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Wcap-10574 Westinghouse Class 3 Decontamination

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Wcap-10574 Westinghouse Class 3 Decontamination WESTINGHOUSE CLASS 3 WCAP-10574 DECONTAMINATION AN0 DECOMMISSIONING OF THE WESTINGHOUSE NUCLEAR FUEL FACILITY AT CHESWICK, PA FOR : UNITED STATES DEPARTMENT OF ENERGY CONTRACT NO. ,DE-AC06-82RL10363 Volume 1 of 2 p4. ;rii -3 J. V. Oenero R. A. Lange M. L. Ray J. L. Shoulders H. C. Woodsum- June 1984 APPROVED: '1 v. cd?po, Manager Engineering and Technology Service Work Performed Under Shop Order Number PFDL-50503 WESTINGHOUSE ELECTRIC CORPORATION NUCLEAR ENERGY SYSTEMS P.O. 80X 3912 PITTSBURGH, PA 15230 7471E:lb/O61384 DISCLAIMER This report was prepared as an account of work sponsored by the United States government. Neither the United States nor the United States Department of Energy, nor any of their employes, nor any of their contractors, subcontractors, or their employes, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, mark manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. I {520B:lb/061884 111 ABSTRACT ..+ This report documents the efforts associated with the decontamination and decommissioning of the Westinghouse Nuclear Fuel Facility at Cheswick, Pennsylvania. The facility and its operations, along with non-destructive assay techniques, the management of transuranic waste, and the equipment required for dismantling and packaging these waste, are described. The report also presents detailed plans and procedures that were developed and implemented for this effort. The construction and use of a sectioning facility for large contaminated items is also discussed, and the results of the radiological survey are summarized. Finally, recommendations are given for the decontamination and decommissioning of existing facilities and for the design and construction of new facilities. V 7471B:lb/O61384 TABLE OF CONTENTS 2 action Title VOLUME 1 1 SITE/FACILITY OESCRIPTION l-l 1.1 INTRODUCTION l-l 1.2 FACILITY AND OPERATIONS l-l 1.2.1 Background l-1 1.2.2 Laboratory Facilities l-4 1.2.3 Other Facilities l-7 1~.3 LABORATORY OPERATIONS l-8 1.3.1 Introduction l-8 1.3.2 Operations Performed l-8 1.3.3 Laboratory Facilities l-9 1.3.4 Support Facilities 1-17 1.3.5 Facilities Equipment 1-18 1.3.5.1 Glove Boxes l-18 1.3.5.2 Glove Box Equipment l-20 1.3.5.3 Fume Hoods l-20 1.3.5.4 Glove Box and Fume Hood Ventilation l-20 1.3.6 Contamination Problems During Operations l-20 2 PROJECT SUMMARY 2-l 2.1 OBJECTIVES 2-l 2.1.1 Initial Work Scope 2-l 2.1.2 Final Scope of Operations 2-6 2.2 HANDLING OF EDUIPMENT FROM GLOVE BOXES FOR DISMANTLING AND DISPOSAL 2-8 2.3 REMOVAL OF LIQUID PROCESS PIPING Z-10 2.4 DECONTAMINATION OF GLOVE BOXES AND HOODS 2-15 2.4.1 Procedure Development 2-15 2.4.2 Development Survey Data Results Z-20 2.5 DISMANTLING FACILITIES 2-22 2.6 SECTIONING OF GLOVE BOXES 2-32 ?' 471B:lb/O60884 vii TABLE OF CONTENTS (Cont) Section 2.7 HANDLING OF THE SINTERING FURNACE 2-34 2.8 HANDLING OF PROCESS TANKS AND GLOVE BOXES 2-38 2.8.1 Glove Box No. 231-A 2-38 2.8.2 Glove Box No. 241 2-40 2.8.3 Glove Box No. 242 2-42 2.8.4 Glove Box No. 233 2-43 2.9 HANDLING OF CONTAMINATED DUCT AND FILTER CAISSONS 2-43 2.9.1 System Description 2-43 2.9.2 ,Removal of Duct 2-45 2.9.3 Filter Caissons 2-46 2.10 SUSPECT WASTE PIPES AND TANKS 2-48 2.10.1 Description of System 2-48 2.10.2 Dismantling Procedure 2-48 2.11 STRUCTURE INTERIOR SURFACES 2-51 2.11.1 Main Laboratory 2-51 2.11.1.1 Walls and Ceiling 2-51 2.11.1.2 Floor 2-51 2.11.2 Penthouse 2-52 2.12 NONDESTRUCTIVE .AS.SAY 2-52 2.13 WASTE MANAGEMENT 2-58 2.13.1 Waste Classification and Definition 2-60 2.13.2 Packaging Z-60 2.13.3 Transport Overpacks 2-76 2.13.3.1 Model N-55 Overpack 2-76 2.13.3.2 Model 6400 Overpack 2-76 2.13.3.3 Model 6272 Overpack 2-84 2.13.4 Containers 2-84 2.13.5 Shipments 2-84 2.14 RADIATION EXPOSURE OF PERSONNEL 2-84 2.14.1 Protective Equipment 2-84 . 7471B:lb/O60884 Vlll TABLE OF CONTENTS (Cont) Section Title 2.14.1.1 Protective Clothing 2-84 2.14.1.2 Respiratory Protection 2-91 2.14.2 Air Sampling Program 2-93 2.14.3 Bioassay and In Vivo Measurements 2-94 2.14.4 Personnel Dosimetry 2-94 2.14.4.1 Body Badges 2-94 2.14.4.2 Pocket Dosimeters 2-101 2.14.5 Personnel Exposure History 2-102 2.14.5.1 External Radiation Exposure .2-102 2.14.5.2 1nterna)Radiation Exposure 2-107 2.14.5.3 Results of Bioassay and In Vivo Counting 2-113 2.14.5.3.1 Bioassay Results 2-113 2.14.5.3.2 In Vivo Counting Results 2-115 PROJECT SCHEDULING AND ORGANIZATION 3-l 3.1 SCHEDULE 3-l 3.2 PERSONNEL ORGANIZATION 3-l 3.2.1 Operating technicians 3-l 3.2.2 Health Physics Technicians 3-4 3.2.3 Maintenance Personnel 3-5 3.2.4 Professional Staff 3-5 FINAL SITE CONDITION 4-l 4.1 PROCEDURES FOR RADIATION SURVEYS 4-l 4.2 RESULTS OF WESTINGHOUSE SURVEYS OF FACILITY 4-50 4.2.1 Preliminary Survey Results 4-50 4.2.2 Final Survey Results 4-51 4.2.3 Conclusions 4-53 I 7471B:lb/O60884 ix TABLE OF CONTENTS (Cant) Section Title 4.3 RADIOACTIVE EFFLUENT EFFECTS ON THE SURROUNDING AREA 4-59 4.3.1 Concentrations of Airborne Effluents at Stack Release 4-59 4.3.2 Off-Site Radiation Exposure Estimates from Airborne Effluents 4-61 4.3.3 Concentrations of Liquid Effluents at Release 4-63 4.3.4 Off-Site Radiation Exposure Estimates from Liquid Effluent Releases 4-63 5 CONCLUSIONS AND RECOMMENDATIONS 5-l 5.1 CONCLUSIONS 5-l 5.2 RECOMMENDATIONS FOR DECONTAMINATION AND DECOMMISSIONING OF AN EXISTING FACILITY 5-l 5.3 RECOMMENDATIONS FOR DESIGN OF A NEW FACILITY 5-3 5.3.1 Glove' Boxes and Equipment 5-4 5.3.2 Contaminated Liquid Waste Handling Systems 5-6 5.3.3 Air Handling Filters 5-6 5.3.4 Liquid Waste Monitoring System 5-7 5.3.5 Facility 5-7 6 REFERENCES 6-l APPENDIX A CONTAMINATED EQUIPMENT CONTAINED IN THE PFDL FACILITY A-l APPENDIX B PFDL OPERATING PROCEDURES, PFDL ADMINISTRATIVE B-l PROCEDURES, PFDL ANALYTICAL LABORATORY PROCEDURES, Plus Micro- AND CHESWICK SITE INDUSTRIAL HYGIENE PROCEDURES fiche 747lB:lb/O61384 X TABLE OF CONTENTS (Cmt) Section Title VDLUME 2 ,PPENDIX C REQUESTS FOR APPROVAL AND DRAWINGS FOR GALVANIZED C-l DRUMS, EPOXY COATED CORRUGATED STEEL BOXES, FIBERGlASS-REINFORCED POLYESTER-COATED PLYWOOD BOXES, NON-TRU WASTE CONTAINERS ,PPENDIX 0 CERTIFICATES OF COMPLIANCE FOR OVERPACKS D-l \PPENDIX E TRAINING PROGRAM ON USE OF FULL-FACE RESPIRATORS E-l (PPENDIX F RADIOLOGICAL SURVEY MEASUREMENT EQUIPMENT F-l LPPENDIX G HEALTH PHYSICS CHECKS ON DECONTAMINATED AREAS G-l IDENTIFIED IN ORAU/NRC SURVEY \PPENDIX H TOOLING, EQUIPMENT, AND SUPPLIES H-l xi LIST OF ILLUSTRATIONS Title Figure 1-l Plutonium Fuels Development Laboratory, Building 8, Ground Fiuor l-5 Figure 1-Z Plutonium Fuels Development Laboratory, Building 8 l-6 Figure l-3 Glove Box Containing a V-Cone Blender for 8lending Mixed Oxide Powder l-10 Figure l-4 Glove Box with Typical Air Lock l-11 Figure l-5 Typical Analytical Laboratory Glove Box After Oecontamination of Interior Surfaces l-12 Figure l-6 Glove Boxes Containing the Sintering Boat Return Conveyor System l-13 Figure l-7 Typical Chemical Processing Glove Boxes l-14 Figure l-8 Typical Standard Type Laboratory Glove Boxes l-19 Figure l-9 Typical Analytical Laboratory Fume Hood' l-21 Figure Z-l Overhead View of Typical Chemical Processing Glove Box Plutonium Nitrate Liquid Transfer Piping 2-11 Figure 2-Z Overhead view of Typical Chemical Processing Glove 80x Plutonium Nitrate Liquid Transfer Piping 2-12 Figure 2-3 Technicians Cle'aning Ceramic Laboratory Glove Box 2-16 Figure 2-4 Analytical Laboratory Glove Box After Decontamination and Disconnection, Prior to Dismantling 2-19 Figure 2-5 Construction of a Typical Dismantling Facility Showing Plastic Covered Framework Construction 2-26 Figure 2-6 Typical Dismantling Facility Layout Showing Functional Areas 2-27 Figure 2-7 Typical Dismantling Facility Showing Flow Patterns 2-28 Figure 2-8 Typical Central Communications Center Located Outside a Dismantling Facility 2-30 Figure 2-g Plastic-Wrapped Cut Glove Box Sections on Handling Carts 2-35 Figure 2-10 Plastic-Wrapped Cut Glove Box Sections Stored on Pellets 2-36 . !47lB:lb/O61384 x111 -,,:I ,.&, ‘..., .,: -.. , LIST OF ILLUSTRATIONS (Cant) m Title' Figure Z-11 Ceramics Laboratory Pellet Sintering Furnace Complex 2-37 Figure Z-12 Ceramics Laboratory Sintering.Furnace Main Heating Zone after Disconnecting 2-39 Figure Z-13 Liquid Storage Tank R-15, Located in Glove Box Z+l, with Section Removed Exposing Raschig Rings 2-41 Figure 2-14 Typical Array of Glove Box Air-Handling Duct with Smaller Sections Removed 2-44 Figure 2-15 Typical Glove Box and Room Air-Handling Filter Caissions Located in the Penthouse 2-47 Figure 2-16 Partially Exposed Suspect Liquid Waste Holding Tanks, Located Outside the PFDL Building 8 2-49 Figure 2-17 Suspect Liquid Waste Holding Tanks After Removal from the Ground 2-50 Figure 2-18a Waste Segregation 2-61 Figure 2-18b Packaging -- Hard Combustible Waste 2-62 Figure 2-18~ Packaging -- Hard Noncombustible Waste 2-63 Figure 2-18d Packaging -- Soft Combustible Waste 2-64 Figure 2-18e Packaging -- Special Casesd of Waste 2-65 Figure 2-18f TRU Waste Packaging for Shipment in Galvanized Drums 2-66 Figure 2-18g TRU, Waste Packaging for Shipment
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