Control room consolidation at Hanford tank farms for improved conduct of operation - 15345
Washington River Protection Solutions (WRPS) manages the underground waste storage tanks at the Hanford site in Washington State on behalf of the DOE Office of River Protection. There are 177 tanks distributed among 18 tank farms spread across an area of desert scrub covering about 20 square miles. A single evaporator facility supports the tanks to provide waste reduction activities. Farms and associated equipment, including exhausters, have been operated locally since installation. Upgrades over time introduced limited automation, but using inconsistent platforms, and providing isolated control locations around the farms. However, as the Tank Farms move from maintenance operations to production operations, with increased numbers of waste transfers and evaporator campaigns, and also prepare for integration with the adjacent Hanford Waste Treatment Plant, then operational improvements were planned and are being implemented. Infrastructure improvement projects included upgrades of control systems to a common platform, and installation of a fiber optic based local area network to the majority of farms, which together provided a distributed control system supporting tank farms. This new infrastructure provided the basis to propose consolidation of control and monitoring operations to a single location. More than a single location, the new Central Control Room was to increase effectiveness of operations by providing full status of all activities being performed across the Tank Farms and the Evaporator. The recent addition of productivity e-tools also would provide capability for management, supervisors and operators to make informed decisions regarding facility operations, through custom online applications designed to provide real time information derived from operational data. For example, tracking turnover activities between shifts, and maintaining compliance with limited conditions for operations. The Central Control Room would also have a single supervisor able to effectively manage the status of all assets and processes. The expected benefits of this arrangement include increased operator utility, increased situational awareness, improved response time for upset conditions, improvement in operator environment, and reductions in operating costs. The projected ROI for the Central Control Room when fully operational was projected to be about two years based on reduced costs from freeing up operations staff to perform other work plus the time and material savings realized by operations being performed with increased situational awareness. So the Central Control Room would become a hub for monitoring and controlling facility operations while responding to real time information affecting productivity and performance, from a centralized location customized to a fresh working environment. Over a 14-month period, WRPS developed the concept and engineering, procured over 500 items, modified and installed in renovated building, and completed transition and testing of this new Central Control Room, turning over the initial phase to Operations for 24/7 use in April 2014. (authors)