𝑇𝑇𝐴𝐴𝑐𝑐𝑐𝑐 𝑇𝑇𝑜𝑜 𝑅𝑅𝑐𝑐𝐹𝐹𝐴𝐴𝑜𝑜𝐹𝐹𝑐𝑐

The System/Plant Availability can be calculated by:

𝑃𝑃𝐴𝐴𝐴𝐴𝑎𝑎𝐴𝐴 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 =𝐴𝐴𝐴𝐴𝑐𝑐𝐹𝐹𝐴𝐴𝐴𝐴𝑐𝑐 𝐴𝐴𝑎𝑎𝑎𝑎𝑖𝑖𝐴𝐴𝐴𝐴 𝑃𝑃𝐹𝐹𝑜𝑜𝑐𝑐𝑐𝑐𝐹𝐹𝐹𝐹𝐴𝐴𝑎𝑎𝐴𝐴 𝑅𝑅𝐴𝐴𝐴𝐴𝑐𝑐 (𝑀𝑀𝑇𝑇 𝑁𝑁𝐴𝐴/𝐴𝐴𝐹𝐹)𝐴𝐴𝑎𝑎𝑎𝑎𝑖𝑖𝐴𝐴𝐴𝐴 𝐷𝐷𝑐𝑐𝐹𝐹𝐴𝐴𝐴𝐴𝑎𝑎 𝑃𝑃𝐹𝐹𝑜𝑜𝑐𝑐𝑐𝑐𝐹𝐹𝐹𝐹𝐴𝐴𝑎𝑎𝐴𝐴 𝑅𝑅𝐴𝐴𝐴𝐴𝑐𝑐 (𝑀𝑀𝑇𝑇 𝑁𝑁𝐴𝐴/𝐴𝐴𝐹𝐹)

where: Annual Design Processing Rate (MT Na/yr) = Annual processing rate, measured in MT Na per year, is what the system has been designed to achieve.

Average Annual Processing Rate (MT Na/yr) = Average annual processing rate, measured in MT Na per year, is what the system can achieve taking into consideration equipment downtime and other losses.

Design Life: The intended normal and reliable life of SSCs.

High-dose Configuration: The waste transfer and processing equipment (piping, valves, instruments, etc.) that typically requires the use of jumpers and remotely-controlled tools for maintenance because of the potential for high-radiation doses to workers.

Low-dose Configuration: The waste transfer equipment (piping, valves, instruments, etc.) on which workers can perform hands-on maintenance. Flanged connections can be used in this instance, since the use of remote tools is not required.

Remote: Features required to service, maintain, reconfigure, or replace components in radioactive systems.

Reliability: The probability of a system or component to perform a required function under stated conditions for a specified period of time.

Requirement ID: It is recommended that requirements be uniquely numbered as a standard practice, which makes referring to them easier. Unique identification is required if using in a database format which may become desirable for some projects.

Requirement Source: Source document(s) of the requirement.


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Requirement Text: Extract of the text of the requirement. Include a description of any design assumptions made for this requirement.

WTP LAW Facility: A facility which immobilizes low-activity waste received from the TSCR system and the WTP Pretreatment Facility.

9.3 LIST OF ACRONYMS

ACI American Concrete Institute ACGIH® American Conference of Governmental Industrial Hygienists 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 ASHRAE® American Society of Heating, Refrigeration, and Air Conditioning 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 CGD commercial grade dedication CGI commercial grade items CLD Control Logic Diagram CMTR Certified Material Test Report CST Crystalline Silicotitanate CWI Certified Welding Inspector DRCM Design Review Compliance Matrix DOE U.S. Department of Energy DST double-shell tank EIN Equipment Identification Number EPDM ethylene propylene diene monomer EMT electrical metallic tubing ESL Evaluated Suppliers List FAT Factory Acceptance Testing FPE Fire Protection Engineer HAC hazard area classification HART Highway Addressable Remote Transducer HEPA high-efficiency particulate air HIHTL hose-in-hose transfer line HLAN Hanford Local Area Network HLW high-level waste HMI® human-machine interface HPS Health Physics Society


9-3

HSS hollow structural sections HTWOS Hanford Tank Waste Operations Simulator HVAC heating, ventilation, and air conditioning IBC® International Building Code® ICC International Code Council ICD Interface Control Document ICS Industrial Control Systems IEEE® Institute of Electrical and Electronics Engineers, Inc. IES Illuminating Engineering Society ILAW immobilized low-activity waste IMC intermediate metal conduit ISA International Society of Automation LAW low-activity waste LAWPS Low-Activity Waste Pretreatment System LSC® Life Safety Code® MSS Manufacturers Standardization Society NBBI National Board of Boiler and Pressure Vessel Inspectors NBIC National Board Inspection Code NEC® National Electrical Code® NDC NPH Design Category NDE nondestructive examination NEMA National Electrical Manufacturers Association NESC® National Electrical Safety Code® NFASC® National Fire Alarm and Signaling 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 PFI Pipe Fabrication Institute PMI Positive Material Identification PQR Procedure Qualification Record PSSH packaging, storage, shipping, and load handling PWHT post-weld heat treatment QA quality assurance QL Quality Level RCRA Resource Conservation and Recovery Act of 1976 RCW Revised Code of Washington RFI Request for Information RMC rigid metal conduit RPP River Protection Project SDC Seismic Design Category SEPA State and Environmental Policy Act SIS safety instrumented system SP Special Publication SSC structures, systems, and components


9-4

TFLAN Tank Farm Local Area Network TSCR Tank-Side Cesium Removal UL® Underwriters Laboratories, Inc. USC United States Code V&ID ventilation and instrument diagram VFD variable frequency drive WAC Washington Administrative Code WPS Welding Procedure Specification WRC Welding Research Council, Inc. WRPS Washington River Protection Solutions, LLC 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 gallons per liter g/mL gallons per milliliter gmole/L gram mole per liter gpm gallons per minute in. inch mm millimeter 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


9-5

9.5 TRADEMARKS

ACGIH is a registered trademark of American Conference of Governmental Industrial Hygienists, Cincinnati, Ohio.

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.

ASHRAE is a registered trademark of the American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc., Atlanta, Georgia.

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.

IBC and International Building Code are registered trademarks of the International Code Council, Inc., Whittier, California.

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.

NFASC and National Fire Alarm and Signaling Code are registered trademarks of the National Fire Protection Association, Quincy, Massachusetts.

NFPA is a registered trademark of The National Fire Protection Association, Inc., Quincy, Massachusetts.


9-6

NFPA 70E and Standard for Electrical Safety in the Workplace are registered trademarks of The National Fire Protection Association, Inc., Quincy, Massachusetts.

SmartPlant is a registered trademark of Intergraph Corporation d/b/a Hexagon Safety & Infrastructure, Madison, Alabama.

Teflon is a registered trademark of The Chemours Company, Wilmington, Delaware.

UL is a registered trademark of Underwriters Laboratories, Inc., Northbrook, Illinois.

9.6 REFERENCES

00-05-006, Hanford Site Air Operating Permit, U.S. Department of Energy – Hanford Operations, Richland, Washington.

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.

Drawing H-14-107606, 2017, “Valve Indicator Plate Details,” Washington River Protection Solutions, LLC, Richland, Washington.

Drawing H-14-107471, 2009, “Valve Funnel Receiver Assemblies,” Washington River Protection Solutions, LLC, Richland, Washington.

Hader, W.E. and K.W. Smith, 2016, “Contract No. DE-AC27-08RV14800 – Approval of Washington River Protection Solutions LLC Request to Continue to Use the Currently Implemented Industry Standard ANSI/ISA-84.00.01-2004 in Lieu of DOE-STD-1195 for the Low-Activity Waste Pretreatments System Project” (external letter 15-NSD-0033 to M. Lindholm, Washington River Protection Solutions, LLC, February 17), U.S. Department of Energy, Office of River Protection, Richland, Washington.

HNF-5183, Tank Farms Radiological Control Manual, Revision 5N, Washington River Protection Solution, LLC, Richland, Washington.

ORP-11242, 2017, River Protection Project System Plan, Revision 8, U.S. Department of Energy, Office of River Protection, Richland, Washington.

PNL-10173, 1994, Ammonia in Simulated Hanford Double-Shell Tank Wastes: Solubility and Effects on Surface Tension, Pacific Northwest Laboratory, Richland, Washington.

PNNL-20646, 2011, Hanford Waste Physical and Rheological Properties: Data and Gaps, Pacific Northwest National Laboratory, Richland, Washington.

QA-AVS, 2016, “Procurement Quality Clauses,” Acquisition Verification Services, Richland, Washington.


9-7

RPP-14541, Jumper Fabrication and Testing Specification for Tank Farms, Revision 8, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-14859, 2016, Specification for Hose-In-Hose Transfer Line and Hose Jumpers, Revision 13, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-16922, 2017, Environmental Specification Requirements, Revision 34, 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.

RPP-PLAN-34886, 2011, Investigation and Work Plan for the Resolution of Double-Shell Tank Valve Positioning Problems, Revision 5, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-RPT-46618, 2011, Hanford Waste Mineralogy Reference Report, Revision 2, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-RPT-58445, 2016, Basis for Sodium, Potassium, and Cesium Values Used in the Design of LAWPS Ion Exchange System, Revision 3, Washington River Protection Solution, LLC, Richland, Washington.

RPP-RPT-59659, 2016, Waste Characteristics for Inclusion in RPP-SPEC-56967, Project T5L01 Low Activity Waste Pretreatment System Specification, Revision 2, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-RPT-60146, 2017, TOPSim Data Package for the River Protection Project System Plan, Revision 8, Scenarios, Revision 0, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-RPT-60549, 2017, Supernatant Viscosity Assessment to Support Direct Feed Low Activity Waste Treatment, Revision 0, Washington River Protection Solution, LLC, Richland, Washington.

RPP-RPT-60588, 2018, Waste Characterization for Low Activity Waste Pretreatment System Utilizing Non-Elutable Ion Exchange, Revision 0 (draft), Washington River Protection Solution, LLC, Richland, Washington.

RPP-SPEC-60522, 2017, General Procurement Specification for Standard Nuclear Grade High Efficiency Particulate Air (HEPA) Filters (ASME AG-1, Section FC Compliant Filters), Revision 1, Washington River Protection Solution, LLC, Richland, Washington.

RPP-SPEC-61095, 2017, General Equipment Procurement Specification for a Fan, Revision 0, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-SPEC-61096, 2017, Filter Housing General Equipment Procurement Specification, Revision 0, Washington River Protection Solutions, LLC, Richland, Washington.


9-8

TR-017218, Guidance for Sampling in the CGI Acceptance Process, Revision 1, Electrical Power Research Institute, Palo Alto, California.

WRC Bulletin 297, 1987, Local Stresses In Cylindrical Shells Due To External Loadings On Nozzles-Supplement to WRC Bulletin No. 107 (Revision 1), Welding Research Council, Shaker Heights, Ohio.

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, Shaker Heights, Ohio.

WRPS-1705804, 2017, “Temperature Ranges for Direct Feed Low-Activity Waste Feed,” Interoffice Memorandum T. J. Wagnon to S. T. Arm, Washington River Protection Solutions, LLC, Richland, Washington.


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APPENDIX A

PIPING PRESSURE TEST CHECKLIST


A-ii



9-1

APPENDIX A – PIPING 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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B-i

APPENDIX B

PIPING PRE-PRESSURE TEST CHECKLIST


B-ii



B-1

APPENDIX B – PIPING 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

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

PWHT = post-weld heat treatment. MT = magnetic testing. NDE = nondestructive examination.

PT = penetrant testing. RT = radiographic testing. UT = ultrasonic testing.


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C-i

APPENDIX C

STATUS OF INSTRUMENTS DURING PRESSURE TEST


C-ii



C-1

APPENDIX C – STATUS 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.


C-2
