1. ECN YY - Digital Library/67531/metadc736218/m2/1/high_res... · 15. Distribution (include name, MSIN, and no. of copies) This ECN does not change collective dose since it does

_ ,

ENGINEERING CHANGE NOTICE I$ Pagel c.f&

2. ECN Category (mark one)

Supplemental t1 Direct Revisio txl Change ECN t1 Temporary [I Standby I1 Supersedure I1 Cancel/Void 11

653'1 YY 1. ECN

...................................... 2

12a. Modification Work

3. Originator's Name, Organization, MSIN,

J.S. Hammers/TWRS/R3-251372- 2657 6. Project Title/No./Work Order No.

and Telephone No.

Project W-314

HNF-SD-W314-TEP-001, Rev 2

9. Document Numbers Changed by this ECN (includes sheet no. and rev.)

[] Yes ( f i l l out Blk.

[XI No (NA Elks. 12b. 12b)

12c, 12d)

4. USQ Required? 5. Date

[I Yes [XI NO 6/2/99

7. Bldg./Sys./Fac. NO. 8. Approval Designator P W w a 200 E DST ES Q

IO. Related ECN No(s). 11. Related PO No.

N/A N/A

12b. Work Package NO.

N/A

13a. Description of Change 13b. Design Baseline Document? [] Yes [XI No Added Technical Performance Measures requirements per HNF-IP-0842, IV, Engineering 2.4. Added Operations and QA to JTRG. Updated references throughout procedure. #71+

Added the -I&' new packages to Appendix B, sIpIF.28Bjh4e( Valve Pit, HNF-4579, 241-AN-04A Pump Pit, HNF-4580, 241-AN-01A Pump Pit, HNF-4581, 241-AN-104 Riser 10 Pit.

Updated Tatle 3.1 responsibilities. tl~F-4578,200 AM , T9R

12c. Modification Work Complete 12d. Restored to Original Condi- tion (Temp. or Standby ECN only)

N/A N/A

Design Authority/Cog. Engineer Design Authority/Cog. Engineer Signature & Date Signature &Date

14a. Justification (mark one) Criteria Change [XI Design Improvement [] Environmental [I Facility Deactivation [] 4s- Found [I Facilitate Const [] Const. Error/Omission [] Design Error/Omission [] 14b. Justification Details Update of procedure to conform with latest program requirements and to clarify information. radiological

The T€ is 0

15. Distribution (include name, MSIN, and no. of copies)

This ECN does not change collective dose since it does not change

I RELEASE STAMP See Attached Distribution Sheet

A-7900-013-2 (05/96) GEF095

A-7900.013-1

960338 ( 9 6 / 5 0 ) E-510-006L-V

., . . i

aiea

DISTRIBUTION SHEET To I From I Page 1 of 1

I Operat ion Project Title/Work Order

P r o j e c t W-314, Tank Farm Restora t ion and Safe Operations, HNF- SD-W314-TEP-001, Rev 3, Test and Evaluat ion Plan f o r W-314

D i s t r i b u t i o n . .

EDT No.

ECN NO. 653199

I Tank Farm Restora t ion and Safe I Date 6/2/99

Name Text Text Only Attach./ EDT/ECN

MSlN With All Appendix Only Attach. anlv

A-6000-135 (01/93) WEF067

HNF-SD-W314-TEP-001, Rev. 3

Test and Evaluation Plan for Project W-314 Tank Farm Restoration and Safe Operations

Jack S. Hammers Numatec Hanford Company, Richland, WA 99352 U.S. Department o f Energy Contract DE-AC06-96RL13200

EDT/ECN: 653199 UC: 2030 Org Code: 8C610 Charge Code: 106065 B&R Code: EW3130010 To ta l Pages : H 5 6 Key Words: Test and Evaluat ion Plan, Tank Farm Restora t ion and Safe Operat ions, P ro jec t W-314.

Abs t rac t : Th is Test and Evaluat ion Plan (TEP) de f ines t h e ob jec t i ves , r o l e s , r e s p o n s i b i l i t i e s , and o v e r a l l s t ra tegy f o r conduct ing t e s t and eva lua t i on a c t i v i t i e s f o r t h e W-314 P r o j e c t .

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

Printed in the United States of America. To obtain copies of this document, contact: Document Control Services. P.O. Box 950. Mailstop H6-08. Richland WA 99352. Phone (509) 372-2420: Fax (509) 376-4989.

7/6/Ts- Date -

Release Stamp

Approved f o r Pub1 i c Re1 ease A-6400-073 (01/97) GEF321

I (1) Document Number I RECORD OF REVISION I HNF-SD-W314-TEP- I Page I

001 ( 2 ) T i t l e

Test and Eva lua t ion Plan

(3) Revision

n I

n L

3 R$

CHANGE CONTROL RECORD

( 4 ) Descr ipt ion o f Change - Replace, Add, and Delete Pages

(7) EDT 622741 Dated October 27, 1977 ECN 644838, HNF-SD-W314-TEP-001 Test and Eva lua t ion Plan renamed Construct ion Acceptance Test (CAT) t o Construct ion Test & Inspec t ion (CTI) . ECN 650516, HNF-SD-W314-TEP-001 Test and Eva lua t ion Plan; Added requirements associated w i t h scope changes due t o g r e e n f i e l d l i n e ECN 653199, HNF-SD-W314-TEP-001, Test and Eva lua t ion Plan: Added Technical Performance Measures Requirements , Added Operations and QA t o JTRG. References, Updated Table 3 .1 , Added f o u r new packages t o Appendix B

Updated

Authori

(5) cog. Engr.

TL Warnick TL Warnick

TL Warnick

JL Gruba

j f o r Release

( 6 ) Cog. Mgr. Date

WH Hays WH Hays

WH Hays

JS Hammers

A-7320.005 (08/91) WEF168

HNF-SD-W314-TEP- 001. Rev. 3

TEST AND EVALUATION PLAN

f o r

PROJECT W-314

TANK FARM RESTORATION AND SAFE OPERATIONS

Prepared by Fluor Daniel Northwest

June 2 . 1999

for

NUMATEC HANFORD CORPORATION

HNF.SD.W314.TEP.001, Rev . 3

TABLE OF CONTENTS

CHAPTER 1

1.1 1.2 1.3

CHAPTER 2

2.1 2.2 2.3 2.4 2.5 2.6

CHAPTER 3

3.1 3.2 3.3

3.4 3 . 5 3.6

3.7

3.9 3.10 3.11 3.12

3.8

CHAPTER 4

4.1 4.2 4.3 4.4

INTRODUCTION. PURPOSE. AND SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GOALS AND OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

GOALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 T&E DESIGN PHASE .................................................... 5 T&E CONSTRUCTION PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

T&E OPERATIONS AND MAINTENANCE PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 T&E TURN-OVER PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ORGANIZATION AND RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DEPARTMENT OF ENERGY (DOE-RL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FLUOR DANIEL HANFORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PROJECT MANAGEMENT (NHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3.1 PROJECT MANAGEMENT AND ENGINEERING . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3.2 TFRSO STARTUP GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

JOINT TEST REVIEW GROUP (LMHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TEST SUPPORT GROUP (FDNW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 TANK FARM OPERATIONS (LMHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.6.1 CHIEF TEST DIRECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

MAINTENANCE GROUP (LMHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESIGN AGENT (FDNW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CONSTRUCTION (FDNW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CONTRACT MANAGEMENT (FDNW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 MATRIXED ORGANIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 QUALIFICATION AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

PROJECT W-314 STRATEGY AND APPROACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6

T&E ADMINISTRATIVE A C T I V I T I E S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 T&E WORK CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PROJECT MANAGEMENT ENGINEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F I L I N G AND RECORDS MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9

i i

HNF-SD-W314-TEP- 001. Rev . 3

TABLE OF CONTENTS (CONT.)

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDICES

APPENDIX A T&E ADMINISTRATIVE PROCEDURES CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX B TEST AND EVALUATION LOGIC DIAGRAM AND OVERVIEW DEFIN IT ION DOCUMENT

2 - 1

3 - 1

A - 1

6 - 1

6 -2

6 -3

6 - 4

8 - 5

6 -6

8-7

8-8

6-9

B - 1 0

6-11

6 - 1 2

L I S T OF TABLES AND FIGURES

W-314 TESTING AND EVALUATION A C T I V I T I E S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESPONSIBILITY ASSIGNMEM MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T&E ADMINISTRATIVE PROCEDURE MATRIX FOR TESTING ......................

OVERVIEW DEFIN IT ION DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TESTING AND EVALUATION LOGIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR MASTER PUMP SHUTDOWN SYSTEM ....................

V&V LOGIC DIAGRAM FOR AN TANK FARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR AZ TANK FARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR 200E/W UPGRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR AW TANK FARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR AY TANK FARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR AP TANK FARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V&V LOGIC DIAGRAM FOR 200E WS ....

V&V LOGIC DIAGRAM FOR AN . 200E WTS

V&V LOGIC DIAGRAM FOR AZ . 200E WTS

i i i

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. . .

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.30

.32

.34

. 37

. 11

.24

.35

.37

.38

.39

.40

.41

.42

.43

.44

.45


8-13 V&V LOGIC DIAGRAM FOR AY - 200E WTS ............... . . . . . . . . . . . . . .......... 49

i v

HNF-SD- W314-TEP -001. Rev. 3

ABBREVIATIONS AND ACRONYMS

ABU

A I ATP ATR B I O CTI CGA CM COTS DOE ECN FT I FDH FDNW HNF HVAC JCS LMHC M&TE MTS NHC O&M OTP OTR P & I D PCP PDS PHMC POTP QA RL ssc STEP su T&E TEP TFRSO TIM TWRS WBS

A- E Acceptance f o r Bene f i c ia l Use Arch i tec t -Eng ineer Acceptance Inspect ion Acceptance Test Procedure Acceptance Test Report B a s i s f o r I n t e r i m Operation Const ruc t ion Tests & Inspect ions C a l i b r a t i o n and Grooming A c t i v i t i e s Const ruc t ion Management Commercial O f f The She l f U.S. Department o f Energy Engineering Change Not ice Factory Tests & Inspect ions F luo r Daniel Hanford F luo r Daniel Northwest Hanford Heating, V e n t i l a t i o n , and Air Cond i t ion ing Job Control System Lockheed M a r t i n Hanford Company Measurement and Test Equipment Master Tracking System Numatec Hanford Corporat ion Operations and Maintenance Operational Test Procedure Operational Test Report P ip ing and Ins t rumenta t ion Diagram Process Control Package P r o j e c t Development Spec i f i ca t i ons P r o j e c t Hanford Management Contractor Pre-Operational Tes t Procedure Q u a l i t y Assurance U.S. Department o f Energy, Richland Operations O f f i c e S t ruc tu res , Systems and Components S p e c i f i c Test & Evaluat ion Plan S ta r tup Test & Eva lua t ion Tes t & Eva lua t ion Plan Tank Farm Restorat ion and Safe Operations T r a i n i n g Implementation M a t r i x Tank Waste Remediation System Work Breakdown S t ruc tu re

HNF-SD-W314-TEP -001. Rev. 3

CHAPTER 1

INTRODUCTION, PURPOSE, AND SCOPE

1.1 INTRODUCTION

The "Tank Farm Restora t ion and Safe Operations" (TFRSO), . :oject W-314 w i l l r e s t o r e and/or upgrade e x i s t i n g Hanford Tank Farm f a c i l i t i e s and systems t o ensure t h a t t h e Tank Farm i n f r a s t r u c t u r e w i l l be ab le t o support near term TWRS P r i v a t i z a t i o n ' s waste feed d e l i v e r y and d isposal system and cont inue safe management o f tank waste.

The c a p i t a l improvements prov ided by t h i s p r o j e c t w i l l increase t h e margin o f s a f e t y f o r Tank Farms operat ions, and w i l l a i d i n a l i g n i n g a f f e c t e d Tank Farm systems w i t h compliance requirements from app l i cab le s t a t e , Federa l , and l o c a l regu la t i ons . Secondary b e n e f i t s w i l l be r e a l i z e d subsequent t o p r o j e c t complet ion i n t h e form o f reduced equipment down-time, reduced hea l th and s a f e t y r i s k s t o workers, reduced opera t ing and maintenance cos ts , and min imiza t ion o f r a d i o a c t i v e and/or hazardous ma te r ia l re leases t o t h e environment.

The o r i g i n a l regu la to ry (e .g . , Execut ive Orders, WACS, CFRs, permi t requirements, requ i red engineer ing standards, e t c . And i n s t i t u t i o n a l (e .g . , DOE Orders, Hanford procedures, e t c . ) Requirements f o r P r o j e c t W-314 were ex t rac ted from t h e TWRS S/RIDs du r ing t h e development o f t h e Funct ions and Requirements (F&Rs). The e n t i r e family o f requirements were then va l i da ted f o r TWRS and P r o j e c t W-314. This i n fo rma t ion was conta ined i n t h e RDD-100 database and used t o e s t a b l i s h t h e o r i g i n a l CDR.

The P r o j e c t Hanford Management Contract (PHMC) team recognizes t h a t s a f e t y , q u a l i t y , and c o s t e f fec t i veness i n t h e Test and Evaluat ion (T&E) program i s achieved through a planned systemat ic approach t o T&E a c t i v i t i e s . It i s t o t h i s end t h a t t h e Test and Eva lua t ion Plan (TEP) i s created.

The TEP f o r t h e TFRSO Pro jec t , was developed based on t h e guidance i n HNF-IP-0842, and t h e Good Prac t i ce Guide GPG-FM-005, "Test and Evaluat ion," which i s de r i ved from DOE Order 430.1, " L i f e Cycle Asset Management." It descr ibes t h e Tes t and Evaluat ion program f o r t h e TFRSO p r o j e c t s t a r t i n g w i t h t h e d e f i n i t i v e des ign phase and ending w i t h opera t iona l t e s t i n g and tu rn -ove r o f t h e upgraded systems t o Tank Farm Operations. The TEP w i l l be updated as requ i red t o r e f l e c t t h e appropr ia te t e s t acceptance and s t a r t u p requirements t o suppor t design, cons t ruc t i on , tu rnover and i n i t i a l opera t ions . Th is TEP embodies t h e f o l l o w i n g purpose and scope o f a p p l i c a t i o n f o r t h e TFRSO P r o j e c t

1

HNF-SD-W314-TEP-001. Rev. 3

1.2 PURPOSE

The purpose o f t h e TFRSO TEP i s t o i d e n t i f y and p lan t h e T&E a c t i v i t i e s and s t r a t e g i e s requ i red t o con f i rm t h a t t h e Systems, S t ruc tures , and Components (SSCs) prov ided by t h e TFRSO w i l l s a t i s f y t h e i r f unc t i ona l requirements as o u t l i n e d i n t h e P r o j e c t Development Spec i f i ca t ion ( P D S ) . The TEP w i l l a l so descr ibe t h e T&E program t o be undertaken du r ing t h e var ious p r o j e c t phases. This TEP es tab l i shes a sequence o f t e s t , suppor t , and eva lua t ion a c t i v i t i e s deemed necessary t o p rov ide conf idence t h a t a l l r equ i red T&E a c t i v i t i e s w i l l be accomplished success fu l l y t o support a smooth and t i m e l y tu rnover o f completed TFRSO upgrades t o t h e Tank Farm Operations customer. The sequence of T&E a c t i v i t i e s can be found i n t h e l o g i c diagrams and Overview D e f i n i t i o n Document OF Appendix B . The Overview D e f i n i t i o n Document and Logic Diagrams prov ide a v i s i b l e i n d i c a t i o n o f t h e type o f t e s t i n g and t h e order o f t e s t i n g r e s p e c t i v e l y . _._.__....l_.______l_______lll____ ' lechnicai Per.foriiiarice Measures i.IWH) _..._l_____l_l_____ wi.11 be u t - i i - i zed oil ci

commerci a1 grade dedi ca t i ons . devel oping system t e s t i n g and acceptancelopera~iona ' l . tests, .in accordance w i t h HKF-IfJ-0842, I\', Enqineering 2.4. I n a d d i t i o n t o p r o v i d i n g a roadmap f o r T&E and r e l a t e d support a c t i v i t i e s , t h e TEP o u t l i n e s o rgan iza t i ona l

' , " l be de l ineated .in spec.if-ic .l- ............................................................... .................................

r e s p o n s i b i l i t i e s f o r managing and performing t h e t e s t i n g and eva lua t i on a c t i v i t i e s . Th is inc ludes an overview of each p a r t i c i p a t i n g o rgan iza t i on ' s management

r e s p o n s i b i l i t i e s , in te r faces , 1 ines o f a u t h o r i t y , a c c o u n t a b i l i t y , q u a l i f i c a t i o n , and independent v e r i f i c a t i o n s .

1.3 SCOPE

The TFRSO Test and Eva lua t ion Plan encompasses t h e o v e r a l l s e t o f T&E a c t i v i t i e s t h a t a re planned f o r P r o j e c t W-314. A graded approach s h a l l be used t o determine what l e v e l o f T&E e f f o r t w i l l be employed on t h e var ious elements o f t h e TFRSO P r o j e c t . Th is graded approach s h a l l ensure t h a t T&E p r i n c i p l e s and p rac t i ces are incorpora ted commensurate w i t h f a c t o r s such as complex i ty , v i s i b i l i t y , and r i s k t o ensure successful p r o j e c t complet ion. Since t h e p r o j e c t encompasses many systems and f a c i l i t i e s spread over a l ong pe r iod o f t ime, separate lower t i e r S p e c i f i c Test and Eva lua t ion Plans (STEPS) w i l l be developed f o r tu rnover segments w i t h i n t h e p r o j e c t . Each o f these separate segments w i l l be a l igned w i t h t h e Acceptance f o r B e n e f i c i a l Use (ABU) packages.

The Acceptance f o r Bene f i c ia l Use process w i l l i d e n t i f y and t r a c k a l l r e levan t documentation f o r p r o j e c t tu rnover . The STEPS w i l l i d e n t i f y s p e c i f i c t e s t i n g a c t i v i t i e s and a t what phase o f t h e p r o j e c t these a c t i v i t i e s should take p lace.

Tes t ing and Eva lua t ion a c t i v i t i e s may inc lude Factory Tests & Inspec t ions (FT Is ) , Const ruc t ion Tests & Inspect ions (CTIs) , Acceptance Tests Procedures (ATPs), Pre-Operat ional Tests Procedures (POTPs), Operat ional Tests Procedures (OTPs), C a l i b r a t i o n , Grooming, and Alignment (CGA) a c t i v i t i e s , In-Process Tes t i ng performed du r ing t h e cons t ruc t i on and procurement phases, and any o the r such t e s t s o r

2


evaluations required t o verify t h a t the end product(s) meet the requirements

eqa.ipiiier!t/s.ys.terns. Rep1 acenien.ts .in-k ind or !iianufactur'ers u.Na.tes to w'isf..ing

developed arid tracked f.0 assure &veloc~:icnt act.ivi.i;.ies wi ' l .1 produce pro(lLic.ts meeting the r'eqiiireiiierits established for the project. Additio!ial ' l .y, these i!ieasiireiiwits wii 1

Speci,f ic 'rest and Evaluation P;ans ( S T E P ) . Descriptions of the various T&E act ivi t ies are discussed i n the corresponding T&E phase found i n chapter 2 .

3

HNF-SD-W314-TEP - 001. Rev. 3

CHAPTER 2

GOALS AND OBJECTIVES

The f o l l o w i n g sec t ions i d e n t i f y t h e goals and ob jec t i ves t h a t t h e TEP w i l l a t t a in . A d d i t i o n a l l y , t h e types o f t e s t i n g conducted du r ing var ious phases (i .e . , design, t u rnove r . . . e t c ) o f t h e P r o j e c t w i l l be descr ibed i n grea ter d e t a i l . A lso , Table 2 - 1 ( found on page 11) prov ides a qu ick re ference t o t h e respec t ive T&E a c t i v i t i e s associated w i t h each phase and t h e i r subsequent ob jec t i ves .

2.1 GOALS

The goal o f t h i s TEP i s t o ensure t h e i n t e g r i t y and o p e r a b i l i t y o f t h e upgraded SSCs a r e i n accordance w i t h t h e i r PDS documents, and t o demonstrate t h e readiness o f operat ions and management t o s a f e l y and e f f e c t i v e l y operate these upgraded SSCs.

2.2 OBJECTIVES

The o v e r a l l ob jec t i ves o f t h e TFRSO T&E program are t o demonstrate t h e TFRSO upgraded SSCs a r e ( a ) compl iant w i t h t h e requirements o f t h e approved PDS: (b ) cons t ruc ted i n accordance w i t h approved design drawings and procurement/construction s p e c i f i c a t i o n s ; c ) i n s t a l l e d p roper l y and approp r ia te l y i n teg ra ted i n t o t h e e x i s t i n g system: and (d ) w i l l operate s a f e l y upon tu rn -ove r t o t h e customer. Th is document w i l l p rov ide t h e i n t e g r a t i o n o f a l l t e s t i n g a c t i v i t i e s t o ensure t h e above ob jec t i ves are met. Th is i n t e g r a t i o n can be seen by rev iewing t h e Logic Diagrams i n Appendix B. t h e t e s t s designated i n t h e corresponding STEP. The STEP def ines t h e SSC(s) t h a t w i l l be tes ted , t h e t e s t boundaries, t h e t e s t acceptance c r i t e r i a , t e s t requ i rements , and t ype o f t e s t s (i .e. , FTIs , CTIs , ATPs. . . e t c . t h a t a r e requ i red .

Complete and successful SSC t e s t i n g w i l l be accomplished by conduct ing

Table 2 - 1 ( found on page 11) provides t h e TFRSO T&E s t ra tegy and approach du r ing t h e p r o j e c t . Note t h a t Table 2 - 1 i s s t ruc tu red t o show t h a t t h e ob jec t i ves o f a g iven T&E a c t i v i t y must be f u l f i l l e d be fore progress ing on t o t h e a c t i v i t y o f t h e nex t phase. A b r i e f d e s c r i p t i o n o f t h e T&E a c t i v i t i e s , as dep ic ted i n Table 2-1, along w i t h a b r i e f d e s c r i p t i o n o f t h e p r o j e c t s t ra tegy lapproach t o accomplish t h e T&E a c t i v i t y , a r e summarized i n t h e f o l l o w i n g sec t ions .

2.3 T&E DESIGN PHASE

Tes t ing and eva lua t i on a c t i v i t i e s du r ing t h e design phase a r e focused on demonstrat ing t h a t t h e SSCs, as designed, meet t h e requirements s p e c i f i e d i n t h e

4


PDS. Th is i s r e f e r r e d t o as "design v e r i f i c a t i o n " i n Table 2-1 and o the r sect ions o f t h i s document. The o v e r a l l o b j e c t i v e o f design v e r i f i c a t i o n i s t o determine i f

t h e des ign o f t h e SSC(s) meet t h e requirements o f t h e PDS. The TFRSO design, as documented i n drawings and construction/procurement s p e c i f i c a t i o n s , i s evaluated aga ins t t h e requirements o f t h e app l i cab le PDS by t h e methods descr ibed i n Sect ion 4 o f t h e PDS. The f o u r poss ib le methods o f design v e r i f i c a t i o n , o r " Q u a l i t y Conformance Inspec t ions" as i t i s r e f e r r e d t o i n t h e PDS, a r e as f o l l o w s :

ANALYSIS - an element o f inspec t ion , t a k i n g t h e form o f t h e processing o f accumulated r e s u l t s and conclus ions, in tended t o p rov ide p r o o f t h a t v e r i f i c a t i o n o f a requi rement(s) has been accomplished. The a n a l y t i c a l r e s u l t s may be comprised o f a compi la t ion o f i n t e r p r e t a t i o n o f e x i s t i n g i n fo rma t ion o r der ived from lower l e v e l examinations, t e s t s , demonstrations, o r ana lys i s .

DEMONSTRATION - an element o f i nspec t i on t h a t i s l i m i t e d t o r e a d i l y observable f u n c t i o n a l opera t ion t o determine compliance w i t h requirements. This element o f i n s p e c t i o n does n o t r e q u i r e t h e use o f spec ia l equipment o r soph is t i ca ted ins t rumenta t ion . du r ing t h e T&E cons t ruc t i on phase.

It should be noted t h a t most o f these a c t i v i t i e s w i l l occur

EXAMINATION - an element o f i nspec t i on cons is t i ng o f i n v e s t i g a t i o n , w i thou t t h e use o f spec ia l l abo ra to ry appl iances o r procedures, t o determine compliance w i t h requirements. t h e T&E cons t ruc t i on phase.

It should be noted t h a t most o f these a c t i v i t i e s w i l l occur du r ing

TEST - an element o f i nspec t i on t h a t employs techn ica l means i n c l u d i n g ( b u t n o t l i m i t e d t o ) t h e eva lua t ion o f f unc t i ona l c h a r a c t e r i s t i c s by use o f spec ia l equipment o r ins t rumenta t ion , s imu la t i on techniques, and t h e a p p l i c a t i o n o f es tab l i shed p r i n c i p l e s and procedures t o determine compliance w i t h requirements.

It should be noted t h a t most o f these a c t i v i t i e s w i l l occur du r ing t h e T&E cons t ruc t i on phase.

The ana lys i s o f data der ived from t e s t i s an i n t e g r a l p a r t o f t h i s inspec t ion .

It should be noted, t h a t any one, o r combinat ion t h e r e o f , o f t h e above methods may be s p e c i f i e d i n t h e PDS as app l i cab le v e r i f i c a t i o n methods.

The des ign approach f o r TFRSO SSCs i s t o incorpora te Commercial O f f The S h e l f (COTS) products as much as poss ib le . Therefore, one o f t h e ob jec t i ves o f des ign v e r i f i c a t i o n w i l l be t o con f i rm t h a t t h e SSC(s) meet t h e requirements o f t h e corresponding PDS(s) through t h e use o f ana lys is , demonstrat ion, and/or examination.

o b j e c t i v e w i l l be met by rev iewing vendor data sheets and ca ta log c u t sheets, eva lua t i on o f s i m i l a r hardware under s i m i l a r usages, review o f t h e des ign drawings and construction/procurement s p e c i f i c a t i o n s by t h e appropr ia te engineers, and any

No spec ia l des ign v e r i f i c a t i o n t e s t s have been i d e n t i f i e d a t t h i s t ime. Th is

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HNF-SD-W314-TEP - 001, Rev. 3

needed analyses u t i l i z i n g such in fo rma t ion w i l l be performed t o accomplish design v e r i f i c a t i o n s .

Other T&E a c t i v i t i e s conducted du r ing t h e design phase inc lude p lann ing o f t h e T&E program f o r t h e TFRSO Pro jec t . Planning inc ludes development o f t h e TFRSO TEP and t h e S p e c i f i c Tes t & Eva lua t ion Plans i d e n t i f i e d i n Appendix B o f t h i s TEP. The purpose and scope o f t h e TFRSO TEP i s descr ibed i n Chapter 1 o f t h i s TEP, however, t h e purpose and scope of each s p e c i f i c STEP w i l l be descr ibed i n each STEP. The needed procedures and p lans w i l l be spec i f ied by t h e STEPS so t h a t s p e c i f i c t e s t s and/or eva lua t ions t o be conducted can be c a r r i e d - o u t i n an o r d e r l y and t i m e l y manner. The o v e r a l l ob jec t i ves t o e f f e c t i v e T&E p lanning a r e t o understand, i n t e g r a t e , schedule, and resource load T&E a c t i v i t i e s and t o communicate, a t var ious l e v e l s , t h e T&E a c t i v i t i e s t o be oerformed on TFRSO SSCs.

2.4 T&E CONSTRUCTION PHASE

Const ruc t ion t e s t i n g a c t i v i t i e s a re comprised o f var ious t e s t s and inspec t ions t h a t demonstrate compliance w i t h procurement and cons t ruc t i on s p e c i f i c a t i o n s . S a t i s f a c t o r y complet ion o f these t e s t s a re requ i red t o a l l ow t r a n s i t i o n i n t o p r e - t e s t i n g a c t i v i t i e s ( f o r POTPs and OTPs), which are comprised o f C a l i b r a t i o n , Grooming, and Alignment (CGA) a c t i v i t i e s fo l lowed by Pre-Operat ional Tests and Operat ional Tes t ing . Thus, t e s t and eva lua t ion a c t i v i t i e s , conducted du r ing t h e cons t ruc t i on phase o f t h e TFRSO p r o j e c t , a re focused on demonstrat ing t h e f o l l o w i n g :

t h e d e l i v e r e d SSCs have been manufactured t o t h e requirements found on t h e approved drawings and s p e c i f i c a t i o n s and

t h e SSCs have been p roper l y const ructed and/or i n s t a l l e d .

To accomplish t h e above, t h e r e are several d i f f e r e n t types o f cons t ruc t i on T&E a c t i v i t i e s t h a t cou ld occur. Factory Tests & Inspect ions (FTIs ) , mock-up t e s t s , Acceptance Test Procedures (ATPs), and o the r Construct ion Tests & Inspec t ions (CT Is ) (e .g . , hydro t e s t s , pneumatic t e s t s , megger t e s t s e t c . . . I w i l l be performed t o demonstrate t h a t t h e TFRSO SSCs w i l l perform per t h e requirements o f t h e approved des ign media. Every e f f o r t w i l l be made t o ensure t h e SSCs have been p roper l y completed, i n s t a l l e d , groomed, and/or inspected f o r completeness p r i o r t o i n i t i a t i o n o f c o n s t r u c t i o n and acceptance t e s t i n g .

The o v e r a l l o b j e c t i v e o f t h e FTIs i s t o determine t h a t t h e manufactured SSC i s adequate and ready f o r i n s t a l l a t i o n . The FT I i s used t o s a t i s f y des ign v e r i f i c a t i o n s by demonstrat ion, examination, and/or t e s t i n g . For t h e F T I , t h e manufactured SSC i s u l t i m a t e l y evaluated aga ins t t h e requirements o f t h e app l i cab le drawings and/or procurement s p e c i f i c a t i o n . acceptance c r i t e r i a s h a l l be based on t h e drawing and/or procurement s p e c i f i c a t i o n

For s p e c i f i c FTIs conducted, t h e

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requirements. A d d i t i o n a l l y , FTIs may be generated and con ta in ho ld p o i n t s t h a t r e q u i r e a wi tness s igna tu re t o “buy o f f ” t h e SSC: t he re fo re , con f i rm ing t h a t a l l

acceptance requirements a re met. A f a c t o r y acceptance t e s t r e p o r t w i l l be generated when a l l t e s t except ions have been c leared and t h e t e s t has been success fu l l y completed.

The TFRSO implementat ion o f FTIs vary depending on t h e r i s k f a c t o r s and complex i ty of t h e SSC. Non-complex SSCs may be evaluated v i a a review o f t h e vendor ’s ca ta log c u t sheets and data sheets. An engineer ing ana lys is may be requ i red t o f u r t h e r assure and document t h e adequacy o f t h e equipment o r SSC be ing evaluated. Th is w i l l p rov ide i n s i g h t i n t o t h e adequacy o f t h e vendor supp l ied COTS equipment i n meeting t h e procurement s p e c i f i c a t i o n . I n some instances, vendor q u a l i f i c a t i o n i s performed by an eva lua t i on o f t h e vendor’s manufactur ing processes and q u a l i t y assurance program. On complex SSCs, more s t r i n g e n t requirements may be imposed t o assure compliance w i t h t h e drawings and/or s p e c i f i c a t i o n s . This may inc lude t h a t t h e buyer be present a t t h e vendor ’s f a c i l i t y t o wi tness t e s t i n g and/or t h e manufactur ing process. SSC complex i ty w i l l be determined by rev iewing t h e procurement and c o n s t r u c t i o n s p e c i f i c a t i o n s and o the r design documents.

A mockup t e s t o f t h e P i t Leak Detectors w i l l be performed p r i o r t o i n s t a l l a t i o n t o ensure t h a t t h e performance requirements, found i n t h e P r o j e c t Development Spec i f i ca t i ons , a r e met. Note t h a t t h i s mockup t e s t w i l l be performed o n l y once t o v e r i f y design.

CTIs w i l l be i d e n t i f i e d i n Construct ion Work Packages (CWPs) based on requirements found on t h e drawings and cons t ruc t i on s p e c i f i c a t i o n s : whereas, ATPs a r e separate “stand alone” documents which o b t a i n t h e i r requirements from t h e app l i cab le PDS and vendor da ta . The CTI i s used t o s a t i s f y design v e r i f i c a t i o n requirements v i a demonstrat ion, examination, and t e s t i n g . ATPs and CTIs w i l l ensure t h a t t h e SSCs are f a b r i c a t e d and/or i n s t a l l e d p roper l y t o p rov ide sa fe and r e l i a b l e opera t ion . De ta i l ed CTI procedures may be requ i red f o r conduct ing non- rou t ine f u n c t i o n a l checks and/or inspec t ions du r ing SSC i n s t a l l a t i o n s . De ta i l ed ATPs w i l l be requ i red a f t e r t h e CTI f u n c t i o n a l checks and/or inspect ions are completed and, w i l l v a l i d a t e o v e r a l l SSC i n s t a l l a t i o n as a whole. s p e c i f i e d i n e i t h e r t h e C T I and/or on approved drawings and s p e c i f i c a t i o n s . ATPs, t h e acceptance c r i t e r i a w i l l be s p e c i f i e d i n t h e ATP.

CTI and ATP implementat ion w i l l a l so vary depending on t h e complex i ty and r i s k f a c t o r i nvo l ved w i t h t h e app l i cab le SSC. CTIs may r e q u i r e Q u a l i t y Assurance (QA) t o wi tness and approve t h e i n s t a l l a t i o n . It w i l l be de l ineated , i n each s p e c i f i c STEP document, who i s requ i red t o wi tness and/or approve t h e respec t ive CTI o r ATP. A l l CTIs and ATPs s h a l l be documented t o record r e s u l t s and any fo l l ow-up a c t i v i t i e s necessary t o accept t h e SSC f o r tu rnover t o t h e customer. CTI’s a re documented i n t h e app l i cab le CWP. An Acceptance Test Report (ATR), f o r each ATP, w i l l be

For CTIs, t h e acceptance c r i t e r i a s h a l l be For


generated when a l l t e s t exceptions have been c leared and t h e t e s t has been success fu l l y completed.

The Design Agent i s requ i red t o prepare t e s t requirements and acceptance c r i t e r i a f o r FTIs and CTI f o r i n c l u s i o n i n procurement and cons t ruc t i on s p e c i f i c a t i o n s . ......................................................... FTI’s and C1’I’s wi11 be prepared by t h e design agent, cons t ruc t i on con t rac to rs , o r vendor /suppl iers W i t / ) t h e ass is tance o f TFRSO Star tup . i n accordance w i t h requirements o f procurement and cons t ruc t i on s p e c i f i c a t i o n s and vendor data. These

p a r t i c i p a n t s as requested by t h e P r o j e c t Manager. The FTIs and CTIs w i l l be performed by t h e respons ib le o rgan iza t i on (i .e . , cons t ruc t i on c o n t r a c t o r o r vendor /supp l ie r ) . These t e s t s may be witnessed by F luo r Daniel Northwest, as requ i red , t o ensure t e s t requirements a re met. The t e s t data w i l l be inc luded i n t h e Acceptance f o r Benef ic ia l Use (ABU) tu rnover packages. S a t i s f a c t o r y complet ion o f cons t ruc t i on and t rans fe r of t h e completed SSC t o t h e user/sponsor o rgan iza t i on w i l l be documented us ing t h e Acceptance o f Completed Work (ACW) form.

I I l:7‘i’s arid GI’s w i l l be reviewed and approved by t h e design agent, and o the r PHMC

are ATP’s i n accordanc ca’i .........

o the r PiiMC par%-ic.ipan.ts as requested b.y the P r q j e c t Manager and speci-fied ‘in ,Lhe

w i l l be present i n an ove rs igh t r o l e t h a t may take a d m i n i s t r a t i v e c o n t r o l o f equipment and po r t i ons o f systems before complet ion o f cons t ruc t i on .in order. t o

or ?OW‘S as soon as poss ih le t o ineet project: m-i ................................................................................................................................................ 1 2.5 T&E TURN-OVER PHASE

The t e s t and eva lua t ion a c t i v i t i e s conducted du r ing t h e tu rn -ove r phase of t h e TFRSO P r o j e c t focus on demonstrat ing t h e f o l l o w i n g :

t h e i n s t a l l e d SSCs f u n c t i o n proper ly w i t h i n t h e system as a whole and

t h e system, w i t h SSCs i n s t a l l e d , w i l l operate under normal opera t ing cond i t ions and/or a n t i c i p a t e d o f f -normal cond i t i ons .

The pr imary T&E a c t i v i t i e s t h a t accomplish t h e previous ob jec t i ves are r e f e r r e d t o as Pre-Operat ional Tests Procedures (POTPs) and Operat ional Test Procedures (OTPs) .

The o v e r a l l o b j e c t i v e o f t h e POTPs i s t o determine i f t h e i n s t a l l e d SSCs f u n c t i o n as in tended when in teg ra ted i n t o t h e system as a whole. A lso, ensure t h a t t h e SSCs operate s a f e l y and r e l i a b l y . For POTPs, t h e i n s t a l l e d SSCs are u l t i m a t e l y evaluated

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aga ins t t h e requirements o f t h e app l i cab le PDS and TWRS Basis f o r Inter im Operat ion (B IO) document. Pre-Operat ional t e s t i n g may be performed on i n d i v i d u a l segments o f SSCs t o demonstrate t h a t p l a n t systems o r subsystems perform as designed. The

des ign agent may be requested t o prepare t e s t s p e c i f i c a t i o n s f o r p re-opera t iona l t e s t s which con ta in t e s t requirements and acceptance c r i t e r i a i n c l u d i n g , requirements and i n s t r u c t i o n s from t h e vendors f o r s p e c i f i c i tems o f equipment. The S ta r tup o rgan iza t i on w i l l ensure t h a t t e s t procedures a r e prepared from these s p e c i f i c a t i o n s which prov ide i n s t r u c t i o n s f o r conduct o f t h e t e s t s . The procedures w i l l be reviewed by t h e owner’s J o i n t Test Review Group (JTRG) p r i o r t o conduct ing t h e t e s t . I f a POTP has been generated b u t t h e t e s t i n g o f t h e corresponding SSC won’t be performed f o r an extended pe r iod o f t ime (e .g . , year o r more), then t h e POTP must be reviewed again, p r i o r t o performance o f t h e t e s t , t o ensure t h a t i t i s s t i l l app l i cab le . A p re-opera t iona l t e s t r e p o r t w i l l be generated when a l l t e s t except ions have been c leared and t h e t e s t has been success fu l l y completed.

Required OTPs w i l l be planned, scheduled. and conducted, on t h e i n s t a l l e d SSCs, a f t e r complet ion and acceptance o f a l l o the r t e s t r e s u l t s . These d e t a i l e d procedures s h a l l determine i f t h e i n s t a l l e d SSCs f u n c t i o n as in tended when i n t e g r a t e d i n t o t h e system as a whole. A l l systems a r e brought o n - l i n e and operated under a n t i c i p a t e d standard opera t ing cond i t ions and of f -normal cond i t i ons : thus , v e r i f y i n g t h a t t h e SSCs operate s a f e l y and r e l i a b l y . acceptance c r i t e r i a t o de l i nea te p a s s l f a i l requirements. Operat ional t e s t i n g i s performed w i t h ac tua l p l a n t equipment, opera t ing procedures, and personnel . I f an OTP has been generated b u t t h e t e s t i n g o f t h e corresponding SSC won’t be performed f o r an extended pe r iod o f t ime ( e . g . , a year o r more), then t h e OTP must be reviewed again, p r i o r t o performance o f t h e t e s t , t o ensure t h a t it i s s t i l l app l i cab le . A Operat ional Tes t Report (OTR) w i l l be generated when a l l t e s t except ions have been c leared and t h e t e s t has been success fu l l y completed.

Since t h i s is an in teg ra ted system l e v e l t e s t , t h e acceptance c r i t e r i a s h a l l be based on t h e requirements s p e c i f i e d i n t h e approved design media, opera t iona l procedures, e x i s t i n g opera t iona l requirements, and t h e B I O .

The process by which t h i s i n fo rma t ion w i l l be tu rned over i s c a l l e d t h e ABU process.

The o b j e c t i v e o f t h e TFRSO P r o j e c t T&E a c t i v i t i e s , conducted du r ing t h e tu rn -ove r phase, i s t o p l a n and execute t h e t e s t s w i t h coo rd ina t i on f rom t h e p r o j e c t s , operat ions, and maintenance organ iza t ions . This coo rd ina t i on w i l l ensure a smooth t r a n s i t i o n du r ing t h e tu rn -ove r process. Inc luded i n t h e tu rnover t o t h e end user w i l l be t h e necessary opera t ing and maintenance procedures, t r a i n i n g on t h e system, and i n i t i a l spare p a r t s l i s t i n g s necessary f o r system maintenance.

Inc luded i n t h e OTP w i l l be

The t e s t and eva lua t i on a c t i v i t i e s conducted du r ing t h e tu rn -ove r phase o f t h e TFRSO P r o j e c t focus on d e l i v e r i n g t h e f o l l o w i n g :

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A l l documents needed t o operate and main ta in t h e SCC prov ide by t h e TFRSO p r o j e c t . Th is inc ludes any opera t ion personnel t r a i n i n g , procedure updates, spare p a r t s a v a i l a b i l i t y , and f i n a l opera t ing t e s t repo r t s .

Any necessary readiness review documents o r assessments procedure t h a t determine whether t h e mod i f ied SSC operate under o r change c u r r e n t Operat ing Safe ty Requirements and t h e c u r r e n t TWRS B I O document.

The process i n which those i tems l i s t e d above are tu rned over t o t h e end user (Tank Farm Operat ion) i s c a l l e d t h e Acceptance o f S t ruc tures , Systems, and Components f o r B e n e f i c i a l Use Process o r ABU. The ABU w i l l i d e n t i f y and t r a c k a l l r e levan t documentation necessary t o complete p r o j e c t tu rnover . The ABU w i l l a l so i d e n t i f y t h e r o l e s , r e s p o n s i b i l i t i e s , of those p a r t i c i p a t i n g i n each tu rnover a c t i v i t y . The ABU w i l l support p r o j e c t p lann ing by p rov id ing a w r i t t e n agreement w i t h t h e end user o f what a r e t h e p r o j e c t de l i ve rab les f o r p r o j e c t c losure . The end user w i l l i d e n t i f y those documents and t r a i n i n g ma te r ia l u p - f r o n t , so t h a t t h e p r o j e c t can budget and schedule t h e work app rop r ia te l y .

For TFRSO p r o j e c t c losure , each design package w i l l have i t s own ABU documentation. This ABU documentation w i l l c o n s t i t u t e c loseout o f t h a t p a r t i c u l a r des ign package

and s i g n i f y “readiness” f o r end user ownership. The ABU w i l l support a smooth t r a n s i t i o n o f ownership o f t h e modif ied SSC from t h e p r o j e c t t o t h e end user . The O f f i c i a l Acceptance o f Construct ion (OAC) w i l l document t h e t r a n s f e r o f a l l t h e ABUs and design packages f o r each cons t ruc t i on phase from cons t ruc t i on t o opera t ions .

The TFRSO p r o j e c t ABUs w i l l be w r i t t e n and fo l lowed i n accordance w i t h HNF-IP-0842, Vol . I V , sec t i on 3.12.

2.6 T&E OPERATIONS AND MAINTENANCE PHASE

Th is phase o f a p r o j e c t as descr ibed i n DOE o rder 430.1 i s supported i n t h e s t a r t u p phase o f t h e TFRSO P r o j e c t . The p r o j e c t suppl ies t h e necessary t o o l s t o t h e Operat ion Manager t o meet these requirements. These t o o l s i nc lude as b u i l t design media, opera t iona l and maintenance procedures, and i n i t i a l s e t o f spare p a r t s , and a spare p a r t s l i s t .

Tes t and eva lua t i on a c t i v i t i e s du r ing t h e operat ions and maintenance (O&M) phase focus on demonstrat ing t h a t t h e SSCs are opera t iona l and per form a t l e v e l s cons is ten t w i t h t h e des ign and opera t iona l requirements. This o b j e c t i v e w i l l be met by ensur ing T&E a c t i v i t i e s a r e conducted i n accordance w i t h d e t a i l e d O&M t e s t procedures.

10


Table 2-1. W-314 TESTING AND EVALUATION ACTIVITIES, OBJECTIVE AND APPROACH

DOE430.1 LWE CYCLE PHASE

TEST & EVALUATION ACTIVITY

o m c m

PROJECT W-314 STRATEGYIAPPROACH

DESIGN

Dwignvdication. ToslPlonning. . TEP/STEP*. . ToSrProcsdures - ATPs. OBrMDonunentation

Determine ifsscs are ready for consmctio". - Venfy desi@ as documented in

d r a w mnrmction and

requirements ofthe PDSr. pr0Nement Jpeciflcatilon meet the

Hnoliro TutPlonning. - TeslPlonr - Schedule andResources.

EXECUTIONPHASE

CONSTRUCTION

AccepianccTesting. . Fastory AsseptMceTests @TI*). - MochpT-t . . GrmmingandAl&ment - AsscptMce Test Pmsedurc (ATPs).

Conrmetlon Testa & Inspections (CTk)

. m1r - Rwiewvendor'r QA proam. .

. Review andwitnurvendor'r testing

- Review wnsmctors PA prosam. . Surveillance of consiruction. .

Ex-e vendor's process. product arrcmbly PrOSCdWW.

CTIr

Revlow and witness constrvction t e r h

TURNOVER

Delemine if installed SSCr funciion properly. . CheckagainrlPDS.

Deternine ifthe cntlrc intemted wstem uerfom zs ~ . . required. - CheckSSC agalnstPDS. - Check ryrtcm qalnst Design Media, Conrt.

soec.. svslem soec.

.. .. for uo Maintenance rystom updated to schedule testing at

Spare parts availability, equipment properly maintahed and protecied dVnng storage & installation.

. Ensuethe above donunentalionis complete,

* 1

appispriale frsquency (FMS).

* ABU DOnunentation checkJirt

ilvding any readinws zssessm~ls needed for lumwer.

OPERATIONS AND

MAINTENANCE

t SSC mover, pmjen complete

11


CHAPTER 3

ORGANIZATION AND RESPONSIBILITIES

The f o l l o w i n g sec t ions i d e n t i f y t h e organizat ions and descr ibe, i n g rea te r d e t a i l , t h e i r r o l e s and r e s p o n s i b i l i t i e s du r ing t h e i r d i r e c t p a r t i c i p a t i o n in t h e T&E process f o r t h e TFRSO p r o j e c t . I n add i t i on , Table 3 - 1 (page 23), communicates each s p e c i f i c r e s p o n s i b i l i t y and t e s t i n g al ignment, respec t i ve l y .

3 . 1

3.2

3.3

DEPARTMENT OF ENERGY (DOE-RL)

The TFRSO p r o j e c t , W-314, w i l l be managed by an i n teg ra ted management team approach. The Department o f Energy, Richland Operations O f f i c e , i s respons ib le f o r t h e p r o j e c t ’ s t o p - l e v e l f unc t i ona l requirements. The PHMC has been delegated t h e r e s p o n s i b i l i t y t o manage and implement t h e day-to-day p r o j e c t a c t i v i t i e s , i n c l u d i n g a l l T&E a c t i v i t i e s .

FLUOR DANIEL HANFORD

F luo r Daniel Hanford i s t h e “ I n t e g r a t i n g Contractor” . The i r r o l e i s t o e s t a b l i s h and manage t h e Hanford s i t e - w i d e c o n f i g u r a t i o n management program as an umbrel la f o r a l l F l u o r Daniel Hanford subcontracts. FDH i s respons ib le f o r a d m i n i s t r a t i v e procedures (e .g . , PHMC guidance f o r per forming inspec t ions and t e s t i n g ) t h a t apply t o t h e P ro jec t .

W-314 TFRSO PROJECT MANAGEMENT (NHC)

3 .3 .1 PROJECT MANAGEMENT AND ENGINEERING

P r o j e c t Management and Engineer ing, which inc ludes t h e P r o j e c t Manager, Lead P r o j e c t Engineer, Q u a l i t y Assurance, Safe ty and Heal th , and Environmental Compliance, i s responsib le f o r p lanning, o rgan iz ing , d i r e c t i n g , and c o n t r o l l i n g p r o j e c t resources f o r t h e c y c l e o f t h e p r o j e c t t o achieve a goal o f complet ing t h e p r o j e c t on schedule and w i t h i n budget. Design A u t h o r i t y and t h e Design Agent. A d d i t i o n a l l y , t h e P r o j e c t Manager w i l l perform w i t h i n gu ide l i nes , p o l i c i e s , procedures, r u l e s , and d i r e c t i v e s o f Tank Farms (LMHC), t h e parent o rgan iza t i on (FDH), and DOE.

Inc luded i s r e s p o n s i b i l i t y t o a c t as an i n t e r f a c e between t h e

Quality Assurance ensures t h a t a l l T&E a c t i v i t i e s w i l l be performed i n accordance w i t h t h e requirements o f t h e Tank Farm Restora t ion and Safe Operations Q u a l i t y Assurance Program Plan, HNF-SD-W314-QAPP-001.

12

HNF-SD-W314-TEP- 001, Rev. 3

Safe ty and Hea l th r e s p o n s i b i l i t y , f o r T&E a c t i v i t i e s , s h a l l be t o manage t h e i r a c t i v i t i e s i n accordance w i t h t h e TFRSO P r o j e c t Execut ion Plan, HNF-SD-W314-PMP-001, t h e P r o j e c t System Safety Program Plan, HNF-SD-W314-SSPP-001, and a l l o the r app l i cab le Federal , DOE, and S t a t e s a f e t y codes and requirements. The TFRSO S ta r tup Group s h a l l be respons ib le f o r i n c l u d i n g elements o f t h e p r o j e c t s a f e t y bas i s documentation i n t o operator t r a i n i n g , operat ions and maintenance procedures, and t e s t procedures.

Environmental Compliance r e s p o n s i b i l i t y , f o r T&E a c t i v i t i e s , s h a l l be t o manage t h e i r a c t i v i t i e s i n accordance w i t h t h e TFRSO P r o j e c t Execut ion Plan, HNF-SO-W314-PMP-001, along w i t h a l l app l i cab le regu la to ry permi ts t h a t apply t o t h e TFRSO Pro jec t .

Inc luded w i t h t h e r e s p o n s i b i l i t i e s mentioned i n t h e paragraphs above, a r e t h e f o l l o w i n g examples:

Witness f a c t o r y t e s t s & inspec t ions , cons t ruc t i on t e s t s & inspec t ions , acceptance t e s t i n g , p re-opera t iona l t e s t i n g , and opera t iona l t e s t i n g .

Review Requirement V e r i f i c a t i o n Reports, procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , and ATPs.

Approve Requirement V e r i f i c a t i o n Reports, procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , ATPs and cons t ruc t i on complet ion r e p o r t (4Cs).

Review and approve Factory Test & Inspec t ion repo r t s , cons t ruc t i on acceptance t e s t repo r t s , ATRs, POTP repo r t s , and OTRs.

Prov ide a p o i n t o f con tac t f o r s t a r t u p a c t i v i t i e s and coord ina te w i t h TFRSO S ta r tup Group.

Prov ide ove rs igh t o f work performed du r ing t e s t i n g and eva lua t i on a c t i v i t i e s .

Prov ide and/or concur w i t h a l l t e s t r e s u l t s o r repo r t s

P a r t i c i p a t e i n J o i n t Tes t Review Group a c t i v i t i e s .

13

HNF-SD - W314-TEP - 001, Rev. 3

3.3.2 TFRSO STARTUP GROUP

The TFRSO S ta r tup Group, which inc ludes t h e Lead Test Engineer, o f t h e P r o j e c t Team and a h i g h l y matr ixed organ iza t ion . This inc ludes FDNW cont rac ted support a s s i s t i n g NHC i n t h e s t a r t u p r o l e by d i r e c t i n g s t a r t u p and tu rnover a c t i v i t i e s . I n i t s i n t e g r a t i o n r o l e , S ta r tup w i l l p rov ide s t a r t u p r e l a t e d techn ica l d i r e c t i o n , c o s t and schedul ing management, c o n t r o l , i n t e g r a t i o n

i s p a r t

ass is tance, app l ied technology, tu rnover , and sa fe ty / regu la to ry compliance support . The S ta r tup organizat ion's management o f t h e T&E a c t i v i t i e s i s developed i n g rea ter depth i n chapter 4. S ta r tup w i l l develop, coord inate, and implement TFRSO P r o j e c t ' s Tes t ing & Eva lua t ion Program. This inc ludes i d e n t i f i c a t i o n , development, and implementat ion o f FTIs , CTIs, ATPs, POTPs, and OTPs: d e t a i l e d t e s t schedule development and implementation: coo rd ina t i on o f t e s t i n g problem r e s o l u t i o n : and coo rd ina t i on o f t e s t i n g support a c t i v i t i e s . A d d i t i o n a l l y , t h e TFRSO S ta r tup Manager has t h e r e s p o n s i b i l i t y t o support t h e p r o j e c t as f o l l o w s :

. Witness fac to ry t e s t s & inspec t ions , cons t ruc t i on t e s t s & inspec t ions , acceptance t e s t i n g , p re-opera t iona l t e s t i n g , and opera t iona l t e s t i n g , as deemed necessary.

FTIs, and POTPs. . Approve cons t ruc t i on t e s t and inspec t i on requirements per CWP,

. Review and approve FTI s p e c i f i c a t i o n s , FT I r e p o r t , ATPs, cons t ruc t i on ' t e s t & i nspec t i on repo r t s , ATRs,' POTP repor t s , and OTRs .

. Review and comment on t h e Design Agent 's system opera t ing

. Manage p lanning, schedul ing, and work f o r c e a l l o c a t i o n , f o r t h e

. Prepare procedures/Tra in ing M a t r i x and Schedule, and T r a i n i n g

desc r ip t i ons , t o be used i n t h e development o f t e s t procedures

s t a r t u p a c t i v i t i e s .

Plan, t o ensure Operat ion personnel a r e t r a i n e d , and q u a l i f i e d t o operate and t e s t t h e system, s t ruc tu res , and components s a f e l y .

. Prepare and submit P r o j e c t documentation generated i n support o f V a l i d a t i o n and V e r i f i c a t i o n ( V & V ) a c t i v i t i e s .

14

HNF-SD-W314-TEP-001, Rev. 3 . Prepare f o r Operations and Maintenance o rgan iza t i on , operat ions and maintenance (i .e. , c a l i b r a t i o n , p revent ive , c o r r e c t i v e . . . . e t c . procedures.

. Inc lude app l i cab le elements o f t h e p r o j e c t s a f e t y bas is and regu la to ry documentation i n t o operator t ra in ing, opera t ing , maintenance (i .e . , c a l i b r a t i o n , p revent ive , c o r r e c t i v e . . . . e t c . ) , and t e s t procedures.

. Prepare opera t ing s u r v e i l lance procedures and assure t h a t they

Ensure maintenance o f t e s t i n g acceptance records through

Document and Prepare Turnover documentation t o t h e f a c i l i t y owner

i nco rpo ra te a1 1 app l i cab le techn ica l s a f e t y requirements.

. complet ion and tu rnover o f t h e p r o j e c t .

. as p a r t o f t h e ABU process. Develop an e l e c t r o n i c format f o r r e a l - t ime r e t r i e v a l o f tu rnover m a t e r i a l .

. Provide t r a i n i n g plans f o r Tank Farm maintenance and opera tor t r a i n i n g .

. Prepare ATP’s POTPs, OTPs, and t h e associated Test Reports .................. generated from completed t e s t s ( i . e . , FTIS, CTIs, ATPs). [The p repara t i on o f t h e POTPs and OTPs i s t h e o v e r a l l r e s p o n s i b i l i t y o f LMHC Tank Farm Operations organ iza t ion . Tank Farm Operations has cont rac ted w i t h t h e TFRSO S ta r tup Group t o c rea te t h e POTPs and OTPs . I

Provide support t o Tank Farm Operations schedul ing and i n t e g r a t i o n a c t i v i t i e s f o r T&E a c t i v i t i e s .

. Develop i nven to ry c o n t r o l ( e . g . , spare p a r t s , storage, spec ia l sh ipp ing) t o ensure spare p a r t s a re a v a i l a b l e f o r c o n s t r u c t i o n and t e s t i n g .

. Prepare and main ta in TEP.

. Prepare STEPS.

3.4 JOINT TEST REVIEW GROUP (LMHC)

The JTRG w i l l c o n s i s t o f t h e Chief Test D i r e c t o r ( f rom t h e LMHC Test and S ta r tup Organ iza t ion) , Engineer ing manager ( o f t h e f a c i l i t y t h a t w i l l operate t h e equipment), t h e Design Au tho r i t y , Operat ions. CA, app l i cab le Test D i r e c t o r f o r I

15


each ATP, POTP, and OTP, and W-314 TFRSO S ta r tup Manager. The JTRG prov ides Tank Farm Operations w i t h a h igh l e v e l o f conf idence t h a t t h e t e s t can be done s a f e l y and e f f i c i e n t l y . The review by t h e JTRG prov ides a bas is ( re fe rence HNF-IP-0842) f o r t e s t re lease. The JTRG may conduct thorough reviews o f ATPs t o ensure compliance w i t h app l i cab le procedural requirements, t o ensure they can be done s a f e l y , and t o ensure t h e scope o f t e s t i n g and inspec t ions p rov ide a product t h a t s a t i s f i e s opera t iona l and s a f e t y requirements. The JTRG reviews t e s t procedure data, and provides t h e i r recommendation concerning t h e f i n a l acceptance t h a t t e s t r e s u l t s w i l l s a t i s f y t h e design s p e c i f i c a t i o n s as s t a t e d i n t h e t e s t procedures.

3.5 TEST SUPPORT GROUP (FDNW)

The Tes t ing and Eva lua t ion process requ i res e f f e c t i v e support f rom o t h e r TFRSO p r o j e c t p a r t i c i p a n t s i n o rder t o succeed p roper l y . Th is inc ludes p a r t i c i p a n t s t h a t p rov ide Equipment and M a t e r i a l Support, Const ruct ion Management, Construct ion C r a f t Support, Vendor Services Support, Procedure Development Support, and S ta r tup Services Support i n c l u d i n g Q u a l i t y Assurance, Safe ty , and Environmental Support. The S ta r tup Manager w i l l nego t ia te and e s t a b l i s h working arrangements w i t h each respec t ive p a r t i c i p a n t t o ensure t h a t suppor t serv ices (essen t ia l f o r successful and t i m e l y t e s t i n g and eva lua t ion) f o r t h e TFRSO P r o j e c t a re prov ided. Construct ion Forces/Construct ion Management (FDNW) w i l l p rov ide t h e c r a f t and superv is ion t o support t e s t i n g , i n c l u d i n g mock-up, through t h e ATPs, and i n t o t h e POTPs/OTPs, i f requ i red . A d d i t i o n a l l y , Const ruc t ion Management w i l l per form t h e f o l l o w i n g :

Review design v e r i f i c a t i o n repo r t ( s1 , f a c t o r y acceptance t e s t s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , ATPs, FTI Reports,

ATRs , and system tu rnove r .

Cont r ibu te i n p u t f o r cons t ruc t i on complet ion r e p o r t and OTPs

Review and approve CWPs t o i nsu re t h a t requ i red CTIs have been inc luded.

Prepare CTIs and cons t ruc t i on complet ion r e p o r t

3.6 TANK FARM OPERATIONS (LMHC)

Tank Farm Operations w i l l p rov ide i n p u t and p a r t i c i p a t i o n i n techn ica l reviews o f Fac tory Acceptance Tes t ing , Construct ion T&I , acceptance t e s t i n g , C a l i b r a t i o n , Grooming and A1 ignment, Pre-Operat ional Test ing, and Operat ional Tes t ing . A d d i t i o n a l l y , Tank Farms Operations w i l l p rov ide a Tes t D i r e c t o r and maintenance and operat ions support du r ing t h e Pre-Operat ional and opera t iona l

16


phase o f t h e P r o j e c t f o r equipment and systems t h a t a re i n TFRSO P r o j e c t ' s custody. S p e c i f i c areas o f r e s p o n s i b i l i t y i nc lude t h e f o l l o w i n g :

.

.

.

.

.

.

.

.

.

.

.

Assign an Operations representa t ive t o t h e JTRG (p re fe rab ly t h e Operations Tes t D i r e c t o r f o r t h e TFRSO P r o j e c t ) . A lso, s e l e c t a l ead (se lec ted by t h e Operations Manager) t h a t w i l l assign members t o t h e management s e l f assessment team, i f convened.

Prov ide an Operations Engineer t o t h e p r o j e c t t o review, v a l i d a t e , document, and a c t as an Operations Test D i r e c t o r f o r POTPs and OTPs.

Review and approve Technical and Operat ing Spec i f i ca t ions (e .g . , procurement, cons t ruc t i on , and FTIs ) ; ATPs: and Design V e r i f i c a t i o n Reports.

Review and approve opera t ing procedures, maintenance (i .e . , c a l i b r a t i o n , p revent ive , c o r r e c t i v e . . . e t c . 1 procedures, FTI Reports, ATRs, POTP Reports, and OTRs.

Observe FTIs, acceptance t e s t i n g , p re-opera t iona l t e s t i n g , and opera t iona l t e s t i n g , as requ i red .

Witness system tu rnovers .

Approve cons t ruc t i on complet ion repo r t s , operator t r a i n i n g , and s t a r t u p and operat ions t e s t i n g documentation.

P a r t i c i p a t e i n t h e prepara t ion and review o f POTPs and OTPs. p repara t i on o f t h e POTPs and OTPs i s t h e o v e r a l l r e s p o n s i b i l i t y o f LMHC Tank Farm Operations organ iza t ion . Tank Farm Operations has cont rac ted w i t h t h e TFRSO S ta r tup Group t o c rea te t h e POTPs and OTPs.1

A s s i s t i n t h e v a l i d a t i o n o f OTPs.

[The

E s t a b l i s h i n g schedul ing, coord inate work re lease w i t h S tar tup , package rev iew, and f a c i l i t y p ro toco l guidance f o r a l l t e s t a c t i v i t i e s .

Support t e s t i n g schedul ing p r i o r i t i e s .

3 .6.1 CHIEF TEST DIRECTOR

The Ch ie f Tes t D i r e c t o r w i l l p a r t i c i p a t e i n t h e review o f acceptance t e s t i n g documentation as c h a i r o f t h e JTRG, and p rov ide techn ica l overview and dec i s ion support as necessary. Inc luded w i t h t h e r e s p o n s i b i l i t i e s mentioned above a r e t h e f o l l o w i n g :

17

HNF-SD-W314-TEP ~ 001, Rev. 3

. Review selected ATPs, ATRs, POTPs, OTPs, POTP ReDorts, and OTRs

. Observe se lec ted FTIs, CTIs , acceptance t e s t i n g , p re-opera t iona l t e s t i n g , and opera t iona l t e s t i n g .

3.7 MAINTENANCE GROUP (LMHC)

The Maintenance Group w i l l p rov ide i n p u t and p a r t i c i p a t i o n i n techn ica l reviews o f FTIs, CTIs, p re-opera t iona l t e s t s , and c a l i b r a t i o n , grooming and a1 ignment a c t i v i t i e s . Maintenance w i l l p rov ide support du r ing t h e pre-opera t iona l phase o f t h e P r o j e c t f o r equipment and systems t h a t a re i n t h e TFRSO P r o j e c t ' s custody. S p e c i f i c areas o f r e s p o n s i b i l i t y i nc lude t h e f o l l o w i n g :

P a r t i c i p a t e i n t h e prepara t ion and review o f Technical and Operat ing S p e c i f i c a t i o n s .

Review and approve maintenance (i .e . , c a l i b r a t i o n , p revent ive , c o r r e c t i v e . . . e t c . ) procedures.

P a r t i c i p a t e i n t h e prepara t ion and review o f t e s t procedures when requested by t h e W-314 P r o j e c t Manager.

T r a i n and q u a l i f y maintenance personnel i n accordance w i t h t h e Tank Farm's TIM so t h a t maintenance personnel a re q u a l i f i e d t o p a r t i c i p a t e i n t e s t i n g a c t i v i t i e s .

3.8 DESIGN AGENT (FDNW)

The Design Agent support f o r T&E a c t i v i t i e s w i l l i nc lude p r o v i d i n g des ign documents t o i n i t i a t e procedure development, p a r t i c i p a t i o n on t h e JTRG, r e s o l u t i o n o f d e f i c i e n c y p u n c h l i s t i tems, and concurr ing w i t h t e s t r e s u l t s / r e p o r t s . f o l 1 owing :

S p e c i f i c Design Agent r e l a t e d r e s p o n s i b i l i t i e s may inc lude t h e

Prepare Requirements V e r i f i c a t i o n Repor t (s ) , F T I s p e c i f i c a t i o n s , and procurement s p e c i f i c a t i o n s .

Concur w i t h Requirements V e r i f i c a t i o n Repor t (s) , FTI s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , ATPs, f a c t o r y acceptance t e s t i n g , FTI Reports, CTIs, acceptance t e s t i n g , and ATRs.

Witness f a c t o r y acceptance t e s t i n g , CTIs, and acceptance t e s t i n g

Review CTIs.

18


Prov ide Construct ion Spec i f i ca t i ons t h a t de f i ne t e s t requirements f o r SSCs, i n c l u d i n g acceptance c r i t e r i a , t h a t can be used t o v e r i f y t h a t des ign requirements and cons t ruc t i on i n s t a l l a t i o n requirements a re met.

Prepare des ign change requests o r i g i n a t i n g as a r e s u l t o f T&E a c t i v i t i e s

Prepare system opera t ing c h a r a c t e r i s t i c s and desc r ip t i ons t o be used by S t a r t u p and Operations i n development o f SSC S ta r tup and Operat ing Procedures, i f requ i red .

Cont r ibu te i n p u t f o r t h e OTPs and operator t r a i n i n g .

Ma in ta in des ign c o n f i g u r a t i o n c o n t r o l and records through complet ion o f c o n s t r u c t i o n acceptance t e s t i n g i n accordance w i t h HNF-PRO-440, “Engineer ing Documents Change Contro l Requirements”: ......................................... HNF-PRO-I.H1!J, “PHMC Enyinw-ir i _.._.._._.. +.:..:..:..g. Reqcrirements: and HNF-IP-0842, “TWRS Admin is t ra t ion” , VOL. 11, s e c t i o n 4 .8 .3 .

Ensure t h a t a l l design work performed by subcontractors meets t h e p r o j e c t des ign c r i t e r i a and requirements i n c l u d i n g u t i l i z i n g t h e methodologylprocess requ i red by t h e W-314 P r o j e c t Execution Plan, Appendix C ( S E I P ) .

3.9 CONSTRUCTION

F luo r Daniel Northwest i s t h e pr imary cons t ruc t i on con t rac to r f o r t h e TFRSO p r o j e c t . Add i t i ona l con t rac tors may be used t o support work which meets es tab l i shed Hanford S i t e C r i t e r i a f o r compet i t i ve f i x e d p r i c e con t rac ts . PHMC requirements governing cons t ruc t i on a c t i v i t i e s s h a l l apply t o FDNW o r o the r con t rac to rs suppor t ing t h e p r o j e c t . These requirements s h a l l be i d e n t i f i e d in t h e work au tho r i z ing , ( c o n t r a c t ) documents f o r t h e con t rac to r . The r e s p o n s i b i l i t i e s de f ined i n paragraph 2.7 o f t h e P r o j e c t Execut ion Plan w i l l apply t o any f i x e d p r i c e cons t ruc t i on con t rac to r which supports t h e p r o j e c t .

I n t e g r a t i o n o f t h e non-FDNW a c t i v i t i e s w i t h t h e o v e r a l l cons t ruc t i on e f f o r t s h a l l be t h e r e s p o n s i b i l i t y o f FDNW. A s i n g l e p o i n t o f con tac t f o r a l l TFRSO- r e l a t e d work s h a l l be es tab l i shed, w i t h t h e d i r e c t r e p o r t i n g r e s p o n s i b i l i t y t o t h e TFRSO P r o j e c t Manager.

Examples o f cons t ruc t i on r e s p o n s i b i l i t i e s r e l a t i n g t o s t a r t u p a c t i v i t i e s i nc lude t h e f o l l o w i n g :

Witness FTIs, as requ i red

Review FTI ReDorts.

Review procurement and cons t ruc t i on s p e c i f i c a t i o n s

19

HNF-SD-W314-TEP ~ 001, Rev. 3

.

.

.

.

.

.

.

. I

.

.

Construct per t h e Design

Perform CTIs.

Prepare and main ta in CWPs.

Perform F i e l d v e r i f i c a t i o n and Closeout.

Review systems tu rnover documentation

F i e l d v e r i f y p r o j e c t drawings as requ i red .

Support POTPs and OTPs as requ i red

Prepare and main ta in p r o j e c t cons t ruc t i on p u n c h l i s t .

Procure cons t ruc t i on equipment and ma te r ia l s .

Perform prevent ive maintenance as requ i red and main ta in i n -s to rage equipment records.

Perform Quality Assurance ove rs igh t of cons t ruc t i on and f a b r i c a t i o n a c t i v i t i e s ; CTIs: procurement, sh ipp ing, rece iv ing , and s torage o f s a f e t y c lass & s a f e t y s i g n i f i c a n t ma te r ia l s and equipment: c o n t r o l and maintenance o f q u a l i t y records; and Q u a l i t y Assurance review and approval o f CWPs and personnel qual i f i c a t i o n s / r e c o r d s .

Ensure t h a t cons t ruc t i on work and t e s t i n g performed by subcontractors meets t h e p r o j e c t c r i t e r i a and requirements i n c l u d i n g u t i l i z i n g t h e methodologylprocess requ i red by t h e W-314 P r o j e c t Execut ion Plan, Appendix C ( S E I P ) .

3.10 CONTRACT MANAGEMENT (FDNW)

Contract management i s performed i n accordance w i t h s i t e con t rac to r procedures t o ensure a l l p rac t i ces are i n compliance w i t h Federal A c q u i s i t i o n Requirements. Th is process invo lves de terminat ion o f work scopes best s u i t e d f o r performance

by con t rac to rs (makelbuy), b i d request and eva lua t ion , con t rac to r q u a l i f i c a t i o n and s e l e c t i o n , and eva lua t ion o f con t rac t performance. C r i t i c a l t o t h e con t rac t management process i s t h e accurate i n t e g r a t i o n o f requirements i n t o b i d suppor t ing documents such as Statements of Work and S p e c i f i c a t i o n s . Make/buy dec is ions r e l a t e d t o cons t ruc t i on cont rac tors w i l l be determined on a case-by- case bas is . F ixed p r i c e cont rac ts w i l l be considered on a l l work scopes n o t

20


i n v o l v i n g a s i g n i f i c a n t r a d i o l o g i c a l contaminat ion r i s k t o personnel and equipment.

PMHC requirements w i l l apply t o a l l con t rac tors . P r o j e c t s p e c i f i c procedural requirements s h a l l be de l ineated i n t h e work au tho r i za t i on ( c o n t r a c t ) document f o r each respec t ive con t rac to r .

3.11 MATRIXED ORGANIZATIONS

Add i t i ona l suppor t and exper t i se w i l l be requ i red and i s a v a i l a b l e from a v a r i e t y o f o the r o rgan iza t ions . It s h a l l be t h e r e s p o n s i b i l i t y o f these var ious organ iza t ions t o p rov ide i n p u t and t o p a r t i c i p a t e i n t h e T&E a c t i v i t i e s as requested by t h e TFRSO P r o j e c t Manager. Some o f t h e Matr ixed Organizat ions t h a t have been i d e n t i f i e d , a long w i t h r e s p o n s i b i l i t i e s , a re as f o l l o w s :

1) Design A u t h o r i t y (LMHC) - Provide techn ica l overview and approval o f T&E ac t iv i t ies /documents and serve as a member o f t h e JTRG. r e s p o n s i b i l i t i e s mentioned above are t h e f o l l o w i n g :

Review Design V e r i f i c a t i o n Reports, FT I s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , ATPs, CTIs, FTI Report , ATRs, and OTRs.

Inc luded w i t h t h e

Approve Design V e r i f i c a t i o n Reports, FTI s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , FTIs, ATPs, FTI Report, ATRs, system tu rnover , cons t ruc t i on complet ion r e p o r t , care and maintenance i n s t r u c t i o n s , POTPs, POTP Reports, and s t a r t u p and operat ions documentation.

2 ) TWRS T r a i n i n g (LMHC)- which w i l l p rov ide Operator and Maintenance t r a i n i n g , t h e T r a i n i n g Plan, and t h e C e r t i f i c a t i o n Package upgrades requ i red t o perform POTPs and OTPs;

3) F a c i l i t y Cognizant Engineer (LMHC)- W i l l review and approve JCS work c o n t r o l Inc luded w i t h t h e r e s p o n s i b i l i t i e s mentioned above are documents and ECNs.

t h e f o l l o w i n g :

Review Design V e r i f i c a t i o n Reports, FTI s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , ATPs, CTIs, FTI Report , ATRs, and OTRs.

Approve Design V e r i f i c a t i o n Reports, FTI s p e c i f i c a t i o n s , procurement s p e c i f i c a t i o n s , cons t ruc t i on s p e c i f i c a t i o n s , FTIs, ATPs, CTIs, F T I Report ,

21

HNF-SD - W314-TEP ~ 001. Rev. 3

ATRs, system tu rnover , cons t ruc t i on complet ion r e p o r t , care and maintenance i n s t r u c t i o n s , POTPs, POTP Reports, and s t a r t u p and operat ions documentation

Witness se lec ted cons t ruc t i on t e s t and inspec t ion , acceptance t e s t i n g , p re-opera t iona l t e s t i n g , and opera t iona l t e s t i n g .

4) Q u a l i t y Assurance Services (FDH) - Provides t h e independent 3rd p a r t y ( A I ) f o r t h e p r o j e c t . A I performs t h e f o l l o w i n g :

Approval o f systems tu rnovers .

I f requ i red . p rov ide approval f o r f a c t o r y acceptance t e s t i n g , FTI Report , CTI, acceptance t e s t i n g , ATRs, p re-opera t iona l t e s t i n g , POTP Reports, opera t iona l t e s t i n g , and OTRs.

3.12 QUALIFICATION AND TRAINING

For entrance i n t o t h e Tank Farms, S ta r tup Test Engineers, Operations personnel , P r o j e c t Team, and r e l a t e d support personnel w i l l be se lec ted and t r a i n e d i n accordance w i t h t h e requirements o f t h e TIM f o r Tank Farms which implements t h e requirements o f DOE Order 5480.20A, "Personnel Se lec t ion , Q u a l i f i c a t i o n , T r a i n i n g and S t a f f i n g Requirements," a t DOE Reactor and Non-Reactor Nuclear F a c i l i t i e s . The Test D i rec to r conduct ing t h e ATPs w i l l be assigned by t h e Startu!, Planager. Technical p r o f i c i e n c y and/or requirements o f t h e ATP Test D i r e c t o r w i l l be determined by t h e Design Agent. The Tes t D i r e c t o r t h a t w i l l be conduct ing t h e POTPs and OTPs w i l l be a q u a l i f i e d i n accordance w i t h t h e Tank Farm q u a l i f i c a t i o n s f o r a P I C , Operat ing Engineer, and/or S h i f t Manager.

I

22

HNF-SbW3I4-TFP - o b i , Rev. A

Table 3 - 1 RESPONSIBILITY ASSIGNMENT MATRIX (cont . 1 a c t i v i t y , t ask , product, d e s c r i p t i o n column, as requ i red .

W.314 Project Management

1) Project Manager

COI lS tPUCt l on

II I I I I I I

Approve .. ~~~

_ _ _ _ ~ ~ .. .. ..

Rwlew. Approve (1. 2. 3. Review. Approve &4) Review. Approve Review. Approve ..

I I I I I I I I

PrenaP.2 ( 5 ) . nap;zii. Prepare, Approve Review .. kDarove 1 . 2 . 3 . 6

Witness (3&4) Witness Witness As Required

I .. I .. !I Care and maintenance instvuct lons I I Prepare. Review (2&3) I ..

Prepare (3). Review. Approve (1,2,3&4) Approve Review As Required

Operational Test Procedures .. .. Approve PrEOJPe ( 3 : Prepare, Approve Review .. I

~~ .. .. .. Witness (3&4) Witness Witness A i RequiPed ~~~

Operational Test Reports Prepare ( 3 ) . Review.

k&w. Approve Appmve (1.2.3&4) Review. Approve Review As Required .. ..

24

Startup and operations documentation .. .. Approve Prepare ( 3 ) Approve .. ..

CHAPTER 4

PROJECT W-314 STRATEGY AND APPROACH

The pr imary goal o f t h e W-314 St ra tegy and Approach i s t o ensure t h a t T&E a c t i v i t i e s have sound t e c h n i c a l , cos t and schedule bas is , and t h a t a formal system i s i n p lace t o au thor ize and c o n t r o l t h e T&E a c t i v i t i e s . Th is sec t i on descr ibes how t h e W-314 P r o j e c t w i l l es tab l i sh , manage, and c o n t r o l t e s t i n g work scope, cos t , schedul ing, measurement, and work performance. I n a d d i t i o n , t h i s s e c t i o n discusses plans fo r management o f t e s t records and compi la t ion o f h i s t o r i c a l data f o r Lessons Learned b e n e f i t .

4.1 T&E ADMINISTRATIVE ACTIVITIES

This s e c t i o n d e t a i l s and expla ins t h e o v e r a l l Admin i s t ra t i ve tasks f o r T&E a c t i v i t i e s . Tes t ing and Evaluat ion a c t i v i t i e s must be managed i n a manner t o ensure t h a t they a r e performed t o a h igh degree o f q u a l i t y . Th is inc ludes a c t i v i t i e s t o p rov ide proper l e v e l s o f app rop r ia te l y t r a i n e d and experienced s t a f f , develop q u a l i t y t e s t procedures, conduct techn ica l rev iews, ensure q u a l i t y t e s t documentation and records management, and adequate eva lua t ion /ac t ions t o ma in ta in t h e T&E performance a t q u a l i t y l e v e l s .

T&E p lann ing and suppor t , t e s t i n g , and tu rnover schedules w i l l be f u l l y resource loaded t o pe rm i t i d e n t i f i c a t i o n o f a l l necessary personnel requ i red t o support t h e T&E program.

I n order t o ensure q u a l i t y t e s t procedure prepara t ion , a l l ,ATW;S.:, POTPs and OTPs s h a l l be prepared i n accordance t o HNF-IP-0842, Vol 1 (sec 2.11) and HNF-IP-0731 (Wr i ter ’s Guide). A l l o the r t e s t s w i l l be prepared i n accordance w i t h l-lNi:-PRO- l 9 i 8 . P-MC Engineering &qui _lll..___ reiiierits. Test reviews w i l l be conducted be fore , du r ing , and a f t e r t e s t i n g , as requ i red , t o ensure t h e t e s t encompasses a l l app l i cab le requirements and V a l i d a t e t e s t r e s u l t s

Tes t procedures w i l l be developed, approved, and maintained i n accordance w i t h HNF-PRO-229, “TECHNICAL PROCEDURE STANDARD”. c o n t r o l l e d by HNF-PR3-:.81.9. PHMC Engineering Reqi-iirenien~ts. Test s p e c i f i c a t i o n s , I t e s t procedures, and t e s t repo r t s s h a l l be c o n t r o l 1 ed, approved, and re1 eased by approved a d m i n i s t r a t i v e procedures, (see Appendix A ) .

I

P r o j e c t t e s t procedures w i l l be

4.2 T&E WORK CONTROLS

This s e c t i o n communicates a l l a c t i v i t i e s necessary t o manage and c o n t r o l T&E scope o f work. T&E a c t i v i t i e s must be planned, c o n t r o l l e d , scheduled, and managed i n an e f f e c t i v e manner t o ensure t h a t a l l work i s performed t o a h igh degree o f qual i ty, e f f i c i e n c y , and cos t e f fec t i veness . This TEP inc ludes a c t i v i t i e s t h a t develop and implement processes and procedures t o ensure

25

e f f e c t i v e p lanning, schedul ing, work c o n t r o l , and management o f t h e o v e r a l l t e s t i n g program. A lso , T&E a c t i v i t i e s work scope w i l l be es tab l i shed and c o n t r o l l e d i n accordance w i t h t h e TFRSO TEP and t h e TFRSO STEPs

The f i r s t component o f e f f e c t i v e Work Management i s thorough and d e t a i l e d p lann ing . The p lann ing phase of t h e TFRSO T&E program inc ludes t h e f o l l o w i n g a c t i v i t i e s :

1. I d e n t i f i c a t i o n o f SSC t e s t i n g requirements as de f ined i n t h e des ign documentation.

2. I n t e g r a t i o n of t h e T&E schedule data t o t h e TFRSO P r o j e c t Schedule and ref inement , as requ i red .

3. STEPs map o u t l o g i c a l and sequent ia l t e s t i n g a c t i v i t i e s . STEPs w i l l be sequenced and scheduled t o minimize use o f temporary equipment and t o maximize t h e use o f i n - p l a c e tes ted equipment. Test sequencing should a l so be u t i l i z e d t o minimize opera t iona l impacts and downtime o f c r i t i c a l SSCs. De ta i l ed t e s t i n g sequence l o g i c diagrams, w i l l be developed, based on knowledge o f system scoping boundaries, system t e s t i n g requirements, t h e t e s t i n g a c t i v i t y i n t e r f a c e s , o r o the r non - tes t i ng p r o j e c t a c t i v i t i e s , such as c o n s t r u c t i o n tu rnover and readiness review processes. SSC t e s t i n g requirements w i l l be ex t rac ted from a l l app l i cab le documents r e l a t e d t o t h e TFRSO p r o j e c t such as PDS, d e f i n i t i v e des ign drawings ( i n c l u d i n g A-E generated t e s t s p e c i f i c a t i o n s ) , cons t ruc t i on spec i f i ca t i ons , and i d e n t i f i e d DOE Orders.

4. Refinement o f system scoping boundaries t o accura te ly d e f i n e t e s t a b l e packages o f equipment and systems.

The second component o f e f f e c t i v e Work Management i s schedul ing o f T&E a c t i v i t i e s . A l l a c t i v i t i e s addressed i n t h e TEP and/or STEPs w i l l be scheduled and f u l l y i n t e g r a t e d w i t h t h e p r o j e c t cons t ruc t i on schedules and Tank Farm In teg ra ted Schedule. P a r t i c u l a r emphasis s h a l l be placed on those a c t i v i t i e s necessary t o support any P r o j e c t System Readiness A c t i v i t i e s and t h e S t a r t o f I n i t i a l Operat ions.

A S ta r tup Schedule Basel ine w i l l be developed and maintained f o r t h e TFRSO P r o j e c t O f f i c e . The T&E schedule inc ludes two in teg ra ted b u t d i s t i n c t schedules :

1. T&E TURNOVER AND TESTING SCHEDULE - This schedule maps o u t a l l suppor t work f o r t h e T&E program. This inc ludes p lanning and support a c t i v i t i e s by organ iza t ions such as t h e S ta r tup group, PHMC Matr ixed organ iza t ions , t h e Design Agent, cons t ruc t i on cont rac tors , vendors, and o the r TFRSO p a r t i c i p a n t s . Th is schedule i s i n teg ra ted w i t h t h e TFRSO P r o j e c t and/or Const ruc t ion Schedule t o assure t h a t a l l a c t i v i t i e s a re budgeted f o r .

26

2 . SPECIFIC TEST & EVALUATION PLAN SCHEDULE - This schedule i s a detailed sequence of activit ies t h a t establishes SSC turnover dates t o assure t h a t the project deliverables meet their functional requirements.

4.3 PROJECT MANAGEMENT AND ENGINEERING

This section i s provided because i t develops i n greater detail T&E activit ies t h a t will be performed by TFRSO Startup Group. These activit ies must be executed i n a n effective manner t o ensure a safe, technically competent, and expeditious startup of the TFRSO SSCs. This section spans the following activit ies :

Review of appropriate Test Procedures provided by the A-E.

Implementation of specific testing method(s) identified i n the STEP.

Rigorous adherence to testing controls identified i n the STEP.

Development of t e s t sequences and schedules t h a t a l low testing t o proceed in logical steps t h a t b u i l d on each others foundations.

Preparation and issuance of t e s t procedures i n a controlled and timely manner.

Identification and control of t e s t equipment, instrumentation, and other materials required t o support testing activit ies t o assure appropriate and accurate d a t a collection.

Test performance t h a t i s conducted by appropriately trained and experienced personnel.

Post-test reviews and analysis of t e s t results by TFRSO JTRG t o verify acceptability of the tested SSC.

Participate i n construction turnover walkdowns, oversee AI punch1 i s t resolutions, preparing and executing pre-operational t e s t procedures, supporting systems readiness for i n i t i a l hot operations, and supporting the TFRSO Project during ini t ia l hot operations.

Proper documentation of t e s t results and documentation reviews conducted t o verify acceptability of the t e s t results.

Transmittal of documentation associated w i t h testing programs t o project f i l e s and Information Resource Management for storage i n a PHMC records storage fac i l i ty i n accordance w i t h HNF-CM-3-5, "Document Control and Records Management.

27

4.4 FILING AND RECORDS MANAGEMENT

Th is a c t i v i t y inc ludes a l l work a c t i v i t i e s requ i red t o e s t a b l i s h and main ta in t h e T&E f i l e system, a l l T&E records management systems, and Lessons Learned records. The f i l i n g and records management system f o r S ta r tup w i l l be s t r u c t u r e d t o ma in ta in o n - l i n e r e t r i e v a b l e P r o j e c t records. T&E Documents w i l l be maintained and r e t r i e v a b l e on a r e a l - t i m e bas is .

28

REFERENCES

DOE Order 5480.19, Conduct of Operations Requirements for DOE Facilities, U.S. Department o f Energy, Washington, D . C .

DOE Order 5480.20A, Personnel Selection, Qualification, Training, and Staffing Requirements at DOE Reactor and Non-Reactor Nuclear Facilities, U.S. Department o f Energy, Washington, D . C .

DOE Order 55480.31, Startup and Restart of Nuclear Facilities, (DOE 1993), U . S . Department o f Energy, Washington, D . C .

DOE Order 4700.1, 1987, Project Management System, U. S . Department o f Energy, Washington, D . C .

DOE Order 430.1, Life Cycle Asset Management, U.S. Department o f Energy, Washington, D . C .

HNF-PRO-081, Hazardous Energy Control Program, F1 uor Daniel Hanford Company, Rich l and, Washington.

HNF-PRO-229, Technical Procedure Standard, F1 uor Daniel Hanford Company, Richland, Washington.

HNF-PRO-440, Engineering Document Change Control Requirements, F luo r Daniel Hanford Company, Richland, Washington.

HNF-PRO-551, Statement of Work for an Offsite A-E, F luo r Daniel Hanford Company, Rich l and, Washington.

HNF-PRO-572, Project Acceptance and Closeout, F luo r Daniel Hanford Company, R ich l and, Washington.

HNF-PRO-574, Project Plan, F luo r Daniel Hanford Company, Richland, Washington.

HNF - PRO- IH 19 ...................................... Rich 1 and , Was I1 i ngtor;

HNF-CM-1-5, Standard Operating Procedures, F luo r Daniel Hanford Company, Rich l and, Washington.

HNF-CM-1-6, Radiological Control Manual, Fluor Daniel Hanford Company, Richland, Washington.

HNF-CM-1-8, Work Management, F luo r Daniel Hanford Company, Richland, Washington.

HNF-CM-1-10, Safety Manual, Fluor Daniel Hanford Company, Richland, Washington.

29

HNF-CM-2-5, Management Control System, F luo r Daniel Hanford Company, Rich land, Washington .

HNF-CM-3-5, Document Control and Records Management, F luo r Daniel Hanford Company, Richland, Washington.

HNF-CM-4-2, Quality Assurance Manual, Fluor Daniel Hanford Company, Richland, Washington.

HNF-IP-0731, Writer’s Guide, F luo r Daniel Hanford Company, Richland, Washington.

HNF-IP-0842, TWRS Administration, F luo r Daniel Hanford Company, Rich land, Washington.

HNF-SD-W314-PMP-001, Project Execution Plan, Numatec Hanford Corporat ion, Rich land, Washington.

HNF-SD-WM-BID-001, Rev. F, TWRS Basis for Interim Operation, F l u o r Daniel Hanford Corporat ion, R ich l and, Washington.

HNF-SD-W314-QAPP-001, Tank Farm Restoration and Safe Operations Quality Assurance Program P lan, F luo r Daniel Hanford Corporat ion, Richland, Washington.

HNF-SD-W314-SSPP-001, The Project System Safety Program P lan, F luo r Daniel Hanford Corporat ion, R ich l and, Washington.

30

GLOSSARY

Component - A s i n g l e p iece o f equipment (such as a run o f p ipe , va lve, p r o t e c t i v e device, inst rument , w i re , heat exchanger, pump, t u r b i n e , e t c . ) , which w i l l be used w i t h o the r components t o form a system.

I n i t i a l S t a r t u p Tes t - Those t e s t s which r e q u i r e process ma te r ia l o r s imu lan t (water) o f process ma te r ia l which are performed p r i o r t o complet ion o f Operat ion Readiness Eva lua t ion by DOE. des ign bas is and demonstrate t h a t t h e f a c i l i t y i s capable o f opera t ing under normal and abnormal cond i t i ons .

I n i t i a l S ta r tup Tests a r e designed t o con f i rm t h e

Pre-Operat ional Tes t - Test performed on systems, normal ly p r i o r t o f u e l l oad ing o r s imu lan t (water) runs, which may be performed w i thou t process m a t e r i a l , nuc lear f u e l , o r heat . Tests t h a t demonstrate c a p a b i l i t y o f system(s) t o meet opera t iona l and s a f e t y c r i t e r i a , v e r i f y t r i p s , i s o l a t i o n s , alarms and parameter i n d i c a t i o n through t h e systems f u l l opera t ing range.

S t a r t u p - The process o f p l a c i n g o r r e s t a r t i n g a f a c i l i t y or major m o d i f i c a t i o n i n opera t ion . The process may s t a r t w i t h t h e checkout, t e s t , c a l i b r a t i o n , t r i a l , demonstrat ion, and v e r i f i c a t i o n steps on i n d i v i d u a l components o f mechanical and e l e c t r i c a l equipment and ends w i t h re lease f o r normal opera t ion t o F a c i l i t y Operations by t h e ABU process.

Subsystem - A group o f assemblies o r components o r both combined t o perform a s i n g l e f u n c t i o n .

System - A group o f components u n i t e d by some i n t e r a c t i o n o r interdependence b u t f u n c t i o n i n g as a s i n g l e u n i t .

System Index - A l i s t i n g o f systems which represent t h e scope o f t h e f a c i l i t y p r o j e c t t h a t a r e be ing added new o r mod i f ied .

T e s t Procedure - All Sta r tup Tes t Procedures and any Plant Procedures t h a t a r e be ing conducted under t h e S ta r tup Test Program requirements.

Tes t S p e c i f i c a t i o n s - Spec i f i ca t i ons w i l l e s t a b l i s h t e s t requirements and parameters f o r a l l l e v e l s o f t e s t s performed on major components, subsystems, o r systems as app l i cab le t o ensure t h a t essent ia l design, i n t e r f a c e , and performance requirements a re met.

Tes t Summary Reports - A comprehensive summary r e p o r t o f S ta r tup t e s t procedure r e s u l t s t h a t p rov ide f i n a l approval o f t e s t r e s u l t s .

31

HNF- slx w 3 I 4 -r&P-oo/ R E V 3

Work Package - A collection of documents used t o authorize, document, and provide instruction for the performance o f maintenance, testing or modification activity. The work package may include, as applicable, design changes, j o b scope, retest requirements, parts 1 i s t s , d a t a sheets, applicable procedures, e tc .

32

APPENDIX A

T&E Admin i s t ra t i ve Procedures Checkl i s t

The T&E Admin i s t ra t i ve Procedures Checkl i s t w i l l be prepared t o v e r i f y procedures are i n p lace t o c o n t r o l t h e conduct o f t h e W-314 T&E Program a c t i v i t i e s . The c h e c k l i s t w i l l c o n s i s t o f t h r e e sec t ions : Custody Cont ro ls , Work Cont ro ls and Tes t ing Cont ro ls . Each sec t i on o f t h e c h e c k l i s t w i l l i d e n t i f y t h e procedures t h a t d i r e c t t h e conduct of W-314 t e s t i n g and eva lua t i on a c t i v i t i e s . P r o j e c t s p e c i f i c procedures w i l l on l y be prepared i f e x i s t i n g procedures a r e n o t adequate. The t h r e e sect ions are expla ined as f o l l o w s :

* CUSTODY CONTROLS - This sec t i on cons is ts o f procedures t h a t govern t h e conduct o f S ta r tup System Scoping, system Turnover Wal kdowns, System Turnover and Acceptance process, master t r a c k i n g system, t u r n back t o cons t ruc t i on , and re lease t o operat ions a c t i v i t i e s .

WORK CONTROLS - This sec t i on cons is ts of procedures t h a t govern t h e conduct o f engineer ing issues management, requests f o r cons t ruc t i on ass is tance, requests f o r operat ions assistance, c o n t r o l o f temporary mod i f i ca t i ons , c o n t r o l o f Measuring and Test Equipment (M&TE), Lock and Tag, Work Management, and Master Tracking System.

TESTING CONTROLS - This sec t i on cons is ts o f procedures t h a t govern t h e conduct o f t e s t procedure prepara t ion and approval , t e s t procedure implementat ion, post t e s t i n g review and approval , and pos t maintenance t e s t i n g .

The f o l l o w i n g Table A - 1 designates a l l t h e app l i cab le documents/procedures t h a t correspond t o a s p e c i f i c s t a r t u p a c t i v i t y and: t he re fo re , s a t i s f i e s t h e requirements o f t h e c h e c k l i s t . The t a b l e has been broken o u t per t h e t h r e e sec t ions de f i ned above.

33

FDH ManuallDocument s/u Test A C t i V i t v comment* Implement ing Procedure

2 . 1 S t a r t u p System Scoping HNF-SD-W314-TEP-001. W-314 Test and E v a l u a t i o n ~~

4.4 S h i f t Turnover DOE Order 5480.19, Conduct oi Opera t i ons HNF-IP-0842. V o l . 11, S e c t i o n 4.12.1. Requirements For DOE F a c i l i t i e s . Chapter X I I . Turnover o f S h i f t R e s p o n s i b i l i t y o p e r a t i o n s Turnover .

I I I

2.2 SSC Turnover or Turn back From o r To : o n S t w c t i o n

2.3 Release To Operat ions

34

HNF-PRO-572, P r o j e c t Acceptance and Closeout HNF-PRO-572

HNF-PRO-572;

Acceptance f o r B e n e f i c i a l Use

HNF-PRO-572, P r o j e c t Acceptance and C loseou t ; HNF-IP-0842, TWRS A d m i n i s t r a t i o n HNF-IP-0842, Vo1. I V , S e c t i o n 3.12,

3 .1 C o n t r o l l e d ACCBSS

3.2 LockOUtlTagOUt Procedure

3.3 Design Change Request

3.4 s t a r t u p Tes t Program P lann ing and

HNF-CM-1-6, R a d i o l o g i c a l C o n t r o l Manual HNF-IP-0842, Vol . 11, Section 3 . 1 Access C o n t r o l F o r Hazardous F a c i l i t i e s

HNF-PRO-081, Hazardous Energy C o n t r o l Program HNF-IP-0842. V o l . 11, S e c t i o n 4.9.1, LOCkOUtlTaKOUt

HNF-PRO-440, Eng ineer ing Document Change C o n t r o l HNF-PRO-440. Eng ineer ing Document Change Requi rements C o n t r o l Requi cements

HNF-PRO-574. P r o j e c t P lan HNF-PRO-574.

3.5 Readiness Review Requirements

3.6 S t a r t u p O r i g i n a t e d Work Orders

3.7 c o n t r o l o f ~ e m p o r a r y M o d i f i c a t i o n s Dur inK T e s t i n g

3.8 C o n t r o l o f M&TE

4 . 1 P repara t i on . Review. Approva l , and M o d i f i c a t i o n o f P re -Opera t i ona l and O p e r a t i o n a l T e s t Procedure5

4.2 Review and Approval o f C o n s t r u c t i o n

4.3 Conduct o f T e s t i n g

Acceptance Tes t Procedures

HNF-CM-1-5. Standard Opera t i ng Procedures S e c t i o n 1.2, O p e r a t i o n a l Readiness Reviews

HNF-CM-1-8 Work Management HNF-PRO-551. Statement o f Work f o r an O f f s i t e A - E For FDNW use SOW

HNF-CM-1-8, Work Management IP-0842, Vo1. V. S e c t i o n 6.1, Temporary

For FDH use JC5

System A l t e r a t i o n and R e s t o r a t i o n

HNF-CM-4-2. Q u a l i t y A5surance Manual. QR 12.0, IP-0842. V o l . V, S e c t i o n 3.8. C o n t r o l and c o n t r o l o f I ns t rumen ts C a l i b r a t i o n o f Measuring and Test

Equipment

DOCUHENTSlPROCEDURE5 CONTROLLING TESTING

HNF-IP-0842. TWRS A d m i n i s t r a t i o n HNF-IP-0842, V o l . 11, S e c t i o n 4.1.3 J o i n t T e s t Review Group & S e c t i o n 4.16.2 P repar ing , Reviewing and Approv ing Opera t i ng Documents.

fi.?.F.:.??Q.l3.L.2 ,... eE.~~~. . .Enp. ; .~~~.- i .cs . .4~.~~.~~.~~: , .~~~. . S2,2i .. . ... .. I

i & m C Same 1

LD m

APPENDIX B

TEST AND EVALUATION LOGIC DIAGRAFIS AND OVERVIEW DEFINITION DOCUMENT

- / j T!\'R-:]90,J, {:,z Tsnh: Fzr:? i ir;~.r&~c ...................................................................................... :.,:..,i .......... >:.? 8) TWR-2274, SN-634 Transfer Line (A-B t o A X - B ) 9) TWR-2275, A - B Valve Pit Upgrade 10) TWR-2611, AY-OlA Pump Pit Upgrade 11) TWR-2612, 9 - 6 3 5 Transfer Line (AY-OlA t o AY-02A) 12) TWR-2613, AY-02A Pit Upgrade 13) HNF-4578, 200E Waste Transfer System 14) "F-4579, z,f&,@-$.<A &[/;Q i;?t 15 j HNF-4581:, 242 +\,+$.:A PG(Q~ l'!? ........................................................................................ 2 ..... :...:..:. 1.6) }#JF-~$581,, Z.$.:-,L\&-~[)/? /<:s@,r i l; PY' 1.

17) TWR-2276, 3 - 6 3 3 Replacement Line 18) TWR-XXXX, AW-A VaIve Pit Upgrade 19) TWR-XXXX, AW-B Valve P i t Upgrade

36

HNF-SD-W314-TEP -001, Rev. 3

TABLE B - 1 W-314 PHASE I OVERVIEW DEFINITION DOCUMENT

WBSfSlEP #

W e t 4

WBS14A

W B S t 4 C

W B S t 4 D

W B S t 4 E

W B S t 4 F

W B S t 4 G

~

TITLE. DESCRIPTIONS INTERDEPENDENCIES RESPONSIBLE DRG.

W 3 1 4 PHASE I V &V"

"MASTER PUMP SHUTDOWN (MPS) V&V

'AN VALVE PIT UPGRADES V&V"

'AZTANK FARM UPGRADES'

'2WuW UPGRADES'

'AW VALVE PIT UPGRADES'

"AY PIT UPGRADES" II ~ I I I I1

.. W B S .... ........ 14 .< .. ~~

:'li'.ii?.GnhDw

WBS 1.4.L "AN - 2WE WE UPGRADES'

WBS1.4.M 'AZ. ZWEWTSUPGRADES

WBS.t.4.K 'ZWE WTS UPGRADES'

I UPGRADES OTP - This section idenmier and desctibes the POTPs and OTPr required by each architectural dasrificatiun, or I ~lssilicstims amro~riatelv mmbinedl

I

SECllON 1.2

11 SECTION 1.3

"UPGRADES ATP". This section identifies and describes the required construction Mnf(aC101s ATPs to be penormed when constrYction is COmpletB on each architecturn1 classification, or classifications appropriately combined).

I UPGRADES FTF - This section identifier and describes the required factorytmndor acceptance tests required priorto the *em@) VieHanfordSite.

SECTION 1.4

II "UPGRADES CT?. This redon idenllies and describes the required Cllr to be pemformed during the ~ 0 n ~ V u c t i o n phase of u1e Project It MI1 address each architectural ~IaBEifiCation. or~las~if i~at ions appropdately combined. This section of the STEPWill also identify and describe any required tests. orvedficatians, perlofolmed during receipt insp&ian(s). any vendor information verifications required, any vendor qualification verifications required. etc. to ensure the receired item(r) am acceptable perthe design drawings and sp~sifiSati0"s prior to installation.

11 ARCHiTECTURAL CLASSIFICATIONS I These Will bedefined bvtheSTEP andwill beaoiiroilriate tathe amas beino tested. I I II

37

I- N m

I I


FIGURE 6 - 3 V&V LOGIC DIAGRAM FOR MASTER PUMP SHUTDOWN

* Information about t h i s l o g i c diagram has yet t o be determined. Logic Diagram w i l l be added when data becomes avai lab le

39

d m

0 d

HNF-SD-W314-TEP-001t Rev. 3

FIGURE 8-5 V&V LOGIC DIAGRAM FOR AZ TANK FARM

241-AZ-02A UPGRADES F T I

241-AZ-02A 241-AZ-02A 2 4 1 - A Z - 0 2 UPGRADES ATPs UPGRADES OTPs UPGRADES V&V 241-AZ-02A

UPGRADES C T I

241 -A2 - 0 1A UPGRADES FT I

241-AZ-01A 241-AZ-01A 241-AZ-OlA UPGRADES ATPs UPGRADEES UPGRADES V&V

-

OTPs

A 2 UPGRADES -1 WBS 1.4.0 I

241-AZ-01A UPGRADES C T I

41

m

> @ L a a t ;

3"

N 3

t

5: 3 0 u a 0 N >

,1 3" * a N 3

1: 30 u a

N >

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p7

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m


6 - 1 1 V&V LOGIC DIAGRAM FOR AN - 200E GCTS

241-AN-01A 241-AN-01A

241-AN-01A PUMP P I T

r 241-AN-OA 241-AN-01A -

PUMP P I T

PUMP P I T UPGRADES F T I

AN-ZOOE WTS DESIGN 241-AN-04A -

I

241-AN-04A 241-AN-04A 241-AN-04A -..+ PUMP P I T PUMP P I T - PUMP P I T -

UPGRADES ATPs - UPGRADES OTPs UPGRADES V&V

VERlFICATlON

AN RISER 1 0

AN RISER 1 0 AN RISER 1 0 AN RISER 10 V&V

PUMP P I T

AN-ZOOE WTS WBS 1 .4 .L I

UPGRADES C T I -

47

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w a 2

w 0 0 cu

E

4 0 0

I-

cu r(

m

m

m 4

m

i