Project OverviewSurplus Plutonium Disposition (SPD) Project

Savannah River SiteMarch 2021

M3-SR-21-0040, Rev. 1

UNCLASSIFIEDDOES NOT CONTAIN UNCLASSIFED

CONTROLLED NUCLEAR INFORMATIONReviewing Official: C. R. Dyer, QA Specialist, 3/16/2021

Outline

• Mission Need• Project Scope• Process Flow• Background• Roles and Responsibilities• Overview of Modifications• Nuclear Safety• Environmental, Safety and Health• Risks Management

2M3-SR-21-0040, Rev. 1

Background

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• SPD Project will comply with DOE Order 413.3B, Change 5, Program andProject Management for the Acquisition of Capital Assets and DOE-STD-1189-2016, Integration of Safety into the Design Process.

• In accordance with DOE-STD-1189-2016: The project meets the criteria for a Major Modification Safety Design Strategy (SDS) for Hazard Category (HC) -2 nuclear

facility has been completed and reviewed by DOE/NNSA Conceptual Safety Design Report has been submitted to DOE/NNSA for

review and approval

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Background

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• SPD is unique in that the mission need, project management, execution,and integration. funding reside with NNSA while responsibility for the K-Area Complex in which the Project will be installed and operated is with ofthe Department of Energy Savannah River Operations Office (DOE-SR).

• The facility has a DOE-SR approved Documented Safety Analysis (DSA) andTechnical Safety Requirements (TSR) in place.

• Accordingly, DOE-SR, as delegated by the Assistant Secretary for the Officeof Environmental Management (EM-1), has responsibility for the propermanagement of the safety basis and will continue to approve all facilitysafety basis documents, including safety design basis documentsassociated with the Project or any changes to the operational safety basis(i.e., DSA and TSR) needed to support the Project.

• DOE-SR is also the Authority Having Jurisdiction (AHJ) for fire protectionrelated issues and decisions when called for in DOE Orders, Standards,NFPA or related documents.

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Project Reporting Structure

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General Overview105-K Interior Modifications

Presentation:• West Staging Area for in-coming supplies, pre-filled blend cans, empty

CCOs/bins/waste containers, etc.

Final Storage Area:• Process Area (First Floor) - Unpackaging Room, Entry Corridor,

Glovebox Airlocks, Glovebox Rooms, and Packaging Room (CCOPackaging & TRU Waste Handling)

• Support Area (Second Floor) – Service Area, Fire Suppression Rooms 1& 2, and Glovebox HEPA & Fan Room w/ associated Airlock

Shuffler Room:• MC&A Rooms 1&2• North-East Airlock

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General Overview105-K Interior Modifications (Continued)

Water Seal:• MC&A Rooms 3&4• South-East Airlock• East Staging Area for interim storage of out-going filled CCOs

Assembly:• Material Staging/Inspection Area for incoming supplies, pre-filled blend

cans, empty CCO containers/bins/waste containers, etc.• Storage of empty and filled CCOs (single tier and double stacked)• Access stairs to Support Area / Emergency Egress Platform from

Support Area• Jib Crane/Maintenance Platform

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General Overview105-K Exterior Modifications

Exterior Slab Over South Heat Exchanger Bay:• HEPA Fan & Filter Building (HEPA Filter & Fan Rooms 1 & 2 and

Electrical Distribution Room)• Diesel Generator w/ Enclosure

Yard Area:• Vehicle access road for HEPA Filter & Fan Building and Diesel

Generator Enclosure• Exhaust Stacks (Active Confinement & Glovebox Exhaust) and

associated foundations

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Tailored Critical Decisions

• CD-0 (Mission Need) Approved September 2016 Cost Range $200M to $500M Schedule Range for CD-4 Approval 2Q FY2026 to 4Q FY2027

• Analysis of Alternatives (AoA) approved May 8, 2017• Tailoring Strategy Approved October 2019 which allows for CD-3A

Phases• CD-1 (Approve Alternative Selection and Cost Range) Approved

December 2019 Cost Range $448M to $620M Schedule Range for CD-4 Approval 2Q FY2026 to 2Q FY2028

• CD-3A, Phase 1 (Early Site Preparation) Approved January 2020 Cost $28M Forecast completion 3Q FY2021

• CD-3A, Phase 2 (Long Lead Procurements) Approved December 2020 Cost $33.7M Forecast completion 3Q FY2024

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Tailored Critical Decisions Continued

• CD-3A Phase 3, Authorize Additional Site Preparation forecast August 2021 Cost Range $50M to$60M Forecast completion 4Q FY2023

• CD-3A Phase 4, Authorize Additional Long Lead Procurements forecast 1Q, 2022 Cost Range $ 20M to $30M Forecast completion 3Q FY2024

• CD-2/3, Approve Performance Baseline/ Approve Start of Construction forecast 4Q FY2022 (subject to change) Cost Range $448M to $620M Forecast completion 2Q FY2025

• CD-4, Approve Start of Operations or Project Completion 2Q FY2026 to 2Q FY2028

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Project Scope (CD-3A Phase 1)

• Perform re-work/D&R of existing conduits and cables within the project area(Telecommunications, Fire Detection, S&S etc.)

• Cut opening in the South wall of A water seal and install door (3-hour fire rateddoor)

• Install a temporary 3-hour Fire Rated Shaft Wall at the opening (between MSAand Presentation)

• Place concrete infill in existing ventilation opening between the A water seal andA vestibule

• Install security plates over doors (Presentation Side, KAMs Corridor Side, andPresentation Side)

• Cut a 10’ x 12’ Construction access opening in South Wall of Presentation• Cut opening in West wall of A water seal from the Final Storage Area (FSA)• Cut an opening in the South wall of Presentation (leave blocks in place)• Cut two (2) new door openings at +15’ elevations (leave blocks in place)• Remove door frame, and associated gypsum wall system

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CD-3A Phase 2 Summary

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Procurement of the Following Long Lead items:• Safety Class (SC) Gloveboxes

Three (3) gloveboxes with identical specifications Glovebox Shell, Support Frame and Anchorage are Safety Class Glovebox Confinement Boundary is Safety Significant

• Safety Significant (SS) Diesel Generator w/ Enclosure• Safety Significant (SS) HEPA Filter Housings

Two (2) Glovebox Exhaust HEPA Housings Two (2) Glovebox Hood Exhaust HEPA Housings Two (2) Dilute Process Area (DPA) HEPA Housings

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CD-3A Phase 3 Summary

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• Additional concrete cuts not captured in CD-3A Phase 1: West wall of FSA into presentation area East wall of FSA into the B water seal (i.e., shuffler room) South wall of B water seal into A water seal Concrete removal within A and B water seal (Floor and Curtain wall) Concrete removal to support drainpipe work and installation of second floor footings

• Modifications of existing facility drain piping in preparation for installation of new fire suppressionsystem

• Re-work existing expansion joint in FSA Wall• Installation of second floor (Footings, structural steel and reinforced concrete)• Installation of two (2) new doors• D&R of existing commodities within the B water seal to include:

Safeguards and Security Equipment Shaft Wall Fire Suppression items Electrical items

• Installation of new concrete wall and floor slabs in water seal rooms• Removal of Door and placement of concrete in opening• Removal of existing concrete dike South of 105-K (i.e., future stack foundation location)

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CD-3A Phase 4 Summary

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• Additional long lead procurements not captured in CD-3A Phase 2: Safety Class Fire Suppression and Detection System Components HVAC Exhaust Fans and associated components Glovebox Equipment MC&A Assay Equipment Safety Class Electrical Equipment Construction Materials and Equipment needed to support the first 6

months of Post CD-3 approval field work

Note: The content of CD-3A Phase 4 is still under development.

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Environmental, Safety & Health

• NEPA Strategy completed; additional Environmental Checklistcompleted; no further action is required to complete construction andturnover to operations.

• Environmental Compliance Strategy was developed that identifiesenvironmental requirements, permits, and approvals for constructionand operation which are included in the project schedule.

• Preliminary Hazard Analysis Report (PHAR) and Facility Classificationapproved August 2019. Hazards studied include fires, explosions, loss of confinement,

radiation exposure, external events and Natural PhenomenaHazard.

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Status of Safety Basis Documents

Safety Basis Document Status

Safety Design Strategy Complete (will be updated throughout project as needed)

CSDR Complete

KAC DSA Addendum and TSRs for Site Preparation Complete

Safety Documentation For Long Lead Procurements Complete

KAC DSA Revision/ TSRs for Construction In-ProcessFinish: 3/25/2021

PDSA In-ProcessFinish: 10/21/2022

KAC DSA and TSR Revision to Incorporate SPD ScheduledStart: 1/9/2023Finish: 9/5/2024

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Risk Management

• Project utilizes risk analysis software Active Risk Manager(ARM) based on DOE Guide (G) 413.3-7A, Risk ManagementGuide.

• MR and DOE Contingency are based on detailed quantitativerisk analysis.

• Monte Carlo analysis includes both discrete risk/opportunitiesand cost and schedule uncertainty analysis.

• We review all the project risks on a monthly basis as a team.

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Top Project Risks

Risk Handling Strategy Description

Funding Delays Accept Lack of funds will increase cost and schedule.

Mitigated dose consequences challenge regulatory limits requiring additional modifications

Mitigate Preliminary accident analysis calculations are being performed early to minimize design impacts

Life Safety and building occupancy codes increase fire suppression and fire alarm requirements

Mitigate Early and continued engagement with DOE and the Authority Having Jurisdiction (AHJ) as the fire protection plan matures.

Safeguards measurement systems do not meet throughput requirements requiring additional units

Mitigate

Early and continued engagement with the Program to ensure activities required to determine uncertainty levels and the count time requirements for the Neutron Multiplicity Counters (NMC) are validated.

Engineered equipment vendors fail to perform Mitigate

Vendors are being audited and qualified early in the design process to ensure sufficient qualified vendors are available once the project is ready to award engineered equipment subcontracts.

EVMS Certification is not obtained prior to CD-2/3 delaying the project schedule

MitigateProject is requesting an early Assist Visit in summer of 2020. Corrective actions will be addressed prior to the Certification Visit.

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Safety-In-Design Project Risks

Record Type

ID Title Handling Strategy Current Risk Level Target Risk Level

Risk 7050 K-Area Safety Basis Increases Consequence Mitigate Moderate (18) Moderate (18)

Risk 6656 Changing requirements for multi-tool Mitigate Moderate (17) Moderate (12)

Risk 3543 Fire Protection system fails seismic qualifications resulting in additional modifications

Accept Moderate (16) Moderate (16)

Risk 3546 Lightning Protection requirements of current codes extended to legacy systems increases

project scope

Mitigate Moderate (16) Moderate (12)

Risk 3547 Fire System Qualification repeated due to vendor design changes and delaying delivery

Accept Moderate (12) Moderate (12)

Risk 6634 Fire Suppression in the HEPA Housing is Required Mitigate Moderate (12) Low (6)

Risk 5391 Adulterant formula increases worker dose and results in changes to project scope

Mitigate Moderate (9) Moderate (9)

Risk 5384 Results of HEPA filter soot loading calculation increases project scope

Accept Low (8) Low (8)

Risk 5379 Fire barrier design is not approved by DOE Mitigate Low (6) Low (6)

Risk 5385 Fire in emergency lights after power is de-energized

Accept Low (6) Low (6)

Risk 5394 Fire caused by security devices after primary power is de-energized

Accept Low (2) Low (2)

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