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Section 1 of 3

Document Information Document # RPP-24544 Revision iB Title DEMONSTRATION BULK VITRIFICATION SYS IQRPE/RCRA DESI6N REVIEW PACKAGE Date 03/03/2006 Originator SHUFORD DH, Originator Co. CH2M, AMEC, JEFFERS J, DMJMH+N FREDERICKSON J, LUEY J Recipient Recipient Co. References ECN-723118-R3 Keywords SUPPL TREATMENT Projects RPP Other Information S

1a. ECN 723118 R 3 CH2M HILL ENGINEERING CHANGE NOTICE

Page 1 of 2 ® DM q FM q TM 1b. Proj. ECN - - R

2. Simple Modification 3. Design Inputs - For full ECNs, record information on the ECN-1 Form (not 4. Date ® Yes q No required for Simple Modifications) 2/28/2006 5. Originator's Name, Organization, MSIN, & Phone No. 6. USQ Number 7. Related ECNs M. J. Holm, Closure Projects Engineering Support, 57-67 No. - - - R- ECN-723118, Rev 0 ECN-723118, Rev 1 N/'4 ECN-723118 Rev 2 8. Title 9. Bldg. I Facility No. 10. Equipment I Component ID 11. Approval Designator Incorporate Dried Waste Handling System Design DBVS/241-G N/A ER Information 12. Engineering Documents/Drawings to be Changed ( Incl. Sheet & Rev. Nos.) 13. Safety Designation 14. Expedited/Off-Shift ECN? RPP-24544, Revision 1a q SC q SS q GS ® N/A q Yes 0 No

15a. Work Package Number 15b. Modification Work Completed 15C. Restored to Original Status (TM) 16. Fabrication Support ECN? N/A q Yes ® No N/A N/A RespomiWe Engineer / Data Responsible Enginear / Date 17. Description of the Change ( Use ECN Continuation pages as needed) This ECN revises RPP-24544, Revision ta, "Demonstration Bulk Vitrification System IQRPE/RCRA Design Review Package" to include the Dried Waste Handling System information in Section 2.4.

Problem: The Dried Waste Handling System portion of the IQRPE/RCRA design package has been completed and requires release/configuration control.

Solution: Update RPP-24544 with RCRA design information on the Dried Waste Handling System so EPA and WDOE can review and approve.

Analysis: The original release and subsequent additions to RPP-24544 are listed below: RPP-24544, Revision 0, Released on EDT-821657 incorporated Section 2.1 Waste Receipt System RPP-24544, Revision 1,Released on ECN-723118, Revision 0, incorporated Section 2.3 Secondary Waste'Systerti RPP-24544, Revision 1a, Released on ECN-7231 18, Revision 1, incorporated Section 2.2 Waste Dryer System. EPA and WDOE comments on released portions of the document were resolved and incorporated where available.

18. Justification of the Change (Use ECN Continuation pages as needed) 19. ECN Category This update to RPP-24544 is to incorporate DBVS Dried Waste Handling System RCRA design information and was performed in accordance with the DBVS project schedule. ® Direct Revision

No USQ screeing is necessary. This document is being transmitted to the Department of Energy, Office of q Void/Cancel River Protection. A Documented Safety Analysis (DSA) will be prepared for DBVS upon completion of final design. Design changes made after publication of the DSA will require a USQ screening. ECN Type

q Supersedure q Revision

20. Distribution se Stamp Name MSIN Name MSIN

DH Shuford S7-67 MJ Sutey S7-70 - O r1 nAA FR Miera H6-03 JE Van Beek 57-67 f{pNFOReDI 1 r TH May S7-67 CA Rieck 57-67 ^^ , t W^$E larA MW Leonard 57-67 RR True R3-26 rj...^l SE Carlson 57-67 RL Brown S7-75 WE Bryan S7-67 JC Hoffman 57-67 MA Fish 57-67 ^CH2M EQRG RI-14 A-6003-563.1 (09/05) 1a. ECN 723118 R 3 CH2M HILL ENGINEERING CHANGE NOTICE

Page 2 of 2 ® DM q FM q TM 1 b. Proj. ECN R

21. Revisions Planned ( Include a brief description of the contents of each revision) ECN-723118, R4 is planned to incorporate the information for the Main Off-Gas Treatment System, Section 2.5 and be released as RPP-24544, Revision 1c.

Note: All revisions shall have the approvals of the affected org anizations as identified in block 11 "Approval Desi nator," on page 1 of this ECN. 22. Commercial Grade Item Dedication Numbers (associated with this 23. Engineering Data Transmittal Numbers ( associated with this design design change) change, e.g., new drawings, new documents) N/A N/A

24. Other Non En ineerin not in HDCS documents that need to be m odified due to this change Type of Document Document Number Update Completed On Responsible Engineer (print/sign and date) Alarm Response Procedure Operations Procedure Maintenance Procedure Type of Document Document Number Type of Document Document Number N/A

25. Field Change Notice(s) Used? NOTE: ECNs are required to record and approve all 26. Design Verification Required? FCNs issued. If the FCNs have not changed the q Yes ® No Yes ® No original design media then they are just incorporated q If Yes, Record Information on the ECN-2 Form, into the design media via an ECN. If the FCN did If Yes, as a minimum attach the one attach form(s), include a description of the interim change the original design media then the ECN will page checklist from TFC-ENG- resolution on ECN Page 1, block 17, and identify include the necessary engineering changes to the DESIGN-P-17. permanent changes. original design media. 27, Approvals Facility/Proje Signatures Date A/E Signatures Date

Resp. Engineer DH ShuforAVr Originator/DesignAgent

Resp. Manager MJ Sutey Professional Engineer

Quality Assurance Project Engineer

IS&H Engineer Quality Assurance

NS&L Engineer Safety

Environ. Engineer FR Miera 3-/-06 Designer

Engineering Checker MJ Holm 3- \-olo Environ. Engineer

Other RL Brown (Rad Con) Y to Cr Other

Other JE Van Beek (P - -' -(f Other Other MW Leonard tl . 1I. 0^ DEPARTMENT OF ENERGY / OFFICE OF RIVER PROTECTION Other Signature or a Control Number that tracks the Approval Signature

Other

Other ADDITIONAL SIGNATURES

Other

Other

A-6003-563.1 (09/05) Document Number Tank Farm Contractor (TFC) (1) RPP-24544 RECORD OF REVISION Page (2) Title Demonstration Bulk Vitrification System IQRPE/RCRA De sign Review Package

Change Control Record Authorized for Release (3) (4) Description of Change - Replace, Add, and Delete Pages Revision (5) Resp. Engr. (PrinUsi9n/date) (6) Resp. Mgr. (print/sign/date) 0 Initial release See EDT 821657 See EDT 821657

CA Direct revision - see ECN 722947, RO See ECN 722947, RO See ECN 722947, RO

1 Direct revision - see ECN 723118, RO See ECN 723118, RO See ECN 723118, RO

la Direct revision - see ECN 723118, R1 See ECN 723118, R1 See ECN 723118, R1

lb Direct revision - see ECN 723118, R3 D.H. Shuf rd ^ Z O6 M.J. u y 7j a pG l(X r(^

A-6003-835 (05/04) BEST 1VAlLABLE COPY

RPP-24544, Rev. lb

Demonstration Bulk Vitrification System IQRPE/RCRA Design Review Package

D.H. Shuford CH2M HILL Hanford Group, Inc. Richland, WA 99352 U.S. Department of Energy Contract DE-AC27-99RL14047

EDT/ECN: 72311e-R3 UC: Cost Center: Charge Code: 501907 B&R Code: Total Pages: 2446

Key Words: Design Review, Independent Qualified Registered Professional Engineer, Supplemental Treatment, Bulk Vitrification, IQRPE

Abstract: The Supplemental Treatment Test and Demonstration Project is a research, development and demonstration (RD&D) project with the goal of providing the suitability of Bulk Vitrification as an acceptable process for the treatment of tank farm Low Activity Waste. This document provides design information for the regulator's approval in accordance with the requirements of the RD&D permit issued for the project.

TRADEMARK DISCLAIMER. 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 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.

M A R nnS ^^^ NANFORD ST^ RELEA86 4 ^49

Release Approval Date Release Stamp

Approved For Public Release

A-6002-767 (03/01) BEST A" COPY RPP-24544 Revisicut 1 b

Demonstration Bulk Vitrification System IQRPE/ RCRA Design Review Package

Prepared for the U.S. Department of Energy Assistant Secretary for Environmental Management Contractor for the U.S. Department of Energy Office of River Protection under Contract DE-AC27-99RL74047 CH2MHILL Hanford Group, Inc. P.O. Box 1500 Richland, Washington

BEST AYAM COPY RPP-24544 Revision 1 b

Demonstration Bulk Vitrification System IQRPE/ RCRA Design Review Package

D.H. Shuford J. Jeffers J. Frederickson CH2M HILL Hanford Group, Inc. AMEC Earth and Environmental J. Luey DMJM Technology

Date Published March 2006 Prepared for the U.S. Department of Energy Assistant Secretary for Environmental Management

Contractor for the U.S. Department of Energy Office of River Protection under Contract DE-AC27-99RL14047 CH2MHILL Hanford C'iroup, Inc. P.O. Box 1500 Richland, Washington

Release Approval Date RPP-24544 Revision 1 b

TRADEMARK DISCLAIMER 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 or its contractors or subcaWactors.

This report has been reproduced from the best available copy.

mmIa m the tma.d swo or^m® RPP-24544 lb

EXECUTIVE SUMMARY

This document provides design information for the Demonstration Bulk Vitrification System Dried Waste Handling System as well as an overview of the system. This information is provided in accordance with the requirements of Permit No. WA 7890008967, "PERMIT FOR DANGEROUS AND OR MIXED WASTE RESEARCH, DEVELOPMENT, AND DEMONSTRATION."

Specific design information is provided in this report for Dried Waste Handling System, with details for installation and the Demonstration Bulk Vitrification System site to follow in a separate installation package. Specific design information discussed in the report is presented in the following areas:

• System description,

• System location,

• Calculations,

• System sketches,

• Design codes and standards,

• Waste assessment,

• Controls,

• Secondary containment and leak detection,

• Corrosion assessment,

• Inspection schedule, and

• Installation assessment.

ES-I RPP-245441b

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ES-2 RPP-245441b

CONTENTS

1.0 I'tTRODUCTION ...... 1-1

2.0 SYSTEM ASSESSMENTS ...... ?-1 2.2 WASTE DRYER SYSTEM ...... _...... 2-13 2.3 SECONDARY WASTE SYSTEYI...... 2-29 2.4 DRIED WASTE HANDLING SYSTEM ...... 2-d 1 2.4.1 System Description ...... 2-41 2.4.2 System Location ...... 2-42 2.4.3 Calculations ...... 2-43 2.4.4 Dried Waste Handling System Sketches ...... 2-43 2.4.5 Design Codes and Standards ...... 2-43 2.4.6 Waste Assessment ...... 2-44 2.4.7 Controls ...... 2-44 2.4.8 Secondary Containment and Leak Detection ...... 2-46 2.4.9 Corrosion Assessment ...... 2-47 2.4.10 Inspection Schedule ...... 2-47 2.4.11 Installation Assessment ...... 2-48 2. MA l,, OFF-GAS T1tLA-1'Mt NT Sl'S'11::M...... )-51 3.6 lU-C"C?NJAINE.R V1TR11=1CA 1lOti SYS 1 f3:Vl ...... _._.2-51

3.0 REFERENCES ...... 3-1

i RPP-24544 lb

APPENDICES

A Demonstration Bulk Vitrification System Calculations Al Waste Receipt System ...... Al-1 A2 Waste Dryer System ...... A2-1 A3 Secondary Waste System ...... A3-1. A4 Dried Waste Handling System ...... A4-1 A5 Main Off-GasTreatment Svstem ...... A5-1 A6 In-Container Vitrilication System ...... A6-1

B Demonstration Bulk Vitrification System Site Maps...... B-i

C Demonstration Bulk Vitrification System Drawings and Sketches ...... C-i Cl. Waste Receipt System ...... Cl - I C2 Waste Dryer System ...... _ C2-1 C'3 Secondary Waste Sysi:em ...... C3-I C4 Dried Waste Handling System ...... :...... C4-1 ('5 Main Off-Gas Treatment Svstem ...... C;-l C6 In-Con.tainer Vitriiicat.ion 5vsterrt...... _...... C'6-1

D Demonstration Bulk Vitrification System Piping and Instrumentation Diagrams...... D-i ^

1)1 Waste Receipt System ...... Dl-1 D2 Waste Dryer Svstc.m ...... _... D2-1 t)3 SeCOIIClar1` Wayte SvSteIl1 ...... I)3-t D4 Dried Waste Handling System ...... D4-1 D5 Nviain Of1-Gas 1'reatment System ...... D5-1 D6 In, Container Vitrifrcation System ...... D6-1 E Demonstration Bulk Vitrification System Process Flow Diagrams ...... E-1

F 1)Ci71Un5t7alion Bulk Vitl7tiC8tloII `..yme1T1 `e-f(ly Waste Sa7111lai^t (:h29r£ti.terlStiGS...... F-1

G Demonstration Bulk Vitrification System Technical Specifications ...... G-i

Cl %kG1ste TieCel}1t 54`StC ll ...... _...... l^t.-^ (,z2 Waste t}i'Yil :'+A'>CCm ...... ,...(12 -1 Ci3 5econchjr - A'4'a^te Ststc:m..._. - ...... _...... ------63-1 G4 Dried Waste Handling System ...... G4-1 G5 m,xtrt i)f'f(it14 1 CLatmCr9i SYEtL'tU...... _. .... , ...... (JK-7 G6 4`t3 CoWall3tr ...... _.....

11 RPP-24544 lb

H Demonstration Bulk Vitrification System Miscellaneous Supporting Data ...... H-i 1-1 1 Waste Receipt System ...... H 1 1 H2 Waste Drver Svstem ...... H2-I H3 Secondary Waste System ...... H3-1 H4 Dried Waste Handling System ...... H4-1 H5 Main Off-Gas'rreatment System ...... _...... H5-1 HXi In-Container Vitrification Svstem ...... 146-1

LIST OF FIGURES

1-1. Bulk'Vitrification LJnit Opcration Snterfaces for th0Main Process `,ystems ...... 1-4

LIST OF TABLES

(-I. Smnniar^,^ of Current[v Planned Fu11-ti^^^le 2e^t^ in the Demcnnstration 13ul,k Vitrification Svsteit3...... 1-6

2-1 Desi^^n d`tles and Stntdard;. for tt1C R ,4tc p.e rit7t ;=at tz^ ...... ?-6

2-2. C3esieJt Codes and, Stu!)dards for the Wactc i)n c t w,tc;n ...... 2-t 6

'-3 Salected 13 a4ta Drvtr Svstem 1ntc:rEoc:(a...... - _... . ?'

2-4. D^i=an (;orle-e and Staudards for the 4ccori&r5 Lt a^re Svsmu ...... 2-;3

2-5. Seiected SecondarvlVastcSrstern Ititerlocks ...... __-...... _ ...... 2-35

2-6. Design Codes and Standards for the Dried Waste Handling System ...... 2-44

2-7. Dried Waste Handling System Interlocks ...... 2-46

iii RPP-24544 lb

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iv RPP-24544 lb

LIST OF TERMS

Editor's Note: The List of Terms and Trademarks include callouts from previous packages.

AMEC AMEC Earth and Environmental, Inc. AWTE ancillary waste transfer enclosure DBVS Demonstration Bulk Vitrification System DCRS Dryer and Condensate Recovery System Ecology Washington State Department of Ecology EPDM ethylene propylene diene monomer ETF Effluent Treatment Facility HEGA high-efficiency gas adsorber HEPA high-efficiency particulate air HIHTL hose-in-hose transfer line ICVTM In-Container VitrificationTM IDF Integrated Disposal Facility ILAW immobilized low-activity waste IQRPE Independent Qualified Registered Professional Engineer ISO International Organization for Standardization LAW low-activity waste MCS Monitoring and Control System OGTS Main Off-Gas Treatment System P&ID piping and instrumentation diagram PFD process flow diagram RD&D Research, Development, and Demonstration S-109 WRS Single-shell Tank 241-S-109 Waste Retrieval System SCR selective catalytic reduction SST Single-shell Tank

v RPP-24544 lb

TRADEMARKS

GeoMelt Registered trademark of Geosafe Corporation. ICV Trademark of AMEC, Inc. MathCad Registered trademark of Mathsoft, Inc. Megger Trademark of Evershed & Vignoles Ltd. Corporation. National Electrical Code Registered trademark of the National Fire Protection Association. NEMA Registered trademark of the National Electrical Manufacturers Association. STAAD Registered trademark of Research Engineers, Inc. Thermeez Registered trademark of Barry D. Reznik. Windows Registered trademark of the Microsoft Corporation.

vi RPP-24544 lb

2.4 DRIED WASTE HANDLING SYSTEM

The Dried Waste Handling System pneumatically conveys dried waste from the Waste Dryer System to the ICV System. The dried waste can be transferred at up to 16,0001b/h. The system uses as little air as required to keep the transfer lines from acquiring buildup or plugging. The system will be used intermittently to transfer the dryer contents to the ICV box, approximately three times a day.

2.4.1 System Description

The components of the Dried Waste Handling System include the Dried Waste Inlet Skid (interfaces with the Waste Dryer System at the discharge flange on the Dryer and Condensate Recovery Skid), the Dried Waste Transfer Skid (provides motive force for material conveyance), the AWTE with associated airlocks and transfer chutes, and the melt area support structure. The AWTE and chute interface with the ICV box lid represent the boundary with the ICV System.

2.4.1.1 Dried Waste Transfer System (Specification 145579-D-SP-032). The waste is to be lifted 28 ft from the dryer discharge to the top of the AWTE. The dryer interface is 12 ft above the ground facing down. The inlet port on the AWTE is 29 ft above the ground facing up (see interface Sketch DBVS-SK-M107, Sheets I through 3, in Appendix C4). While transferring, the waste transfer system will cycle between the two receivers above the AWTE. Dried waste is fed by gravity from the rotary valves into the ICV System. The waste receiver and filter housings are vented using a vacuum blower that draws through sintered metal filters and HEPA filters and then discharges to the OGTS.

During the transfer of dried waste, the interconnecting piping between the discharge of the Waste Dryer System and the waste receiver and filter housings is maintained at a vacuum relative to atmosphere. The gravity-fed line to the ICV System is also maintained at a slight negative pressure relative to atmosphere by the OGTS connection to the AWTE and ICV box plenum space. These conditions maintain both solids and vapors in the piping and transfer equipment with vapors being vented to the OGTS.

2.4.1.2 Ancillary Waste Transfer Enclosure (Specification 145579-D-SP-017). The AWTE provides a contained environment for the connection and disconnection of the dried waste feed chutes, the top-off soil chutes, the ICV box ventilation connection, electrodes, and the ICV off- gas connection.

With the ICV box correctly positioned in the melt station, the interfacing chutes and piping are lowered onto the box lid by a pair of pneumatic actuators and locked in place. Except for the electrodes, each chute and piping from the AWTE has a compressible seal around it that creates an individual seal with the box lid. When lowered onto the box lid, the weight compresses the seals against sealing plates located at each port. Covers on the bottom of the AWTE are opened to allow access to the box lid for removal of the port flanges in preparation for connecting the feed chutes. Each port in the ICV box lid also has a seal, and when the chutes are extended into the box lid a flange on the chute compresses the seal in the port. This effectively provides

2-41 RPP-245441b double containment during the transfer of dried waste into the ICV box. The same system is applied to the ventilation and level indicator openings. All connections to the box lid are locked in place to prevent accidental retraction of the chutes for any reason during the melt process.

The AWTE is vented to the OGTS to maintain a negative pressure inside the AWTE. The pressure inside the ICV box is maintained lower than the pressure inside the AWTE and atmospheric pressure, thus ensuring no leakage from the ICV box.

The dried waste feed chutes interface with the Dried Waste Transfer System at the discharge flange of the rotary feeders, located below the vacuum receiver units in the melt area enclosure. The top-off soil feed chutes interface with the process additive handling system at the discharge flange of the top-off soil impingement tanks in the melt area enclosure. These chutes interface with the AWTE and continue through the AWTE to their respective interface ports on the ICV box lid. The materials are gravity-fed from the discharge flange of the rotary feeders, down the feed chutes, and into the dual isolation airlock system (see Specification 145579-D-SP-018 in Appendix G4). From the airlock, the material is discharged in batches down the chute and into the ICV box. Each chute has a telescopic section located inside the AWTE to allow extension into and retraction from the ICV box lid.

The five discharge chutes within the AWTE interface/mate with discharge chutes attached to the ICV box lid. The chutes on the lid are raised to connect with the AWTE discharge chutes and use a gasket for sealing. An environmental barrier will be used to provide a connection between the AWTE floor and the ICV box for each ICV box connection. The environmental barrier protects the workers, mitigates the spread of contamination, and seals the floor penetrations to the ICV box. The ICV box ventilation inlet and ventilation piping interface/mate with the ICV box lid via piping assembles that are raised to connect with the ventilation piping within the AWTE.

2.4.1.3 Melt Area Structure. The dried waste transfer skid, AWTE, material feed chutes, and process additives handling system equipment are supported by the melt area structure. The melt area structure general arrangement is shown on Drawings F-145579-00-D-0041 and -0051 in Appendix C4. Drawings for the melt area structure are contained in Appendix C4 (see Drawings F-145579-00-B-0001 through -0007, and -0010 through -0012).

2.4.2 System Location

The Dried Waste Handling System is located just south of the ICV Box Storage Area. Piping between the Dried Waste Inlet Skid and the Dried Waste Transfer Skid will be mounted to the melt area structure for its vertical runs and be supported by pipe supports for its horizontal run. The Dried Waste Inlet Skid is located beneath the waste dryer on Foundation Pad #2 (may be anchored to foundation pad if required). The Dried Waste Transfer Skid and AWTE (with associated components) will be mounted to the melt area structure.

2-42 RPP-245441b

2.4.3 Calculations

The Dried Waste Handling System equipment and structures will be analyzed and designed in accordance with UBC (1997) and ASCE 7-98. The calculations will demonstrate that equipment and the structure will withstand applied loads without loss of integrity or release of radioactive/hazardous material. They will also show that the skids will not tip over nor slide. The structural analysis requirements are identified in the specifications (Appendix G4).

Components of the Dried Waste Handling System will be supported by the Melt Area Support Structure. The analysis of the structure to support the equipment loads and meet site requirements is contained in Calculation 145579-B-CA-011 (see Appendix A4).

Mechanical calculations performed for the piping system will be prepared in accordance with piping code requirements in ASME B31.3. Calculations will include the following areas as applicable:

• Pipe wall thickness calculations for pressure;

• Stress calculations for sustained loads because of pressure, dead load, and any other sustained loads;

• Stress calculations for displacement stresses, such as thermal loads; and

• Stress calculations for occasional load such as pressure, dead weight, other sustained loads, and earthquake loads.

Mechanical calculations will also account for compatibility of the selected material components with the waste material to be handled, and assess if an allowance is required for corrosion, or other wear (such as erosion), in the design of the system. Additional calculations that may be performed, if applicable for the assembled system, include: vacuum pump sizing, valve actuator sizing, and wear allowances. An estimate of the heat load to the AWTE from the ICV box lid and components exposed to the interior of the ICV box is provided in Calculation 145579-D-CA-007 (see Appendix A).

2.4.4 Dried Waste Handling System Sketches

The general arrangement of the system relative to the waste dryer and melt area structures is depicted in Drawing DBVS-SK-M107, Sheets 1 through 3 (see Appendix C4). The melt area structure general arrangement, with AWTE and other equipment, is shown on general arrangement Drawings F-145579-00-D-0041 and -0051 in Appendix C4.

2.4.5 Design Codes and Standards

The design codes and standards that apply to the Dried Waste Handling System are identified in Table 2-6. Applicable and relevant portions of the design codes and standards are flowed down

2-43 RPP-24544 1 b into the specifications, drawings and calculations. See Section 3.0 for complete reference information.

Table 2-6. Design Codes and Standards for the Dried Waste Handling System.

10 CFR 830 ASTM A 269 29 CFR 1910 ASTM A 312/A 312M 40 CFR 264 ASTM A 351/A 351M-03 47 ('FR 15 ASrM A 500 AGS-G00I-1998 ASTM A 569 AISC (Allowable Stress Design) ASTM B 187/B 187M-03 AISC (load and Resistance Factor Design) AWS D1.1/DI.IM ANSUAWS DI.3 AWS D1.6 ANSI C63.16 AWS QC-I ANSUIESNA RP-7 DOE/RI. 92-36 ANSEISA-82.02.01 I INF-2962 AN S I/I S A-82_02.02 HNF-SD-GN-ER-50I ANSI Y 14.1 IEC 6 1 000-4-2 ANSI Y 14SM IEEE Sid C3790.2 ASCI-: 4-98 IEEE ('62.41 _ 1 ASCF- 7-98 IEEE C62.41.2 ASIIRAE Fundamen(als I landbook IFFF Std 142 ASME B&PV ('ode NEMA MG-1 Section IX Nll'A 70 ASM E B30.20 TFC-CNG-STD-06 ASME B31.3 UBC, 1997 ASMENQA- I, 1994 UI:Iisted ASNr SNr-I'C-I A UI. 508A ASTM A 36/A 36M UL 840 ASTM A I08 WAC 173-303-640

2.4.6 Waste Assessment

The Dried Waste I landling System is designed to pneumatically convey dried waste material from the Waste Dryer Systcm to the ICV System. Physical properties of the material to be convcycd are contained in the specifications (scc Appendix (4). Because this is a dry system with little potential to introduce moisture into the system, the specifications are mainly focused on the physical characteristics rather than the chemical properties oflhe dried waste material.

Ihe maximum estimated mishielded contact radiation dose is 10,000 R for dried waste- contacting components, and 1,000 R for nonwaste-contacting componcnts, basai on a five-year deSlgn life.

2.4.7 Controls

Itcforence to specitic instrumentation labels are provided in the ttillowing sections to assist the rcadcr; however, it should be noted that these "currently assigned identilication numhers" may

2-44 RPP-24544 lb change as detailed fabrication information is received from the suppliers of equipment. Loop diagrams are provided in Appendix C4 for those instruments discussed.

2.4.7.1 Control of Dry Waste Feed to the ICV System. The criteria for initiating dried waste flow from the waste dryer were discussed in Section 2.2.7.5. Once initiated, dried waste is pneumatically conveyed from the dryer to one of the waste receiver units. Flow is metered into the receiver units using the Waste Receiver Rotary Feeder 33-D85-095 (see Drawing F- 145579- 33-A-01 06 in Appendix D4). As material enters a receiver unit, solids and gases are separated with the solids collecting in the receiver unit and the gases vented through sintered metal filters that are integral to the receiver units (see 33-NO2-101 and 33-NO2-102). Discharge from the receiver units is controlled by rotary airlocks (see 33-D85-090 and 33-D85-091). Flow into the ICV System is also controlled by sequenced, remotely operated valves (see 34-YV-009, 34-YV-010, 34-YV-019, and 34-YV-020 on Drawing F-145579-34-A-0101 in Appendix D4). Specific criteria for the addition of material to the ICV box will be developed as part of firll-scale testing and will be influenced by how material spreads inside the box and how material is incorporated into the melt.

2.4.7.2 Pressure Control. The Dried Waste Handling System piping system is designed to operate at a vacuum relative to atmosphere. For the Dried Waste Transfer System, differential pressure is measured across the sintered metal filters (see 33-PDIT-417 and 33-PDIT-418 on Drawing F-145579-33-A-0106 in Appendix D4) to determine when the sintered metal filters should be pulsed with compressed air to "clean" material back into the receiver unit. Specific set-points will be based on manufacturer recommendations and the results from full-scale integration testing. Differential pressure is also measured across the HEPA filters leading to the blower unit (see 33-PDIT-419 and 33-PDIT-424). The purpose of these filters is to minimize the contamination potential for the OGTS piping. Once a first-stage filter becomes loaded, it can be valved out of service to allow for change-out of the filter.

The AWTE is vented to the OGTS and maintained at a negative pressure relative to atmosphere. Flow is controlled by 34-HV-111 and 34-HV-113 (see Drawing F-145579-34-A-0101 in Appendix D4). Flow rate is monitored using 34-FE-114. Inlet air is provided through a filtered inlet, with the differential pressure across the inlet filter monitored by 34-PDIT-112. Pressures and flows are monitored and controlled such that the ICV box is maintained at a greater vacuum than the AWTE, thus containing gases generated by the process to the ICV box. The relative pressure between the AWTE and ICV box is measured by 34-PDIT-115.

2.4.7.3 Interlock Philosophy. Two types of interlocks are shown on the P&ID drawings associated with the Dried Waste Handling System:

Safety Hardwired Interlocks consist of those interlocks that are necessary to prevent or mitigate a hazard that, if not addressed, could lead to a safety event. This event could be a release of radiological or hazardous gases.

2. Control System (safety related) Interlocks are associated with safety interlocks, but do not meet the threshold requiring a "credited" safety interlock. Automatic and immediate

2-45 RPP-24544 lb

action will occur using the non-safety control system. Credited refers to items specifically listed as required in the Documented Safety Analysis (DSA).

As shown in Table 2-7, interlocks are grouped based on the initiating signal type and are uniquely identified by a number. Typically, the interlock number is based on the initiator of the interlock, examples include pressure or flow. A description is located on both the source sheet as well as each designation sheet on the P&IDs.

Table 2-7. Dried W aste Handling System Interlocks.

s: n

Low ICVT"' Inlet Air Flow (safety) from 16 Stop all waste transfer by Drawing F-145579-35-A-0100 (hardwired) • De-energizes (shuts) Dried Waste Dryer Discharge Valve 33-YV-013. (See Drawing F-145579-33-A-0100) • De-energizes (shuts) Dried Waste Airlock Valves 34-YV-009, 34-YV-010, 34-YV-019, and 34-YV-020. (See Drawing F-145579-34-A-0101) Low ICV Inlet Air Flow (non-safety) from 17 Stops the Waste Feed Vacuum Blower Drawing F-145579-35-A-0100 (control system) 33-D61-094. ( See Drawing F- 145579-33-A-0106) Only one valve can be operated ( open) at a 19 Prevents both airlock valves in a line from time from Drawing F-145579-34-A-0101 (hardwired) being opened at the same time. To open either valve, the paired valve must be closed. • 34-YV-009 and 34-YV-O10 • 34-YV-019 and 34-YV-020. ICV = In-Container Vitrification (Trademark of AMEC, Inc.) MCS = Monitoring and Control System.

Note that normal MCS control sequences, or normal protection of equipment, are not shown to reduce drawing clutter and to focus on these significant interlocks. Normal control functions are presented to the MCS operator on the operating system computer screens.

2.4.8 Secondary Containment and Leak Detection

Containment for the Dried Waste Handling System is accomplished through operation of the system at a vacuum relative to atmosphere, use of pressure tested components, and use of secondary containment for the interconnecting piping between the dried waste inlet skid and the dried waste transfer skid. Secondary containment will also be placed under the waste dryer at the point of waste discharge into the dried waste inlet skid. Liquids are not present in the system, thus a leak detection system for liquids is not provided.

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The dried waste feed chutes provide primary containment for the dried waste as it is delivered to the ICV box. The AWTE provides secondary containment at the process connections with the ICV box. The melt area enclosure provides additional containment around the AWTE and dried waste feed chutes.

Periodic visual inspection of the Dried Waste Handling System will be conducted to look for signs dried waste leaks around the melt and dryer area equipment and to inspect the general condition of the containment system. In summary, the steps that will be taken in the area of leak detection for the Dried Waste Handling System are:

• System will be checked before operation (visual inspection for equipment and piping alignment along with vendor and construction testing for pressure and tightness).

• Pinhole leaks in primary confinement barrier will result in a preferred path into the barrier because the system is operated at a vacuum relative to atmosphere. Sections that have secondary confinement have a pressure gauge on the secondary barrier to identify presence of a breech in the primary barrier.

• Periodic visual inspections will be performed before, and after, a melt campaign.

• Catastrophic failure is not unique to the Dried Waste Handling System and will be observed in a number of ways (e.g., Dried Waste Transfer System alanns will be set-off when not in normal operating range, alarms for other systems will be set- off when not in normal operating range, and locations such as the Waste Dryer and ICV Box are equipped with cameras, linked to the Control Trailer, which will show conditions in two of the processing units).

2.4.9 Corrosion Assessment

An independent corrosion expert has reviewed the specifications and data sheets associated with the Dried Waste Handling System. For the Dried Waste Transfer System (Specification 145579- D-SP-032), no specific concerns were noted (the assessment is provided in Appendix H4). Erosion is a required element to be addressed by the provider of the Dried Waste Transfer System (discussed as a wear allowance in Section 3.3.11.2 specification 145579-D-SP-032 in Appendix G4). There is a concern for scaling of carbon steel in air for the AWTE due to the projected temperatures (Specification 145579-D-SP-017). The effect of erosion in the chutes is a potential concern that requires evaluation, once velocities and mass loadings are determined.

2.4.10 Inspection Schedule

Inspection of the Dried Waste Handling System components will be performed at the applicable supplier's facility to ensure they comply with the design requirements. Additionally, before placing the system into service, the Dried Waste Handling System will be inspected by a

2-47 RPP-24544 lb qualified, independent installation inspector or an IQRPE for structural damage and for proper installation. This individual is responsible for certifying to Ecology that the Dried Waste Handling System was properly installed. The inspection will include the following:

. Evaluation of welds to verify no cracking or lack of fusion;

• Confirmation that no punctures, scrapes of protective coatings, cracks, corrosion, or other structure damage are present;

• Performance of tank tightness test to verify no leaks are present and that pressure or vacuum did not change beyond specifications over the test period;

• Verification of the protection of ancillary equipment against physical damage and stress; and

• Installation inspection that conforms to consensus-recognized standards including the documentation of findings and corrective actions documented in a post- inspection report.

The need for an annual inspection will be determined by the Owner/Operator in accordance with Permit condition IV.A.8.d.i.

2.4.11 Installation Assessment

Sketch DBVS-SK-M107 (Sheets I through 3), and Drawings F-145579-00-D-0041 and -0051 (Appendix C4) illustrate the projected completed assembly of the installed equipment at the DBVS site. Refinement of the drawings and development of interface and installation details will be performed as detailed drawings and installation instructions from equipment suppliers are received. The modular nature of the Dried Waste Handling System will facilitate installation of the system through the minimization of the number of pieces of equipment that require placement and number of field connections. Installation of the Dried Waste Transfer System is anticipated as being installed after the waste dryer support structure and melt area support structure are assembled and major pieces of equipment (such as the DCRS skid and the AWTE) are in place. Once these other pieces of equipment are in place, the Dried Waste Transfer System can be installed and the pipe runs connected to available places on the support structure.

An assessment of the installation of the Dried Waste Handling System will be performed during the actual installation on site and will include an independent inspection of the following activities by an IQRPE or a Qualified Independent Inspector:

Visual inspection and pressure testing of connected piping systems;

Placement of anchor bolts and connection to equipment;

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Placement of the shop-fabricated systems;

Installation of ancillary equipment and connection to facility systems; and

Tightness testing of the assembled system before placement into service.

Upon completion of the final installation, an inspection report documenting the results of the tank system installation will be prepared by the IQRPE. The inspection results will be documented in the report and included in the Operating Record. This record will be accessible at the DBVS site and will contain:

An as-built site plan;

2. An as-built drawing set of the installed Dried Waste Handling System;

3. Inspection notes, photographs, and any other material used to document inspection activities;

4. Documentation of any defects discovered;

Documentation of tightness testing results;

6. A signed and dated statement certifying the corrosion protection system (if installed); and

7. A statement signed by the IQRPE certifying the proper installation of the tank system.

The assembled system will undergo testing as a subsystem and as part of the integrated complete DBVS facility. Subsystem testing that may be performed includes vacuum blower operation and performance of instrumentation. Complete DBVS facility integrated performance testing are projected to involve the use noncontaminated, nonregulated test materials for functional testing of the assembled system.

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3.0 REFERENCES

Editor's Note: The References include citations from previous packages.

10 CFR 830, "Nuclear Safety Management," Code ofFederal Regulations, as amended.

29 CFR 1910, "Occupational Safety and Health Standards," Code ofFederal Regulations, as amended.

40 CFR 264, "Standards for Owners and Operators of Hazardous Waste Treatment, Storage, and Disposal Facilities," Subpart J, Code ofFederal Regulations, as amended.

47 CFR 15, "Radio Frequency Devices," Code ofFederal Regulations, as amended.

AATCC Test Method 27, Water Resistance: Hydrostatic. Pressure Test, American Association of Textile Chemists and Colorists, Research Triangle Park, North Carolina.

ACI 318-02, Building Code Requirements for Structural Concrete (ACI 318-02) and Commentary (A CI 318R-02), American Concrete Institution, Farmington Hills, Michigan.

AGS-G001-1998, Guidelinefor Gloveboxes, American Glovebox Society, Santa Rosa, California.

AISC, Manual ofSteel Construction-Allowable Stress Design, Ninth Edition, American Institute of Steel Construction, Chicago, Illinois.

AISC, Manual ofSteel Construction-Load and Resistance Factor Design, Third Edition, American Institute of Steel Construction, Chicago, Illinois.

ANSI C63.16, American National Standard Guidefor Electrostatic Discharge Test Methodologies and Criteria for Electronic Equipment, American National Standards Institute, Washington, D.C.

ANSI FCI 70-2, Control Valve Seat Leakage, Fluid Controls Institute, Inc., Cleveland, Ohio.

ANSI Y14.1, Drawing Sheet Size and Format, American National Standards Institute, Inc., New York, New York.

ANSI Y14.5M, Dimensioning and Tolerancing, American National Standards Institute, New York, New York.

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ANSUASME 131.20.1, Pipe Threads, General Purpose (Inch), American Societyof Mechanical Engineers, New York, New York. AATCC Test Method 27, Water Resistance: Hydrostatic Pressure Test, American Association of Textile Chemists and Colorists, Research Triangle Park, North Carolina.

ANSI/AWWA D100, A WWA Standardfor Welded Steel Tanks for Water Storage, American Water Works Association, Denver, Colorado.

ANSI/AWS D1.3-98, Structural Welding Code-Sheet Steel, American Welding Society, Miami, Florida.

ANSI/HI 3.1-3.5, American National Standardfor Rotary Pumps for Nomenclature, Definitions, Applications and Operation, Hydraulic Institute, Parsippany, New Jersey.

ANSI/HI 3.6, American National Standardfor Rotary Pump Tests, Hydraulic Institute, Parsippany, New Jersey.

ANSI/IESNA RP-7, Lighting Industrial Facilities, Illuminating Engineering Society of North America, New York, New York.

ANSUISA-82.02.01-1999 (IEC 61010-1 Mod), American National Standardfor Safety Standard for Electrical and Electronic Test, Measuring, Controlling, and Related Equipment- General Requirements, The Instrumentation, Systems, and Automation Society, Research Triangle Park, North Carolina.

ANSI/ISA-82.02.02-1996 (IEC 61010-2-031), American National Standardfor Safety Requirements for Electrical Equipnient for Measurement, Control, and Laboratory Use, The Instrumentation, Systems, and Automation Society, Research Triangle Park, North Carolina.

API Standard 620, Design and Construction ofLarge, Welded, Low-Pressure Storage Tank, American Petroleum Institute, Washington, D.C.

ASCE 4-98, Seismic Analysis ofSafety-Related Nuclear Structures, American Society of Civil Engineers, Reston, Virginia.

ASCE 7-98, Minimum Design Loads for Buildings and Other Structures, American Society of Civil Engineers, Reston, Virginia.

ASHRAE Fundamentals Handbook, 2001 ASHRAE Handbook -- Fundamentals, American Society of Heating, Refrigerating, and Air Conditioning Engineers, Atlanta, Georgia.

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ASME B&PV Code, ASME Boiler and Pressure Vessel Code, American Society of Mechanical Engineers, New York, New York.

Section I, "Power Boilers"

Section VIII, "Rules for Construction of Pressure Vessels"

Section IX, "Welding and Brazing Qualifications"

ASME B 16.5, Pipe Flanges and Flanged Fittings, American Society of Mechanical Engineers, New York, New York.

ASME B 16.9, Factory-Made Wrought Steel Buttwelding Fittings, American Society of Mechanical Engineers, New York, New York.

ASME B16.1 1, Forged Fittings, Socket Welding and Threaded, American Society of Mechanical Engineers, New York, New York.

ASME B 18.2.1, Square and Hex Bolts and Screws Inch Series, American Society of Mechanical Engineers, New York, New York.

ASME B18.2.2, Square and Hex Nuts, American Society of Mechanical Engineers, New York, New York.

ASME B30.20, Below-the-Hook Lifting Devices, American Society of Mechanical Engineers, New York, New York.

ASME B31.3, Process Piping, American Society of Mechanical Engineers, New York, New York.

ASME NQA- 1, 1994, Quality Assurance Program Requirements for Nuclear Facilities, American Society of Mechanical Engineers, New York, New York.

ASME PCC-1, Guidelines for Pressure Boundary Bolted Flange Joint Assembly, American Society of Mechanical Engineers, New York, New York.

ASNT SNT-TC-IA, Recommended Practice, American Society of Nondestructive Testing, Columbus, Ohio.

ASTM A 36/A 36M, Standard Specification for Carbon Structural Steel, American Society of Testing and Materials, New York, New York.

ASTM A 53/A 53M, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless, American Society of Testing and Materials, New York, New York.

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ASTM A 105/A 105M, Standard Specifcation for Carbon Steel Forgingsfor Piping Applications, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 106, Standard Specifcation for Carbon Steel Forgings for Piping Applications, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 108, Standard Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 182/A 182M, Standard Specifcationfor Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Partsfor High-Temperature Service, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 193/A 193M, Standard Specif:cation forAlloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 194/A 194M, Standard Specifcation for Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service, or Both, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 234/A 234M, Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steelfor Moderate and High Temperature Service, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 240/A 240M, Standard Specifzcation for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels andfor General Applications, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 269, Standard Specifcation for Seamless and Welded Austenitic Stainless Steel Tubing for General Service, American Society of Testing and Materials, New York, New York.

ASTM A 276, Standard Specifzcation for Stainless Steel Bars and Shapes, American Society of Testing and Materials, New York, New York.

ASTM A 307, Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 312/A 312M, Standard Specif:cation for Seamless and Welded Austenitic Stainless Steel Pipes, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

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ASTM A 325, Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 351/A 351M-03, Standard Specifcation for Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-Containing Parts, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 354, Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and other Externally Threaded Fasteners, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 403/A 403M, Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 480/A 480M, Standard Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 500, Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 563a, Standard Specifcation for Carbon and Alloy Steel Nuts, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM A 569, Standard Specification for Steel, Carbon (0.15 Maximum, Percent), Hot-Rolled Sheet and Strip Commercial, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM B 187/B 187M-03, Standard Specification for Copper, Bus Bar, Rod, and Shapes and General Purpose Rod, Bar, and Shapes, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM C 518, Standard Test Methodfor Steady-State Thermal Transmission Properties by Means ofthe Heat Flow Meter Apparatus, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM D 1621, Standard Test Methodfor Compressive Properties ofRigid Cellular Plastics, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM D 1622, Standard Test Methodfor Apparent Density ofRigid Cellular Plastics, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

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ASTM D 380, Standard Test Methodfor Rubber Hose, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM D 991, Standard Test Methodfor Rubber Property-Volume Resistivity OfElectrically Conductive and Antistatic Products, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM D 5162, Standard Practice for Discountability (Holiday) Testing ofNonconductive Protective Coating on Metallic Substrates, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM E 84, Standard Test Methodfor Surface Burning Characteristics ofBuilding Materials, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

ASTM E 96, Standard Test Methods for Water Vapor Transmission ofMaterials, American Society for Testing and.Materials, West Conshohocken, Pennsylvania.

ASTM E 285, Standard Test Methodfor Oxyacetylene Ablation Testing of Thermal Insulation Materials, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

AWS DI.1/D1.1M, Structural Welding Code-Steel, American Welding Society, Miami, Florida.

AWS D1.6, Structural Welding Code-Stainless Steel, American Welding Society, Miami, Florida.

AWS QC-l, StandardforAWS Certif:cation of Welding Inspectors, American Welding Society, Miami, Florida.

Bagaasen, L.M., J.H. Westsik, Jr., and T.M. Brouns, 2005, Waste-Form Qualification Compliance Strategy for Bulk Vitrification, PNNL-15048, Pacific Northwest National Laboratory, Richland, Washington.

DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual, U.S. Department of Energy, Richland, Washington.

Fuller, P., 2004, Hydraulic Fluid Compatibility with TraceTek Leak Detection System and Mini-Probe, RPP-19524, Revision 1, CH2M HILL Hanford Group, Inc., Richland, Washington.

HNF-2962, A List ofEMI/EMC Requirements, Revision 0, Numatec Hanford Corporation for Fluor Daniel Hanford, Inc., Richland, Washington.

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HNF-SD-GN-ER-501, Natural Phenomena Hazards, Hanford Site, Washington, Revision I B, Westinghouse Hanford Company, Richland, Washington.

IEC 61000-4-2, Electromagnetic Compatibility (EMC) - Part 4-2: Testing and Measurement Techniques - Electrostatic Discharge Immunity Test, International Engineering Consortium, Chicago, Illinois.

IEEE C62.41.1, IEEE Guide on the Surge Environment in Low- Voltage (1000 V and Less) A C Power Circuits, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE C62.41.2, IEEE Recommended Practice on Characterization ofSurges in Low Voltage (1000 V and Less) AC Power Circuits, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE Std C37.90.2, IEEE Standardfor Withstand Capability ofRelay Systems to Radiated Electromagnetic Interference from Transceivers, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE Std 141, IEEE Recommended Practicefor Electric Power Distribution for Industrial Plants, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE Std 142, IEEE Recommended Practice for Grounding ofIndustrial and Commercial Power Systems, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE Std 242, IEEE Recommended Practicefor Protection and Coordination ofIndustrial and Commercial Power Systems, Institute of Electrical and Electronics Engineers, New York, New York.

IEEE Std 519, Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems, Institute of Electrical and Electronics Engineers, New York, New York.

IESNA HB-9, IESNA Lighting Handbook, 9°i Edition, Illuminating Engineering Society of North America, New York, New York.

IP-2, The 2003 Hose Handbook, 7th Edition, Rubber Manufacturers of America, Washington, D.C.

ISO 668, Series I Freight Containers Classification, Dimensions and Ratings, International Organization for Standardization, Geneva, Switzerland.

ISO 1161, Series I Freight Containers -- Corner Fittings -- Specification, International Organization for Standardization, Geneva, Switzerland.

ISO 1496-2, Series 1 Freight Containers -Specification and Testing - Part 2: Thermal Containers, International Organization for Standardization, Geneva, Switzerland.

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Leonard, M.W., 2004, Interface Control Document Between the Demonstration Bulk Vitrification System (DBVS) [CH2M HILL Hanford Group, Inc.] and the Effuent Treatment Facility (ETF) [Fluor Hanford], Revision 0, CH2M HILL Hanford Group, Inc., Richland, Washington.

MSS SP-72, Ball Valves with Flanged or Butt-Welding Endsfor General Service, Manufacturing Standardization Society of the Valve and Fittings Industry, Inc., Vienna, Virginia.

MSS SP-82, Valve Pressure Testing Methods, Manufacturing Standardization Society of the Valve and Fittings Industry, Inc., Vienna, Virginia.

NEMA MG-1, Motors and Generators, National Electrical Manufacturers Association, Rosslyn, Virginia.

NEMA MG-13, Frame Assignments for Alternating-Current Integral-Horsepower Induction Motors, National Electrical Manufacturers Association, Rosslyn, Virginia.

NFPA 70, National Electrical Code, 2002 Edition, National Fire Protection Association, Quincy, Massachusetts.

SAE J429, Mechanical and Material Requirements for Externally Threaded Fasteners, Society of Automotive Engineers, Warrendale, Pennsylvania. I TFC-ENG-STD-06, Design Loadsfor Tank Farm Facilities, Revision A, CH2M HILL Hanford Group, Richland, Washington.

TFC-ENG-STD-21, Hose-in-Hose Transfer Lines, Revision A, CH2M HILL Hanford Group, Richland, Washington.

TFC-ESHQ-Q_C-C-03, Control ofSuspect Counterfeit Items, Revision B, CH2M HILL Hanford Group, Richland, Washington.

TFC-PLN-09, Human Factors Program, Revision A-1, CH2M HILL Hanford Group, Richland, Washington.

UBC, 1997, 1997 Uniform Building Code, International Conference of Building Officials, Whittier, California.

UL 142, Standardfor Safety-Steel Aboveground Tanks for Flammable and Combustible Liquids, Underwriters Laboratories, Inc., Northbrook, Illinois.

UL 508A, Standardfor Industrial Control Panels, Underwriters Laboratories, Inc., Northbrook, Illinois.

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UL-listed, Electrical Appliance and Utilization Equipment Directory, Underwriters Laboratories, Inc., Northbrook, Illinois.

WAC 173-303-640, "Tank Systems," Washington Administrative Code, as amended.

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APPENDIX A4

DRIED WASTE HANDLING SYSTEM

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QneO CALCULATION COVER SHEET

cALC. tw : 145579 B-CA-011 -j REV: F4 uATE: Ocwer 12, 20U5 CAM Tm.e: MeR Area Support SVucWre PROJECT No.: 145579 Final DBVS Design

Design Verification Required: q Yes q No _--.._.... _... Caloulation Type: q Scoping q PrelimMtary ® Final

Superseded by Cala4aBa'1 No.: q Voided

ORIGINAL AND ii6VLSED CALCULASIONSiANALYSIS APPROVAL REV. ORIOp1ATOR: MTE CFY:CIIED: DATE: APPROV6D DATE 0 PaW Mayer 19-JanWS DWane WhMay 19jaoAS Paul M"ar 19J0n-05 I PaI MGM -05 Divana W John Slaphems -0S 2 Pau{ MeM OB,krWS DWWMWhftv 0&JUmO5 T HaYn 09JUt06 3 Paul MOM 1 Unds Sawa 17 T 17 4 I - 12 04 ob 12 -414-05 •. v AFFEC'tED DOCUMENTS REV. EM. LE DOCOMEIITFRIMBER: 7I116: NO.: IN71AL8 F-145578-00-B-0005 MBR Area Structural Steel F1aos and Uelad6 H F-145579-000.B&0006 MeR Area Structural Steel Efeva6ons and DetaNe F / F-1455794)0-8-0001 Melk Area - Grali & Floor Plate Layout F F145579-049-0010 MeR Area - S1nupuei Steel StaEs and Details C r/A F-145579-00-B-OD13 MeRArea - Structural S8 Connection DeteNe A F-146579-00-B-0028 Melt Area - Structural Steel Connection Details A

RECORD OF REVISION REV. NO. REA80N FOR REVI&ON: 0 Issued for Cmstnicion I Reviaed to bicaparafe apptlcable IQRPE and CH2M comments amde on Wasea Dryer Supporl Strudure steel design celtula0on 145579-8-CA-012 Rev 2, indudfng addtlon of mrrectlon details and calculallon.s. Alla0echmenls op3 and JY4 revised. 2 Assumption added to section 2.3 concerNng small eccentrki0es In 6ghOy loeded horizontal Maces The toAaMaO page replaCernavits were n1a[!e in attachments as noled: Attadanant 1, page 24: Document reference mrreded- AOatlaneM 1, pa®e 37: Cmss references to attschmenl9 added. Attachment 1, page 172 referenoe to USC clause 1ar non-concenak braces added. Attachment 1, page 200: Sketch corr®eled to show 1' OdGc ea30 gusset plate. A9adnreM 10. page 1: Note added indtcafbng lerge blank space on page is ImenOonal. AtlacirneM 5 F-145579-00-a-0005 updated to Rev G.: drall ing enors consded. 3 ABadment S11 added, povidin9 design infoma8on for halaontal bracing wnnedlons. Dravhig F-145579-U0.B-0026 added to Attadimcnt 5. stawirg horizontal bracing connec6oms. Drawing F-145579-009-0005 in Attachment 5 revised to reference Drawing F145579-00-B-0026. - Drawma' 14 106789 added to Attachment 51o^mdde location and concnete datator toundation. ++ 1 M+.e,ywn } .ad,. Page1aF10

A4-3 RPP-24544 REV lb

CALCULATION SHEET ^

cALc. NO.: 11145579-B-CA-011 REV: 4 I uATE: October 12, 2005 ca.c. TrtLE: MeR Area Support SUuaWre PRaECTNO.: 148679 PROUECTTRLE: Final DBVS DeSiSBt

4 A#KdgmM#q, page 172 redeed. Fqet earience debted asreqwsftd by Reviewer. AwdmneM#11, p®pe 2 revleed to add delnNorw at Fp LaVRWhel and FpTransverse. AwdnreM N11. PW4e added, P+ovidtrp more delaMed mphna8on of inetlads as requested by ReviBwer

ATTACHMENTS TOfAI 0O6UNENT MIMBERBD: 7IRE: PAAES ABadunMrt I Melt SIe61 CMadeBpre 287 Atlechmemt2 AAe6Area Support StrucduslS4ea1 ST 30 Afrodrnent3 NINIAreo Support 34ucWalsteelAtldftndReferencas 16 Aftadmant 4 Fowdban InbrmNlm Ciart Shov*w Perfamence Category I Apedmment8 MeRAre®3 17 AMadpnent8 MeRAroa Support StructlxslS" Reactions STAAD-Fro 8 AttadWment 7 Me8 Area Support 34uciuwl Steel Node Report STAAD-Pro 76 Attadrment 8 Melt Area Support ShWural Steel 8ean End Fomes Envdope Report 44 9TAA6PYo AtOaduneM9 bteltAree Support Strudwal3tee18aanFoaceDetdl Report AAD-Pro 968 ABadpnen110 M6RAtw Suppon fttdwalSteel STAAD-Pro 24 Attachment 11 MeR Area Support Strudual Steel tbrizontel Brechg Connection Deelgn and 167 De1Aas

ftpws^>^..^ • Page 2ato

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MK CALCULATION SHEET

cA.C. 145579-B-CA-011 j ttEV: F4 -1 oATE: October 12, 2005 CAM TMX-- Melt Area Support Structure PRaECrrm•: 145579 FsalDBVSDesign

1 INTRODUCTION

1.1 Purpose

The purpose of this calculation is to determinelverify the member sizes for the Melt Area Support Structure (MASS) steel frames and platforms. Column loads devebped in these calculations are used in the design of the Melt Area Support Structure Foundation, calculation 145579-C-CAd011.

12 Scope

The scope of this calculation includes gathering vendor loading and geometry data for mechanical equipment that will be supported by the structure. Where such InFormation is not yet available, conservative estimates and calculations of self- weight and contents weight, plus any dynamic loadings, have been included. The resulting calculations for the design of the stnucturat steel frame and platform tlooring, inctudmg access, provide frame member sizes, gaometry and detaiis for any non-standard or seismicapy loaded-connections. The results are presented on Included drawings and are complete with references to specifications and standards sheets.

2 BASIS

2.1 Design Inputs

The primary design input for this calculation is the attached structural steel drawings. This calculation determines the forces and stresses at the selected members when subject to site environmental loads (Natural Phenomena Hazards). The drawings are derived from an iterative process of selection, calculation and possible re-selection If members are found to be overstressed. This calculation includes verification of only the final member sizes selected.

Layout of the steel in the drawings is derived from Mechanical General Arrangements and the locations of supported equipment as shown in the 3-D computer model of the Melt Area.

arowhstiV" ^^ U Paga3af10

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me& CALCULATION SHEET

CALC. No- 145579^$-CI4g11 ^ REV: 4Q DATH: October 12, 2005 CA!Q TFMF-: Melt Area Suptrort Structure PROJECT NO.: 14$879 PROJECT Tn-c- Fknal DBVS Desiart

Other design Inputs Iriclude the merhanical equipment list which provides weight and size data, nomrepy from vendor information where available. Where Vendor infomatlon Is not avaiiabie, the date provided in the equipment 6st has been conservatively estimated by the Mechanical designers. It Is expected that actual equipment ioafs will be lesa than the estimated values. This e>pectstion will be verlfied when final vendor mfoimation becomes avaiiabie and remedial action taken, if required.

The provision of radiation shielding in the Melt Area Support Structure consists of steel piate floors above and below the AWTE levei, and in the centre of iha structure at the "waste bk' fbor level.

2.2 Crlteria

TFC-ENG-STD-O6 Rev B-1, October 27, 2003.

The Melt Area Support Structure is Performance Category PC-2. This was provided at the March 11, 2004, design review meeting. The attach®d foundations chart (Attachment 4) was included In an e-mail from David Shuford CH2M Hill to John Stephens AMEC confirming the Performance Categories of SSCs.

Design I.oads:

Loads on the structure are as provided in the Design Caiteria TFGENGSTD-06, and as discussed below.

Dead Load: Includes self-weight of the structure and permanent equipment. Equipment weights have been detemdned by referencing Vendor data, or the Mechanical equipment list. Where information was not readily available, equipment weights were conservatively estimated by the mechanical designers using "worst case'scenarios.

A Mechanical allowance under floors of 50 pef ma)dmum, 10 psf minimum as appropriate to give the worst effect for a given Ioad combination.

^ a..^ ^ aege 4 a io

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^ CALCULATION SHEET

CALG pO» 45579-8-COr011 R6V: F 4 -1 DATH: October 12, 2005 CAM 'nTM' Met Area Support Structure PROJEcT 1455/9 PROJEM TmE Fbud DBVS Desien

Live Loads: Floor loading of 100 psf - Floors must serve as'exit" paths. Mass of top-off soB and dried waste

Seismic Loading: Zone 2B as defined in the UBC.

Wind, Snow and Ashfall loads are resisted by the pre-engineered weather enclosure, not the MASS. Weather enclosure design Is not part of this calculation and will be provided by the Vendor of the Pre-engineered metal enclosure system.

Flood: the DBVS site is at elevation 663 feet and is not In any of the flood areas identified in HNF-SD-GN-ER-501 Natura! Phenomena Hazaids, Hanfwd Site, Washington. Flood loads may safely be ignored.

Groundwater Pressure: the DBVS site is at elevation 663 feet. The Geotechnical report notes that groundwater levels are approximately 300 feet below the ground surface. Groundwater pressure may safely be Ignored.

Thermal: like any structure, the MASS Is subjected to normal annual and daily temperature variations. it is not constrained from expansion or contraction by the pre-eng weather enclosure. The MASS shape Is a simple rectangular framewrk, and no change In the basic geometry occurs due to thermal expansion or oantraction. The ICVTM Box does not contact the MASS at any point, and it is our understanding that the temperature of the floor above the MASS will be at "safe-to- touch" temperatures. Thermal stresses win be smaq and may safely be ignored.

Concrete creep: the structure is all steel supported on a slab-on-grade foundation. Concrete creep stresses may safely be ignored.

Lightning: the entire DBVS site will have a grounding grid installed. Pigtails are provided from the grounding grid through the foundations for attachment to the supported structures, systems or components. Grounding calculations are not part of this calculation.

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meO CALCULATION SHEET

ca.c. ttac 1145579-B-CA-011 REV: 4 DATE: October 12, 2005 CAG T^:* Matt Area Support Structure PROJECT NQ-= 145579 PROJECT TITLE: Firai DBVS Desinn

2.3 Assuroptians

1. The structural steel fiarning supporting the elevated bins and associated equipment Is being designed in advance of final binfequipment design andlor Vendor inforrration. Bin and equipment dimensions and support points are defined, but precise connection detaBs are not. The designerlsupplier of the bins and equipment Will ensure that the connection between the bins and equipment and the supporting steel frame is adequate to transnrt all forces, both laterat and vertical, due to all design ioads, tnc^ seismic. In some cases this may require fleid-weided connections.

2. The pre-engineered weather enclosure surrounding the meit area support steel will have no sgniiicant effect on the frame design, except to shield the frame from wind, snow and ashfaN loads. The two structures are not connected in any structurally significant way. 3. The temperature of the AWTE floor and nearby structural steel will remain 'safe-to-touch.' This is a requkement for safe operation of the DBVS. 4. Horizontal braces with design loads less than 9 kips may have an eccentricity of up to 6 inches as detailed on drawing F-146579-004"0l)2. The moments caused by this eccentricity are small refative to the size of the columns in question and may safey be ignored. At all cofumns, there are beams framing in from at least two directions where such braces occur, the beneficial effects of the stiffening provided by the beam framing connections Is conservatively ignored (by assuming pinned connections) but is similar in magnitude to the minor torsional moments caused by slightly eccentric iI loaded braces.

.^ Pagesalo

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amft CALCULATION SHEET

cnt.C. No.: 145579-B-CA-011 nev: F-4 I uATS: October 12, 2005 CALo- TtT-L Melt Area StrouortStnxture PROJECT NO.: 145579 PROJECT TME Final DBVS Design

3

1. UMimm BuNdhig Code, 1997. Intematlonal Conference of Building Officials, Whittier, CalfFonda

2. ACf Manual of Concrnte Practice, 1997. Amertpn Concrete institute, Farmington HiOs, WAchigan.

3. TFC-ENG-STD-06 Rev B-1, Design Loads for Tank Farm Faalities, Issued October 22, 2003 by CH2M Hill Hanford Group Inc. Hanford, Washington.

4. Repwt of Geotechnical Engineerhg Senvices, Bulk Vftrffication Process Par8a1 DBVS Richland Washington. April 2004. AMEC E&E Inc., Portland, OR.

5. HNF-SD-GN-ER-501 Rev 18, Natural Phenomena Hazards, Hanford Site, Washington. As revised by ECN 672877, May 15, 2002. Numaiec Hanford Company, Richland, Washington.

6. DOE-STD-1020-2002 Natural Phenomena Hazards Design and Evaluation Cntarfa for DepaRinent of Energy FacB#les Jan 2002. U.S. Department of Energy, Washington, D.C.

7. AISC Manual of Steel Construction - Allowable Stress Destgn, 9° EdiUan 1989, 4° impression 9/00 American Institute of Steel Construction Chicago, Illinois.

8. AISC Manual of Steel Construction Volume 2 Connectrons ASLVI.RFD 1992, American Institute of Steel Construction Chicago, Illinois.

9. 145579-GLI-001 DBVS Equipment Ust Revision. G, October 15, 2004. Issued by AMEC Trail Mechanical Group for this pn7jecL

10. STAAD-Pro 2003, Publfshed by Research Engineers Intemstional, Yorba Linda, California.

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CALCULATION SHEET

ca.c. tw.; 145ST9-B-CA-tt11 nev: ^ DATE: October 12 2005 CALc. MILE: Malt Area Support Structure PRWECT NO.: 145579 Final DBVS DeWgn

4 METHODS

Frame dimensions have been determined based on a number of factors insktding:

• to overall size and mass of supported equiprrent, and bins,

• the relative locations of this equipment,

• the required interstorey height to suit equipment sizes, services running through the structure and derived structural frame sizes, and

• requirerrerNs for structural stiifness, kmits of deflection, bracing geometry to suit access requirements while resisting seismic and gravity forces.

Mechardcal general arrangements have been develcped in conjunction with the development of the stesi framing, but have not been certified as final. Final designs are dependent upon receipt of Vendor information. The primary steel support framing will not be affected by changes in Vendor details, as Vendors are required to supply equipment of certain sizes to fit on and within the primary steel structure.

Based on the derived and estimated weights of the stmdure, gravity and seismic forces on the structure have been ealcuiated using the Tank Farm Facilities Design Loads and the methods prescribed In the Uniform Building Code.

Frame members have been selected for their suitaMAty to support the calculated nmments, shears, torsion, and axial forces and to comply with geometry restrictions. Anaysis of the structure was completed foiiowing the AISC Service design method. The STAAD Pro for Windows release 2003 oomputer program was used, combined with hand-checkirg of members to verify the output.

The preparation, running and evaluation of the STAAD-Pro model for the steel frame is an iterattve process. Preliminary member sizes are used to develop the computer model and to input ioads. Loads are mode4ed fk>or ievei by floor level using the live and dead area loads as well as equipment loads, seismic, ata Derivation of loads is provided in Attachment #1. These "raw" ioads are input into the computer model of the structure. The designer then instructs the computer

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aneO CALCULATION SHEET

Cai C. NO.: C45b79•B-CA-011 1 Rev: ^ o^Te: October 12, 2005 CALC, TITl.E Melt Area Support Struchxe rRwECr No.: 145579 t+ROJwr TrrLe: F1nal t)BVS Design

progran to combine the loads In various oombinatkms as required by the Unifarm Building Code. The designer may also choose to evakiate other load combinations not required by Code, but which he belleves, are neoessary to ensure the structure is capable of safely supporting all the forces it is Bkeiy to be subjected to.

The oomputer program uses standard engineering Wkxtlation methods to dist+iwte bads and forces between the various members of the steel frame and uHknateiy determine the forces In each member due to the various load combinations. fMce the various required koed-combinations have been evaks3ted, the designer can kientify members that are oversbessed (if any) which will be iricreased in size. The designer examines the column reactione derived by the computer program, based on the `ravW' loads to verify that k>ads have been entered in the correct orientation and magnihade. The key advantage of the computer program Is that It allows for a rapid means of determining the effects of the different load combinations on the overall structure and the detemtlnatbn of the reactions at the foundatfons.

Once the overall distribution of forces and the member end forces are detemuned using the computer program, an individual calculation Is made for each steel member within the structure. These calculations take Into account the specific loading conditiais on each member, including point loads, sifght variations In tributary width and any other special conditions. The member end forces from the computer run are combined with the calculated forces due to specific loading conditions and the total forces on the member are derived. These are than compared to the values derived by the computer program as a check. The maximum bending moment and axial forces In the members are combined and checked using a simple spreadsheet program. This calculates a total stress ratio for each member. Values of total stress ratio less than 1.00 meet the code requirements.

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CALCULATION SHEET a^ cat c Na; 114Si79a-CA-011 rtav: ^ DAw-: October 12, 2005 cAt.c. rrrLE: MeR Area Support Sbtwdare PROJECT No.: 145579 PROJECTITIM Final DBVS DesifNt

5 RESULTS AND CQWCLU810NS

Strucdxal steel8•aming suitable for the purpose of process equipment support and maintenance access has been designed. The design conionns to applicable DOE and USC standaids. Beam and colurm stress n#tos are limited to ims than 1.0. A value of 1.0 means that the effect of the factored loads on the member Is equal to the eNowabie Wads. Given the sefely factors "buiW to the 9uiiding Code, a value of 1.0 doas not imply -just about to fad" but rafher impGes a design that meets the Code requirements and is completely safe. By limiting stress ratios to a value of kess than 1.0, an additional margin of safety Is olNsined. The strees ratio of each beam and aolumn Is Included with the calculation provided for each member.

The cDhurin with the highest stress ratio is column M1flub. It Is a W14x53 section. Its maximum stress ratio Is 0.35. See Attadsnent 1, page 155 of 287.

The beam with the highest stress ratio Is at Elevation 705'-9". it Is a W18x71 section. Its maximum stnes,s ratio is 0.58. See Attachment 1, page 74 of 287.

The horizontal brace with the highest stress ratio Is at elevation 896-9". It is a WT5x11. its maximum stress ratio is 0.68. See Attachment 1, page 124 of 287.

The vertical brace with the highest stress ratio Is at grid M1. It Is a WT6x22.5. Its maximum stress ratio is 0.83. See Atfachment 1, page 169 of 287.

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A4-12 RPP-24544 REV lb 02/21/2000 16:58 FAX 5093763407 DBY Pro,ject 272WA 0002

REY A-14 ENGINEERING Document 1'FC-RNGDESIGN-C•1q Page 17 o[25 February16,2006 ENGINEE.RiNGCALCIII.A't1ONS ERSCtiv Date

Figure 4. Subconerector Calculation Review (]uckDst.

Page_]- of_1_-

Subject: i a e e

The eubject document has been revktved by the undersigned. The reciewer miewed and verified the foUowiug item AS aPPlicabk.

Docamnmts Reviewed- i acc^o nrem t R t' a

Analysis Perfonned By: AMEC

• Des3gn Input • Basic Assumptions • ApproacNDesign Methodology • Com3srerwy+viPo item or document supported by the calculation • ConclusiodReaults Interpretation • impaot on extisting reqmrements • ._. . _. _ __

Reviewer (printed neme, sigr,etnrc, and dere)_ Organixa9aml Manager (Prmted name, signature a Z,/.,/.b

] 21-dlv

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CALCULATION SHEET arr^

CALC. NO.: `145579-D-CA-007 Rev: F-0 ] DATE: February20, 2006 CALC. TTrLE: Heat Transfer Analysis - AWTE

PROJECT NO.: 145579 PROJECT TITLE: Final D6VS Design

Design Verification Required: q Yes ® No Calculation Type: q Sooping q Preliminary Final Superseded by Calculation No.: q Voided

ORIGINAL AND REVISED CALCULATIONS/ANALYSIS APPROVAL REV. ORIGINATOR: DATE: CHECKED: DATE: APPROVED DATE A G.J. for D. MCCmn 04-Apr-06 G.J. for S. Polegaj 04 -05 Frank Sweet N-A" 8 J. Luey 24-G0-05 K. McCracken 24-OCt-05 K. McCrerkan 24-Oc1-05 C J. Luey 02.feb-06 K. HkCrorken 02-Fea,06 K. A/U:ratlrer I 02.Feb46 0 J. they 20.Feb.00 K. hlcCracken 20-Feb-06 K. McCacken 20-Feb-06

RECORD OF REVISION REV. ^ NO- REASON FOR REVISION: A tssued for CH2M HILL Approval B Evaluate impact from ICV Box design changes. C Evaluate impact from AWTE design cRa s. 0 I ncorpwated Client Comments

ATTACHMENTS TOTAL UOCUqENTNUMRERn6: T1TLE: PAGES

Attachment t _ T hermal Load Inventory 160 Calculation 0509206A1-M-004:.__.-._..-.,_OBVS AWTE .._. Attachment 2 BWk Vilriflcati0n Design.,_._.__._....;a._.._.v_...... _,..,.__..._...Orawin s 9 TOTAL PAGE COUN7 173

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CALCULATION SHEET ane&

CALC. NO.: 1451519-D-CA-007--J Rw: F-o-JpATe: February 20, 2008 cALc. TtttE: Heat Transfer Anafysis - AWTE PROJECT No•: 145579 PROJeCT'nttE: Finai DBVS Oesign

INTRODUCTION

The Andllary Waste Transfer Enclosure (AWTE) design concept has evolved from one in which operators did activities via glove ports through the enclosure was to one that is more of an AWtE "room' in which operators will enter_ The new AWTE concept will address operational Issues with the prior design. This calculation utilizes conceptual drawings provided in Attachment 2 and evaluates projected heat bads within the AWTE and estimates required cooling that will need to be accounted for in the final AWTE design.

1.1 PURPOSE A heating, ventilation and air conditioning (HVAC) system is to be designed to maintain the temperature In the AWTE at a level compatible with the components contained therein. At present, the AWTE room design temperature is 1400F (-60'C). This calculation estimates the thermal loads to this room contributed by the major components in the room, assuming the room temperature is maintained at 77°F (25°C) to allow for margin to protect components in the AWTE room. The thermal loads include the electrodes, electrode bus bar, material feed chutes, off-gas inlet and exhaust lines, and heat transfer through the AWTE fbor from the ICV lid below.

1.2 SCOPE This calculation determines the projected heat load into the AWTE from heat transferred to the AWTE floor (from the ICV lid located beneath the floor) and from heat transferred along the components that penetrate into the ICV lid from the AWTE (chutes and electrodes). Heat is transferred to the components through direct contact with the melt and radiation transfer from the melt.

BASIS

2.1 DESIGN INPUTS Heat transfer model input speciiics are discussed in Attachment t(Section 1.0).

2.2 ASSUMPTIONS

Assumptions requiring verification were not identified for this calculation. Conservative values have been selected for estimating the beat load to the AWTE.

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CALCULATION SHEET ameO

CALC. No.: 145579-D-CAr007 -1 Ry: rp DATE: February 20. 2006 CALC. m LE: Heat Transfer Analysis - AWTE ^^4-'T'40.: 145579 PRWECTTM-E: Final DBVS Design

CRITERIA

1. AWTE air space is maintained at 77°F (25°C). Conservative to estimate heat load. Design temperattae of A4VTE components is 140°F (60°C), but target operating conditions should not be at this Emit. 2. tvtaterial handling chutes are kept below 482°F (250°C). Engineering judgment to prevent potential for collecting low-melting point material on the chute surface.

REFERENCES

References are discussed in Attachment 1, Section 9.0.

METHODS

Calculation methods are discussed in Attachment 1, Appendices C through G.

RESULTS AND CONCLUSIONS

Table 1 from Attachment 1, AWTE Floor Cooling Capacity and Bottom Surface Temperature Sensitivity Analysis, is reproduced below. This analysis was performed to provide an estimate of the energy removal required to achieve a target temperature of 77°F (25°C) at the top surface of the AWTE floor. Table 2 from Attachment 1, Component Heat Loads to the AWTE Air Space, is also reproduced below. Results in Table 2 summarize the analysis of the heat load contribution from the bus bar, exposed electrode segment, and material feed chute. The'unit" loads of each assembly included in the model are provided in this table, along with the number of units present. The total heat load to the AWTE is obtained by multiplying the unit loads with the number of units. The model results indicate that the chute wall temperature in the lower portion of the material feed chute exceeds the desired 482°F (250°C) target. If a supplementary cooling capacity of 5 to 51/2 kW (-1'h to 1% tons refrigeration) is applied to the chute wall in the vicinity of the chute penetration though the AWTE floor and off-gas hood port, the temperature of the chute wall can be reduced to below the 482"F (250"C) target.

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CALCULATION SHEET amec^

CALC. NO.: 145579-D-CA-007 __] REV: F-0 ] oATE: February20, 2006 CALC. TiTLE: Heat Transfer AWTE

PROJECT NO.: 145579 PROJECT TITLE: Final DBVS Design

Table 1- AWTE Floor Cooling Capacity and Bottom Surface Temperature Sensitivity Analysis ^r^o^^g AWTE Floor". 5'a AS^Ije^

^T^ ^v^ *^ Stirfacd ri ^t ^ . ._, rE 570 106 43 500 R266 76 38 450 205 60 35 400 155 45 33 350 115 33 31

Table 2 - Component Heat Loads to the AWTE Air-Spacetrl.

'Unit" Heat Number Total Component Total Component Component LOad of AWTE Heat to the AWTE Load AWTE Heat Load units (kW) (kW) (tons refrig.) Bus Bar/Clamp Assy. 0.25 2 % 0.14 Exposed Electrode 12Y: 2 25 7.14 Seg ment Material Feed Chute 10 5 50 14.28 Off-Gas Inlet Line 2%: 1 2%: 0.71 Off-Gas Exhaust Line 2'lz 1 2Y: 0.71 Total -80Y: -23 raote: (1) tieat loads from the off-gas hood to the AWTE floor are handled by the AWTE floor cooling system. Therefore, there is no net heat load from the off-gas hood to the AWTE air-space.

As seen by comparing the estimated cooling requirements in Tables 1 and 2, the heat load from the ICV lid to the AWTE floor is the dominant contributor. If this intermediate cooling is not provided, the heat load into the AWTE air space will increase. The specific design load for the AWTE Floor cooling system may be lowered if excess cooling is provided in the AWTE Air Space.

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CALCULATION SHEET aff^

CALC. NO.: 148578-D-CA-007 REV: Q DATE: February 20, 2006 CAi.C. m-E: Heat Transfer Analysis -AWTE PRO.n Cr Ro.: 145579 PROaECr mi.e: Flnal DBVS Design

Attachment I DBVS AVYTE Themial Load tmrentory. 050920&01•4A-004 Revision I (160 pages bdUding Attachment Cover)

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Pa¢No. 1°f 159 A. kf S CALCULATION COVER SHEET OOOPOa6t10M (.'atCntat^0llt't0. 0509?A6.01-M-004 AqectNO. ProjatTitic pim[: 0504206.01 DBVS Thermal AnaPsis Attthotiution AMEGDMIMH+N Tite DBVS AWTE'1Lermal Load Inventory Parpose and Objective:

A heating, ventilation and air conditioning 01VAC? system is to be designed to maintain the tempeyeture in the Ancillary Waste 7Yansfor Bncltutrze (AWTE) at a level compatible with the components contained therein. At present, the AWTE roorn design temperature is 140eF (-60"C). This cahadation estimates the thermall loads to this room contributed by the major components in the noom, assuming the room temperature is maintained at 77°F (25°Cj. The thesrnal loads include t(wse arising from the electrodes, electrode bus bar, material feed chutes, off-gas inlet and exhaust lines, and heat transfer through the AWTB floor resulting form the high operating temperature of the off-gas hood. The AWtE air-space HVAC and the AWTE floor cooling systems will be designed by others.

Rev. Total Revision Description Prepared By Checked By PM/Tt. No. Pages ueaconr,^tmaearwq.l..a) NamdDate Name/Date ApprovRYDate 0 99 Original P.S. Lowery S.R. Pierce S.R. Pierce

1 159 Revised to include P.S. owery S.R. Pierce S.R. Pierce additional heat loads to AWTE & to incotporatc us CHG comments 2l^Zl0'0

CakvM,bn Co+er Shcn: QM'?.1, R,. 6111.15dri)

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CALCUI.A'nON REVIEW CHECKLLST projatNo. CabetwWaNO. Rea PagWto. 0509206.01 0509206.01-M-004 1 2 of 159 Y Accart A I79mtsl]cst.7^o INnuWers

I. Cova sheeta property compRted.

Z. Celc aheetbeWeracolnpktewithcaletw,n:v,eto.

3. Cak sheet oonama complete per fornret. ^

4. [.ated attachmeMa ircladed.

5. CSk objective olearly described. 6. Critaria are saiuble and properly rekrenlxd to task t/ ific documents. 7. Awmlptiona and iqRu data descrn'bcd and attached or refenmced to task documents. & Calc nxOnd identified and appropriate for the deei activit . 9. Cek results reasonable and correctly described in results and cronciutionb. 10. Computer program identified with version and revision. 11. Compater inpnUomput provided or referenced.

12. Computer ron trnceable to calcalafion (file 4, etc.). 17 - 13. Computer input data within permissible design input range- 14. Computer progrom validation/verificarion addressed. Discrepancies i Comments:

Checker (Prim Name and Si Date: S.R. Pierce ( (Niginator(Print N n): Da : P.S. Lowery t7lw Signatures obtained onl affer diSCfCpancio are cmYecled and Comment5 are ref0.11ved.

Cutcnlvqa Roar,a Cho[kllzr, QAP 3. 1. Rev. 6( i 1-15-05)

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A R E S CALCULATION SHEET

ProjeaNo.0509706.01 Calcu)atloaTb.0509206.01-M-004 Rev.No.l Per lto.3of159 Title: DBVS AWTE 7Mmul Load Invenrory Premred By. PS. Loxery Date: 2.14.06 Chedeed By: 3.R. Pietce Datr. 2.15.06

Tab1e otContalb

1.0 INTRODUCTION ...... _...... ,...... _...... 5 2.0 ELECTRODE BUS BAR JOULE HEAT D)SSIPATION ...... _...... 6 3.0 ELECTRODE SURFACE HEAT DISSIPATION TO THE AWTE ...... _ ...... ,8 4.0 MATERIAL FEED CHUTE HEAT DISSIPATION TO THE AWTE...... 9 5.0 OFF-GAS INLET LINE HEAT LOAD TO THE AWTE ...... 12 6.0 OFF-GAS EXHAUST LINE HEAT LOAD TO THE AWTE ...... _...... 14 7.0 AWTE FLOOR HEAT LOAD FROM THE OFF-GAS HOOD ...... :.17 8.0 CONCLUSIONS...... _...... 18 9,0 REFERENCES...... ^------...... 20

APPENDICES

Appendix A DMJM H+N Statement of Work and Correspondence with DMJM H+N Appendix B Graphite Electrode and off-gas exhaust line insulation Property Data TransmittalS Appendix C Mathcad Model to Estimate the Temperature Distribution and Heat Loss Off the Exposed Electrode Surfaces in the AWTE Appendix D Mathcad Model to Estimate the Temperature Distribution and Heat Loss Off the Exposed Material Feed Chute Surfaces in the AWTE Appendix E Mathcad Model to Estimate the Temperature Distribution and Heat Loss Off the off-gas inlet line in the AWTE Appendix F Mathcad Model to Estimate the Temperature Distribution and tleat Loss Off the off-gas exhaust line in the AWTE Appendix G Mathcad Model to Estimate the Temperature Distribution and Heat load from the off-gas hood to the Awtc floor

CtlwWiionSMn: Q.0.1'i.1.R.w.v1^41SG>7

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A R.E S CALCULATION SHEET

ProjxtNo. Q51192nut CbkulationNo.l)509206At•M-OOd Rev.NO.I PageNo.4ofi59 Tntc DeVS AWTE7fiermd t.oad ]nvaatory Prepared By: PS. Lowery Date: 2.14.06 (:hxked Sy: S.R Ptvice Daa 7.15-06

Figures

Figure 1. Schematic Diagram ofthe DBVS ICVTM Electrode Bus Bar and Clamp Assembly...... 6 Figure 2. Conrtected Material Feed Chute - Section View...... ----...... ---- .....-...... 1Q Figure 3. Overall Elevation View of the Material Feed Chute (Post-Vitrification Configuration)...... 11 Figure 4. Elevation view of the off-gas line in the vicinity of its penetration through ...... 13 the AWTE floor and off-gas hood...... 13 Figure S. Elevation view of the off-gas inlet line run in the AWTE ...... 14 Figure 6. Elevation view of the off-gas exhaust line in the vicinity of its penetration through ...... 15 the AWTE floor and off-gas hood...... 15 Figure 7. Elevation view of the off-gas exhaust line run in the A WTE ...... 16

Tables

Table 1. AWTE floor cooling capacity and bottom surface temperature sensitivity analysis...... 18 Table 2. Component heat loads to the AWTE air-space(t)...... 19

Acronyms

acfm actual cubic feet per minute AWTE Ancillary Waste Transfer Enclosure DBVS Demonstration Bulk Vitrification System Gr Grashof Number HVAC Heat ing. Ventilation, and Air Conditioning 1CVT'" In Container Vitrification Pr Prandtl Number

Cnkula^ SAecr. QAP 3 f. Rer 6 (U15-0>)

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CALCULATION SHEET ^ Pnqed tio. 0504506.01 Cah.utation No. 0509206A1-M-004 Rev. Na 1 Page Na 5 of 159 Titk: DBVS AWTE Thermel Load inventory Prepared By: PS. Lowery Date: 214.0a Cbecked By: S.R. Pierce Da^ 3.15.06

1.0 INTRODUCTION

The Ancillary Waste Transfer Enclosure (AWTE) is located directly over the BulkVit iCVTA+ box during processing. It is separated from the BulkVit processing container by a 3W' steel plate floor and a 2'f," to 4'h" air-space. There are a number of penetrations in the AWTE floor. These penetrations provide access to the ICVT"t box for a number of major system components. Among t)cese are the:

• electrodes (2); • material feed chutes (5); and • ICVrM hood off-gas inlet and exhaust piping.

This calculation addresses the heat loads to the A WTE air-space from the Joule heat associated with passage of current to the electrodes through the electrode copper bus bars, the exposed surfaces of the two electrodes, the exposed surfaces of the material feed chutes, and the off-gas inlet and exhaust lines. As specified in the statement of work (ref. I & Appendix A), this analysis assumes no active cooling in the AWTE. The heat load from the off-gas hood through the AWTE floor and into the AWTE air-space is handled by the AWTE floor cooling system. Therefore, the off-gas hood does not directly contribute a net heat load to the AWTE air-space. The AWTE floor cooling capacity required to offset the beat load emanating from the off-gas hood is inciuded in this calculation.

The electrodes penetrate through the AWTE floor and into the melt contained in the ICVTM box. The material feed chutes provide conduits through which the waste feed is transfetred to the top surfaee of the melt during processing. As such, these components are exposed to the very high temperatures of the 1CV^ internals throughout processing.

Boundary conditions for the problem are provided in Ref 1, 9, 11 and 12 (for QA purposes, copies of these references are provided in Appendices A and B). These boundary conditions are:

+ mth surface temperature is 1922°F ( 1050°C); • off-gas hood panels are assumed to be at their design temperature (570°C); • off-gas air-space plenum temperature is 875°F (-470°C); and • design current to the electrodes is 4000A.

During discussions with engineers at Meier Enterprises (Ref. 10) the suggestion was made that the upper-bound temperature for a number of components in the A WTE air-space is 140°F (-60°C). However, to provide a conservatively high estimate of the heat load to the A WTE air-space, a low temperature is assumed for the A WTE air-space. 77'F (25°C).

The design temperature for the off-gas hood and associated snvctures is 5700C For conservatism, this temperature was assumed for the air-space between the off-gas hood and AWTE floor. For additional conservatism in the AWTE air-space heat load calcufations. the bottom surface of the AWTE Iloor (the surface exposed to the ICVTM off-gas hood) was also assumed to be 570°C. The temperature for the off-gas inlet air was assumed to be 50°C (corresponding to operating during a verv hot summer day). Ca4vfmro+shen; QnPi.^,Rn^.6p615-051

A4-1680 RPP-24544 REV 1b

A it E S CALCULAT'>TON SHEET

RojaxNu.0509206.01 calculatiooNo.0509206.01-iN-004 Rev.No.1 PageNo.6of159 T'nk: DBVS AWTE7hunwl Lmd ]nventory Prepred BY., P.S. lAwey Dote; 214.06 Gliceked By: S.R Pieree D^e: 2.15.Od

The Joule heat dissipated in the electrode bus bar is addressed in Section 2.0. The energy dissipated to the AWTE through the exposed electrode stems is considered in Section 3.0. Section 4.0 covers the heat transfer and temperature distribution in the material feed chute and the corresponding heat transfer to the AWTE. Section 5.0 addresses the but load to the AWTE air-space from the off-gas inlet line. Section 6.0 addresses the heat load to the AWTE air-space from the off-gas exhaust line. Section 7.0 addresses the t.ool3ng capacity required to handle the heat load associated with heat transfer from the off-gas hood to the AWTE floor such that the top surface ofthe floor is maintained at 77°F. Section 8.0 provides a summary ofthe results and tabulation of the constituent AWTE heat loads. to ELECTRODE BUS BAR JOULE HEAT DISSIPATION

Figure 1 provides a schematic drawing ofthe electrode bus bar and clamp asseniblies. Detailed dimensions are provided in the drawings listed in Ref. 2. The bus bar is nominally'/.' thick by 8" wide. The overall length of the bar, from the connection with the power'supply cables to the electrode contactor is approximately 9'-1'/,". The bus bar is constructed of copper. A nominal copper electrical resistivity of 1.8µt2-cm was obtained from Ref. 3.

--- .^.,

Mt bR1-^i"^iW^-L•4^^".

x --. -_. - .yru,na

Figure 1. Schematic Diagram of the DBVS ICVr" Electrode Bus Bar and Clamp Assembly.

['alvWwwnShar Rer6(1iJ5-U5)

A4-1681 RPP-24544 REV lb

CALCULATION SHEET ( PrqettNo.0SO4206A1 CakuLtbuNa0509206Ai•M-004 Ror.Db.! PspsNo.9of159 TiUa DBVS AW78nertm) t.ad ]nvanory PrepveA By: P.S. Lowdy Dsta 2.14.06 (Teckad By: S.R. Pimee Dstc 2.15.06

With this infonna6on, the bus bar eiectrical resistance and heat load is computed as follows:

Assurne that each bus ber passes the design limit o14000A (Ret 11)

Copper electr(cai reaistHYy ...

PCu s 1.8x 10 6R•as (CRC HCP, 56(h Ed, p E-84)

Buss bar dimensions are...

t:=0.75n w:gje

,dy:= 9t1 + 1.29s

L = 2.775m Rasistance...

A;=Pcy'w or R=1.29xIlI5fE

With a current of...

1 = 400D1

The Joule heat power dissipated is...

P=12.R or P=206.457W There are two bus bar arrangements in the AWTE. Therefore the total heat load is ...

Pb,= 2-P or Pld ' 413 W

Rounding this up a bit yields ...

Z,,:s0.5kW

Calv^lauenShrct OAP31.km^.GI1IISAS)

A4-1682 RPP-24544 REV 1b

S 9E CALCULATION SHEET

Prqed No. Q509206.01 Cakulation No. 05092qi.nr-M-004 ltav. Ab. 1 PWNo. a of 159 Tnle DBVS AW787harmd Load ]nveotory Preparcd BY. P.S. t.owery tkte:214.06 Checked By: S.R. PSnee I?.ete: 215.06

10 ELECTRODE SDRFACE }IEAT DTSSSPATION TO THE AWTE

Figure 1 provides a sketch of the electrode configuration inside the AWTE. The dimensions in this figure, combined with the dimensions provided in the schematic included in Appendix A indicate that the overall length ofthe exposed portion ofthe electrode is approximately 6. The bottom 30" of this length is located in the iCVzM off-gas hood, from the top of the melt srnfnce to the penetration in the off-gas hood. The electrode passes through the 4'h" air-space between the off-gas hood and bottom stetbce of the AWTE floor. It then passes through the 3'h" thick steel plate making-up the AWTE floor. The uppemmst 36" resides in the AWTE.

Convection, conduction, and radiation beat transfer between the electrode and its surroundings is modeled in this analysis. Joule heat dissipation in the electrode resulting from passing 4000A is also included in this analysis. The MathCad software package is used to set-up and solve the governing system of equations and associated input data (Ref. 4). The complete MathCad model of this system is provided in Appendix C. For the purposes of this analysis, the temperature of the bottom surface of the modeled electrode segment (the face in contact with the melt surface) is set at 1350°C. The top surface of the melt is set at 1050"C. The off-gas plenum air-space is set at 875°F. Since the bulk flow speeds within the off-gas hood are relatively low, convection heat losses from the surface ofthe electrode are modeled using a natural convection correlation for the convection heat transfer coefficient, assuming turbulent conditions (i.e. - GrPr y 1 Q). This correlation is provided in Ref. S. The exterior surface of the electrode "sees" a melt surface at a temperature of i 050°C, and 1CVTM hood and box surfaces at 570°C. This letter temperature is based upon design conditions for the off-gas hood and appurtenances. The temperature in the region between the top of the off-gas hood and the lower surface of the AWTE floor is also assumed to be 570°C for conservatism. The AWTE air-space and upper surface of the AWTE floor are assumed to be at a temperature of 77°F (25°C).

This calculation assumes no active cooling in the AWTE. Therefore, the correlation for natural convection heat transfer described above is again used to compute the convective heat transfer coefficient for the electrode surfaces exposed to the AWTE. An emissivity of0.7 is used to represent the electrode and melt surfaces in the model. The emissivity of the hood surfaces is set at a value of 0.85. These values are consistent with the values used in the Ref. 6 calculation. Radiation configuration factors were computed andlor obtained from the relationships provided in Ref 7. The thermal and electrical conductivity of the electrode was obtained from vendor data. Appendix B provides a copy of this vendor transmittal supplying this information. The upper- bound value of 230 Wfm-°C is used in this analysis. An electrical resistivity value of 210 pS2-in was used for the Joule heat calculations (reference provided in Appendix B).

As the MathCad model presented in Appendix C indicates, the 72" length of electrode stem is broken-up into 3" segments. The temperature distribution in this representation of the electrode is obtained by solution of a system of coupled, non-linear equations, each equation representing an energy balance on each of the 24 segments of the model. A 251" electrode "element" is used to represent losses off the top surface of the electrode.

The results obtained from this model indicate that the electrode temperature decreases from a value of 1350°C at the electrode=melt surface interface. to a value of approximately 310°C at its top surface inside the A WTE.

Cakularon SImeC QAY 31. aa. 6(11-I5A5)

A4-1683 RPP-24544 REV lb

A;,,, „" CALCULATION SHEET

Yraj^iNo.OS09206.01 GkaluloaNa0509206A1-M-004 Rev.Nlo.l PageNo.9of159 Tide: DBVS AWTE 7Lermd t.oad tnvenbry Preparcd By: PB. Lowery lhte: 2.14.06 Chacked By: S.R. Pkru Date: 2.15.06 The tenperature and heat dissipation profiles computed for the electrode are presented in Appendix C. These results indicate that the overall heat loss to the AWTE is approximately 12%s kW per electrode.

4.0 MATERIAL FEED CHM HEAT DIS$IPATION TO THE AWTE

The dimensions and configuration data for the DBVS ICV*t+ material feed chutes are obtained from the drawings provided in Ref. S. Relevant portions oftheae drawings are reproduced here in Figures 2 and 3. The drawings indicate that, during melt operations, the material feed chute protrudes through the ICVn+ off-gas hood approximately 2'fi". The chutaextends from its penetration in the off-gas hood, up through the AWTE floor, through the AWTE air-space, and out the "valve florn" which comprises the ceiling of the AWTE. The lower -l' section bf the chute, where it extends from the off-gas hood through the AWTE floor, is nominally 12'/." in diameter. The remaining portions of the chute are composed of 8" diameter tubing. The wall thickness of the chute is 0.148". For the purposes of this analysis, the entire length of the chute is modeled using the g" diameter dimension. Moreover, the rather complicated double-wall configuration in the vicinity of the penetration through the AWTE floor is represented with the 8" diameter dimension as well.

Convection, conduction, and radiation heat transfer between the chute and its surroundings are modeled in this analysis. The complete MathCad model ofthis system is provided in Appendix D. For the purposes of this analysis, the temperature of the top surface of the melt is set at 1050°C. The off-gas plenum airspace is set at 875°F. Since the flow velocities within the off-gas hood are relatively low, convection heat losses from the surface of the electrode are modeled using a natural convection eorrelation for the convection beat transfer coefficient, assuming turbulent conditions (i.e. - GrPr> 10). This correlation is provided in Ref. 5. The AWTE air-space and upper surface of the AWTE floor are assumed to be at a temperature of 77°F.

The temperature distribution along the-12' length of chute extending from the penetration in the off-gas hood to the AWTE ceiling is represented by discretizing the chute into 1' segments. The steel walls of the chute are modeled in each segment, as is the column of air contained within the chute. Both convection and radiation heat transfer from the external surfaces of the chute to the AWTE surroundings are modeled in this analysis. Conduction heat transfer in the steel walls along the length of the chute from one chute segment to its adjoining segments is also modeled. Convection heat transfer between the interior surfaces of the chute walls to the air column within is modeled.

The off-gas plenum temperature is nominally 875°F; the AWTE room temperature is nominally 77°F. Since the chute is relatively long, and much of it is exposed to the cooler temperature of the AWTE environment, it is likely that a "chimney llow-' will develop within the chute due to the relative density difference of the air over this temperature range. A simple model was developed using a Boussinesq approximation to estimate the flow associated with the density difference. This is estimated using the relation obtained from a simplified version of the axial momentum equation ...

l _ rhi2 ^ P ^- ° iPtrr -Prirt)S

CalruUron S)wa. V.M' 3.1, Rr1. 6 P 1^ 15-05)

A4-1684 RPP-24544 REV lb

A^if CALCULATION SHEET

PmjeU Ma 0509m6.01 Caku(uion Na 0509206.01-M-004 Rev. No. I Page No.10 of 159 9-Nlc DBVS AW1E 7Trcanul Load ]nventu(y Prep«ed By. P.S Luwery DAc 214.06 l:heeked By: SR Pierce Dalc 215A6 Assuming air properties apply, this model suggests that a mass flow rate of approximately 0.2 kglsee could be developed in this chute. In actuality, the chute is closed-off at its upper and. As a consequence, the hot gases rising in the chute will be balanced with a corresponding downwash ofrelatively cooler air. For conservatism bowcver, when the chimney effect is modeled, it is assumed to occur as if the rising gases travel up the chute in single-pass fashion. To help put this effect in perspective, the analysis is also perfonned when this feature is turned-off.

. •wme.mNnn..

(IP d) (n.'^ t'•y' ^NP OI^E

pt.rl

Mltl^A^L O M(4M[ M I b ^^

t ^ I{VrB n^ ngy^.

' tYwrw^o^-^^ a1K rMals ^jjgqaN^M1 61WtV

^„( V11 f1Vp! ^e011-IOYOIWa[ ^IIOIOVt

. ^afir^

an rwu ;uaq

w.rw^m

Figure 2. Connected Material Feed Chute - Section View.

CakvlulRm Shcac QAP 3 1 Rro6 ( I I-ig95)

A4-1685 RPP-24544 REV lb

CALCULATION SHEET

ProjeetNa 0509206.01 C.sleuktlonNo.0509201iA1-M-004 Rev.No.l PeysNo.lloFi59 71dk: ABVS AW7B Thanut Lad Inventoty Prepued BY: P.S. Lowary DatrK 214.06 ClKdced BY: SA P(ema Dma 2.15A6

1rwv'T'•cZ^i.1Ofir

rw ^ ^

wo.Y

^isdWF

ne.w

' wrsYt. Rogow

ws

Figure 3. Overall Elevation View of the Material Feed Chute (Post-Vitrification Configuration).

Ca.vLUfon Sha* QAP sJ . rzo.=. a ^ ^ ^-i3-os)

A4-1686 RPP-24544 REV lb

A;S CALCULATION SHEET

PmjeerNo.05092t16AI CakuwaaNo.05119]06A1-M-0M Rev.Tb.l PaseNa12of 159 Tkk: DBVSAW7EThanrell.adbrvemory Preprad By: P.S. Lowery DWe: 2.14.06 CUedced By: S.R Pierca Ikae: 2.15.06 The coupled system ofnon-linear equations arising fmm performing an energy balance on each model segment used to represent the material feed cute and associated air column is solved using MathW. The complete model and system ofequations is presented in Appendix D. The results obtained from this model, for the case when the chimney effect is included, indicate that the steel walls ofthe chute range in temperature from approximately 484°C near the connection with the off-gas hood, down to approximately 168°C near the AWTE ceiling. The temperature of the air column contained within the chute is essentially uniform over the entire length, at a temperature of approximately 450'C - very nearly equal to the 470°C temperature in the off-gas plenum. For this case, the radiative and convective losses to the AWTE are -10 kW per chute. For comparison, when the chimney effect is not included in the analysis, the chute temperatures range from 482°C down to 25°C. The temperature in the air column inside the chute spans a similar range - from 480°C to 25°C. The heat losses from the chute's external surfaces to the AWTE air-space are computed to be approximately 5 kW per chute for this scenario, approximately halfthat realized when an approximation of the chimney effect isincluded.

It is desired to maintain the chute wall temperatures below 250°C to preclude partial-mehing of the feedstock and consequent potential cake and blockage issues. As the results indicate, for most of the chute run, the wall temperature is below this value - even when the chimney effect is included. However, the temperature of the chute walls is well above this level in the vicinity of the penetration through the off-gas hood. Therefore, a supplementary means of cooling the chute in this region will be required. In order to estimate the magnitude of cooling required, the model includes a feature to extract a prescribed quantity of power from each ring-segment used to represent the chute. In this analysis, the cooling "load" is adjusted for the bottom segment of the model until a chute wall temperature of approximately 250°C is obtained. For the case wherein the chimney effect is included (a condition that is not quite consistent with ongoing material feed operations), the analysis indicates that, without supplementary cooling, the lowermost chute segment is approximately 484°C. The segment immediately above this lowermost one is at 260"C. The other segments of the model indicate chute wall temperatures below 250°C. If a supplementary cooling feature is employed to remove 4.3 kW from The lower segment, the maximum chute wa[l temperature is below 250°C for the entire length of the chute. When the chimney effect is not included in the model, the lower most chute segment is still approximately 482°C without supplementary cooling. For this case however, a supplementary energy removal rate of 4 kW applied to the lowermost chute segment results in chute wall temperatures below 250°C over its entire length.

5.0 OFF-GAS INLET LINE HEAT LOAD TO THE AWTE

The dimensions and configuration data for the DBVS ICVTM off-gas inlet line are obtained from the drawings provided in Ref. S. Relevant portions of these drawings are reproduced here in Figures 4 and 5. The drawings indicate that, during melt operations, the off-gas inlet line protrudes through the ICVT"' off-gas hood approximately 2'h". The line extends from its penetration in the off-gas hood, up through the AWTE floor, through the AWTE air-space, and out an AWTE side wall. The off-gas inlet line is composed of 4" diameter tubing. The wall thickness of the chute is 0.237". The line is not insulated. The line draws ambient air into the off-gas hood. The temperature of this inlet air is assumed to be 50°C, corresponding to operating during a hot sunmter day. An off-gas inlet volumetric flow rate of 115 acfm was modeled (Appendix A).

Cnlunlaunn SMm[ QAY 31. aev „11615-051

A4-1687 RPP-24544 REV lb

CALCULATION SHEET

ProjeaNa 0509206,01 cakvleBanTb.0504206.01-M-064 Rev.No.1 Paga14o.13of159 Tnla t)BVS AW7E 7hmnd Lnad hrvmtory PRpared By: P.S.l.oway [7M: 2.14.06 (]Mxked By: S.R. Pienx pab:2t4.06 Convection, conduction, and radiation hest transfer between the inlet line and its surroundings are modeled in this analysis. The complete h9athCad model ofthis system is provided in Appendix E. For the pmposes ofthis analysis, the temperature ofthe top surfatx of the meh is set at 1050°C. The off-gas plenum air-space is set at 875°F. Since the flow velocities within the AWTE are relatively low, convection heat losses from the surface of the inlet line are modeled using a natural convection correlation for the convection heat transfer coefficient, assumingturbulentconditiona t09}. ThiscotreiationisprovidedinRef.S. TheAWTEair-space and upper surface ofthe AWTE floor are assumed to be at a temperature of 77°F.

The temperature distribution along the-I8' length of inlet line extending from the penetration in the ofRgaa hood through the AWTE wall penetration is represented by discretizing the chate into 18" segments. The steel walls of the chute are modeled in each segntent, as is the column of air contained within the chute. Both convection and radiation heat transfer from the external surfaces of the chute to the AWTE surroundings are modeled in this analysis. Conduction heat transfer in the steel walls along the length of the chute from one chute segment to its adjoining segments is also modeled. Convection heat transfer between the interior surfaces of the chute walls to the inlet air flow within is modeled.

.«..'.",^'r...

.p,...,a.... ^^^ ,...... a..

^ a

aro ^+ti r.nrY.w .oowa.w"

wu.T Wmnnrqu foat cUrolECttn - 3CCnM w[W wu: r.r.e

Figure 4. Elevation view of the off-gas line in the vicinity of its penetration through the AWTE floor and off-gas hood.

CukvfmanS4crt OAP3.J,R

A4-1688 RPP-24544 REV 1b

PF E S CALCULATION SHEET

Projec[Na.t1509206.01 C.akufetiooTlo.o509306.D1-M-004 Rev.Nal PageNo.14uf159 Tkk: DBVSAWTB7Aermall.oedlnventory Propaed By: P.S. l.oway IHte: 214A6 (Tecked By: S.iL Pieree Dtle: 2.15.06

eReuuo duaft

WARI pa.. . - t :t- y .,, ...... ^aRrt•.ss8atr . ^ ^ so-2

ah u63rua . ^ ♦

.^ I

t +waa: raNoa rJaaav.5MM

Figure 5. Elevation view of the off-gas inlet line run in the AWTE. The coupled system of non-linear equations arising from performing an energy balance on each model segment used to represent the off-gas inlet line and associated air column is solved using MathCad. The complete model and system of equations is presented in Appendix E. The results obtained from this model indicate that the steel walls of the inlet line range in temperature from approximately 415°C near the connection with the off-gas hood, down to approximately 43°C near the AWTE side wall penetration. The convective and radiative losses to the AWTE air-space are -2'/, kW.

6.0 OFF-GAS EXHAUST LINE HEAT LOAD TO THE AWTE

The dimensions and configuration data for the DBVS ICVTM off-gas exhaust line are obtained from the drawings provided in ReG 8. Relevant portions of these drawings are reproduced here in Figures 6 and 7. The drawings indicate that, during melt operations, the off-gas exhaust line protrudes through the ICVTM off-gas hood approximately 2'l2'. The iine extends from its penetration in the off-gas hood, up through the AWTE floor, through the AWTE air-space, and out an AWTE side wall. The off-gas inlet line is composed of 6" diameter tubing. The wall thickness of the chute is 0.280"- The line draws hot off-gases generated during

CbkWolion SMec QAP i 1 Rn 6111-IS-Oil

A4-1689 RPP-24544 REV lb

CALCULATION SHEET 4i PtojatNo.6509206.01 caleutubnTio.0509206.o1-Af-004 Bav.No.l PqeNo.lSof1S9 Tnlm DBVS AWTE T6enml i.oadtnvenmry Prepued By: P.S.l.owny Date: 2.14A6 theekod By: SR Piaee D^ 2.ISA6

o e : ,,, e

uv^^m +.w

.ww

l.w.... ^ i

Olf-c+5 txwWSr roRT CWMrGnn 6aD ^MSUUIED- SCCIroN wc r.r.r

Figure 6. Elevation view of the off-gas exhaust line in the vicinity of its penetration through the AWTE floor and off-gas hood.

CalnJmanJ'lwac QN'3J.Rcv6411-15-05)

A4-1690 RPP-24544 REV 1b

A-^ CALCULATION SHEET

Po'aie"Tb.0509206.01 CabulationNo.0309bD6.01-M-004 Rev. No. I PageNo.16of1i9 TAIe: bBYS AWTE Tbernal laad ]nvt»bry Preparcd By: P.S.I.owary Date: 2.14416 Chedud By: SR Piem Dne:2.15.06

( WEiaw wa eaitaiie oWnri 1 I a°" a""M" 1

. aanno ^ ^ t ^ .. t a^^ ro W3 ' -^- ' ^ 1 ^'^ rsof j ^ I vetm.A*+oM 1 MWW ( „ _ . we? ¢ucr

nFCUaae 1 Y_ t ^sxonw 1 t raa twwr. 1 t t t ►t

Figure 7. Elevation view of the off-gas exhaust line rnn in the AWTE.

processing from the off-gas hood. The temperature of this exhaust air is assumed to be 875°F (-470°C) per the 1 flow sheet provided in Appendix A. The off-gas exhaust volumetric flow rate is 406 acfm (per Appendix A t process flow sheet). The entire length of the exhaust line located inside the AWTE is wrapped with a 2" thick t I insulation blanket (or better), enclosed in a stainless steel jacket (Cotronics data sheet, Appendix B). I 1 Convection, conduction, and radiation heat transfer between the exhaust line and its surtoundings are modeled 1 in this analysis. The complete MathCad model of this system is provided in Appendix F. For the purposes of this analysis, the temperature of the top surface of the melt is set at 1050°C. The off-gas plenum air-space is set at 875°F. Since the flow velocities within the AWTE are relatively low, convection heat losses from the surface of the exhaust line are modeled using a natural convection correlation for the convection heat transfer t 1 coefficient, assuming turbulent conditions (i.e. - 6r-Pr> 10). This correlation is provided in ReL 5. 1 Convection beat transfer from the hot off-gas exhaust to the inner surfaces of the exhaust line are modeled using I 1 a Nusselt number corresponding to turbulent tube flow. The AWTE air-space and upper surface of the AWTE 1 floor are assumed to be at a temperature of 77°F.

1 The temperature distribution along the -18' length of exhaust line extending from the penetration in the off-gas hood through the AWTE wall penetration is represented by discretizing the chute into 18" segments- The steel 1 walls of the chute are modeled in each segment, as is the column of air contained within the chute. Both 1 convection and radiation heat transfer from the external surfaces of the chute to the AWTE surroundings are 1

1------CSkdaaun$hen. QAP3.I.R^6111-13-031

A4-1691 RPP-24544 REV lb

CALCULATION SHEET 9R Pro]ectNo.a509206.01 7leulatanTb.0509206.01-M-0p4 Rev.No.l PageNo,l7ofi59 TAk: DBVS AWT@ 7hamal Load Invenkay Prapand By: P.3.l.rnmy Date: 1 14A6 Checked By: SR Pkra Dam 2.15.06 modeled in this analysis. Conduction heat transfer in the steel vrells abng the length of the chute from one chute segment to its adjoining segments is also modeled. Convection heat trensfer between the interior surfaces ofthe chute walls to the exhaust air flow within is modeled.

The coupled system of non-linear equations arising from perfonning an energy balance on each model segment used to represent the off-gas exhaust line and associated air column is solved using MathCad. The complete model and system of equations is presented in Appendix F. The results obtained from this model indicate that the steel walls of the exhaust line range in temperature fiom approximately 800°C near the connection with the off-gas hood, down to approxnnateiy 440'C near the AWTE side wall penetration. The temperatures on the exterior surface of the exhaust line insulation jacket range from -130°C aear its connection with the off-gas hood, down to -90°C at the AWTE sidewall penetration. The convective and radiative losses to the AWTE air- space are-2Y: kW.

7.0 AWTE FLOOR HEAT LOAD FROM THE OFRGAS HOOD

A simplified model of the heat exchange between the off-gas hood and AWTE floor was developed. The model incorporates the effects of radiation heat transfer from the off-gas hood to the bottom surface of the AWTE floor. The temperature of the off-gas hood is assumed to be at its design limit, 570°C. The heat transferred to the bottom surface of the AWTE is either convected back to the air space between the off-gas hood and AWTE floor (assumed to be at a temperature equal to the average of the off-gas hood and AWTE floor bottom surface temperatures), or it is conducted to the top surface of the AWTE floor. The temperature of this surface is assumed to be 77°F. The heat transferred by conduction through the AWTE floor is to be removed by a supplementary A WTE floor cooling system so that the 77°F AWTE floor upper surface can be maintained.

The MathCad model generated for this analysis is provided in Appendix C3. The results of this analysis indicate that the temperature of the bottom surface of the AWTE floor is 43'/.°C. With the top surface at 77°F (25°C), this results in a net heat transfer by conduction through the 3h" steel floorof 372 kW (-106 tons refrigeration). This energy transfer must be handled by the AWTE floor cooling system.

Table I provides the results for the AWTE floor cooling load and bottom surface temperature for a number of assumed hood surface temperatures. These results provide a means to evaluate the sensitivity of the results to changes in ,his parameter.

Ca1cWm1on56cn 0AP31 Rcv.611I13-05)

A4-1692 RPP-24544 REV I b

A? c S CALCULATION SIIEET

Project No. 0509206.01 Calculation No. 0509206.01-M-004 Rev. No. 1 Page No. I S of 159 7itlc: DBVS AWTE 7hamat Load Inventory --^ -7 Prepared By: P.S. t.owery I uate 2.14.0(i Checkcd IIv: S.R Pierce 1 llate: 2.15.05

Table 1. AWTE floor cooling capacity and bottom surface temperature sensitivity analysis.

f 'W S' sY .3'. '• t d +„^. Mj i i` ^S+•^ m ett^ t^`S } ^te^a x oyt ^ ^^^ *^^^^x. W^^r^^ 570 372 _106 43 500 266 _ 76 38 450 205 60 35 400 155 45 33 - _._----- 350 115 33 31

8.0 CONCLUSIONS

Computer models are generated to estimate the temperature distribution and associated heat losses off the major components housed within the All'TE. 7hese include the electrode bus bar and contactor assembly, the portion of the electrodes exposed to the A WIL environment. the material feed chutes and the off-gas inlet and exhaust lines. The heat load ernanating from the elevated temperatures of the off-gas hood and delivercd to the A W'iE air-space by conduction throueh the AWTE floor is also estimated in this analysis. The results presented herein assume that this heat load will be hsndled by a separate cooling system located in the A WTL (loor. Therefore, this load is not transmittcd to the AWTF air-space

The results obtained from the analysis of the bus bar, exposed electrode seome-nt, material feed chutes, nnd off- gas inlet and exhaust lines are summarized in Table 2 below. the -'unit" loads ofeach assembly modeled :ne provided in this table, along with the number of rmits present. The total heat load to the AW'TE is obtained by multiplying the unit loads by the number of units. This total load is also presented in Table 2.

'the model results indicate that the chute wall temperature in the lo^rer portion of the rnaterial feed chutc exceeds the desirrd 250°C limit_ If n supplemen7ary ( oolin- system is nnplo}-ed to remove 4 to 4! k4J (-I Y, tons rcfri R uration) from the chute v,'all in the vicinity of the chute penetration throuvh the A11'"fE. floor and ofi gas hood port. the temperature of the chute wall can be reduced to below the 25o'C tarl-et. This cooling capaeity represents the cnerev that most be rcrnoved frum the chute. II docs not account for incfficiencies in the chute cooling system employed for this purpose ^

A sepnrate analysis of the euugv excham>e betwcen the olf"as hood and A1Vlli floor ^eas perfamed to provide an cstitnate oflhe t nei,,v rcmoval capacitv reyuircd to maintain the top surface ofthe AWTE floor at the t u2ct 777 _ Ihe results of this rmal}sis indicated that. mhen the ofl-^^ns hood Icmperaturc is at its desi^n limu of 770_C tlic ,A Wl G fxxk coelin 2 111stent nIust be capahlr of removin> >72 kW (- 10(, lons retiigeration) in order to maintain this AWI LL top _urface temperature. This r.nenv rcnro•"id culvacity dors not inelude the cftccts of Ihermnl mclliciendes in the utcrry renInv d pr^sces;. Ui course_ los^erine the hood ternpmrturrs

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ProjeetNo.0509206.01 CalculationNo.0509206A1-M-004 Rev.NO.I PageNo.l9of159 75tb: DBVS AWTE Thermal6oad Inventory Prepared By; P.S. Lowery Date: 2.14.06 Checked By: S.R. Pierce Date: 2.15.06 results in a corresponding reduction in the required AWTE floor cooling capacity. The results presented in Table I above illustrate the relationship between these parameters.

Table 2. Component heat loads to the AWTE air-spacett).

"I)ilif I^eatLoad Numher TotalComponen k! ^mponenC : i to ihe V1^ ot `i AWT^ Heat T oz^ ^S^TE ^^4:^_ Bus Bar/Clam p Assy . 0.25 2 Y: 0.14 Exposed Electrode Segment 12Y: 2 25 7.14 Material Feed Chute 10 5 50 14.28 Ot7Gas Inlet Line 2% 1 2%: 0.71 Off-Gas Exhaus Line 2% I 2% 0.71 Total -80%z -23 Note: (1) Heat loads from the off-gas hood to the AWTE floor are handled by the AWTE floor cooling system. Therefore, there is no net heat load from the off-gas hood to the AWTE air-space. The AWTE floor cooling system load is discussed in Section 7.0.

As the results in Table 2 indicate, the largest contributor to the AWTE air-space heat load derives from the five material feed chutes. The results presented in this table reflect the case when the "chimney effect" is modeled. If this effect is neglected, the contribution to the AWTE air-space heat (oad is reduced roughly in half, to 5 kW per chute. Incorporating this into the inventory list would result in an overall reduction in heat load to the AWTE air-space of 55 kW (- 16 tons refrigeration).

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Pn+jeetNo.0509206.01 (:alaltl0onNo.0509206,01-M-004 Rer.No.t PageAlo.20d'159 ]file: ABVS AWTE 7hanql Lmd inveabry PreparolHy:P.S.t.ovrery i)ote.2.14.06 C7teckedBy_S.R.Piaee tMw 2.15.06

9.0 R)vA'EI2ENCES l. oM]M H+N Amendttwntto Consulting Agreement No. A77977-CA-003, Rev. 3. January 25, 2006. 2. AMEC drnwings: • Draft F-145579-34p-0004, Rev. G, "AWTE Floor- Electrode Cable Clamp Installation" • Draft.F-145579-34-D-0012 thru .0016, Rev. A, "AWTE Floor- Electrode Cable Clamp"

3. Handbook of Chemistry and Physics, 56a' Edition, 1975, CRC Press, Inc. 4. MathCad 2001 i, Mathsoft Engineering & Education, Inc., 20D1. 5. Holman, J.P., Heat 7tansfer. 31d Edition, 1972, McGraw-Hill Publishing Coritpany. 6. ARES Calculation 0509206.01-M-002, Rev. 0, "DBVS OtiGas Hood Thermal Analysis." 7. Siegel, Robert and J.R. Howell, Thermal Radiation Heat Ttansfer. 3rd Edition, 1992. Hemisphere Publishing Company. 8. Thompson Mechanical Inc. drawings: • H F-745579-D-SP-017-M-101, Rev. G, "AW'f'E ICV Box Lid Material Feed Port," 1/25l06. • # F-145579-D-SP-017-M-102, Rev. G, "A WTE ICV Box Lid lnlet & Exhaust Ports," 1/25/06. 9. Email, Ja-Kael Lucy to PS Lowery, "Outline of Work Scope for ICV Box Lid. Calculation," dated 11.23.05Q13:51. 10. Personal Communication, PS Lowery (ARES) with Steve Strecker (Meier), 1.27.06 @ 09:30. 11. Email, Jerid Mauss to Pat Lowery, `FW: Amp Draw for Electrodes', dated 02/14/06 Q 08:14. 12. Email, Jerid Mauss to Pat Lowery, "FW: Scanned from MPP-OOE53240 02/13/2006 12:03", dated 2113/06 ® 17:05.

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APPENDIX A

DMJM H+N STATEMENT OA WORK AND CORRESPONDENCE WITH DMdM H+N

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JrKeN GENERAI 1. FormalaWq4slbnperAF^Bpraosdtns. EkWCiyPonbbrsameMOddrgandaollatMaveitleNnnae pedmnM la ARES Cakuwan No.0518¢00.01-M^001. 2. Aseune that an bAb) naelYig to 6sprs bandery eoMUens wt be held kr AM$ EbE, CiRU NBA, and OpUM H6N to wnwe Wh bedel SM^np. 3. ASwmerAONWonwlOberwkredbyAMECE3E.ObUAlHedi.endqi2AAHYLInpmeM. 4. AsswemeeYn9brawlveanuNNSWrituica)oda6oniswa. 5. Cakumiw+rriAaaUmmlNadfo0M3htH&NfdA-sbbNlonbre'ri9sere. GLLp/4ATPON I. PWp0a dthccelnde6d1hh1WmMNSihelemPerabredMlelCVBmttld. 2. Scope: Cordtmn to be avYmled is when the yess melao levd is cl)seat to the ICV 0ett Yd. See enedotd Ne1w mdgmMion b M cunsidersd. Asn^dVN69na,tha MrtpxMVeabOV1 tlmsWN3^o &ecrbavadeENbovideryoorMWon. Thrcecassarsbbeave)oaNtlbrtlrAWfENrSpacct)T. 77F. Y) T=Q6UF. aM T- WOF. RCf IIieee aaMitlOn6 tlm MlnpefaRUe q tlN fCV bGlf W 8MM M9M plnN Iqur arrd hleraN (tlda wp puideaie tleaign of etry needed cm6rg ahova tlw sNN noor to adibre a byatld EanplfaNfe). 3. AnIVnp6ma idtatlpdhaNewNhhptild•aWx+ga TheaodiawingesnalnppbCrodavNoptoedd9•e mwM. 9imp6gM1gae. sf.u^nplaK Mr this calaAatlwl bnrArde Yna1Mp tlw Id n a ahgbaodep witlbW the PdNlfadpnaraheBvq^eOt.:a8^B^1NMWWqdpBnetra^dla. aetabTBn(^bdN^a^fronr meee assumqWns Is expawd In 8» edaaalbn (La. wMmer the restAs aro. or arc M. mtWavalNe by not btlutling nw etlqed w+nparoMe and esaoci8ted llurmd nx War). As neelbd. clob WIrer ssanwfbns mada to• ttte cakWeEm. 4. MeHtoddtgy Sbte metlwd end appoaah used 5. Resutx and Coectusbnc As appwpriete. 6. SonwarsVaiaWOnandvnYlcrbre Provbeasapqapdate.

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APPENDIX B

GRAPHITE ELECTRODE AND OFF-GAS EXHAUST LINE INSULATION PROPERTY DATA TRANSMIITALS

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ProjatNo.0309206.01 [email protected] Rev.Nu.7 Ps®tNo.29of139 Titic DBVS AWTE SLamRI [aRd ImefMSy Ptepced By: PS Lowety DRte: 2.14A6 Qir,dted 8y: SR Ptatce Daox 215.06

smtts Mandey, FeMvuy 13. 2pq6 2=19 Vx Tot 2eithaN, Millian Oobjeot: ttl: yOSOnW V^ 1!B}0851240 02113/2006 12,03

Prow: Pat Lowery IReilto.picrery^aieatOrypration.conj xont: lWSday, Ys)QVOSy 13, 200'6,.12:10 1M' 'ib. MeOSS, desld 'lub)ectt FM. Bcatmad fics 1VP.00293RaU 02/13/2006 12,03 Jerid -

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----_Ori0inal MmeaqR-__-- Froe: RicRland Capiat (Aailto:Rlchlaad0opieriueecotyoation:eav] Sent, ibnduy, Pebroaxy 13, 2006 12:04 IM 10: Pat Lol+ety 6ublects 8camed froW iVG-0OR53260 02/13/2006 12:03 Stazmed fYam RFF00853240. nato: 02/i311006 12:03 FaYee:i floaolutioo:200x200 riPI ------.,-^e.._.._

9M inlvtmation contained in this e-mail is intended only tor the fadividuRi or entity to Mrc# it is addreseed.

Its contsOte fincludin® any attac/uentei may contain t•onfidential and/or priyllegad inforeetion.

if YOU are not an intended taciyient yau Rast not nxa, diaclosc, diaesainatn. copy or print it0 contentc.

If voo reeeive this e-mail in error, plose notify th0 Sender by reply e-sail and delete and destroy eno nasaa0e.

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J¢ddM9n85 The lnfonnalionemmined in this o-ma7 is irxendal only for the individual or entity W wlwm fl Is addmax& its conwus fumluding wy avac>h*nts) may contain coufideniipi anW/w privSteatd qd'wagrion. if you ue not an inlended recipient you muu net va, dpcluse, dksemwaw, copy or qwr in canlenb. If you receivc this e-mail in wror, Pleme owNy The senda by nplY e-mail and delde and destroy the uwange.

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APPENDIX C

MATHCAD MODEL TO ESTIMATE THE TEMPERATURE DISTRIBUTION AND HEAT LOSS OFF THE EXPOSED ELECiRODE SURFACFS IN THE AWTE

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