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DOE OSTI2013

Grout Long Radius Flow Testing to Support Saltstone Disposal Unit 6 Design - 13352

The Saltstone Facility, located within the Savannah River Site (SRS) near Aiken, South Carolina, consists of two facility segments: The Saltstone Production Facility (SPF) and the Saltstone Disposal Facility (SDF). The SPF receives decontaminated legacy low level sodium salt waste solution that is a byproduct of prior nuclear material processing. The salt solution is mixed with cementitious materials to form a grout slurry known as 'Saltstone'. The grout is pumped to the SDF where it is placed in a Saltstone Disposal Unit (SDU) to solidify. SDU 6 is referred to as a 'mega vault' and is currently in the design stage. The conceptual design for SDU 6 is a single cell, cylindrical geometry approximately 114.3 meters in diameter by 13.1 meter high and is larger than previous cylindrical SDU designs, 45.7 meters in diameter by 7.01 meters high (30 million gallons versus 2.9 million gallons of capacity). Saltstone slurry will be pumped into the new waste disposal unit through roof openings at a projected flow rate of about 34.1 cubic meters per hour. Nine roof openings are included in the design to discharge material into the SDU with an estimated grout pour radius of 22.9 to 24.4 meters and initial drop height of 13.1 meters. The conceptual design for the new SDU does not include partitions to limit the pour radius of the grout slurry during placement other than introducing material from different pour points. This paper addresses two technical issues associated with the larger diameter of SDU 6; Saltstone flow distance in a tank 114.3 meters in diameter and quality of the grout. A long-radius flow test scaled to match the velocity of an advancing grout front was designed to address these technology gaps. The emphasis of the test was to quantify the flow distance and to collect samples to evaluate cured properties including compressive strength, porosity, density, and saturated hydraulic conductivity. Two clean cap surrogate mixes (Saltstone premix plus water) were designed to simulate slurry with the reference Saltstone rheology and a Saltstone with extra water from the process flushing operation. Long-radius flow tests were run using approximately 4.6 cubic meters of each of these mixes. In both tests the pump rate was 0.063 liters/second (1 gpm). A higher pump rate, 0.19 liters/second (3 gpm), was used in a third long-radius flow test. The angle of repose of the grout wedges increased as a function of time in all three tests. The final angles of repose were measured at 3.0 deg., 2.4 deg., and 0.72 deg.. The pump rate had the largest effect on the radial flow distance and slope of the grout surface. The slope on the pour placed at 0.19 liters/second (3 gpm) was most representative of the slope on the grout currently being pumped into SDU 2 which is estimated to be 0.7 deg. to 0.9 deg. The final grout heights at 1/3 of a meter from the discharge point were 115, 105, and 38 cm. Entrapped air (≥ 0.25 cm bubbles) was also observed in all of the mixes. The entrapped air appeared to be released from the flows within about 3.1 meters (10 feet) of the discharge point. The bleed water was clear but had a thin layer of floating particulates. The bleed water should be retrievable by a drain water collection system in SDU 6 assuming the system does not get clogged. Layering was observed and was attributed to intervals when the hopper was being cleaned. Heat from the hydration reactions was noticeable to the touch. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Middlesex FUSRAP Site - A Path to Site-Wide Closure - 13416

The road-map to obtaining closure of the Middlesex Sampling Plant FUSRAP site in Middlesex, New Jersey (NJ) has required a multi-faceted approach, following the CERCLA Process. Since 1998, the US ACE, ECC, and other contractors have completed much of the work required for regulatory acceptance of site closure with unrestricted use. To date, three buildings have been decontaminated, demolished, and disposed of. Two interim storage piles have been removed and disposed of, followed by the additional removal and disposal of over 87,000 tons of radiologically and chemically-impacted subsurface soils by the summer of 2008. The US ACE received a determination from the EPA for the soils Operable Unit, (OU)-1, in September 2010 that the remedial excavations were acceptable, and meet the criteria for unrestricted use as required by the 2004 Record of Decision (ROD) for OU-1. Following the completion of OU-1, the project delivery team performed additional field investigation of the final Operable Unit for Middlesex, OU-2, Groundwater. As of December 2012, the project delivery team has completed a Supplemental Remedial Investigation, which will be followed with a streamlined Feasibility Study, Proposed Plan, and ROD. Several years of historical groundwater data was available from previous investigations and the FUSRAP Environmental Surveillance Program. Historical data indicated sporadic detections of Volatile Organic Compounds (VOCs), primarily trichloroethylene (TCE), carbon tetrachloride (CT), and methyl tert-butyl ether (MTBE), with no apparent trend or pattern indicating extent or source of the VOC impact. In 2008, the project delivery team initiated efforts to re-assess the Conceptual Site Model (CSM) for groundwater. The bedrock was re-evaluated as a leaky multi-unit aquifer, and a plan was developed for additional investigations for adequate bedrock characterization and delineation of groundwater contaminated primarily by CT, TCE, and tetrachloroethene (PCE). The investigation was designed to accumulate multiple lines of evidence to determine the source and to delineate the extent of contamination, as required to complete the CERCLA Process and gain regulatory acceptance. Investigative techniques included in-well vertical flow tracing, borehole geophysics and packer testing of temporary test holes to characterize contamination in the bedrock fractures beneath the site, and to delineate likely source areas. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Development of a Performance and Processing Property Acceptance Region for Cementitious Low-Level Waste Forms at Savannah River Site - 13174

The Saltstone Production and Disposal Facilities (SPF and SDF) at the Savannah River Site (SRS) have been treating decontaminated salt solution, a low-level aqueous waste stream (LLW) since facility commissioning in 1990. In 2012, the Saltstone Facilities implemented a new Performance Assessment (PA) that incorporates an alternate design for the disposal facility to ensure that the performance objectives of DOE Order 435.1 and the National Defense Authorization Act (NDAA) of Fiscal Year 2005 Section 3116 are met. The PA performs long term modeling of the waste form, disposal facility, and disposal site hydrogeology to determine the transport history of radionuclides disposed in the LLW. Saltstone has been successfully used to dispose of LLW in a grout waste form for 15 years. Numerous waste form property assumptions directly impact the fate and transport modeling performed in the PA. The extent of process variability and consequence on performance properties are critical to meeting the assumptions of the PA. The SPF has ensured performance property acceptability by way of implementing control strategies that ensure the process operates within the analyzed limits of variability, but efforts continue to improve the understanding of facility performance in relation to the PA analysis. A similar understanding of the impact of variability on processing parameters is important from the standpoint of the operability of the production facility. The fresh grout slurry properties (particularly slurry rheology and the rate of hydration and structure formation) of the waste form directly impact the pressure and flow rates that can be reliably processed. It is thus equally important to quantify the impact of variability on processing parameters to ensure that the design basis assumptions for the production facility are maintained. Savannah River Remediation (SRR) has been pursuing a process that will ultimately establish a property acceptance region (PAR) to incorporate elements important to both processability and long-term performance properties. This process involves characterization of both emplaced product samples from the disposal facility and laboratory-simulated samples to demonstrate the effectiveness of the lab simulation. With that basis confirmed, a comprehensive variability study using non-radioactive simulants will define the acceptable PAR, or 'operating window' for Saltstone production and disposal. This same process will be used in the future to evaluate new waste streams for disposal or changes to the existing process flowsheet. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Radioactive Waste Management and Nuclear Facility Decommissioning Progress in Iraq - 13216

Management of Iraq's radioactive wastes and decommissioning of Iraq's former nuclear facilities are the responsibility of Iraq's Ministry of Science and Technology (MoST). The majority of Iraq's former nuclear facilities are in the Al-Tuwaitha Nuclear Research Center located a few kilometers from the edge of Baghdad. These facilities include bombed and partially destroyed research reactors, a fuel fabrication facility and radioisotope production facilities. Within these facilities are large numbers of silos, approximately 30 process or waste storage tanks and thousands of drums of uncharacterised radioactive waste. There are also former nuclear facilities/sites that are outside of Al-Tuwaitha and these include the former uranium processing and waste storage facility at Jesira, the dump site near Adaya, the former centrifuge facility at Rashdiya and the former enrichment plant at Tarmiya. In 2005, Iraq lacked the infrastructure needed to decommission its nuclear facilities and manage its radioactive wastes. The lack of infrastructure included: (1) the lack of an organization responsible for decommissioning and radioactive waste management, (2) the lack of a storage facility for radioactive wastes, (3) the lack of professionals with experience in decommissioning and modern waste management practices, (4) the lack of laws and regulations governing decommissioning or radioactive waste management, (5) ongoing security concerns, and (6) limited availability of electricity and internet. Since its creation eight years ago, the MoST has worked with the international community and developed an organizational structure, trained staff, and made great progress in managing radioactive wastes and decommissioning Iraq's former nuclear facilities. This progress has been made, despite the very difficult implementing conditions in Iraq. Within MoST, the Radioactive Waste Treatment and Management Directorate (RWTMD) is responsible for waste management and the Iraqi Decommissioning Directorate (IDD) is responsible for decommissioning activities. The IDD and the RWTMD work together on decommissioning projects. The IDD has developed plans and has completed decommissioning of the GeoPilot Facility in Baghdad and the Active Metallurgical Testing Laboratory (LAMA) in Al-Tuwaitha. Given this experience, the IDD has initiated work on more dangerous facilities. Plans are being developed to characterize, decontaminate and decommission the Tamuz II Research Reactor. The Tammuz Reactor was destroyed by an Israeli air-strike in 1981 and the Tammuz II Reactor was destroyed during the First Gulf War in 1991. In addition to being responsible for managing the decommissioning wastes, the RWTMD is responsible for more than 950 disused sealed radioactive sources, contaminated debris from the first Gulf War and (approximately 900 tons) of naturally-occurring radioactive materials wastes from oil production in Iraq. The RWTMD has trained staff, rehabilitated the Building 39 Radioactive Waste Storage building, rehabilitated portions of the French-built Radioactive Waste Treatment Station, organized and secured thousands of drums of radioactive waste organized and secured the stores of disused sealed radioactive sources. Currently, the IDD and the RWTMD are finalizing plans for the decommissioning of the Tammuz II Research Reactor. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Integrated High-Level Waste System Planning - Utilizing an Integrated Systems Planning Approach to Ensure End-State Definitions are Met and Executed - 13244

The Savannah River Site (SRS) is a Department of Energy site which has produced nuclear materials for national defense, research, space, and medical programs since the 1950's. As a by-product of this activity, approximately 37 million gallons of high-level liquid waste containing approximately 292 million curies of radioactivity is stored on an interim basis in 45 underground storage tanks. Originally, 51 tanks were constructed and utilized to support the mission. Four tanks have been closed and taken out of service and two are currently undergoing the closure process. The Liquid Waste System is a highly integrated operation involving safely storing liquid waste in underground storage tanks; removing, treating, and dispositioning the low-level waste fraction in grout; vitrifying the higher activity waste at the Defense Waste Processing Facility; and storing the vitrified waste in stainless steel canisters until permanent disposition. After waste removal and processing, the storage and processing facilities are decontaminated and closed. A Liquid Waste System Plan (hereinafter referred to as the Plan) was developed to integrate and document the activities required to disposition legacy and future High-Level Waste and to remove from service radioactive liquid waste tanks and facilities. It establishes and records a planning basis for waste processing in the liquid waste system through the end of the program mission. The integrated Plan which recognizes the challenges of constrained funding provides a path forward to complete the liquid waste mission within all regulatory and legal requirements. The overarching objective of the Plan is to meet all Federal Facility Agreement and Site Treatment Plan regulatory commitments on or ahead of schedule while preserving as much life cycle acceleration as possible through incorporation of numerous cost savings initiatives, elimination of non-essential scope, and deferral of other scope not on the critical path to compliance. There is currently a premium on processing and storage space in the radioactive liquid waste tank system. To enable continuation of risk reduction initiatives, the Plan establishes a processing strategy that provides tank space required to meet, or minimizes the impacts to meeting, programmatic objectives. The Plan also addresses perturbations in funding and schedule impacts. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Decommissioning and Dismantling of the Floating Maintenance Base 'Lepse' - 13316

The Lepse was built in Russia in 1934 and commissioned as a dry cargo ship. In 1961 she was re-equipped for use as a nuclear service ship (NSS), specifically a floating maintenance base (FMB), to support the operation of the civilian nuclear fleet (ice-breakers) of the USSR. In 1988 Lepse was taken out of service and in 1990 she was re-classified as a 'berth connected ship', located at a berth near the port of Murmansk under the ownership of Federal State Unitary Enterprise (FSUE) Atomflot. Lepse has special storage facilities for spent nuclear fuel assemblies (SFA) that have been used to store several hundred SFAs for nearly 40 years. High and intermediate-level liquid radioactive waste (LRW) is also present in the spent nuclear fuel assembly storage channels, in special tanks and also in the SFA cooling circuit. Many of the SFAs stored in Lepse are classified as damaged and cannot be removed using standard procedures. The removal of the SFA and LRW from the Lepse storage facilities is a hazardous task and requires specially designed tools, equipment and an infrastructure in which these can be deployed safely. Lepse is a significant environmental hazard in the North West of Russia. Storing spent nuclear fuel and high-level liquid radioactive waste on board Lepse in the current conditions is not acceptable with respect to Russian Federation health, safety and environmental standards and with international best practice. The approved concept design for the removal of the SFA and LRW and dismantling of Lepse requires that the ship be transported to Nerpa shipyard where specialist infrastructure will be constructed and equipment installed. One of the main complexities of the Project lies within the number of interested stakeholders involved in the Project. The Lepse project has been high focus on the international stage for many years with previous international efforts failing to make significant progress towards the objective of decommissioning Lepse. The Northern Dimension Environmental Partnership (NDEP) approved an internationally funded project to identify and prioritise nuclear and environmental hazards in NW Russia. Within this project the Lepse was recognised as being one of the highest nuclear hazards in NW Russia. Removal of SNF, SRW and LRW from Lepse requires innovative design and development of bespoke equipment. The main drivers of the NDEP Donors are first to safely transport Lepse in 2012 from her current berth close to the local population in Murmansk to the nominated dismantling shipyard, and secondly to raise Lepse from the water in 2013 onto the slip-way at the dismantling shipyard. A description is provided of the approach and progress towards preparing the Lepse for the removal of SFAs and other radioactive waste, to decontaminate and then dismantle the vessel under international donor funding. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Removal of the Plutonium Recycle Test Reactor - 13031

The 309 Facility housed the Plutonium Recycle Test Reactor (PRTR), an operating test reactor in the 300 Area at Hanford, Washington. The reactor first went critical in 1960 and was originally used for experiments under the Hanford Site Plutonium Fuels Utilization Program. The facility was decontaminated and decommissioned in 1988-1989, and the facility was deactivated in 1994. The 309 facility was added to Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) response actions as established in an Interim Record of Decision (IROD) and Action Memorandum (AM). The IROD directs a remedial action for the 309 facility, associated waste sites, associated underground piping and contaminated soils resulting from past unplanned releases. The AM directs a removal action through physical demolition of the facility, including removal of the reactor. Both CERCLA actions are implemented in accordance with U.S. EPA approved Remedial Action Work Plan, and the Remedial Design Report / Remedial Action Report associated with the Hanford 300-FF-2 Operable Unit. The selected method for remedy was to conventionally demolish above grade structures including the easily distinguished containment vessel dome, remove the PRTR and a minimum of 300 mm (12 in) of shielding as a single 560 Ton unit, and conventionally demolish the below grade structure. Initial sample core drilling in the Bio-Shield for radiological surveys showed evidence that the Bio-Shield was of sound structure. Core drills for the separation process of the PRTR from the 309 structure began at the deck level and revealed substantial thermal degradation of at least the top 1.2 m (4LF) of Bio-Shield structure. The degraded structure combined with the original materials used in the Bio-Shield would not allow for a stable structure to be extracted. The water used in the core drilling process proved to erode the sand mixture of the Bio-Shield leaving the steel aggregate to act as ball bearings against the core drill bit. A redesign is being completed to extract the 309 PRTR and entire Bio-Shield structure together as one monolith weighing 1100 Ton by cutting structural concrete supports. In addition, the PRTR has hundreds of contaminated process tubes and pipes that have to be severed to allow for a uniformly flush fit with a lower lifting frame. Thirty-two 50 mm (2 in) core drills must be connected with thirty-two wire saw cuts to allow for lifting columns to be inserted. Then eight primary saw cuts must be completed to severe the PRTR from the 309 Facility. Once the weight of the PRTR is transferred to the lifting frame, then the PRTR may be lifted out of the facility. The critical lift will be executed using four 450 Ton strand jacks mounted on a 9 m (30 LF) tall mobile lifting frame that will allow the PRTR to be transported by eight 600 mm (24 in) Slide Shoes. The PRTR will then be placed on a twenty-four line, double wide, self powered Goldhofer for transfer to the onsite CERCLA Disposal Cell (ERDF Facility), approximately 33 km (20 miles) away. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Rapid Radiochemical Analyses in Support of Fukushima Nuclear Accident - 13196

There is an increasing need to develop faster analytical methods for emergency response, including emergency soil and air filter samples [1, 2]. The Savannah River National Laboratory (SRNL) performed analyses on samples received from Japan in April, 2011 as part of a U.S. Department of Energy effort to provide assistance to the government of Japan, following the nuclear event at Fukushima Daiichi, resulting from the earthquake and tsunami on March 11, 2011. Of particular concern was whether it was safe to plant rice in certain areas (prefectures) near Fukushima. The primary objectives of the sample collection, sample analysis, and data assessment teams were to evaluate personnel exposure hazards, identify the nuclear power plant radiological source term and plume deposition, and assist the government of Japan in assessing any environmental and agricultural impacts associated with the nuclear event. SRNL analyzed approximately 250 samples and reported approximately 500 analytical method determinations. Samples included soil from farmland surrounding the Fukushima reactors and air monitoring samples of national interest, including those collected at the U.S. Embassy and American military bases. Samples were analyzed for a wide range of radionuclides, including strontium-89, strontium-90, gamma-emitting radionuclides, and plutonium, uranium, americium and curium isotopes. Technical aspects of the rapid soil and air filter analyses will be described. The extent of radiostrontium contamination was a significant concern. For {sup 89,90}Sr analyses on soil samples, a rapid fusion technique using 1.5 gram soil aliquots to enable a Minimum Detectable Activity (MDA) of <1 pCi {sup 89,90}Sr /g of soil was employed. This sequential technique has been published recently by this laboratory for actinides and radiostrontium in soil and vegetation [3, 4]. It consists of a rapid sodium hydroxide fusion, pre-concentration steps using iron hydroxide and calcium fluoride precipitations, followed by Sr-Resin separation and gas flow proportional counting. To achieve a lower detection limit for analysis of some of the Japanese soil samples, a 10 gram aliquot of soil was taken, acid-leached and processed with similar preconcentration chemistry. The MDA using this approach was ∼0.03 pCi/g (1.1 mBq/g)/, which is less than the 0.05-0.10 pCi/g {sup 90}Sr levels found in soil as a result of global fallout. The chemical yields observed for the Japanese soil samples was typically 75-80% and the laboratory control sample (LCS) and matrix spike (MS) results looked very good for this work Individual QC results were well within the ± 25% acceptable range and the average of these results does not show significant bias. Additional data for a radiostrontium in soil method for 50 gram samples will also be presented, which appears to be a significant step forward based on looking at the current literature, with higher chemical yields for even larger sample aliquots and lower MDA [5, 6, 7] Hou et al surveyed a wide range of separation methods for Pu in waters and environmental solid samples [8]. While there are many actinide methods in the scientific literature, few would be considered rapid due to the tedious and time-consuming steps involved. For actinide analyses in soil, a new rapid method for the determination of actinide isotopes in soil samples using both alpha spectrometry and inductively-coupled plasma mass spectrometry was employed. The new rapid soil method utilizes an acid leaching method, iron/titanium hydroxide precipitation, a lanthanum fluoride soil matrix removal step, and a rapid column separation process with TEVA Resin. The large soil matrix is removed easily and rapidly using these two simple precipitations with high chemical recoveries and effective removal of interferences. [9, 10] Vacuum box technology and rapid flow rates were used to reduce analytical time. Challenges associated with the mineral content in the volcanic soil will be discussed. Air filter samples were reported within twenty-four (24) hours of receipt using rapid techniques published previously. [11] The rapid reporting of high quality analytical data arranged through the U.S. Department of Energy Consequence Management Home Team was critical to allow the government of Japan to readily evaluate radiological impacts from the nuclear reactor incident to both personnel and the environment. SRNL employed unique rapid methods capability for radionuclides to support Japan that can also be applied to environmental, bioassay and waste management samples. New rapid radiochemical techniques for radionuclides in soil and other environmental matrices as well as some of the unique challenges associated with this work will be presented that can be used for application to environmental monitoring, environmental remediation, decommissioning and decontamination activities. (authors)

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Second Validation Testing of Canberra-Obayashi Mobile type TruckScan Pre-production Unit - 17214

Canberra Industries, Inc., (Now, Mirion Technologies (Canberra), Inc.), has developed and validated a new truck monitoring system 'Mobile TruckScan (MTSCAN)' for use with the Interim Storage Facilities (ISF) in Japan. MTSCAN consists of eight shielded LED-stabilized 3x3' NaI detectors. Each detector has a lead shield with a collimated view of the truck. Four detectors are placed on each side of the truck, thus 8 in total, each at about 1.1 meter from the side of the truck. These NaI detectors and collimators were calibrated by the Canberra In-Situ Object Counting System (ISOCS) mathematical efficiency calculation tool. Around the Fukushima Daiichi NPS area, the decontaminated waste was put into flexible containers called Super Sacks (SS), for transportation to the ISF, typically in 10 metric ton dump trucks. The MTSCAN pre-production unit was used to measure multiple SSs loaded into 10 ton trucks, and was able to accurately report the activity of each individual SS, with around 10-20 second acquisition time. The system can also accommodate smaller 2 ton and larger 20 ton trucks. The system is relatively compact, and therefore easy to move and setup at a different location. MTSCAN is expected to measure the SSs after loading onto trucks at the Temporary Storage Area (TSA), and at the entrance of the ISF. The MTSCAN assay results showed good accuracy in this demonstration which simulated the actual operation. From these tests, the combined standard deviation for each SS is about 20%, when compared to the reference activity from multiple Ge measurements of each sack. (authors)

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2017

Savannah River Remediation Liquid Waste Operations Making the Workplace Safer - Lean and Human Performance Improvement Initiatives - 17244

The Savannah River Site, a U.S. Department of Energy facility, contracted Savannah River Remediation (SRR) to manage its liquid waste project, which is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51, one million gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for a decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 of the 51 tanks have been closed to date. Over the past three years, SRR implemented a Lean Business Management System to address site inefficiencies, aging infrastructure concerns and budget constraints. The Lean philosophy started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. Like safety, continuous improvement is a fundamental core business value that starts at the top. The Lean Business System, led by our executive management team, drives quality, production and waste elimination by focusing on People using a structured Process that allows the workforce to identify and fix problems in their workplace. Many inefficiencies and quality related issues start with the desire to make systems fail-safe without defining the core requirements for which that process or program was created. This leads to added complexity and latent or inherent human performance issues embedded within our processes. While Lean can't fix all problems, a combination of strong nuclear safety culture, robust conduct of operations, active human performance improvement process, and a business practice of continuously looking for improvements leads to excellence across our industry and creates a culture that is worthy of promoting. Without strong management, our systems fail because no one sponsors or encourages those attributes we covet. Leadership starts at the top with our customer defining what provides 'value' to them, and filters down through to the organization and ultimately the workforce in day to day conduct of operations. It is imperative that our customer drives these desirable ideals through recognition and contractual requirements to encourage and support those behavioral traits that are critical to our ongoing success.This paper focuses on how the Lean Business Management System supports those attributes that we value: a strong nuclear safety culture; disciplined conduct of operations; and a culture of robust human performance and continuous improvement. These attributes in our daily work environment propel a safer, more consistent, more efficient workplace. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Savannah River Remediation Liquid Waste Operations Lifecycle Savings through a Lean Business System at the Savannah River Site - 17245

Savannah River Remediation (SRR) was contracted by the U.S. Department of Energy (DOE) to manage its liquid waste project at the Savannah River Site. The liquid waste project is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51 one million-gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for lower radioactive decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 tanks have been closed to date. The Lean philosophy took root decades ago in the manufacturing sector and started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. At SRR, a Lean business management system was adopted to address site inefficiencies, aging infrastructure concerns and budget constraints. With yearly escalation and flat budgets, continuous improvement is taking on a larger role - improving the work accomplished for each dollar. This paper focuses on the program results achieved to date, including the lifecycle savings identified through the Rapid Improvement Event (RIE) process. The RIE process is a Lean tool which creates a cross-functional team to analyze, develop and implement improvements for a given process. DOE-EM has recently emphasized the value of contractor's continuous improvement programs through their implementation of Plan of Action and Milestone (POAM): Goal 2 (Increase Efficiency/Improve Performance) Reduce EM Operations Cost in FY16. POAM Goal 2 was a FY 16 effort to achieve 5% cost savings across most programs. This past year's cost savings initiatives will likely become a trend as DOE and its contractors look to do more with less. In support of our own business objectives, as well as, DOE's motivation to improve efficiencies, SRR has held over one hundred formal Lean events and dozens of 5S events that have driven improvement across the Project, including tank closure and production facilities. These improvements have significantly reduced the time required to process material and achieve the overall goal of hazard reduction and tank closure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

SRR's 'Next Step' in the Lean Journey -Taking Lean to the Workforce - 17247

The Savannah River Site, a U.S. Department of Energy (DOE) facility, contracted Savannah River Remediation (SRR) to manage its liquid waste project, which is a unique, high hazard nuclear waste treatment and disposal facility consisting of 51, one million-gallon underground waste tanks, a solvent extraction processing unit, a vitrification facility for the highest radioactive waste, and a grout solidification and disposal facility for a decontaminated salt solution. Our Project mission is to treat the nuclear waste and close the associated storage and treatment facilities, of which, 8 tanks have been closed to date. At SRR, the Lean business management system has been adopted to address site inefficiencies, aging infrastructure concerns and budget constraints. The Lean philosophy took root decades ago in the manufacturing sector and started with the work of W. Edwards Deming and his contemporaries. In more recent years the process has matured in the Toyota Production System and migrated into fields as diverse as services industries, health-care, and now the DOE complex. The first step of the SRR Lean Journey was to formally identify areas of improvement and initiate Value Stream Analysis (VSAs) and Rapid Improvement Events (RIEs). SRR has achieved improvements in procedure implementation, work planning and control, project schedule compression, and engineering requirements. SRR is now phasing in the next phase of Lean through Managing for Daily Improvement (MDI), Visual Management and 5S (sort, set in order, shine, standardize, and sustain). MDI is a fundamental Lean principle in that we use our most valuable asset, our employees, to drive continuous improvement versus a smaller population through formal events. Part of MDI includes visual management where the workforce can go to a 'dashboard' to see and understand the company mission and status. 5S is a process where a work group improves performance in an area by addressing physical organization, efficiency, uniformity, standardization, and mechanisms to sustain improvements. 5S stands for: Sort, Set in Order, Shine, Standardize, and Sustain. This paper will focus on the 'Next Step' in SRR's Lean journey by address how SRR is implementing MDI and 5S to improve CONOPs, Project efficiencies, and worker engagement in day to day operations. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Upfront Update on Barsebaeck 1-2 Reactor Internals Segmentation Project - 17382

Westinghouse is currently executing a contract, awarded in June 2015 from Barsebaeck Kraft AB, to segment all the reactor vessel (RV) internal parts in the two units 1 and 2. The scope of work covers the dismantling and segmentation of the RV internals under water, including the upfront engineering studies and equipment manufacturing and qualification. It also includes the loading of the segmented parts into waste cassettes, handling the cassettes, reactor internals sampling (73 samples), complementary water filtration system to catch the segmentation chips and contribute to maintaining water clarity during the segmentation work. Before leaving the site, the pool environment must be restored to the initial condition and all equipment will be decontaminated and shipped off site. The site work started in August 2016 with the mobilization on the Unit 2 and the actual cutting of the first component (steam dryer) started in September. Cutting will be performed with different types of Westinghouse designed cutting equipment. This paper presents the conceptual design of the reactor internals segmentation and packaging process that will be implemented at Barsebaeck, including the planning, methodology, equipment, waste management and packaging strategy. A first feedback on the site work will be provided for the segmentation of the Unit 2 reactor internals. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Deployment of large tank monosodium titanate strike to increase salt processing at the Savannah river site - 15115

The treatment of high level waste (HLW) salt solutions using the Actinide Removal Process (ARP) and Modular Caustic Side Solvent Extraction Unit (MCU) began at Savannah River Site (SRS) in 2008. Since that time, over 6 million gallons of liquid HLW have been treated and the resulting low level waste (LLW) effluent immobilized in cementitious grout at salt-stone. In addition to the continued stabilization of liquid HLW, operating experience from the ARP/MCU facilities has also been valuable in considering the design and construction of the Salt Waste Processing Facility (SWPF) which will utilize similar unit operations on a much larger scale. ARP removes actinides by contacting waste with monosodium titanate (MST) which is a solid adsorbent for soluble strontium and actinides. Once the sorption reaction is complete, the MST solids are separated from salt solution via ultrafiltration through a crossflow filter. The throughput of initial operations of ARP/MCU was limited by the flowrate through the extraction process. However, after the implementation of a new solvent flowsheet, filtration of MST will be the rate limiting step in salt processing. For the entirety of ARP/MCU operation, Savannah River Remediation (SRR) has sought to improve process efficiency and performance through optimization and modification of the original facility design. These efforts have resulted in a best-single-year throughput of 4.9 million liters of decontaminated salt solution. In keeping with these practices, SRR recently initiated a project to improve filtration throughput by relocating the MST strike from small batches immediately upstream of the filtration unit to the underground waste tank used to batch and store salt solution feed for ARP/MCU. This process change will allow the bulk of MST solids to decant in the waste tank prior to filtration which should improve both the nominal operational filter flux as well as the achieved utility of filter operation. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Validation testing of Canberra-Obayashi TruckScan calculation method - 15409

Canberra Industries, Inc. [CI] has designed a new truck monitoring system 'TruckScan' for Interim Storage Facilities [ISF] in Japan. CI and Canberra Japan K.K. [CJKK] have performed validation testing of it with Obayashi Corporation at a temporary storage area in Fukushima prefecture. Decontaminated waste was put into flexible containers called Super Sacks [SS]. The customer desires to quantify the Cs-137 and Cs-134 content of each individual SS, while a group of them are on a truck. This would be done when leaving a temporary waste consolidation area and entering an ISF. The content of SSs is some combination of sand, soil, and vegetation with densities ranging from 0.3 g/cc - 1.6 g/cc. The typical weight of the trucks will be approximately 10 tons, but can vary between 4 and 20 tons. The system must be sensitive enough to detect 100 Bq/kg in 10 - 30 seconds but still have enough dynamic range to measure 1,000,000 Bq/kg material. The system will be operated in an outdoor environment. The desire to separately quantify Cs-137 and Cs-134 favors the use of a spectroscopic system as a solution. The full-scale TruckScan will consist of eight 3x3' NaI detectors, each in a lead shield with a collimated view of the truck. Four detectors are on each side of the truck, at about 1 meter from the truck, spaced at equal distances. These NaI detectors and collimators were calibrated by In Situ Object Counting System (ISOCS) mathematical efficiency calculation tool. The truck stops in-between the two sets of detectors for the short measurement period - typically 15 seconds. The special software performs gamma spectroscopy on each of the 8 spectra, and then decodes the results to determine the activity in each of the 8 [typically] SSs using a Maximum Entropy Analysis Method. Validation testing was done by using SSs filled with known material types and known concentrations of material. The results of the TruckScan assay indicate good accuracy for the wide range of conditions. In spite of the conditions being more severe than normal operations, the combined standard deviation was 20.1% for the 6 detector version and 16.6% for the 8 detector version TruckScan. When the TruckScan results were compared to the known concentrations, there was minimal bias and good correlation [y = 1.0029x, R{sup 2} = 0.914]. (authors)

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DOE OSTI2015

Salt Waste Processing Facility project lessons learned: Acquisition through construction - 15518

The Salt Waste Processing Facility (SWPF), located at the Savannah River Site (SRS) in Aiken, South Carolina, is a multi-billion dollar Liquid Radioactive Waste (LRW) processing facility that represents the keystone for the U.S. Department of Energy (DOE)-EM clean-up mission at SRS. The SWPF facilitates DOE-EM clean-up at SRS by decontaminating the salt waste, which is the dominant volumetric component in the LRW tanks, thereby allowing the cleaned salt waste to be removed from the tanks and stabilized into an approved grout-based final waste form. The small volume of removed radionuclides is sent to the Defense Waste Processing Facility (DWPF) for vitrification. Emptied LRW storage tanks are then grouted into an approved configuration for final closure. The SWPF project is currently 100% complete with design, 80% complete with construction, and 10% complete with commissioning. To date there have been numerous lessons learned with regard to project acquisition, design, procurement, construction, and quality assurance (QA) approaches (both good practices and mistakes) that are considered to be of significant value in improving the state of major project execution within the DOE-EM clean-up program as well as to the wider DOE enterprise. An overview of the current SWPF project status is provided and key lessons learned in the aforementioned areas are presented relative to improving future DOE major project execution performance. Specific areas to be addressed include strategies to optimize integration of design and nuclear safety, constructability tools for design and construction synchronization, commercial grade dedication (CGD) approaches to mitigate atrophy in the nuclear supply chain, and QA perspectives to facilitate effective and efficient project execution. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Best practices mobile application for D and D KM-IT - 15712

The Deactivation and Decommissioning Knowledge Management Information Tool (D and D KM-IT) is the repository of useful information built specifically for D and D community. The knowledge provided by the D and D KM-IT is the experience and expertise gained by people within the field and fellow employees of the Department of Energy (DOE). This information has been the result of gathering, analyzing, storing, and sharing knowledge to help reduce time spent on discovering previously found data. In order to help in organizing all the data from all the professional contributors, the D and D KM-IT has been divided into 12 different modules. Each individual module pertains to a different area of information for users, such as vendor and technology information, collaboration tools, and even a hotline that contains problems posted by the users. Purpose: - Design and develop the module for the Best Practices on D and D KM-IT mobile platform deployed at https://m.dndkm.org; - The Best Practices mobile module should integrate with existing modules seamlessly; - Use the D and D KM-IT existing database to consume information for the mobile system. jQuery Mobile framework was used to develop Best Practices module for mobile devices. jQuery Mobile framework provides support for responsive web design (RWD). RWD allows adaptation of the layout and user interface of web sites and web apps to different device resolutions, screen densities, and views. UI design was implemented with three fundamental elements: CSS media queries, An adaptable grid, Flexible images and media. Advantages/benefits: - A responsive web design adapts to any-sized screen / resolution and orientation view; - ASP.NET compatible which allows the D and D KM-IT database to support all platforms accessing the system; - Navigating pages is more bandwidth efficient by refreshing data in small section with Ajax instead of reloading the entire page; - Multiple parts of a page can perform different tasks resulting in improved user's experience. Results: - Mobile system is accessible on compatible devices running Android, Apple, Blackberry, Palm, and Windows devices; - Best Practices searches through Characterization, Decontamination, Dismantlement, Material Disposition, and Worker Safety; - Keyword search is enabled for the best practices that are available on both the desktop and mobile systems - Documents are formatted into a PDF file format to ensure compatibility on any device. Conclusion: - Fully integrated with the desktop Best Practices module and displays documents that are uploaded on web platform; - Fast-loading with D and D KM-IT mobile system and downloadable documents; - Responsive design which gives the same user experience when either viewed on smart phone or tablet.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2016

Facility Improvements and Modifications to Extend the Operational Life of the Modular Caustic-Side Solvent Extraction Process - 16082

Savannah River Remediation, LLC (SRR) is working to remove, stabilize, and dispose of approximately 36.7 million gallons (138.9 million liters) of liquid radioactive waste currently stored in 43 underground waste tanks, and ultimately close waste tanks. In 2008, as an interim salt treatment system to remove cesium from high level waste salt solutions prior to the Salt Waste Processing Facility start up, the Modular Caustic-Side Solvent Extraction Unit (MCU) initiated the removal of cesium from liquid radioactive salt waste prior to disposal. The MCU was designed and built for an expected three-year operational life and five-year design life. The first MCU cold runs began in June 2007 and hot startup was completed in April 2008. MCU remains in hot operation to this day, aiding in multiple, high-level tank closures. In an effort to continue liquid waste disposition at the Savannah River Site (SRS), equipment upgrades and operational improvements have been made to extend the life of the MCU beyond the original three years. Several pieces of fixed equipment have been converted into removable equipment which reduces the downtime associated with equipment change-outs and thereby reduces the dose to workers and processing impacts. Multiple pumps and filters have been upgraded to more robust designs. Process monitoring and controls have been upgraded to improve process performance. Redundant centrifugal contactor vibration equipment has been installed on each contactor in order to better assess the reliability, processing performance, and lifetime of the contactors. A new Solvent Hold Tank (SHT) Sampler has been installed to minimize the organic cross-contamination within the sampler, dose to workers, and sample analysis time. To increase processing availability and aid in visually obtained data, camera port has been added to the Salt Solution Feed Tank (SSFT). In order to decrease the overall background dose to the workers, the Process Vessel Ventilation (PVV) duct work now has the capability to be flushed to remove contamination. The caustic wash addition system has been modified to be a once-through system to improve equipment reliability, decrease downtime, and decrease dose to workers. In addition, the solvent that MCU utilizes to extract Cesium out of salt waste has been upgraded to Next Generation Solvent (NGS) which is based on MaxCalix extractant instead of a BobCalix extractant. Further, these upgrades and improvements have allowed MCU to be able to process at higher flow rates (up to 8.5 GPM) and with increased throughput (as high as 1.3 million gallons in FY13 and 5.3 million gallons since hot operations initiated) that have allowed SRR to continue the disposition of nuclear salt waste. The continued operation of MCU ensures more curies are stabilized into a glass matrix at SRS's Defense Waste Processing Facility (DWPF) and less curies are retained within South Carolina at SRS's Saltstone Disposal Facility (SDF). Unique challenges associated with modifying and improving a demonstration plant that is in hot operations and was designed to be temporary with a limited plant footprint have been successfully overcome. Further, creative strategies for removing old equipment have been utilized given the limited decontamination agents available for use that will not interfere with the organic solvent. This paper presents and discusses the deployment of these upgrades and operational improvements to MCU in order to allow continued, increased salt waste processing beyond the initial design life. (authors)

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