mCMSSIFIED 1

ARH-MA-119

2^2-S E¥AP0R4TOR-CRySTALLIZER IIFOmmTIOH PIAKUAL

R. R. Henderson Waste Handling and Plutonium F in i sh ing Process Engineering

Operat ions Technica l Support Department

September 1975

Operated f o r the Energy Research and Development Adminis t ra t ion by A t l a n t i c R ich f i e ld Hanford Company under Contract E(45- l ) -2130

mCMSSIFIED

Hus teport was psepmed as an actoont c-t work spoiiisoEed h\ the L'liited States (>o^emment Neither the I'nited States nor the I'mted States Department ot Fneigv, nm anv of Aeu empkness, nur aii> of then tOsUratt"S's subi.ofitras,EoJS, cr their employees flakes am w^aiiantv, e\press 01 iinphed, or assumes aiiv legal hahihty or responsibihtv for tiie accuiaiV. completeness o* usefulness ot any mionmtum. apparatus, prod^tt or psot*fss di'^closed. Of represents that its u ^ v^tmld not mfdsioa pm^tel> owned nghts

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency Thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.

2 ARH-

TABEE OF COITENTS

Page

INTRODUCTIOH - — - » - » — . — — — — — — — — — — . — — » — — — — k

PROCESS DESCRIPTIOl — — — — — . — » _ — » — — — — ™ _ — — — h

FACILITIES DESCRIPTIOl - — — « — » — - — — . — ^ — . — — — — » — . - 9

General -——-™_^_^_-___»._-._—._____«_____________«____ 9

Reboiler (E-A-l) — — . — . — — — » — » - _ - — -__-._-™™____ n

Evaporator (C-A-l) - — » — — - . — — » — — - » » . __»»„_._„__ 12

Recirculation Pump (P-B-l) ™ — — — ^ _ — — . — — — — » _ — - - ik

Bottoms Pump (P-B-2) — — — — » - — — — - . — — — - . — » — — lii.

Primary Condenser (E-C-l) — — . _ — — — . — — — — — _ > _ _ _ _ _ 16

Inter-Condenser ( E - C - 2 ) - » — — — - - — - » _ , 16

After Condenser ( E - C ~ 3 ) — ._-__-„_ — __>_ 17

Vessel Ventilation System — -—• -——•—.-——- 18

Building Ventilation — — ™ — .___„___„__„ 19 Seirice Area ------- .—.—-—.— . .—.-—,_-__ 20 Process Area »—-™~-.».-——_____-_->_ _..«—„«_«_ 2I Operating Area —----—,__>____.___„______,___«„_-_ 22

Condensate Tank (TK-C-lOO) -——.———.—.»._———™— 22

Condensate Pump (P-C-lOO) - . — — — — » . — — — — — — » - 23

Condensate F i l t e r (P-C-l) ——• «_>-.-.-.«_»>_—_»-»—._— 23

Ion Exchange Column (iX-D-l) --—_—.———. _„„_.„__ 23

Eluant Tank (TK-E-101) ^ — — — — — — — — — - ™ — — — 26

Eluant Pump (P-E-lOl) —™™-.™»-.———™-™——.-.»——— 26

Anti-Foam Tank (TK-E-102) —— - » - » — _ — _ . - . _ ™ — 26

Anti-Foam Bmp (P-E-102) -«—»»———.——»—-—»- 2T

3 ARH-M-119

TABM OF CdfTEWTS CONTIHUED

Page

Decontamination Tank (TK-E--104) — ™ — — ~ — - ^ — — — . — ^ 27

Decontamination Pump (P-E-104) - — ,»»—.____«>____- 27

Pump Room Sump .-»—™——-.—___«____^».___»______..^_ 27

Steam Condensate Radiation Monitoring, Proportional Sampling, and Diversion System (R-C-l) — — - « — — — — - 28

Cooling Water Radiation Monitoring and Proportional Psampling System (R-C-2) - . — — » . — — — , — - 29

Process Condensate Radiation Monitoring, Proportional

Sampling, and Diversion System (R-C-.3) - — ™ — — — — 30

Air Sample Radiation Monitoring Systems --»_-—_-«-—-- 31

Slurry Sampler ——~-.-.—__«__>____-_».___»._.^ ____„___ 33 Process Air Supply System — » — — — — — — — ~ — — . ™ - — 33

Overhead Crane -——-.—--_—-.—____-.™__-_™_™_._.^ ___» 35

Interlocks -—-—-.>___..-.—.—.—--—,_-.--.-——.-.»-_--——_- 35 Number One -———.—>__._.»__„._„«_„«»_.„»___ 35 lumber Two « — — . » — — — . « - » . — — — » — — » » ™ - 37 lumber Three » — - — . . ^ — — » - - — » . — . — — ™ — — 38 Number Four - ™ — — — — - — - > _ — „ „ « _ _ - _ . . _ _ - _ 39 Number Five — - - — - - — — . - « — _>„>._..«,.«» kO lumber Six — ™ — • ,__»_.___>____»»______»__„ kO lumber Seven —.»___»._«»._____—.—____—_—-__ kl Number Eight » — — » — — - » — — — » « — » — — — k2 Number Nine — . ™ — — ™ » — . — „ » _ _ _ _ » »____—_ k3 Number Ten - » — — — . — — — — - ™ — — — — » — — 43 N\imber Eleven —-.—-™-—————"-——"-—--— hk Number Twelve » — — — — — — - » — — — — — — 44 Number Thi r teen —.__-.»»™™—._— ™_____>_™„__ 45

APPfflDIX —————.—™———._-- .——.—^——»—_—™—»,^ 1+7

REPEEENCES — — — — — — — , ___._>_«„_„___.„__.__ kj

ACKNOWLEDGMENTS ^ — — » — — _ — » — — — — — — — — ™ — k8

LIST OF FIGURES - » — ^ - ™ - » ™ — » . ~ ™ » ^ - — — — — ^ - » - » - ^ — 49

h Affl-MA-119

242-S EVAPORATOR-CRYSTALLIZER IiP0H4ATI0N MANUAL

INTRODUCTION

Low heat wastes, which contain relatively small quantities of

fission products, are stored in the Hanford nonboiling waste tank

farms. A major portion of the Waste Management Program at Hanford

is concerned with the immobilization of these radionuclide-bearing

waste solutions. The 242-S Evaporator-Ciystallizer is utilized to

reduce the mobility of aqueous waste solutions which do not self-

boil. The evaporator operates under a vacuum, employing evaporative

concentration with subsequent crystallization and precipitation of

salt crystals. This process allows for greater sludge-slurry con­

centrations, thereby reducing the number of underground storage

tanks required.

This manual describes the process, facilities, and equipment

associated with the 242-S Evaporator-Crystallizer. Figures referred

to in the text can be found in the Appendix.

PROCESS DESCBIPTION

The 242-S evaporator process employs a conventional forced-

circulation, vacuum evaporation system to concentrate radioactive

waste solutions. Main process components of the evaporator-

crystallizer system located in the 242-S building are the reboiler,

vapor-liquid separator, recirculation pximp and pipe loop, slurry

product pump, primary condenser, jet vacuum system, condensate

5 ARH-MA-119

collection tank, and ion exchange column. (See Fig. 1 for an over­

all view of the systemj flow rates, capacities, and other informa­

tion shown on this flow diagram are design data only.)

The evaporator system receives a feed blend from the 102-S

tank which consists of unprocessed waste and recycled supeitiatant

which has been decanted from the bottoms settling tanks. The feed

is pumped into the recirculation line on the upstream side of the

reboiler (see Fig. 2) at a rate controlled to maintain a constant

crystallizer weight factor. As the feed enters the recirculation

line, it blends with the main process sluriy stream which flows to

the reboiler. In the reboiler, the mixture is heated slightly to

a specified operating temperature, normally I30 °F to I70 F, by

using 3 to 10 psig steam. The low pressure steam provides adequate

heat transfer, and the resulting low temperature differential helps

minimize scale formation on the heat transfer surfaces.

The heated slurry stream is discharged from the reboiler to

the vapor-liquid separator, which is maintained at approximately 0.8

psia. Under this reduced pressure, a fraction of the water in the

salt slurry concentrate flashes to steam and is drawn through two

wire mesh deentrainer pads into a 42-inch vapor line leading to the

primary condenser. As evaporation takes place in the separator ves­

sel, further super-saturation occurs in the salt liquor sluriy which

creates new salt crystal nuclei and promotes growth of existing

crystals in the slurry liquor. After the process slurry has remained

6 ARH-14A-119

in the vapor-liquid separator approximately one and one-half minutes,

it flows to the recirculation pump suction via the separator vessel

drop-out leg and lower recirculation line. The recirculation pump

discharges the slurry back to the ireboiler via the upper recircu­

lation line, thus completing the process circuit. 0!he process is

continuous with typical stream rates of 90 to 110 gpm for the feed

from 102-S, 30 to 50 gpm for the condensate, and 50 to 70 gpm for

the slurry discharge.

The recirculation pump (P-B-l) moves waste at high velocities

through the reboiler in order to:

1. improve the heat transfer coefficient,

2. reduce fouling of heat transfer surfaces,

3. keep solids in suspension, and

h. permit transfer of large quantities of heat with only a small change in temperature of the solution being heated. Thus, the static pressure of the solution above the reboiler is sufficient to suppress the boiling point such that the solution will not boil in the tubes. Boiling occurs only near or at the liquid surface in the vapor-liquid separator.

When the process solution has been concentrated to the point

where it contains 20 to 30 percent solids or the nonnal operating

temperature has been reached, a small fraction is withdrawn from

the upper recirculation line and is pumped by the slurry pump to

underground storage tanks. In the storage tanks, the sluriy is

allowed to settle into a salt cake layer and a supernatant liquor

layer. The supernatant layer is decanted and pumped to the feed

7 ARH-MA-119

tank (102-S) where it is mixed with other waste feed stocks to

maintain the solids concenti'ation in the evaporator feed stream

at a desired level.

Because of the high concentration of solids in the slurry,

pluggage of the transfer lines from the evaporator to the tank

farm settling tanks may occur due to solids settling. The slurry

puii5> (P-B-2) is designed for high pressures so that the slurry

can be transferred at high velocities to help alleviate this

problem.

Vapors removed from the vapor-liquid separator are condensed

in the primary condenser, which then drains to the condensate

collection tank (C-lOO) (see Pig. 3). An in-line pump (P-C-lOO)

moves the process condensate from the tank through a filter

(P-C-l) to remove solids, and downflow through the ion exchange

column (IX-D-I) to reduce the final cesium and strontium concen­

trations (see Fig. h)^ The condensate exits from the column, flows

through a seal loop that maintains a flooded bed, and is discharged

to the 216-S-25 crib after passing through an in-line filter which

collects any resin that escapes the column. A small portion of

the condensate flow is routed from the discharge line through the

R-C-3 proportional sampler and radiation monitor and is returned

to tank C-100.

Regeneration of the ion exchange resin bed is required when

the bed becomes saturated with cesium and strontium, as indicated

8 ARH-MA-119

by the process condensate discharge samples (RC3), or iresin samples

obtained through the resin addition port. Regeneration is accomp­

lished by pumping hot, concentrated sodium nitrate solution from

TK-E-101 upflow through the column, followed by a water-wash to

remove the eluant solution and accumulated resin fines.

Resin particles in the ion exchange column may break down due

to the effects of radiation, abrasion, and the caustic nature of

the process condensate. Fines produced by this breakdown may cause

partial pluggage of the resin bed and restrict the flow of conden­

sate to the crib, as well as increase the column dp. The column may

be backflushed to remove the fines by flushing upflow with process

condensate. If the cesium loading capacity of the resin becomes too

low, the resin is replaced.

Vacuum in the vapor-liquid separator is maintained at approxi­

mately 0.8 psia via the primary condenser and process vapor line by

a two-stage jet eductor system. Motive steam fixsm the primary jet

and the secondaiy jet discharges, respectively, to the inter-

condenser and after condenser. Both condensers drain to the

process condensate collection tank, while non-condensibles are

filtered and discharged to the atmosphere via the vessel vent

system (see Fig. 4).

There are three streams leaving the building that are dis­

charged to the ground! the process condensate discharged to the

216-S-25 crib, the steam condensate from the reboiler discharged

to the 216-U-lO pond, and the cooling water from the condensers

9 ARH-MA-119

also discharged to the pond. These three streams are provided

with continuous proportional sampling systems including radia­

tion monitoring equipment.

The R-C-1 radiation monitor and proportional sampler

monitors the steam condensate from the reboiler. Its diversion

valve can route the condensate to the 103-S tank if it does not

meet specifications. The R-C-2 system monitors the cooling water

stream. It is not equipped with a diversion valve since the

potential for radionuclide contamination of this stream is very

low. A plant shutdown would be required if it should become

contaminated. Finally, the process condensate is monitored by

the R-C-3 system, which can divert the condensate flow to the

C-100 tank to be recycled via the I03-S tank as feed for the

evaporator.

FACILITIES DESCRIPTION

General

The 242-S building is located north of the 241-S and 24l-

SX tank farms in the 200 West Area of the Hanford reservation

(see Fig, 8). It consists of the following:

storage and maintenance roomj

lunch roomi

lavatories and change roomj

clean and soiled clothes storage;

control room, containing the control panelsj

10 ARH-MA-119

aqueous make-up (AMU) room, containing the process air supply system and the anti-foam, decontami­nation, and eluant tanksj

condenser room, containing the primary condenser, jet vacuum system, condensate collection tank, and vessel ventilation systemi

loading roomj

load-out and hot equipment storage, which contains two sumps that drain to the pump room sumpj

pump room, which has removable cover blocks and con­tains the slurry and recirculation pumps as well as the pump room sumpj

evaporator room, which contains the vapor-liquid separator and the reboilerj

heating, ventilation and air conditioning (HVAC) room, located above the AMU room and containing the steam supply system, building ventilation system, and raw water filters;

ion exchange column room.

See Figures 9 and 10 for relative locations.

Steam and raw water are both supplied to the 242-S building

from the power plant in the 200 West Area.

Descriptions of the important facilities in the evaporator

system are included in the sections following. Drawings, flow

diagrams and construction specifications used for reference are

listed in the Appendix; their reference numbers are listed prior

to each individual section.

11 ARH-MA-119

Reboiler (E-A-l) Ref. 2, p. 92| 12; 13

Slurry is heated in the reboiler prior to entering the

vapor-liquid separator. The 2«5 x 10* Btu/hr duty reboiler is

a vertical tube unit with steam shell side and process solution

tube side with standard operating parameters of 0.8 psia pres­

sure and 130 Op to 170 °P temperature. It consists of 364 tubes,

each having a l4'-l/8" length and I-1/2" outside diameter (OD),

arranged with a I-7/8" triangular pitch. The tubes are encased

by a 40-I/2" OD, 15' long stainless steel shell. Temperature

elements TE-CAl-2 and Bil-EAl-1 are located respectively at the

reboiler inlet and outlet. It has three equally spaced baffles,

as well as an impingement baffle which foims a vapor belt at

the steam inlet (see Pig. 11).

The steam required for the evaporation process is supplied

to the 242-S building from the 200 W Area high pressure steam

loop, and is reduced from 225 pounds to 90 pounds outside the

building. The 90-pound steam is reduced to 10-pound steam which

passes through a desuperheater to reduce the temperature and

ensure saturation by the addition of filtered raw water before

it is used in the reboiler. The 90-pound steam is also routed

to the desuperheater to atomize the filtered water. The carbon

steel desuperheater, designed to handle steam at 2.7 x 10^ Ib/hr,

is the steam ejector, atomizing type.

Steam condensate normally goes to the U Plant pond (216-U-IO)

12 ARH-M-119

but can be diverted to 103-S if a leak should occur in the reboiler.

The steam condensate line is continuously monitored with radiation

reading instruments (RE-EAl-l) to detect such a leak, as is the

steam condensate in the condensate sampler (RE-RCl-l). Readings

above a set level at either of these instruments will automatically

divert the steam condensate from the pond to tank 103-S.

Evaporator (C-A-l) Ref. l4; 15; 21; 22

Process solution from the reboiler discharges to the vapor-

liquid separator via the upper recirculation line. The separator

consists of two basic sections (see Fig. 12), The lower (liquid)

section is a l4-foot OD stainless steel shell with a 22,500-gallon

to 25,OOO-gallon normal operating capacity (including recirculation

loop and reboiler). The vapor section is an 11'-6" OD stainless

steel shell, making the overall height of the separator 4l'-l 3/ "«

Total volume is 35^600 gallons when filled to the top of the vapor

section. Steam flows out of the separator through a 42-inch vapor

line at the top, and concentrated slurry exits via the vessel's

28-inch recirculation line.

The top section of the evaporator contains two deentrainer

pads approximately 3'-^ I/2" apart. The lower pad is four inches

thick, and the upper one is six inches thick; both are 0.011-inch

wire mesh packed to a density of 12 lb/ft3. A total of sixteen

spray nozzles, four on top and four on bottom of each pad, are

equally spaced and alternated for even distribution of water to

13 ABH-MA-119

the pads. The sprays on top of each pad are controlled auto­

matically for sequential operation, while the bottom sprays are

on a distribution ring and are controlled manually. The bottom

sprays on the lower pad also spray the sides of the evaporator.

Located on the 28-inch recirculation line are the feed line

from TK-241-S-102, the slurry line to underground storage tanks,

and an emergency dump line which routes the slurry to the 103-S

tank. In addition, if the dump valves should fail to operate or

the slurry line to 103-S is plugged, an emergency method of

dumping the sluriy is provided in the fonn of a four-inch nozzle

on the bottom of the recirculation line. A blank connector head

can be remotely removed from it, thus dumping the contents of the

system to the pump room floor. The pump room sump overflows to

TK-I03-S.

There are provisions for flushing the vapor-liquid separator

and recirculation loop to remove any residual solids from the sys­

tem and/or to reduce radiation levels. Water or other flush solu­

tion from TK-E-104 can be added via the slurry product line flush

system, the deentrainer spray system, and/or the feed line from

tank 102-S flush pit. The dump line to 103-S may also be flushed

with water or chemical solution from the decontamination header.

(This is accomplished with BDV-CAl-7 closed and POV-CAl-9 open.)

The magnetic flow meter (FM-CAI-3) is located in a small (3-

inch diameter) by-pass line connecting the recirculation pump

1^ ARH-MA-119

discharge with the pump suction. The flow measured through this

line is indirectly a measure of the flow through the reboiler.

A radiation monitor (RE-CAl-l) is installed in the 42-inch

vapor line leading to the primary condenser. Normally, entrained

liquid is removed from the vapor and does not reach the conden­

ser. However, the line is monitored due to the potential for

foaming or bumping of contaminated liquid out of the evaporator.

Other instrumentation includes expansion bellows in the 42-

inch vapor line, and two dip tube assemblies (DTA) in the evapo­

rator. One DTA (CA-1-1 and CA-1-2) measures weight factor/specific

gravity (WP/SpG); the other HEA (CA-1-3) measures W only. Both

consist of 1/2-inch schedule 40 stainless pipe dip tubes. Also

located in the evaporator itself is a temperature element, TE-CAl-1.

Recirculation Pump (P-B-l) Ref. 1

The stainless steel recirculation pump discharges slurry

back to the reboiler via the upper recirculation line. The

28-inch vertical propeller pxanp has a 14,000 gpm output with a

12.55-foot total dynamic head and is designed to handle waste

containing up to 65 percent solids by volume.

Bottoms Pump (P-B-2) Ref. 4; 30

The slurry pump has a total dynamic head of 5OO feet and is

constructed of 30^ L stainless steel. It is a single stage,

horizontal, centrifugal pump driven by a variable speed motor

15 ARH-m-119

with a 50 to 100 gpm normal flow. It pumps concentrated slurry

from the recirculation line to the tank farm settling tanks.

Both the recirculation pump and the slurry pump are equipped

with a dual seal with high pressure water introduced between the

seals to prevent process solution from leaking out of the system.

Because the water pressure is maintained at a value in excess of

the process pressure at the seal, water can leak either into the

system or out of the pump, but the process solution cannot leak

out of the pump as long as the required water pressure is main­

tained between the seals.

Slurry transfer to the settling tanks is monitored with a

magnetic flow meter (FM-rAl-4). A decrease in flow below a

specified value will automatically shut the pump down and initiate

a line flush with water. A sight glass is installed in a by-pass

line for the purpose of checking the solids content of the slurry

stream, although this method is not used currently.

The slurry transfer line can be flushed in either direction

using manual controls. Flushing involves positioning POV-CAl-2

and P0V-CA1-2A for the operation—'either to the evaporator or to

the tank farm—and flushing with water or a chemical solution from

the decontamination header.

16 ARH-m-119

Primary Condenser (E-C-l) Ref. 7; 8; 9; 10; 11

The vapors removed from the evaporator are condensed in the

primary condenser. The 2.2 x loT Btu/hr duty, carbon steel con­

denser measures 17'-5 7/8" long and has an 85" inside diameter (ID)

(see Pig. 13). It consists of 2950 equally spaced tubes (see

Pig. 14) with a 3/4" OD and ll'-ll 3/4" length. The four-pass,

water-cooled heat exchanger has a 4'-6" impingement plate located

at the vapor inlet, and a total of seven baffles (see Fig. I5),

five of which are evenly spaced through the length of the condenser,

and two acting as a shroud over the vapor outlets.

Vapor enters through a 42-inch vapor line, contacts the cooling

tubes, and exits to the inter-condenser via two six-inch lines

located on either side of the condenser. Condensibles drain to the

collection tank through a 20-inch hot well. Cooling water passes

through the cooling tubes at a maximum rate of 3500 gpm; a small

portion of the used raw water is routed through the R-C-2 radiation

monitor and proportional sampler as the stream exits to the 216-U-lO

pond. Should this stream become contaminated, a plant shutdown

would be required, as the cooling water cannot be diverted.

Inter-Coodenser (E-C-2) Ref. I6

The evaporator pressure of approximately 0.8 psia is maintained

by a two-stage jet system (see Fig. I6). The first stage maintains

a vacuum on the primary condenser and consists of a steam Jet, air

17 AKH-MA-119

bleed-in valve (DOV-ECl-2), and the inter-condenser. Steam pressure

is controlled at 90 pounds, and the desired vacuum is obtained by

bleeding ambient air into a 6-inch vapor header through an air in­

take filter (F-C-2). The air bleed-in valve is controlled by a

pressure-recorder controller which receives its signal from the

weight factor reference pressure tap in the vapor-liquid separator.

Vapor discharged from the jet contacts the cooling tubes in the

inter-condenser, and the condensate drains to the condensate col­

lection tank. Non-condensibles are routed to the after condenser,

as is the used cooling water, which is transferred to the after

condenser for reuse.

The carbon steel inter-condenser has a service of 1 x 10^

Btu/hr and measures 87 inches long with a l6-inch ID. The four-

pass water, one-pass steam heat exchanger uses raw water at 100 gpm.

It contains 144 straight tubes (B¥G I6) on a 0.9375-inch pitch.

The 0.75-inch OD tubes are 66 inches long.

After Condenser (E-C-3) Ref. I6

Vapor discharged from the inter-condenser enters the second

stage of the vacuum system. This stage consists of another steam

jet and the after condenser. Steam pressure is again controlled

at 90 pounds, and discharged vapor contacts cooling tubes in the

after condenser. Condensate is routed to the C-100 tank, while

the non-condensibles are filtered and discharged to the atmosphere

18 AKH-MA-H9

through the vessel vent system. Cooling water from this condenser

comes from the inter-condenser at a rate of 100 gpm; it drains to

the 216-U-lO pond except for a small amount routed through the

R-C-2 sampler and monitor.

The 7 X 105 Btu/hr duty carbon steel after condenser is two-

pass water, one-pass steam. Its shell has an 8-inch ID and 93-7/8"

overall length and encases 45 tubes. The tubes are 0.75-inch OD,

BWG 16, 72 inches long arranged with a 0.9375-inch pitch.

Vessel Ventilation System Ref. 2, pp. 87, 95; 26

Non-condensibles are filtered and discharged to the atmosphere

via the vessel vent system. This system consists of a deentrain-

ment pad (DU-C-l), prefilter (F-C-6), heater (H-C-l), high efficiency

filter assembly (F-C-5)> and vessel vent exhauster (EX-C-l). See

Figure 17»

The deentrainment unit and prefilter each measures 16-I/2"

by 14-I/2" by 7", The deentrainment pad is provided with a lower

raw water spray as well as an upper spray nozzle from the decon­

tamination tank for flushing operations.

The carbon steel vessel vent heater has the dimensions of

12" total length by II-I/2" overall casing width and has a capacity

of 200 scfm. It is an extended surface heater which uses 100 psig

saturated steam to obtain a 50 °F design temperature differential.

19 ARH-MA-119

The high efficiency filter section consists of two dry filter

cartridges. The cartridges are replaceable and measure 24" by 24"

by 11-1/2".

The carbon steel vessel vent exhauster delivers 200 cfm at

10" HoO GA. The off-gas system discharge is continuously monitored

by an alpha monitor for build-up of radionuclides on a sample filter

paper as it filters a continuous sample of the stack discharge.

Another filter paper is routinely collected to check beta and

gamma readings. In addition, the vessel vent exhaust fan filter

differential pressures are monitored for both high and low dif­

ferential readings.

The vessel vent system has three drain lines to the 27-gallon

seal pot J an overflow line from directly above the heater, a one-

inch line from the vessel vent exhauster, and a drain inmediately

before the exhauster. The system is also equipped with a tempera­

ture element (TE-HCl-l) downstream of the heater and a pressure

indicator upstream of the deentrainment unit.

Building Ventilation

The ventilation system for the 242-S building is designed for

air flow from the non-contaminated to progressively more contaminated

zones. The contaminated zones are held at a negative pressure, while

the non-contaminated zones are positive. Each zone is supplied by

a separate air system. Seventy percent of the air supplied to the

cold zones is exhausted from the AMJ room and the restroom exhaust

20 ARH-MA-119

f a n s , while the remaining leaves v i a g r a v i t y dampers and leakage .

The a i r suppl ied t o the contaminated zones, as we l l as a l l i n -

leakage , i s d ischarged through a f i l t e r system c o n s i s t i n g of two

f i l t e r s (high e f f i c i e n c y p a r t i c u l a t e a r r e s t e r s : HB-PA) in s e r i e s .

A 21,800-cfm capac i ty e l e c t r i c exhaust fan (KI-5-3) i s i n s t a l l e d

t h a t w i l l c a r ry the e n t i r e load; a second fan (Kl-5-2) of iden 'c ica l

s i z e , powered by a steam t u r b i n e , i s a v a i l a b l e as a bacgup. F a i l ­

ure of the e l e c t r i c exhaust fan to maintain a spec i f i ed flow wilL

i n i t i a t e the shutdown of the e l e c t r i c fan and the s t a r t u p of r;he

steam tui-bine.

Service Area

The s e rv i ce area i s p r e s s u r i z e d by s t a r t i n g the sei-vice area

supply f an . The exhaust fans f o r t h i s a rea a re con t ro l l ed by

p r e s su re swi t ches , which s t a r t the fans when the supply a i r has

inc reased the s e r v i c e area p r e s su re to a s e t p o s i t i v e v a l u e . The

exhaust fans a re a l s o shut down by the p re s su re switches when the

p r e s s u r e drops below a s e t p o s i t i v e v a l u e . The s e rv i ce a reas w i l l

always be a t a p o s i t i v e p r e s s u r e as long as the supply fan runs .

P re s su re i s maintained by modulating dampers in the supply fan

c o n t r o l l e d by a s i g n a l from the s t a t i c p res su re ins t rument in the

c o n t r o l room. The a i r supply to the s e r v i c e a r ea s i s l imi t ed by

a s i g n a l from the flow measuring element in the supply fan d i s ­

charge duc t . Tliis s i g n a l o v e r r i d e s the s i g n a l from the s t a t i c

p r e s s u r e ins t rument i f the supply exceeds a p r e s e t l i m i t .

21 ARH-HA-119

The supply fan motor automatically shuts off on a signal

from the flow instrument if the fan has failed. Shuttin£; off the

supply fan motor is aniunciated in the concrol rooiiu

Process Area

The negative pressure in the process area is aormally waia-

tained by operating tae electric exhaust fan. After startinff tais

fan, the supply fan starts automatically as the pressure in the

pump room approaches the required negative Talue. The arnoimb of

supply air is limited to a pi-eset value and is controlled by

modulating dampers in the supply fan. A signal from the flow

measuring element in the supply fan duct controls the dampers,

A loss of flow from bhe supply fans signals for a shutdown of the

supply fan motor which is annunciated in the control room.

The exhaust air from bhe process area is monitored for radi­

ation. Any indication of filter breakthrough will shut ao' m both

the electric and the steam turbine exhaust fans, which in turn

will shut down the supply fan upon loss of nei a&ive pressure in

the process zones.

The differential pressures across both the first and second

HEPA filters in the exhaust system for the process areas are also

monitored. A low differential pressure across either the first or

second filters could indicate a filter breakthrough while a high

differential pressure across the first filter could indicate filter

pluggage with a potential for breakthrough. Each is annunciated in

the control room.

22 ARH-MA-119

Operat ing Area

The operat ing, a rea p r e s su re i s con t ro l l ed a t a spec i f i ed

nega t ive p r e s su re by modulating dampers in the exhaust fan . These

dampers modulate on a s i g n a l from the ins t rument monitor ing the

s t a t i c p r e s s u r e in the pump room. This p re s su re c o n t r o l l e r a l so

shu t s dovra the supply i f the requi red nega t ive p r e s su re cannot be

maintained by completely opening the modulating dampers in the

exhaust fan .

Condensate Tank (TK-C-lOO) Ref. 24

Condensibles from the v a p o r - l i q u i d s e p a r a t o r a re co l l ec ted

in a 17,OOO-gallon, s t a i n l e s s s t e e l , round-bottomed tank (see

F i g . i B ) . Condensate d r a i n s i n t o t h i s tank from the primary

condenser, the i n t e r - and a f t e r condensers , and the v e s s e l vent

s e a l p o t . An i n l i n e pump (P-C-lOO) moves the condensate through

a f i l t e r (F -C- l ) to an ion exchange column ( i X - B - l ) , a f t e r which

i t may be d ive r t ed by the R-C-3 d i v e r t e r valve back to the C-lOO

catch tank i f i t does no t meet d i scharge s p e c i f i c a t i o n s . Condensate

meeting s p e c i f i c a t i o n s i s routed to the 216-S-25 c r i b .

The condensate catch tank has overflow and d ra in l i n e s to

tank 103-S. A vent l ead ing to the v e s s e l vent system i s equipped

with a manually c o n t r o l l e d a i r b l e e d - i n valve which provides

s u f f i c i e n t a i r flow to p reven t the f i l t e r low dp i n t e r l o c k from

s h u t t i n g down the v e s s e l ven t exhaus t e r . The bank has a vent

from the flow measurement tank (C-IO3), a p a r t of the R-C-1

23 ARH-MA-119

sampling system. It is also equipped with a liquid level gauge,

agitator, temperature element, W/SpG Instrumentatioa, and two

interface instruments to detect any organic that may accumulate

in the tank. A spray nozzle from the decot.taraiiiation tank is

provided for flushing of the tank. (This flush solution may also

be used to flush the condensate filter and then be rtcycled back

to TK-C-100.)

Condensate Pump (P-C-lOO) Ref. 2, p. 102

The carbon steel condensate pump transfers condensate fz'om

the C-lOO catch tank to the ion exchange column. Its normal

operating capacity is 60 gpm, while maximum capacity is 75 gpm-

The 10 HP centrifugal pump has a total dynamic head of I63 feet.

Condensate Filter (F-C-l) Ref. 2, p. 104

The condensate filter with a 5-micron rating is located on

the process condensate line to prevent particulate matter from

reaching the ion exchange column. It consists of cellulose fiber

material and melamine resin. The Cuno filter assembly has 36 dis­

posable cartridges and can handle a flow rate of 220 gpm when clean.

Two pressure indicators are located upstream and downstream of the

filter to determine the differential pressure.

Ion Exchange Column (IX-D-I) Rpf. 25

Process condensate collected in tbe C-lOO tank is pumped

through the 1133-gallon ion exchange column for reduction of

24 ARH-MA-119

137 • 'Cs concentration. Strontium-90 is also removed by filtration.

The column, which has a four-foot OD and a l6'-l" overall height,

normally contains approximately 125 ft3 of Zeolon-900 resin

provided in the form of a dry, granular solid. The exchange

column, designed for do-smflow loading and upflow elution, is

regenerated as necessary by pumping the eluant from the aqueous

makeup tank (E-lOl) upflow through the column and discharging it

to TK-103-S. Raw water is also piped to the ion exchange column

to serve both for backflushing the colxomn and for displacing the

old resin whenever necessary. The upflow can exit either through

a three-inch drain at the top of the column or through a bhree-inch

drain located immediately below the upper screen.

Screens in the exchange column are situated 7'-8" apart and

are l6 x 200 mesh Dutch weave. Three pressure indicators are

located in the column: one directly below the top screen, and one

on either side of the lower screen.

Process condensate enters the bop of the column from the C-100

tank, and exits through the bottom to the 216-S-25 crib, via the

in-line filter and R-C-3 diversion valve. A small portion of the

flow is drawn through the R-C-3 proportional sampler and radiation

monitor and then discharged bo tank C-100. Two three-inch drains

(located on top and bottom of the column) lead to TK-103-3, as do

the overflow and resin drain lines. A three-inch line is also

provided to funnel resin into the column (see Fig. 19)•

25 ARH-MA-119

An in-line filter is installed in the process condensate

line downstream of the ion exchange bed to collect resin which

escapes through the bottom screen of the column. The filter

arrangement consists of two parallel filters with removable

baskets, both of which are provided with 200-mesh screens dur­

ing normal operation. It is also equipped with a filter by-pass

line, pressure gauges upstream and downstream of the filter, and

a sight glass located upstream of the filter arrangement.

A new ion exchange column (Fig. 20) is being aesigned at the

time of this writing and can be found in drawings H-2-46040 through

H-2-46o44. Major features of the new design include the following:

1. Diverter valve P0V-RC3-1 can divert process conden­sate from the 216-S-25 crib bo either the C-100 or 103-S tanks.

2. The integrator at the control panel for flow meter FM-RC3-1 will shut off when the diverter valve is in the C-100 or IO3-S position, measuring only the flow to the crib.

3. A new PRV (and by-pass line) located after FM-RC3-1 to maintain sufficient flow through the flow meter.

4. A flange Installed in the column 12 inches above the lower screen and bolted upper and lower screen assemblies provide for screen inspection and/or re­placement.

5. Two new three-inch side pipe connections installed slightly above the lower screen for resin removal and to provide a by-pass supply of water for back-flow operation.

6. The upper screen mil be 50 mesh stainless steel, while the lower one will be 100 mesh stainless steel with a l40-micron retention.

26 AM-MA-119

Eluant Tank (TK-E-lOl) Ref, 2, p. 93? 23

The eluant tank is a ^,200-gallonj stainless steel tank which

measures nine feet high by nine feet in diameter (see Fig. 21), It

is heated by a steam jacket with a minimum heating surface of

197 f't'« Condensate from the jacket is routed to 216-U-lO pond.

The tank is provided with a centrally located^ stainless steel

agitator to improve heat transfer and to keep solids in suspension.

It is also equipped with a temperature element and w/SpG instru­

mentation. Overflow and drain lines lead to tank 103-S, and it

has a pump-out line to the ion exchange column. The E-101 tank

is vented to the roof and is provided with a three-inch line and

a 10-inch port for raw water and chemical addition, respectively.

Eluant Pump (P-E-lOl) Ref. 2, p. 98

The carbon steel eluant pump, which has a total dynamic head

of 105 fee'c, pumps eluant to the ion exchatige column for regeneration

of the resin. The 7 o HP centrifugal pump has a normal operating

capacity of 100 gpm and a maximum capacity of 120 gpm.

Anti-Foam Tank (TK-E-102) Ref. 28

The anti-foam tank (see Fig. 22) is a 100-gallon, stainless

steel tank equipped with an agitator and weight factor instrumenta­

tion. It has a pump-out line to the evaporator , and its overflow

and drain lines flow to tank IO3-S. The tank is vented to the roof

and has lines for the addition of filtered raw water and chemicals.

27 ARH-iiA-119

Anti-Foam Pump (P-E-102)

Tae v a r i a b l e speodj l/k HP ant;i-foam pump ope ra t e s a t a

0 .01 to 0 .1 gpm capac i t y .

Deecntamination Tank ( T K - E - H ^ ) Ref. ?7

i'he 620-gallon s t a i n l e s s s t e e l decontamination tank (see

F i g . 23) i s heated by a steam j a c k e t which has a minipmrn hea t ing

surface of 2^ f t - . Condensace from i,he j s c t c t , d r a i n s to the

216-U-lO pond. The t a n k ' s overflow and d ra in l i n e s flow to tank

103-S. I t s pump-out l i n e leads to spray nozz les a t the v e s s e l

vent deentrainment unit;, the C-100 tank, the hot equipment room

sumps, and the primary j e t in che jet-vacuum system, as we l l as

to a b lank hose connection in the hot equipment room and pump room.

The tank i s ventea to the roof and has a l i n e for the add i t ion of

raw water and a 10-inch p o r t for chemical a d d i t i o n s . I t i s a l s o

equipped with an a g i t a t o r , a temperature element , and w/SpG

instrumen-ca t i o n .

Decontamination Pump (P-E-10i|) Ref. 2, p . 100

The s t a i n l e s s s t e e l deconiaminaLion pump ope ra t e s a t a 50 to

60 gpm c a p a c i t y . The c e n t r i f u g a l pximp has a t o t a l dynamic head of

196 f e e t and a 10 HP r a t i n g .

Puiffp Room Sump Ref. JQ

The pump room sump, \rhich i s loca ted in the sou theas t corner

of the pump room, measures 60" by 60" by 7 ? - l / 4 " in o v e r a l l depth

28 ARH-MJ\-119

and is lined with l/4" stainless steel. Its contents are routed

to tank 103-S via a steam jet system which utilizes high and low

level switches for automatic startup and shutdown. The addition

of raw -srater allows the minimum level to be maintained. The

loading dock and evaporator room floor drains, ho: equipment

room floor drain and sumps, and the P-B-1 and P-B-2 seal water

flow into the pump room sump. In addition, a drain funnel which

collects any leakage from vacuum relief valves on the anti-foam

line 1301 and decontamination line fiOl drains to the sump. The

sump is also equipped with instruments to measure specific gravity.

R-C-1 Ref. 20

Steam condensate from the 242-S evaporator reboiler is

normally discharged to the 216-U-lO pond, but can be diverted to

tank 103-S. The stream is continuously monitored with radiation

detection instruments, as well as by using a proportional sampler

for obtaining samples for laboratory analyses.

The steam condensate is routed through a ^OO-gallon flow

measurement tank (TK-C-IO3) which is equipped with a flow measure­

ment weir (see Pig. 2^). A continuous sample from TK-C-IO3 is

pumped (by P-RCl-l) through a sample cooler to reduce the conden­

sate temperature, and then through a sample valve, which is monitored

by a rotameter (see Fig. I6). The sample continues on through the

radiation detector and is then returned to the sampled stream. How­

ever, the sample flow can be diverted to by-pass Ae radiation

29 ARH-M-119

cell (KE-RCl-l) and allow the cell to drain to obtain a background

radiation reading. The radiation cell is flushed if the back­

ground level is increasing. If high radiation is detected in the

cell or the in-line radiation monitor (RE-EAl-l), the steam con­

densate flow is diverted from tne 216-U-lO pond to TK-103-3.

The proportional sampler is controlled by the steam condensate

flow over the weir such that when a specific volume of condensate

(normally 10 gallons) has passed over the weir, a signal is re­

ceived from the flow totalizer. This signal triggers the operation

of the proportional sample valve which turns to discharge the small

increment of sample contained in the valve to the sample receiver.

Meanwhile, the main sample stream continues to flow through the by­

pass. After discharging the sample increment, the valve repositions

for sample flow through the valve. The sample valve is air blown

each sampling operation to ensure that the entire sample reaches the

sample receiver. The remaining contents of the sample receiver after

the sample for the lab has been taken is drained into the sample

drainline, which returns to the flow measurement tank dovmstream of

the weir.

R-C-2 Ref. 20

Used raw cooling water from the primary and after condensers is

discharged to the 216-U-lO pond. A small portion of this flow is

routed through the R-C-2 proportional sampler and radiation detector,

30 ARH-ivlA-119

which works e s s e n t i a l l y the same as the R-C-1. The sample stream

i s then re tu rned to the normal flow (see F i g . 2k). The d i f f e r e n t i a l

p r e s su re ac ross an o r i f i c e mainta ins sample flow to the sampler; a

manual valve doisTistream of the o r i f i c e flow meter mainta ins p res su re

on the l i n e to assure t h a t the l i n e i s completely f i l l e d a t the

o r i f i c e . The p r o p o r t i o n a l sampler i s con t ro l l ed by the o r i f i c e

flow meter such t h a t when a s p e c i f i c volume of waste cooling water

(normally 1000ga l lons ) has passed through the meter , a small amount

of waste i s d ischarged to the a i r - s p a r g e d sample r ece iv ing tank for

a l a t sample to be ta-:en. A programmer au toma t i ca l l y a i v e r t s the

sample flow t o by -pass the r a d i a t i o n c e l l (KE-RC2-1) for f ive

minutes each hour while the c e l l i s allowed to dra in to check the

r a d i a t i o n background read ing , A high r a d i a t i o n reading on the coo l ­

ing water stream i s not a n t i c i p a t e d , and t h i s stream cannot be

d i v e r t e d . I f the stream becomes contaminated, a p l a n t shutdoim i s

r e q u i r e d .

R-C-3 Ref. 20

Process condensate from the 2'i2-S evaporator is normally dis­

charged to the 216-S-25 crib via the C-100 tank and ion exchange

column. A portion of the ion exchange discharge stream is pumped

(by P-RC3-1) through a proportional sampling, radiation monitoring,

diversion system (R-C-3) which is similar to R-C-1 and R-('-2j this

sample stream is routed to TK-C-100 after passing throi^h R-C-3. A

31 ARH-I'lA-119

magnetic flow meter controls the proportional sampler such that

small amounts of condensate are discharged periodically (usually

every 10 gallons) to the sample receiving tank. Condensate flow

is diverted for five minutes each hour to allow the radiation

cell (RE-RC3-1) to drain to provide a check of the radiation back­

ground (see Fig. 24). Radiation readings above a specified amount

result in diversion of the process condensate back to the C-100

tank.

Air Sample Radiation Monitoring Systems Ref. 3J 19

The air sample radiation monitoring systems include (l) the

room air sample radiation monitorsj (2) the building exhaust stack

radiation monitors; and (3) the vessel vent stack radiation moni­

tors. Refer to Figure 25 for an engineering flow diagram of these

systems.

The room air systems each consist of a beta-gamma Geiger

Mueller (GM) tube mounted in an air sampler, a preamplifier, and

a linear count rate meter with an integral power supply and alarm

circuit. The solid state count rate meter has a potentioraetric

output; it converts input pulses from the preamplifier into a

direct current (DC) voltage proportional to the average count rate.

It is provided with two adjustable alarm settings: one for an

"alert" condition and the second for a "high" condition. The room

air radiation monitors are located in the AiU room (R-AS-l), change

32 ARH-M-119

room (R-AS-2), control room (R-.AS-3), and the instrument loft

of the condenser room (R-AS-4).

Air is drawn through the room air samplers by a vacuum pump

(P-AS-l). The air sampling piimp also drax/s air samples from the

ion exchange column room, the loading dock room, loadout and hot

equipment storage room, pump room, and evaporator room, as well as

two samples from the JiEPA filters of the building exhaust system

(see Fig. 25). The flows are regulated in each case by means of a

flow indicator; they flow into a two-inch line passing through an

air filter (F-AS-1), the air sampling pump, air/water separator-

silencer, and into the vessel vent exhaust stack. The air sampling

pump operates at 125 scfm and 6" Hg vacuum. Raw water to maintain

the pump seal is supplied at approximately k gpm.

An air sampler probe draws air from the vessel vent stack into

the radiation monitoring system. To prevent condensation in the

sample stream, instrument air (20-pound) passes through an air dryer

and a heater into the stream. The sample stream is then divided into

two parts, each passing through a filter paper, and pumped by a vacuum

pump (P-AS-2) back to the vessel vent stack. Particulate matter

collected on one filter paper is continuously monitored for alpha by

the vessel vent radiation monitor, while the other is routinely col­

lected for beta and gaiama readings. The vessel vent radiation moni­

tor includes a GM counter, solid state high voltage DC power supply,

amplifier-discriminator, and a count rate meter. The GM counter has

33 ARH-l.m-119

a background of 60 counts per minute maximum (at operating voltage

and shielded by l/4" aluminum inside 2" of lead) and is utilized

for alpha, beta, and gamma energy detection. The transistorized

count rate meter is provided with a choice of linear or logarithmic

presentation and has a potentiometrie output.

Air from the building exhaust system enters the building

exhaust stack where a portion of it is dra>m through an air

sampler probe. Process air (90-pound) passes through an air dryer,

a PRY, and a heater and is added to the stream to prevent condensa­

tion. The sample stream is monitored for radiation (the monitor is

similar to the vessel vent radiation monitor) and pumped back to the

exhaust stack by a vacuum pump (P-Kl-l).

Slurry Sampler Ref. 17

A sampler arrangement is attached to the slurry recirculation

loop by-pass line in order to obtain slurry samples for laboratory

analyses. Data from the slurry samples will provide a basis for more

precise control of the 242-S operating parameters affecting process

quality. The sampler is located on the south wall of the hot equip­

ment storage room. It is being redesigned at the time of this

writing.

Process Air Supply System Ref. 2, p. 64; l8

Components of the process air system include two identical air

compressors (CP-E-1, CP-E--2) installed in parallel, an air receiver

(R-E-I), an aftercooler (E-E-6), a separator, and two dryers (DR-E-1,

3^ ARH-14A-119

DR-E-2) (see F i g . 7 ) . The compressors a re v e r t i c a l , r e c i p r o c a t i n g ,

non - lub r i ca t ed compressors and are designed to d e l i v e r 100 scfm

a t 100 p s i g . Each i s cooled with a t rater j a c k e t using water a t a

maximum of 70 "^F. Used cool ing water i s routed to the 216-U-lO pond.

One compressor i s used as the o n - l i n e u n i t ; the o the r i s used as a

stand-by u n i t which i s u t i l i z e d only i f the o n - l i n e compressor f a i l s .

Such a f a i l u r e could be the r e s u l t of l o s s of o i l p ressure , , or com­

pressed a i r o r cooling water temperatures above p r e s e t l i m i t s . In

a d d i t i o n , the s tand-by u n i t s t a r t s end the o n - l i n e compressor shuts

off i f the ope ra t ing p res su re drops below a p r e s e t v a l u e .

The a f t e r c o o l e r i s a h o r i z o n t a l p i p e l i n e type t h a t inc ludes a

moisture s e p a r a t o r , a s igh t - f l ow cooling water d i scharge and a

s e p a r a t o r d ra in valve (both of which dra in to the 21b-U-10 pond), an

automat ic condensate t r a p , and a d ischarge a i r temperature i n d i c a t o r .

The u n i t , s i zed to h a a i l e a minimum of 200 scfm of a i r , i s designed

as a w e t - s h e l l u n i t wi th an a i r tube s i d e .

From the a f t e r c o o l e r the process a i r i s routed to the a i r

r e c e i v e r , a s t e e l upr igh t tank with a volume of l l j cubic f e e t . The

15-foot high a i r r e c e i / e r i s equipped with a manhole, a s a fe ty r e l i e f

va lve s e t a t 125 p s i g , a p r e s su re gauge, a mois ture t r a p , and a d ra in

valve to the 216-U-lO pond. Process a i r i s routed from the a i r r e ­

c e i v e r to va r ious l o c a t i o n s in the o p e r a t i o n , such as the R-C-1,

R-C-2, R-C-3 samplers , while ins t rument a i r cont inues on through a

d rye r system. This system c o n s i s t s of a twin tower Onad dryer with

35 ARH-I.m-119

steam heat reactivation. Its operation is fully automatic; it

operates on a txrelve-hour reversal cycle with a four-hour re­

activation heating period. Each dryer is equipped with a steam

trap and drain lines for routing steam condensate to the 216-U-lO

pond. After drying, the instrument air passes through a I-I/2"

line to various locations such as WP/SpG tubes and remotely oper­

ated valves.

Overhead Crane Ref. 5

A 5-1/2-ton bridge crane services the pump room, loadout and

hot equipment storage room, and the loading room. It consists of

a motor-driven, under-running bridge with a single girder supporting

its five-ton hoist and an outrigger supporting its one-half-ton hoist.

Its combined hoist capacity is 11,000 pounds and it is capable of

handling a load of 125 percent of that capacity. In the event of

electrical or mechanical failure of any of the bridge drive com­

ponents, the crane retrieval system moves the crane bridge (with a

two-ton load) to the north extremity of the crane rails.

Interlocks

Interlock Mumber One

Interlock number one is activated if the bottoms concentrate

flow decreases below a specified value. It initiates a shutdown of

the slurry pump (P-B-2) and a line flush with water. The interlock

will perform the following functions automatically:

36 ARH-MA-119

1. An indication of low flow sounds alarm FA-C#l-4 (low slurry flow annunciator), and s t a r t s the time delay relay timing out.

2. After the eight-minute time delay relay has timed out, the selector switch SS-CAl-2 (which i s normally in the number one posit ion to set the system for automatic flushing of the slurry pump-out l ine) i s by-passed regardless of the operation that had been manually selected.

3. Solenoid valves are energiztd so that POV-CAl-2 and P0V-CA1-2A are positioned for flushing back to tne evaporator, tsius shutting off flow to the bottoms concentrate pump.

4. P-B-2 pump i s shut off.

5. After the timed flush of the l ine back to the evaporator, POV-CAl-2 and POV-CAl-3 are positioned for a timed flush of the bottoms concentrate l ine to the pump and on to the bottoms receiving tank.

6. After the tank farm flush, P0Y-CA1-2A i s positioned for flushing towards the evaporator. With POV-CAl-2 positioned to flush the tank farm, there i s no flow and the flush i s completed.

The P-B-2 pump remains off, and POV-CAl-2 and P0V-CA1-2A remain

in the "no flow" position un t i l a reset button i s pushed. Upon r e ­

se t t ing , the slurry pump r e s t a r t s and s lurry flow to the farm i s

resumed.

liJhen the low flow alann switch i s opened, i t s t a r t s a timer on

the main panel boara. This timer, which i s manually controlled,

t e l l s the operator how long he has to correct the problem before the

s lurry pump shuts off and the automatic flush of the slurry l ine

begins. The timer can be rese t by pushing a rese t button (IIS-CA1-4C);

a selector switch SS-CAl-4 i s also provided for by-passing the auto­

matic flush provisions i f so desired.

37 ARH-m-119

Interlock Mumber Two

A loss of power to the recirculation pump (P-B-l) will

activate the number two interlock to initiate automatically a

complete shutdown and dumping of the slurry from the evaporator.

The interlock performs the following operations:

1. Alarm FA-CA1-3B (28-inch recirculation line by­pass low flow annunciator) sounds, Indicating loss of flow.

2. Interlock number ten is activated, which shuts off steam to the reboiler and desuperheater. The reboiler chest is also pressurized with 20 psig air.

3. A time delay relay is started; the operator has a preset length of time (adjusted from one to ten minutes) to correct the problem and restart the recirculation pump before the automatic inter­lock circuit initiates a dump of the evaporator contents. Auditional time can be obtained by pushing a manual switch (MS-PBl-2 "start") to re­set the circuit. Switch IIS-PBl-2 "stop" must be pushed to reinitiate the automatic dump sequence.

4. When the time delay relay has timed out, automatic shutdown of the evaporator is initiated in the following sequence:

a. evaporator feed valve DOV-CAl-1 is closed;

b. evaporator feed pump 241-S-P-102 is stopped;

c. vacuum breaker valve POV-PX'l-l is opened;

d. steam valve to the inter- and after con­denser vent jets is closed.

5. Automatic dump of the evaporator is initiated by the following:

a. bottoms dump valve BDV-CAl-7 is opened and a time delay relay started;

38 ARH-I4A-119

b. SS-CAl-9 is by-passed to ensure that POV-CAl-9 is closed. (During normal operation, POV-CAl-3 is open.) With POV-CAl-9 closed and BDV-CAl-7 open, a flush to the evaporator is accomp­lished.

6. When the time delay relay has timed out, POV-CAl-55 closes, shutting off the flush water. POV-CAl-9 opens to permit the contents of the evaporator to dump to tank IO3-S.

7. Evaporator dump valves remain in the dump position until the manual switch IIS-PBl-2 "start" is pushed, resetting the control circuitry so that the evapo­rator can be Tilled and the recirculation pump started.

8. BDV-CAl-7 and POV-CAl-9 are closed, and POV-CAl-8 opens, turning on flush water between the closed BDV-CAl-7 and POV-CAl-9. During operation, water pressure between these valves prevents leakage of process solution into the dump line which could plug it.

Interlock Mumber Three

A high radiation i-eading in the 42-inch vapor line leading

to the primary condenser will automatically shut down the operation

and is designated as interlock number three. The shutdo-vm entails

the following steps:

1. RA-CAl-1 (42-lnch vapor line high radiation annunciator) is activated.

2. DOV-CAl-1 closes, shutting off feed to the evaporator.

3. Feed pump 241-S-P-102 is shut down.

4. DOV-EAl-1 closes, shutting off steam to the reboiler.

5. The reboiler chest is pressurized with 20 psig air.

39 ARH-im-119

6. The a i r to DC/-EA1-4 i s turned off, s h u t t i n g off steam t o the desuperhea te r .

I n t e r l o c k number Four

The number four i i t e r l o c k system i s designed to shut down

the v e s s e l vent exhaus te r and the evapora tor in the event the

v e s s e l vent f i l t e r s slrould f a l l o r f a i l u r e appears imminent.

There a re four monitoiLng systems tha t can i n i t i a t e t h i s s n t t -

down:

a . High r a d i a t i o n in the s tack gas a c t i v a t e s RA-AS-5 ( v e s s e l vent rxhaust s tack high r a d i a t i o n annunci ­a t o r ) .

b . Low d i f f e r e n - l a l ac ros s the number one ilEPA f i l t e r could i n d i c a t e f i l t e r breakthi-ough and a c t i v a t e s DPA-FC5-1 ( F - . - 5 , low d i f f e r e n t i a l p r e s su re annunci ­a t o r ) .

c . Low d i f f e r e n t i a l a c ro s s the number two HEPA f i l t e r s i m i l a r l y a c t i v a t e s DPA-FC5-2 ( F - C - 5 , low d i f f e r e n ­t i a l p r e s su re a n n u n c i a t o r ) .

d. High d i f f e r e n t i a l ac ros s the number one HEPA f i l t e r I n d i c a t e s the f i l t e r i s plugging o r wet. I t a c t i v a t e s DPA-FC5-IA (F-C-5, high d i f f e r e n t i a l p r e s su re a n n u n c i a t o r ) .

The shutdown e n t a i l s the fol lowing s t e p s :

1. BOV-CAl-1 c l o s e s , s h u t t i n g off feed t o the evapora to r .

2 . Feed pump 241-S-P-102 i s shut down.

3 . POV-ECl-1 opens, b leeding a i r from the evapora tor room i n t o the vent system to break the vacuum to the evapo ra to r .

4 . POV-EC2/EC3-1 c l o s e s , s h u t t i n g off the steam t o the vacuum j e t s .

40 ARH-M-119

5. DOV-EAl-1 closes to shut off steam to the re­boiler.

6. EV-EAI-3 is deenergized, turning on 20 psig air to the reboiler.

7. DOV-EAl-4 closes to shut off the steam to the desuperheater.

Interlock Humber Five

A high radiation reading on the process condensate monitor

(RE-RC3-1) will activate the following operations:

1. EV-RC3-3 is deenergized; it operates P0V-RC3-1 to divert the process condensate from the crib back to tank C-lOO,

2. The proportional sampler valve is held in the straight-through flow position, so that no more sample is collected in the sample collection tank after the condensate stream is diverted. The sample represents only that condensate which has been I'outed to the crib,

3. Process condensate pump (P-C-lOO) is shut doim.

4. RA-RC3-1 (process condensate high radiation annunciator) is activated.

Interlock Mumber Six

1. A high radiation in the steam condensate Line (monitored by RE-EAl-1) initiates number six inter­lock, which will:

a. activate RA-EAl-1 (steam condensate high radiation annunciator);

b. deenergize EV-EAl-1, shutting off steam to the reboiler;

c. position POV-EAl-2 to divert the steam con­densate from the pond to the waste storage tank 103-S, by-passing the steam condensate proportional sampler.

41 ARH-M-119

2. Should the high radiation alarm on the steam con­densate line fail to catch a breakthrough of contamination, the steam condensate proportional sampler and monitor should pick it up. A high radiation reading at the monitor (EE-RCl-l) will:

a. activate RA-RCl-1 (steam condensate, high radiation annunciator);

b. deenergize EV-EAl-1, shutting off steam to the reboiler;

c. position POV-RCl-1 to divert the steam con­densate to the waste storage tank 103-S;

d. hold the proportional sampler valve in the flow-through position so that no more sample is collected after the condensate stream is diverted. The sample represents only that condensate which has been routed to the pond.

Interlock Mumber Seven

The supernatant pumps in the bottoms tanks and the slurry

pump (P-B-2) have interlocks to prevent the pumping of waste solu­

tion into the steam and water flush lines. Limit switches are

installed on the flush valves in the supernatant system flush jum­

pers located in the valve pits. Opening any flush valve shuts

down all supernatant pumps. Pressure switches on the flush headers

in the flush pits prevent pump operation if a flush header is

pressurized.

1. The opening of any LS-241- or PS-24l-contacts in the supernatant pump controls interlock circuit leads to shutting down the supernatant pumps.

2. The opening of any PS-24l-contacts in the slurry pump control interlock circuit will:

a. activate PA-24lS/SX-l (slurry flush line high Dressure annunciator);

b. shut down the slurry pump (P-B-2).

42 ARII-M-119

Further protection is provided by monitoring the flush supply

lines for radiation at a point where the lines enter the farm.

Should all other devices fail and waste is pumped back through

the supply lines, the radiation detector Interlock shuts dovm all

supernatant pumps and the slurry pump, and activates RA-SP-1 (raw

water and steam line high radiation annunciator).

Interlocks installed on the feed pump for protecting the

water and steam flush headers are the same as for the supernatant

and slurry pumps. Pressure switch PS-241-S-102, limit switch

LS-241-S-102, and the radiation alarm relay all have contacts in

the feed pump control circuit.

Interlock Humber Eight

The evaporator-crystallizer normally operates at a negative

pressure of approximately 28 inches of Hg vacuum. Any increase in

pressure is an indication of trouble, such as foaming, deentrainer

flooding, or insufficient cooling of the vapor. An evaporator

pressure that exceeds a maximum acceptable level will:

1. activate PA-CAl-4 (vapor-liquid separator high pressure annunciator);

2. close DOV-EAl-1, shutting off steam to the re­boiler;

3. close DOV-CAl-1, shutting off the feed to the evaporator;

4. shut down the feed pump (241-S-P-102).

43 ARH-M-119

I n t e r l o c k Mumber Hine

I n t e r l o c k number nine i s i n i t i a t e d by a low weight f a c t o r

reading in any of the fol lowing t a n k s : condensate c o l l e c t i o n

(C-lOO); e l u a n t ( E - l O l ) ; ant i - foam (E-102); or decontamination

(E-104) . A low l i q u i d l e v e l in any of these tanks w i l l a u t o ­

m a t i c a l l y s top the r e s p e c t i v e pump and a g i t a t o r a s soc i a t ed with

t h a t t ank .

I n t e r l o c k Mumber Ten

The flow meter FM-CAl-3 i s located in a t h r e e - i n c h l i n e which

by-passes a smal l f r a c t i o n of the so lu t i on being recycled in the

evapora to r . The most l i k e l y causes for a decrease in the r e c i r c u ­

l a t i o n r a t e a re due t o a bu i ldup of sca le in the r e b o i l e r tubes or

a plugging of the r e c i r c u l a t i o n l i n e wi th s o l i d s . Flow r a t e s

through the by-pass l i n e t h a t a re e i t h e r h igher (due to s ca l e b u i l d ­

up in the r e b o i l e r o r s o l i d s bui ldup upstream of P -B- l ) or lower

(due to s o l i d s bu i ldup in the suc t ion s ide of P-B- l ) than the r a t e s

normally obta ined i n i t i a t e i n t e r l o c k number t e n . The i n t e r l o c k

w i l l :

1. activate either FA-CA1-3A (recirculation line by-pass high flow annunciator) or FA-CA1-3B (low flow annunciator);

2. close DOV-EAl-1, which shuts off the steam to the reboiler.

Shutting off the steam to the reboiler with both the feed and

the bottoms slurry pump continuing to run dilutes the contents of

the evaporator. Dilution should alleviate the plugging problem,

44 ARH-M-119

and the recirculation flow should return to normal. When the

recirculation rate has returned to normal, the flow alarm

switch which is tripped resets and the steam is turned back on

to the reboiler. Process parameters should be evaluated in order

to make the necessary adjustments to prevent overconcentration

from recuri-ing.

Interlock Mumber Eleven

A high radiation reading in the builaing exhaust stream

initiates the number eleven interlock, which will:

1. alai'm RA-Kl-1 (building exhaust stack high radiation annunciator);

2. shut down electrical exhaust fan (Kl-5-3);

3. prevent the backup fan (powered by a steam turbine) from starting.

The building supply fan will shut off automatically due to the

pressure Interlock,

Interlock Mumber Twelve

The liquid level in the vapor-liquid separator is monitored

with weight factor dip tubes. If the weight factor controller

fails, interlock number twelve prevents overfilling of the evapo­

rator by the following:

1. Two alarm switches are set to trip if the liquid level exceeds a preset value. If both high weight factor alarm switches l-JPAS-CAl-lB and WAS-CA1-2B trip:

a. DOV-CAl-1 closes, shutting off feed to the evaporator;

b. the feed pump (241-3-P-102) shuts off.

45 ARH-M-119

High l e v e l alarm switches VJFAS-CAl-lA and WFA3-CA1-2A are

s e t t o alarm a t a lower l i q u i d l e v e l than the i n t e r l o c k swi tches .

This a l e r t s the ope ra to r t o the problem p r i o r to the i n t e r l o c k

shutdown of the feed pump.

WAS-CAl-lB and WFAS-CA1-2B a re normally closed and a re

arranged in p a r a l l e l , making i t necessary to have both t r i p to

a c t i v a t e the i n t e r l o c k . These switches opera te from sepa ra t e d ip

legs to prevent a plug in only one a i p tube from a c t i v a t i n g the

i n t e r l o c k .

A s i m i l a r system i s employed for low l i q u i d l e v e l s in the

evapora to r . I f both low weight f a c t o r alarm switches WAS-CAl-lC

and WFAS-CA1-2C t r i p , pumps P-B- l and P-B-2 shut dowti. Th i s , in

t u r n , i n i t i a t e s the number two i n t e r l o c k c i r c u i t .

I n t e r l o c k Mumber Thi r teen

Both the r e c i r c u l a t i o n pump and the s l u r r y pump are equipped

with a water s e a l t o prevent p rocess so lu t i on from leaking out of

the system. The water p r e s su re a t the pump s e a l i s monitored and

p r e s su re switches a re s e t t o shut down the pumps i f the p res su re

drops to a value lov/er than t h a t r e q u i r e d .

Mormal raw water p r e s su re i s s u f f i c i e n t for c los ing p res su re

alarm switch PAS-CAl-3 which i n d i c a t e s t h a t t h e r e i s water p re s su re

a t the pump s e a l fo r P - B - l . Booster pump F-C-I05 must be running to

i nc rea se the water p re s su re so t h a t p r e s su re alarm switch PAS-CAl-2

46 AEH-M-119

closes, indicating that there is water pressure at the pump seal

for P-B-2.

1. A drop in the water pressure to the slurry pump seal (P-B-2) opens PAS-CAl-2, which will:

a. alarm PA-CAl-2 (purge seal to P-B-2 low pressure annunciator);

b, shut down slurry pump P-B-2.

2. Shutting down of the slurry pump results in a "LO Slurry Flow" alarm, activating the number one interlock circuit. The operator has the time it takes for the delay relay to time out to correct the problem before the automatic flush of the slurry line is initiated.

The sequence of operation for a "Lo Pressure Alarm" (PA-CAl-3)

on the water seal to the recirculation pump is identical to the

slurry pump. Interlock circuit number two is activated, rather

than interlock number one, if pressure is not reestablished before

the time delay relay times out.

47 ARH-M-119

APPMDIX

REFEREMCES

1. ffifS-9099 Procurement Specification for Evaporator Recirculation Pump; Hanford Engineering Services

2. HlAfS-9125 Construction Specifications for Evaporator F a c i l i t i e s ; Vitro Fngiueering

3. HWS-9127 Procurement Specification for Air Sample Raaiation Monitoring Systems; Vitro Engineering

4. IWS-9130 Procurement Specification for Bottom Slurry Pump; Vitro Engineering

5. HVJS-9195 Procurement Specification for 5-l/2-Ton Bridge Crane;

Vitro Engineering

6. Exchanger Specification Sheet; Scbutte & Koerting Co.

Struthers

7. 71-04-30917 CI fube Layout for Surface Condenser

3. 71-04-30917 Dll Surface Condenser

9. 71-04-30917 D12 Surface Condenser Details

10. 71-04-30917 DI3 Bundle Details for Surface Condenser

11. 71-04-30917 Dl4 Chanuel Details for Surface Condenser

Tube Layout for Reboiler

Reboiler

Evaporator Crystallizer Outline

Evaporator Details

12. 71-04-31000 C2

13. 71-04-31000 Dl

14. 71-05-10132 Fl

15. 71-07-31027 Fl

Schutte & Koertigg

16. 72-X-E-OOl-J Two-Stage Steam Jet

48 ARK-.M-119

Vitro Engineering

17. H-2-38403 Sampler Enclosure Piping

18. H-2-46327 EFD - Control and AMU Rooms

19. H-2-46330 EFD - Air Sampling

20. H-2-46331 lEFD - Sampling, Monitoring, and Diversion Diagrams

21. H-2-46339 Piping Arrangement - Evaporator Room Plans

22. H-2-46340 Piping Arrangement - Evaporator Room Sections

23. H-2-46355 Eluant Tank (TK-E-lOl) Assembly and Details

24. H-2-46357 Condensate Tank (TK-C-lOO) Assembly and Details

25. H-2-36420 Ion Exchange Column (iX-D-l) Assembly

26. H-2-46361 Vessel Vent System Arrangement

27. H-2-46365 Decontamination Tank (TK-E-104) Assembly and Details

28. H-2-4tS367 Anti-Foam Tank (TK-E-102) Assembly and Details

29. H-2-46369 Pump Room Sump Assembly and Details

30. H-2-46371 Bottoms Pump (P-B-2) Assembly

Unit Job Manual TF-VII, 242-S Evaporator, C. A. Lorenzen

ARH-l601 (unclass i f ied) , Specifications and Standards for the Operation of Radioactive Waste Tank Farms and Associated Facilities, Operations Support Engineering, August 20, 1973J Section J: Specii'lcations and Standards for the Operation

of the 242-S Evaporator-Crystallizer and Associated Waste Storage Tanks, June 30, 1975? W. R. Christensen

ACKMOWLEDGl-'MITS

The author would like to acknowledge W. R. Christensen for his valuable assistance in preparing this information manual.

h9 AEH-M-119

LIST OF FIGURES

Mumber Title

1 Process Flow Diagram

2 EFD - Pump and Evaporator Rooms

3 EFD - Condenser Room

4 EFD - Condenser Room and Ion Exchange Column

5 EFD - Instrument Area, Control and AMU Rooms

6 EFD - Instrument Area and Control Room

7 EFD - Control and Al-O Rooms

8 Vicinity Plot Plan

9 First Floor Plan

10 Second Floor Plan

11 Reboiler

12 Evaporator-Crystallizer

13 Primary Condenser

14 Tube Layout for Primary Condenser

15 Bundle Details for Primary Condenser

16 Tvro-Stage Steam Jet

17 Vessel Vent System Arrangement

18 Condensate Catch Tank

19 Ion Exchange Column

20 Mew Ion Exchange Column

50 Affl-M-119

21 Eluant Tank

22 Anti-Foam Tank

23 Decontamination Tank

24 EFD - Sampling, Monitoring, and Diversion Diagrams

25 EFD - Air Sampling System

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