Title: 242-A Evaporator System Integrity Assessment

Title: 242-A Evaporator System Integrity Assessment

STATEMENT OF WORK

Requisition #: 291870

Title: 242-A Evaporator System Integrity Assessment

Revision Number: 0

Date:8/4/2016

1.0Objective

The purpose of this statement of work (SOW) is to procure the services of an engineering firm to provide a professional engineer registered by the Washington State Department of Licensing, or by a state that has reciprocity with the State of Washington, to serve as an independent qualified registered professional engineer (IQRPE) to prepare and certify a 242-A Evaporator (242-A) system integrity assessment report in accordance with 40CFR265.191, Assessment of existing tank system's integrity, Washington Administrative Code WAC173303640(2) Tank Systems: Assessment of existing tank system's integrity, 40CFR270.11(d) Signatories to permit applications and reports, and WAC173303810(13)(a) General permit conditions: Certification.

Integrity assessments must determine that existing Resource Conservation and Recovery Act (RCRA) Hazardous Waste Treatment, Storage, and Disposal (TSD) unit/components are adequately designed and have sufficient structural strength and compatibility with the waste to be stored or treated, to ensure that it will not collapse, rupture, or fail. For each existing TSD unit/component, it must be determined that the system is not leaking or is unfit for use. A written assessment reviewed and certified by an IQRPE must be obtained and maintained as a record. The integrity assessment report should include a review of the elements identified in 40CFR265.191(b).

The 242-A system is classified by RCRA regulations, and WAC173303640, Tank Systems, as a final status, permitted treatment, storage, and disposal (TSD) existing tank system, operating in accordance with Dangerous Waste Permit WA 7890008967. Washington River Protection Solutions LLC (WRPS operates and maintains the 242A system on behalf of the U.S. Department of Energy (DOE) Office of River Protection (ORP). The State of Washington, Department of Ecology (Ecology) has regulatory authority for the 242-A System under WAC173303. To ensure environmental protection, Ecology requires that an integrity assessment of the 242-A system be performed on a periodic basis.

The last242-A System Integrity Assessment certified 242-A as fit for use, and recommended a ten year integrity assessment interval. The work described in this SOW is for the fourth242-A system integrity assessment covering the period from December 26, 2007, through September30, 2017 (the time period since completion of the 2007 integrity assessment), and certifying the 242A is fit for use. The integrity assessment is expected to utilize the contents of the earlier integrity assessments as its foundation. During the December 26, 2007, through September30,2017 period new design, construction and installation of 242-A system units/components have required an independent qualified installation inspector (QII) or and IQRPE to inspect the new units/components before covering, enclosing, or placing them in use in accordance with regulations in 40CFR265.192 and WAC173303640(3).

Except as necessary to support certification of the 242-A system there is no expectation that the work completed during the previous integrity assessments will have to be repeated. The 242-A system integrity assessment report, approved by WRPS and ORP, is to be completed by December 14, 2017, for submittal to Ecology by December 26, 2017.

The scope of the IQRPE assessment per WAC173303640 is to:

  • Determine that the 242-A system is not leaking or is unfit for use.
  • Determine that the 242-A system is adequately designed and has sufficient structural strength and compatibility with the waste(s) to be stored or treated to ensure that it will not collapse, rupture, or fail. At a minimum, this assessment must consider the following:

-Design standard(s), if available, according to which the tank and ancillary equipment were constructed;

-Dangerous characteristics of the waste(s) that have been or will be handled;

-Existing corrosion protection measures;

-Documented age of the tank system, if available, (otherwise, an estimate of the age); and

-Results of a leak test, internal inspection, or other tank integrity examinations.

2.0Background/Introduction

The 242-A system has been designated as a tank system under (WAC)173303640(2). For existing tank systems, an integrity assessment must be performed to conform to the requirements found in 40CFR265.191 and WAC173303-640(2 certified by an IQRPE in accordance with 40CFR270.11(d) Signatories to permit applications and reports, and WAC173303810(13) a) Certification.

The 242-A system consists of the 242-A structure providing secondary containment, process vessels and ancillary equipment and the PC-5000 process condensate system supporting treatment of the radioactive, hazardous waste stored in the Hanford Tank Farms’ double-shell tanks.

An last assessment of the 242-A system was completed in 2007. The assessment is published in two volumes: RPP-RPT-33306, Rev. 0, IQRPE Integrity Assessment Report for the 242-A Evaporator Tank System;and RPP-RPT-33307, Rev. 0, IQRPE Integrity Assessment Report for the 242-A PC-5000 Transfer Pipeline.

The IQRPE certified the integrity of the 242-A system and made 53 recommendations (47 in RPP-RPT-33306 and six in RPP-RPT-33307) to maintain this certification. The recommendations have been dispositioned in RPP-44603, Rev. 1,242-A Evaporator Startup Report: Campaigns 2010-01 & 2010-02 (AW-102/AW-106 Slurry).

3.0Scope

The Subcontractor shall provide engineering services of an IQRPE for the development, preparation and certification of the 242-AEvaporator System Integrity Assessment report in accordance with the requirements of WAC 173-303-640(2), and 40 CFR 265.191. These services shall include development and preparation of the report, and any supporting reports prepared to determine the system’s fitness for use. The WRPS shall supply all necessary support services including publication and document control, etc.

The 242-A System Integrity Assessment Report must be certified by an IQRPE.

The Subcontractor shall ensure 242-A Evaporator System Integrity Assessment independence by utilizing a management chain-of-command and reporting structure that is separate from WRPS management reporting structure, and by utilizing staff with broad industrial experience applicable to this assessment.

The Subcontractor shall be responsible for managing the performance of the services including management and oversight of the work and Subcontractor personnel to ensure assignments are accomplished in an effective and efficient manner. The Subcontractor shall assign qualified personnel to individual tasks, and cooperatively and collaboratively work with WRPS in resolving and managing the review, and review findings, concerns, and issues that result from the Subcontractor’s integrity assessment.

3.1Integrity Assessment

The Subcontractor shall perform the integrity assessment on the existing 242-A system. The integrity assessment will review work performed by QII's and IQRPEs that inspected and certified project-related modifications to the 242-A system subject to 40CFR265.192 and WAC173303640(3) requirements during the period December 26, 2007, through September30,2017.

The integrity assessment will use the Code of Record current at the time the inspections and certifications were performed. Re-evaluation of work performed during the 2007 integrity assessment and post-2007 evaluations certified by IQRPEs shall be limited to the effort necessary to ensure the inspection work complied with the 40CFR265.192 and WAC 173303640(3) requirements. Other IQRPE and QII work that has been performed after the 2007 integrity assessment is listed in RPP-PLAN-60924.

The intent of the integrity assessment per WAC173303640 is to:

  1. Determine that the 242-A system is not leaking or is unfit for use.
  1. Determine that the 242-A system is adequately designed and has sufficient structural strength and compatibility with the waste(s) to be stored or treated to ensure that it will not collapse, rupture, or fail. At a minimum, this assessment must consider the following:
  1. Design standard(s), if available, according to which the tank and ancillary equipment were constructed;
  1. Hazardous characteristics of the waste(s) that have been or will be handled;
  1. Existing corrosion protection measures;
  1. Documented age of the tank system, if available, (otherwise, an estimate of the age); and;
  1. Results of a leak test, internal inspection, or other tank and ancillary equipment integrity examinations.

In addition the integrity assessment will include the following:

  1. Evaluation of the 242-A system structural integrity physical examination program (e.g., ultrasonic, video examinations, and leak testing).
  2. Results of the secondary containment assessment.
  3. Evaluation of the 242-A system corrosion protection measures that includes comparison and trending of tank and piping wall thickness data collected from initiation of inspections through the latest inspection (refer to RPPPLAN-69024, Table 1-1, and RPP-PLAN-60780, 242-A Evaporator Inspection Plan).
  4. Description of the spill prevention and overfill prevention controls and an evaluation of whether the equipment is in proper working order.
  5. Results of the review of the tank venting system contained within the integrity assessment scope boundary.
  6. Evaluation of the bonding and grounding system and its adequacy.
  7. Review of the efficacy of adoption of the 53recommendations identified in the 2007 Integrity Assessment Reports (RPP-RPT-33306 and RPP-RPT-33307).[1]
  8. An estimate of remaining useful life of the 242-A system, if practical.
  9. A recommended schedule of future 242-A system integrity assessments, “to ensure that the tank retains its structural integrity and will not collapse, rupture, or fail.”

The IQRPE shall make the following certification:

  • WAC 173-303-810(13)(a) Certification Statement for Final Status

“I certify under penalty of the law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fine or imprisonment for knowing violations.”

Integrity Assessment Exclusions

The following facilities and ancillary equipment are excluded from the 242-A System integrity assessment:

  1. Structuralfeaturesnotrelatedtodangerouswastesecondarycontainment.
  2. Architecturalfeatures notrelatedtodangerouswaste secondary containment.
  3. Lighting systems.
  4. System designfeaturesrelatedtoprotectionofthesystem due tovehiculartraffic.
  5. Functionalhardware/software logic foroperationandcontrolofthe 242-A system.
  6. Tank Farm Waste Transfer System supernatant lines (SN) upstream, slurry lines (SL), and drain lines downstream of the 242-A facility, including first valved or flanged connection inside facility structure. These lines were included in the 2016 DST integrity assessment, RPP-RPT-58441, Double-Shell Tank System Integrity Assessment Report (DSTAR).
  7. Air handling systems used to ventilate the 242-A system. The vessel ventilation system, including condensers E-C-1, E-C-2, and E-C-3, and the process condensate handling systems, includingthesealpotandassociateddrainlines and collection features of the vessel ventilation system upstream of the E-C-3 after-condenser air discharge, are included in the assessment.
  8. Plant utilities and services, including chemical supply storage and piping systems, instrument and plant air supply lines, steam supply and condensate handling, raw water handling and disposal and electrical power beyond the first upstream device or uninterruptible power supply systems that do not directly affect the ability of the system to prevent the collapse, rupture, or failure of components handling dangerous wastes.
  9. Instrumentationorsignal linesbeyond thefirstupstreamfieldterminationbox(FTB),motor control center(MCC),orinstrumentcontrolpanel (JCS). Electricalfeed,including wiring,localhandswitches,terminations,breakers,andotherequipmentor instrumentslocatedinmotor controlcenterswillbereviewedtotheextent theyaffect the abilityofthesystemtopreventthecollapse, rupture,orfailureofcomponents handlingdangerouswastes. Instrumentcablingand termination assessments willbe limitedto locallymounteddevicesandfieldterminationboxesand/orlocalinstrumentationand controlpanels to theextenttheyaffecttheabilityofthesystemtopreventthe collapse, rupture,orfailureofcomponentshandlingdangerouswastes.
  10. Radionuclide andradiationcontrol subsystems astheyareoutsidethescopeoftheWACdangerouswasteregulations. These include:
  11. Radiationmonitoringordetectioncomponentsthatmaybemountedatvarious locationsthroughoutthe system.
  12. Requirementsregardingwastefeedradionuclideproperties,includingradioactive andradionuclidepropertyconsiderations.
  13. Requirementsdevelopedtoensureexposureof plantoperatingpersonnelto radioactiveprocessstreams (radiation) isas lowasreasonablyachievable(ALARA).
  14. System safety features related to Personnel Safety, Fire Protection and Nuclear Criticality Safety.
  15. 242-A system dangerous waste treatment modifications for which design, construction or construction acceptance have not been completed.

At completion of the integrity assessment the Subcontractor shall provide the242-A System Integrity Assessment Report (as documented in the Master Submittal Register) that describes the evaluations performed, and provides WAC73303810(13)(a) certification by the IQRPE supervising the integrity assessment that the 242-A Evaporator system are fit-for-use, pursuant to WAC173303640(3).

4.0Submittals

In support of the work scope established in Section 3.0 above, submittals are listed on the Master Submittal Register (MSR).

Submittals shall be provided using the WRPS Incoming Letter of Transmittal (form A-6005-315). All transmittal subject headings shall contain, at a minimum, the subcontract number, submittal number, and submittal description.

Submittals shall be provided in electronic format unless available only as a hard copy. Electronic submittals may be sent to or delivered via a WRPS designated File Transfer Protocol (FTP) site. Electronic formats must be non-password protected in one of the following formats:

  • Microsoft® Office Compatible
/
  • Moving Picture Expert Group (MPEG)

  • Portable Document Format (PDF)
/
  • Extensible Markup Language (XML)

  • Tagged Image File Format (TIFF)
/
  • HyperText Markup Language (HTML)

  • Graphics Interchange Format (GIF)
/
  • Comma Separated Values (CSV)

  • Joint Photographic Experts Group (JPEG)
/
  • Text (TXT)

  • Windows Media Video (WMV)

Submittals identified in Section 4.0 shall be submitted in Microsoft Office Compatible format only. Portable Document Format shall not be used for Section 4.0 submittals.

The technical submittals include:

242-A Evaporator System Integrity Assessment Report

The report will provide the integrity assessment, and the observations, recommendations and findings (if any) identified during the integrity assessment. Observations, recommendations and findings will be described in sufficient detail to clearly indicate a resolution path if resolution is required, and will include the completion criteria that will allow closure.

The 242-A System Integrity Assessment Report shall include a crosswalk demonstrating how the requirements identified in WAC 173-303-640(2) have been met by the assessment. The crosswalk will include appropriate references to applicable documents, with a reference for each applicable component with regard to its assessment document, paragraph, or section. It is intended that the crosswalk will ultimately serve as a type of compliance matrix for the assessment of each applicable component. The RPPPLAN-60924, Section 7, lists components within the 242-A system that will be assessed.

Different organization and presentation of the 242-A System Integrity Assessment Report from that illustrated in RPP-PLAN-60924 may be proposed by the Subcontractor, subject to WRPS acceptance.

242-A System Integrity Assessment Submittal Review and Approval Planning Assumptions

  • The Subcontractor shall plan that the 242-ASystem Integrity Assessment Report will require preparation of:
  1. A draft “Revision A” report submitted for WRPS review and comment;
  1. A WRPS-approved “Revision 0” report with WRPS review comments incorporated for submittal for DOE-ORP review and comment;
  1. A final WRPS-approved, DOEORP approved “Revision 1” report for submittal to Ecology for review and comment;
  • Following the 242-A System Integrity Assessment Report submittal to Ecology, the Subcontractor shall plan that an additional review and comment incorporation cycle will be required to resolve Ecology comments.
  1. A final WRPS-approved, DOE-ORP-approved “Revision 2” report with dispositions of Ecology review comments incorporated.

All review comments will be prepared by the reviewers in writing and dispositioned by the Subcontractor in writing.

  • The Subcontractor shall plan that supporting reports if used, will require preparation of both a draft report submitted for to the WRPS for review; and a final, report submitted for WRPS approval. All review comments will be submitted in writing and dispositioned by the Subcontractor in writing.

Correction of Substantial Errors in Published 242-AEvaporator System Integrity Assessment Report and Supporting Reports, Documentation and Appendices

To make necessary substantive changes to an issued 242-A System Integrity Assessment Report and other reports (i.e., those that affect the IQRPE’s conclusions) a supplemental report must be prepared by the IQRPE. This process is consistent with applicable regulatory requirements provisions which provide that when an engineer reviews work done by another professional engineer, he/she must prepare a report addressing his/her findings, including supporting details. This report would make reference to, or be attached to, the original documents reviewed by the IQRPE.

5.0Acceptance Criteria

Subcontract work products and services shall meet applicable standards as referenced in 6.2 below. All deliverable documentation shall be complete, accurate, legible, and reproducible. Before delivery, design media and documents shall be reviewed by qualified Subcontractor personnel for technical adequacy and appropriate content. The Subcontractor shall attest, in writing, to the accuracy and completeness of the information contained in the final deliverables.

Submittals must be formally conveyed under retrievable letter. A registered professional engineer must stamp assessments, and all assessments shall meet the appropriate WAC requirements.

Work products and services provided must meet applicable WRPS procedures for control and review of work products.

6.0Configuration Management and Standards

6.1Configuration Management Requirements

Configuration management requirements for this Release are based upon the types of engineering services being procured and include the WRPS standards listed in Section 6.2 Applicable Standardsand the statements below.

New or revised Technical Documents shall be prepared in accordance with TFC-BSM-AD-STD-02, Editorial Standards for Technical Documents,and meet the document release criteria found in Table 3 of TFCENGDESIGNC25, Technical Document Control.

Reports prepared by the Subcontractor will be controlled by WRPS upon final acceptance.

6.2Applicable Standards

APPLICABLE CODES AND STANDARDS

Number / Title
1. / TFC-ENG-DESIGN-C-25 / Technical Document Control
2. / TFC-BSM-AD-STD-02 / Editorial Standards for Technical Documents

7.0ESH&Q Requirements

7.1Quality Assurance Requirements

The Subcontractor shall have an implemented Quality Assurance Program. This work is designated as Quality Level 3.

The subcontractor’s program shall be submitted for review/approval against the requirements identified on site form A-6006-661 Quality Assurance Requirements dated July 28, 2016. This work is designated as Quality Level 3.

7.1.1Supplier Quality Assurance Program

The Subcontractor's Quality Assurance Program shall be subject to review at all times, including prior to award.

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