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Document #: SD-SNF-ATR-010

TitlelDesc: ACCEPTANCE TEST REPORT FOR THE HIGH PRESSURE WATER JET SYSTEM CANISTER CLEANING FIXTURE

Page 1 O f 1 -

1.EOT 140379 ENGINEERING DATA TRANSMllTAL OCT 2 6 ! 9 5

2. To: (Receiving Organization)

SNF K-Basins Pro jects 5. P ro j ./Prog. /Dept ./D iv. :

Spent Nuclear Fuel

3. Frm: (Or ig inat ing Organization) 4. Related EDT No.:

SNF K-Basins Pro jects 140380 6. Cog. Engr.: 7. Purchase O r d e r No.:

J. 8. Crysta l NIA 8. Or ig inator Remarks:

For Release

11. Receiver Remarks:

9. Equip./Cnponent No.:

N/A 10. Sys tem/B Ida. /Feci l i t y :

105-KE 12. Major Asm. Dug. No.:

N/A 13. Permit lPtrrnit Appl icat ion No.:

N/A 14. Required Response Date:

ILIA-

1

-

mmai .man r m n

WHC-SD-SNF-ATR- ALL 0 Acceptance Test N/A 2 1 010, Rev. 0 Report f o r t he High

Pressure Water J e t System Canister Cleaning F i x tu re

BD-7400-172-1 (07/31)

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l!fiIS PAGE INTENTIONALLY LEFTBLANK

THIS PAGE INTENTIONALLY LEFT BLANK

THIS PAGE INTENTIONALLY LEFT BLANK

WHC-SO-SNF-ATR-010, Rev. 0

ACCEPTANCE TEST REPORT FOR THE HIGH PRESSURE HATER JET SYSTEM

CANISTER CLEANING FIXTURE

1 .O INTRODUCTION

The Scientific Ecology Group (SEGe), in conjunction with the Spent Nuclear Fuel (SNF) Process Systems Group and the Engineering Testing Laboratory (ETL), tested the High Pressure Water Jet System and Canister Cleaning System. These systems were designed and fabricated by SEGe based on the results of the development testing conducted during April and May, 1995 and reported in Reference 1. The equipment will be used in the decontamination of empty fuel storage canisters in KE-Basin to support the clean-up of the South Loadout Pit and ultimately Spent Nuclear Fuel removal from the K-Basins.

These Acceptance Tests were conducted to confirm optimum water pressure, water flow rate, nozzle size and overall configuration needed to effectively decontaminate empty fuel storage canisters in KE-Basin. conducted in accordance with References 2 and 3 and occurred in mid-August 1995, at the Cold Test Facility in the ETL.

The test basin dimensions are 4.6m wide x 6.0m Jong x 4.6m deep (15' x 18' x 15') and the basin contains approximately 130 m (30,000 gallons) of demineralized water. testing was performed on the east side of the test basin.

These tests were

The Canister Cleaning Fixture was assembled and all

1

WHC-SD-SNF-ATR-010, Rev. 0

2.0 TEST DESCRIPTION

SLIDE@ Thin Line Layout Blue (manufactured by the Percy Harms Corporation, Wheeling, I l l i n o i s ) and Dykem Spray Steel Blue SP-100 (manufactured by the Dykem Company, S t . Louis, Missour i ) were used t o simulate oxide contamination on the canis ters . They were chosen because they provided a comprable base f o r w i re brushing versus high pressure water j e t washing o f contaminated canis ters . The s imulant was applied t o a t l e a s t 98% o f the surface o f the fue l storage canis ters and allowed t o d ry away from d i r e c t sun l igh t f o r approximately 24 hours p r i o r t o removal w i th the high pressure water j e t system.

The canis ters were placed on the Canister Cleaning Cradle and the Nozzle Cleaning Assembly was posi t ioned and used t o remove the simulant. aluminum and sta in less s tee l canis ters were cleaned. recorded dur ing the cleaning operations:

Both The fo l low ing data was

. Cleaning Water Pressure (psig)

Cleaning Water Flowrate (gpm)

Cleaning Time (minutes)

Number o f Passes required f o r cleaning

A pass was defined as the number o f t imes a surface had t o be cleaned; i . e . removal o f the simulant oxide. Therefore, cleaning the i n t e r i o r o f both chambers o f the canis ter AND the e x t e r i o r o f both chambers o f the can is te r i s defined as one (1) pass.

The top o f the canis ter was approximately e igh t f e e t beneath the surface o f the water dur ing cleaning operations and the operator was posi t ioned on the g ra t i ng o f the t e s t basin t o simulate the actual operating condi t ions which w i l l be encountered a t the K-Basins. A s imp l i f i ed drawing o f the Canister Cleaning F i x tu re and the r e l a t i v e elevat ions are shown i n Figures 1 and 2. References 4 and 5 are the de ta i led fabr ica t ion drawings o f the Canister Cleaning F ix tu re .

I n s t a l l e d as p a r t o f the Canister Cleaning Fixture, s p e c i f i c a l l y the Nozzle Cleaning Assembly was the fo l lowing equipment: .

8

One (1) O'Connell fabr icated "T" nozzle spin f i x t u r e w i t h two (2) .047"/15" (1.1938m/15") nozzles, o f f s e t 4'' (1.27cm) from the canis ter surface, w i th a f low r a t e 7.5gpm/nozzle (28.38751 pm/nozzle) f o r i n t e r i o r cleaning.

Two (2) Stoneage RJV3, Model 15K, Rotary Nozzle Heads each w i th two ( 2 ) .033"/0' (O.8382mm/O0) nozzles, located 180" apart, o f f s e t 2" (5.08cm) from the can is te r surface, w i t h a f low r a t e o f 3.6gpm/nozzle (13.6261pm/nozzle) f o r e x t e r i o r cleaning .

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I

a

W

E s 5 c i?

Figure 1

3


- BOTOM OF MONOPAL BEAM (EL. +7'-0")

TOP HAND RAIL CENTERLINE (EL. CY-5") TOP ROLLER CONMYOR (EL. +3'-

L CENTERLINE (EL. +3'-5) BOnOM HANO RAIL CENTERLINE (EL. +? RAIL CENTERLINE (4. +1'-lb)

TOP OF GRATING (EL. +O'-d') Z'x.l-l/T CONCENTRIC REDUCER (EL. - 1 ' 4 ' )

TOP OF CANISTERS IN SOUTH LOADOUT PIT (EL -8'-9') II - TOP OF CANISTER DURING CLEANING (EL -12'4")

CANISTER CLEANING TABLE (EL. -15'-5-1/2")

BPSlN FLOOR (EL. -20'-9")

SOUTH LOAOOVT PIT FLOOR (EL. -25'-9')

Figure 2

This development t e s t i n g o f these nozzles i s described i n Reference 1. cleaning water pressure dur ing t e s t i n g was approximately 15,OOOpsi (103,425kPa).

Technical d i r e c t i o n f o r t e s t i n g was provided by q u a l i f i e d SEGe personnel. A l l safety requirements were i d e n t i f i e d through a Job Safety Review p r i o r t o the s t a r t o f tes t ing . A Pre-Job Safety Meeting was also conducted p r i o r t o the t e s t .

The P&ID f o r the HPWJS (SK-1-33488) i s included as Appendix 11. However, a submersible pump i n s t a l l e d i n the t e s t basin was used as a feedpump instead o f the sk id mounted cent r i fuga l pump conf igurat ion t h a t w i l l be used i n actual operation.

The

4


3.0 TEST RESULTS

Two can is te rs coated w i t h simulant were successfu l ly cleaned on August 18, 1995, one ( 1 ) aluminum Mk 0 can is te r and one (1) s ta in less s tee l Mk I1 canis ter . "Removal o f 80% o f the simulant [sic] (dye coating) from the i nne r and ou te r surfaces o f each o f the canisters." The Acceptance Test Data sheets are included i n Appendix I , a summary o f t he t e s t data i s provided i n Table 1.

Successful cleaning was def ined as the fo l l ow ing i n Reference 3,

Table 1 - -

CANISTER CLEANING TEST DATA SUMNARY

Notes: 1. The Number o f Passes i s defined as, the number o f times a surface had t o be cleaned. Therefore, cleaning the i n t e r i o r o f both chambers o f t he can is te r AND the e x t e r i o r o f both chambers o f t he can is te r i s defined as one ( 1 ) pass.

The percentage cleaned was determined as fo l lows: 2.

Percent Clean = 1

Remaining Dye:

H:

SUPPLEMENTAL TESTS

- . Remaining D y e

The amount o f dye remaining on the canis ter , i n square inches, as measured w i t h a tape a f t e r cleaning

Canister Height Aluminum Canister: S.S. Canister:

H = 28" H = 27"

Though n o t spec i f ied as p a r t o f the Acceptance Test Procedure, two add i t iona l aluminum (Mk 0) can is te rs were a lso successfu l ly cleaned. described below.

Results are

The f i r s t aluminum (Mk 0) can is te r was obtained from the IOOK Area where it had been stored f o r an unknown per iod o f t ime outside and was covered w i t h " s a l t - l i k e " deposits s i m i l a r i n appearance t o those recorded on the video survey o f t he can is te rs i n the KE-Basin. the aluminum surface was severely p i t t e d . One chamber o f t he can is te r was "cleaned;" t he deposits were removed from the surface w i t h no res idue i n the

Underlying the " s a l t - l i k e " deposits

5


pitted aluminum. Time for cleaning was consistent with the times recorded in Table 1.

The second canister was corroded at the Cold Test Facility by immersion in a 55 gallon (208.175 liters) carbon steel drum filled with demineralized water and heated to approximately 14OoF (60'C) for approximately three weeks. After that time commercial baking soda (sodium bicarbonate - NaHCO,) was added to the water and the pH was raised to approximately 8 and the canister remained in the water several additional weeks resulting in a dull film deposit on the canister surface. removed from the surface. Again, time for cleaning was consistent with the times recorded in Table 1.

Prior to the successful tests completed above, one unsuccessful attempt was made to clean a Mk 0 canister. The interior of the canister was cleaned, however, not to the extent achieved in the development tests and only irregular cleaning was achieved on the exterior of the canister. documented on Test Log Number 001 included in Appendix 1. failure were determined to be:

One chamber of the canister was "cleaned;" the film was

This test is The reasons for

. The surface standoff of the exterior nozzles was greater than the desired two inches.

The canister had previously been stored outside and exposed to heat and sunlight for several days.

. As a result of this test, the Nozzle Cleaning Assembly was modified slightly and these modifications documented on the Canister Cleaning Fixture Drawings. These modifications were implemented prior to beginning the successful tests described above.

WATER DEPTH

The depth of canister cleaning operations selected during the development tests is adequate for actual canister cleaning operations. The depth selected for canister placement during development testing positions the top of canister at an elevation of (-)12'-9" (-3.89111) based on a grating elevation of 0'-0" (Om) i.e., the top of the canister is eight feet (2.44m) below the surface of the water. disturbances at the surface of the water during cleaning and the length of the cleaning fixture.

During testing, water surface disturbance was minimal consisting of minor ripples and fine bubbles generated from the cleaning process. primarily during the start of cleaning operations when there is entrained air within the system. The configuration tested is acceptable for use in the basins, however, Operational Health Physics should evaluate the water disturbance during training and after installation in the Basin to verify that further engineering controls are not required for contamination control. This was a subjective evaluation made by the WHC Test Engineer, the SEGQ Technical Advisor and the WHC QA/QC Witness.

This location provides a compromise between

This occurred

6


6.0 REFERENCES

1. WHC-SD-SNF-DTR-001, Revision 0, Development Test Report f o r the High Pressure Water J e t System Nozzles, Westinghouse Hanford Company, R i ch l and, Washington .

2. WHC-SD-SNF-TP-001, Revision 0, K-Basins Debris Removal Equipment Test Plan, Westinghouse Hanford Company, Richland, Washington.

WHC-SD-SNF-ATP-010, Revision 0, Acceptance Test Procedure f o r the High Pressure Water J e t System, Westinghouse Hanford Company, Rich1 and, Washington.

3 .

4.

5. SEG@ Drawing No. KEM102, Canister Cleaning Sta t ion Support Riser

SEG@ Drawing No. KEM101, 5, 6, and 7 o f 7

Deta i l s , sheet 1 o f 1

Canister Cleaning F ix ture, sheets 1, 2, 3, 4,

9


APPENDIX I

ACCEPTANCE TEST PROCEDURE AND TEST DATA SHEETS

1-1

n

.__-_._-_.-.--.-- 2. TO: (Receiving Organization) 3. Fran: Originetiry Organ rocion)

SNF K Basins P r o j e c t s 5. Proj .IProg.lDept.lDiv.:

SNF/K Basins P r o j e c t s 0. Originator Remarks:

P lease rev iew f o r approval .

SNF K Basins P r o j e c t s 6. Ccg. Ewtr.:

Jeremy t l . C r y s t a l

I.. Related EOT No.:

N/A

N/A

High Pressure Water J e t

7. Purchase Order No.:

9 . Eqip.lCnponent No.:

10. SystenVBldg./Facility:

11. RKeiver RaMrks:

1 WHC-SD-SNF-ATP- 0 Acceptance Test QS 010 Procedure f o r High

Pressure Water J e t System

305/300

N/A

N/A

12. Major Aasm. Dug. No.:

13. Pecmit/Pemit Appl i c a t i m No.:

14. Required Response Date:

I ~

I I

SUPPORTING I1OC:UM EFlT I 1. Total Pages 17 ~y 2. T i t l e 3. Nuher 4 . Rev No.

kceptance Test Procedure for High Pressure Water WHC-SD-SNF-ATP-010 0 Jet System 5. Key Words 6. Author

High Pressure Water Jet Operation Procedure RTP

N-: JB Crystal

I OrganirationlCharge cede 2GOOO/LD24C 1. Abtrac t

kceptance test procedure for the High Pressure Water Jet.

a. RELEASE STUIP

A-6400-073 (OBl96) K F l Z L

WHC-SD-SNF-ATR-010, REV. 0 W H C - S D - S ~ T ~ ~ O , Rev. 0 1-6 ACCEPTANCE TEST PROCEDURE

HIGH PRESSURE WATER JET SYSTEM

1.0 TEST ITEM IDENTIFICATION

The test items are a specially designed water jet cleaning fixture and the associated support equipment. These include the High Pressure Water Jet System (HPWJS), hoses, control valves, associated nozzles, hand1 ing tools, positioning and support equipment to retrieve, hold and transfer canisters.

2.0 GENERAL DESCRIPTION

The overall objective of the acceptance test is to demonstrate a This includes associated tools and equipment necessary to combined system.

perform cleaning in the 105 K East Basin (KE) for achieving optimum reduction in the level of contamination/dose rate on canisters prior to removal from the KE Basin and subsequent packaging for disposal. include necessary hardware to achieve acceptance of the cleaning phase of canisters.

This acceptance test procedure will define the acceptance testing criteria of the high pressure water jet cleaning fixture. The focus of this procedure will be to provide guidelines and instructions to control, evaluate and document the acceptance testing for cleaning effectiveness and method(s) of removing the contaminated surface layer from the canister presently identified in KE Basin. test will be to deliver to K Basins a thoroughly tested and proven system for underwater decontamination and dose reduction.

Acceptance tests shall

Additionally, the desired result o f the acceptance

3.0 TEST OBJECTIVES

Utilizing the HPWJS connected to specially designed water jet cleaning fixture: . .

Clean surfaces of canister witti simulated contamination ensuring safe and efficient decontamination process.

Demonstrate a controlled process for the decontamination . . of canisters,

"f""k""B""p f f b d / Q T Demonstrate the best combination of water jet nozzle configuration, water pressure, water flow rate and cleaning speed to decontaminate canisters.

Perform the acceptance testing for the most effective combinations of fixtures and nozzles as determined during development testing.

m i c r n c

J TEST CONTROL copy SLIDE is a Registered Trademark 6f Percy Arms, Inc.

3.1 DESIGN CRITERIA

WHC-SD-SNF-ATR-010, REV. 0 1-7

The following design criteria shall be considered in changes to the designs developed during the development testing phase: . . . . . .

As Low As Reasonably Achievable (ALARA), engineered into the process.

Minimize handling of items to be decontaminated.

Minimize the moving parts of the special support equipment and water jet fixture heads.'

Ease of operation by the operators.

Ease of maintenance; rep1 acement of degraded nozzles.

Minimize cleaning time for each canister.

3.2 ACCEPTANCE TEST CRITERION FOR DECONTAMINATION

in evaluation for effectiveness of the HPWJS fixture and nozzles: The following acceptance test criterion for cleaning shall be utilized

. Removal of 80% of the simulate (dye coating) from the inner and outer surfaces of each of the canisters. y5 -,t,& Lc, I-W ct k s r 2 4 L . 4 aY r0o-l b - p e c7u.F).

3.3 TEST METHOD /-= 8he?Py The test shall be performed under water within a mocked up controlled

The cleaning fixture and/or water pressure and water flow may require

radiological environment to simulate normal work conditions at KE Basin.

adjustment if acceptance is not reached during the first test. The tests may be performed as many times as necessary to reach the expected results of removing 80% of the simulated contamination (dye coating) from the canisters in an effective and efficient manner., Each test re-test shall require a newly coated canister.

4.0 TEST CONDITION LIMITS

Personnel involved in these tests shall use, wear and employ required

Protective equipment shall be provided for safety equipment and practices during the operation of the HPWJS and associated tools and'equipment. the eyes, ears, face, head and feet.

At the start of each test and before starting the HPWJS, the Safety Checklist (Attachment A) will be completed by the Scientific Ecology Group (SEG) Technical Advisor after a walkdown o f the system is completed to ensure and verify that tools and equipment are safe to operate.

TEST CONTROL COPY /%

WHC-SD-SNF-ATR-010, REV. 0 WHC-SD-SN& Rev. 0 . 1-8

Only t ra ined and q u a l i f i e d personnel sha l l s tar t -up and operate the HPWJS. techn ica l d i r e c t i o n f o r the se t up o f cleaning f i x t u r e and associated hardware.

coated w i t h dye t o simulate the contaminated surface.

During these tes ts , SEG personnel sha l l be present and provide ove ra l l

(See Section 10.2 f o r r e s p o n s i b i l i t i e s )

The simulated coat ing mater ia l c r i t e r i a i s t h a t 98% o f the surfaces be

5.0 INSTRUMENTS AND CALIBRATION

Pressure gauges are ca l i b ra ted by the vendor p r i o r t o shipping. No other c a l i b r a t i o n i s required.

6.0 FACILITIES, EQUIPMENT AND MATERIALS

6.1 FACILITIES

The 305 Cold Test F a c i l i t y t e s t basin w i l l be u t i l i z e d f o r t he

The HPWJS w i l l provide water a t the desired pressures and f low ra te .

acceptance t e s t program.

The system can provide up t o 15,000 p s i w i t h a f low r a t e o f up t o 15 gpm. The water j e t sk id w i l l be located outside o f the 305 b u i l d i n g on the south east corner. E l e c t r i c a l service t o the sk id w i l l be provided by a por tab le d iese l generator u n i t connected d i r e c t l y t o the motor cont ro l panel and grounded t o a b u i l d i n g ground. Feed water w i l l be pumped from the t e s t basin t o the water j e t pump through a 2 i nch PVC l i n e from an a u x i l i a r y feed pump. E l e c t r i c a l serv ice t o the feed pump w i l l be provided v i a a cont ro l panel from the 480 v o l t , 3 phase o u t l e t near the t e s t basin. The h igh pressure hose w i l l be run t o and be discharged through cont ro l valve and the f i x t u r e s and/or heads t o the t e s t basin. basin.

305 Cold Test F a c i l i t y . The i tem t o be cleaned w i l l be placed i n t o the t e s t basin. f l ow r a t e s w i l l be d i rec ted a t the surfaces t o be cleaned through nozzles on the water j e t f i x tu res . An assortment o f t o o l s and equipment w i l l be u t i l i z e d t o l i f t , hold, place, p o s i t i o n and manipulate can is te rs under water dur ing c leaning a c t i v i t i e s . Add i t iona l l y , mockups o f the associated process equipment and t o o l s may be set up separately (mocked up) t o v e r i f y process f l ow and o p e r a b i l i t y .

Any one o f the fo l lowing type can is te rs can be used f o r the acceptance t e s t and sha l l be stained w i t h dye t o simulate surface contaminates: Mark I , and Mark I 1 Fuel Storage Canisters. aluminum can is te r sha l l be tested.

NOTE:

Bypass water and dra ins w i l l be routed back t o the

A work s t a t i o n w i l l be se t up i n the t e s t basin on the east s ide a t the

A h igh pressure water j e t nozzle w i t h varying discharge pressures and

Mark 0, Both a s ta in less s tee l and

The dye t o be used i s SLIDE @ Th in - l ine Layout Blue

WHC-SO-SNF-ATR-010, REV. 0 1-10

8.0 MAINTENANCE AND FAILURES

Use only products intended for high pressure water jetting. damaged items. Immediately inform test supervision of any water or oil leakages. result in equipment damage. A logbook will be kept by the operator of the HPWJS concerning all breakdowns, repairs, or leaks. The log book will be located at or near the unit; it shall be reviewed and initialed at the end o f each shift by the SEG Technical Advisor to ensure proper maintenance is performed.

Do not alter products. Products should be used only as intended.

Do not touch water coming from weep holes on fittings and parts with

Do not use Inspect condition of all parts prior to use.

Failure to do so may

. . bare hands or try to stop the leakage by plugging the holes. Water coming from the weep holes is at high pressure and will cause injury by penetrating the skin. .

.

.

Check condition of all high pressure threads. Use Teflon tape only on male threads on low pressure pipe and fittings before connection. Do not let tape overlap and block end of tubing. Use "Never Seize" thread lubricant on high pressure pipe and fittings. Be sure there is a minimum engagement of four threads. Do not use pipe wrenches on high pressure pipe or fittings.

Any protective shielding removed from high pressure tubing and hoses during servicing must be replaced when servicing is complete. Failure to replace shielding may result in serious injury to personnel or damage to the equipment.

Prior to water jet cleaning, operate pump at low flow and low pressure (500 psi) to flush debris from system before attaching nozzle. Stop pump and relieve all pressure If adjustments are needed and prior to installing nozzle. If properly working, install nozzle, slowly increase flow and pressure until operating pressure is reached. , . . Only trained personnel should perform maintenance or repair. . In case.of freezing conditions, drain water from all components.

WHC-SD-SNF-ATR-010, REV. 0 W H C - S D d R e v . 0 1-11

9.0 ACCEPTANCE TEST DATA

The acceptance . t es t data sha l l 'be recorded f o r the ef fect iveness and r a t e o f surface area cleaned a t the associated f low and pressure f o r each o f the i d e n t i f i e d simulated t e s t s per sect ion 11.0, Acceptance Test Execution.

10.0 PERSONNEL REQUIREHENTS

10.1 Oual i f i c a t i o n s / T r a i n i n q

Personnel performing these t e s t s sha l l be t ra ined and q u a l i f i e d by the HPWJS vendor representat ive o r a vendor c e r t i f i e d person f o r the safe s t a r t up, operation and shutdown o f the HPWJS.

10.2 &SD onsi b i l i t i e s

10.2.1 Jest T echni c i aQ

The Test Technician (305 F a c i l i t y Technician) i s responsible f o r performing the physical hands on manipulat ion o f t oo l s and equipment and f o r general f a c i l i t y support.

10.2.2 WHC Test Enaineer

The Test Engineer i s responsible f o r ensuring t h a t the t e s t i s performed per the Acceptance T e s t Procedure and sha l l sign o f f on the T e s t Data Sheets v e r i f y i n g t h a t the t e s t 'was performed, va l idated and acceptable.

10.2.3 SEG Technical Advisor

The SEG Technical Advisor(s) a r e responsible f o r the overa l l coord inat ion o f the special f i x tu res and equipment inc lud ing i n te r fac ing w i t h equipment vendors f o r SEG procured equipment. ensure proper equipment set up and safe operation. acceptance t e s t he sha l l per fo ry the Safety Checkl ist (Attachment A) o f the system and complete the i n i t i a l input t o the Acceptance T e s t D a t a Sheet (Attachment B) .

A m a j o r r o l e i s t o P r io r t o the

10.2.4 Oua l i t v Assurance

Witnessing by q u a l i t y assurance/qual i t y cont ro l (QA/QC) personnel sha l l be requ i red f o r the va l idated t e s t resu l ts ; and sha l l be ind icated by s ign o f f s on Attachment 8, Acceptance Test Data Sheet.

/TEST CON-WOL COPY

WHC-SO-SNF-A

11.0 TEST. EXECUTION


11.1 Sa.fetv M eetinq

A pre-job safety meeting will be conducted with test personnel prior to starting acceptance testing .

11.2 Safetv Walk Down

A Pre-test safety walk down will be performed by the SEG Technical Advisor prior to starting the acceptance test.

11.3 Water Jet Fixture Confiauration

The water jet fixture design is the result o f the development testing. Any adjustments and/or changes to the fixture during the acceptance testing shall be noted on an "as-built" drawing to identify the final acceptance test configuration.

11.4 Test Conduct

Testing shall be documented by recording acceptance test data. The Acceptance Test Data Sheet (Attachment B) will be utilized to record specific test information. The water jet fixture and associated support equipment configurations will be tested for process flow and compatibility with interfaces. The water pressures and flows for the test configuration along with nozzle size, type and arrangement shall be recorded. Manifolds, control valve type and hose arrangement will also be included and recorded in a sketch or an as-built drawing.

11.5 Set UD

The operations procedure for the HPWJS and/or vendor manual shall be utilized in conjunction with this acceptance test procedure. .This skid mounted pump system provides water at various pressures and flow rates. The high pressure hose will be connected through a manifold to 2 foot control valves. water jet cleaning fixtures From the foot control valves.

Special handling tools and equipment will be used for positioning and manipulating the canister through the cleaning jet fixture. These fixtures may be supported from the hand rail of the test basin. or jib may be used to manipulate the canisters.

High pressure hose/pipe will be connected to the under

A crane

11.6 Scope

Test the effectiveness of fixtures configuration for cleaning the simulated surface contamination on a canister underwater. The test will be performed on at least one of both stainless steel and aluminum material type canisters.

TEST CONTROL COPY

WHC-SD-SNF-AT 10, Rev. 0 Y

ATTACHHENT A

SAFETY CHECKLIST

px


WHC-SO-SN# Rev. 0 WHC-SO-SNF-ATR-010, REV. 0 1-15

* SAFETY CHECK LIST * Test Log Number 2 FOR

HIGH PRESSURE WATER JETTING SYSTER

Date - . - SEG Technical Advisor ,ho, kr

1.

2.

3.

4.

5.

6.

7.

8.

9.

Has the Pre-job b r i e f i n g been completed?

Are personnel t ra ined and q u a l i f i e d t o operate the HPWJS?

YES

J A

4 I s personnel sa fe ty equipment ava i lab le a t the j o b s i t e ?

AL Have the work area and the s k i d area been roped p f f with proper signs posted?

Have precautions been taken t o p ro tec t e l e c t r i c a l equipment?

Is t h e area cleared o f t r i p p i n g hazards?

Is t h e operat ing pressure o f the f i t t i n g s greater than the planned t e s t pressure? (max t e s t pressure i s 15,000 ps i )

Are a l l hoses, lances, guns and foo t cont ro l valves ra ted f o r t he maximum operating pressure? L

Are a l l f i t t i n g s , hoses, lances, guns and foo t cont ro l valves i n good working condi t ion?

10. I s t he feed water pump proper ly placed i n the basin an- connected t o the pump sk id and has it been flushed? L

11. Has the f i l t e r and Y-strainer been checked f o r cleanness and i s it i n good operat ing condi t ion? _rL

NO

-

TEST CONTROL COPY


12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

YES Are the skid drains, cooling water and dump water properly routed? JL Are the safety shrouds on guns, valves and hoses?

Confirm electrical service connections are properly connected and power from the Portable Generator is avai 1 ab1 e? - J

Have the high pressure hoses been flushed and all air removed

Is the cooling water to the plungers operating properly?

Has the oil level been checked on the sight glass for

Has the Pressure Regulator been charged with nitrogen to

Has hookup, including pipes, hoses and connections, been pressure tested with water at, the maximum operating

Is the dump pressure regulator drain line connected

prior to nozzle being installed? 1 1

the power end? 1

the desired operating pressure? 4

pressure? 4L

proper1 y? L Has Job site been examined for environmental considerations, with action as appropriate?

Are a1 1 control systems operational ?

JL

REMARKS :

TEST CONTROL COPY

WHC-SO-SNF-ATR-010. REV. 0 , Rev. 0 1-23 T&k m13

Single Line Sketch o f Fixture and Control Valve Arrangement or Drawing lumber X 6- p&cd

A=

- WHC-SO-SNF-ATR-010, REV. 0

305 BUILDING WORK PLAN/INSTRUCTION

System

Originator GREG WAGNER

Location Impact Level

Date Cost Code 305 BUILDING -

07/07/95 L024C

AFTER THE ABOVE CHECKOUT, THE JETING SYSTEM WILL BE RELOCATED I N TO THE TEST BASIN FOR ACCEPTANCE TESTING.

Restrictions - Special Conditions - Sequence and End Use THE P I T ACCESS SHALL BE ROPED OFF AND CONTROLLED, L I M I T I N G PERSONNEL ACCESS DURING TEST A C T I V I T I E S . HIGH PRESSURE WATER, 15,000 P S I IS AVAILABLE AT THE SPRAY NOZZELS. HIGH PITCH NOISE IS MADE BY THE FLOW OF L I Q U I D THROUGH THE HOSES AN0 EQUIPMENT.

PERSONNEL INVOLVED I N TESTING WILL WORK I N ACCORDANCE TO THE 305 F A C I L I T Y PROCEDURES. HOLD PRE JOB SAFETY MEETING. PRIOR TO START OF TESTING F I L L OUT SAFETY CHECK L I S T FOR PUMP. MASK OFF ELECTRICAL OUTLETS I N TEST AREA TO PREVENT WATER FROM ENTERING.

EQUIPMENT SKETCHES AN0 ASSEMBLIES TO BE SUPPLIED BY SEG COG ENGINEER.

Hold Points - Tests - Inspections - and Other Verification

Supporting Documents (i.e., Drawings, ECMs, Test Plans, etc.)

Materials Needed MATERIALS TO BE SUPPLIED BY SEG.

Special Tools, Building Modifications, (supplied by whom?) NO SPECIAL TOOLS OR BUILDING MODIFICATIONS AT THIS TIME.

Schedule AUGUST 7 THROUGH AUGUST 10, 1995 / . 1, MJ’ 5 c I L Building

P 7 - 9s-

ADDITIONAL INFORMATION Requester Signature Date

(continued - Safety Review, see back page) A-sODOBSI LOJIOZ)


APPENDIX 111

STONEAGE RJV3 ROTARY WATERBLAST NOZZLES OPERATOR'S MANUAL

111-1

Please deliver to:

STONEAGE inc WATERJET ENGINEERING

54 Girard Street Durango, Colorado 81301 FAX 970-259-2868 Phone 970-259-2869

Jared Burdin Scientific Ecology Group 509-372-2403

From: John Wolgamott Date: Sep. 12, 1995

Re: RJVTools

We are pleased that you have had success using the RJV tools in your application.

You have our authorization to use the associated “Operation and Maintenance Manual for the RJV” in your reporting process.

Please let me know if we can be of further assistance.

Best Regards

Total number of pages 1 including this cover sheet. If all pages are not received, please call 970-259-2869.

'WC-SD-SNF-AT7-010, REV. 0 I 11-05 ...-

Rotary Nozzle f For Waterblast Cleaning

The RJV3 is specifically designed for hand held waterblast cleaning. The rotating jets are hard-hitting and cover a large area for eficient cleaning. The jet reaction force powers the head to rotate up to 2000 rpm. The speed is controlled by an internal viscous fluid governor. A single high pressure seal provides leak-free operation so that no power is wasted. The seal is economical and easy to change.

The tool is simple to work on and can be serviced in the field. Two models are available, one rated to 15,000 psi and the other to 20,000 psi. t -

FEATURES: No-leak seal will not waste power Controlled rotation speed Easy to maintain and repair Rugged. compact design Replaceable carbide nozzles Operating pressures to 20,000 psi

~

W A T E R J E T E N G I N E E R I N G Q Y l Y 4

WHC-SD-SNF-ATR-010, REV. 0 111-07 -

These guidelines were prepared to provide the operator of the RJV3 rotary nozzle with the basic information needed to use and sewice these tools. All operators or sewice personnel responsible for the care of this equipment should be familiar with the information in this manual.

-. ,

. :. .. . . .. . . . .. .

WARNING: HIGH PRESSURE FLUID SYSTEMS ARE POTENTIALLY DANGEROUS AND ONLY COMPETENT AND TRAINED PERSONS SHOULD BE INVOLVED IN THE MAINTENANCE AND OPERATION OF THESE TOOLS.

If you have any questions or problems with this product, please contact the distributor you obtained the tool from, or the manufacturer:

StoneAge, lnc. 54 Girard Street

Durango. CO 81301 3 0 3 - 2 5 9 - 2 8 6 9 -

The RJV3 is specifically designed for hand held waterblast cleaning. The roataing jets are hard-hitting and cover a large area for efficient cleaning. The jet reaction force powers the head to rotate at up to 2000 rpm. The speed is controlled by an internal viscous fluid governor. A single high pressure seal provides leak-free'operation so that no power is wasted. The seal is eonomical and easy to change.

2.1 RJV3 15y

The RJV3 can be used at operating pressures of 6000 to 15.000 psi. Standard nozzle heads are available for normal operating pressures and flow rates. These heads have 114 npt ports for using common replaceable nozzles. However the correct combination of head and nozzle size KWJ be used. Please refer to the "Head and nozzle selection guide" on the back of the data sheet.

2.2 RJV3-20K

The RJV3-20K is designed for operating pressures of up to 20.000 psi. The RJV3-20K has an inlet nut with 9/16 medium pressure cone ti thread connection.

The nozzle head needs to be fined with the proper size of nozzle. Please refer to section 5 for nozzle size selection. Please refer to the "Head and nozzle selection guide" on the back of the data sheet.

WHC-SO-SNF-ATR-010, REV; 0 111-08

2 L b u L H w

A series of four nozzle heads are available. They have a jet angle of 12". 15'. 18", and 2 4 O . All will fit on the RJV3 and are used for both the 15K and 20K models. It is important to select the head angle that matches the nozzle size for the operating pressure intended. These factors determine the rotating torque and the ability of the RJV3 to govern the speed. Too little toque and the head will not rotate fast enough or at all. Too much torque will over spin the head and wearout the high pressure seal quickly. Please refer to the 'Head and nozzle selection guide" on the back of the data sheet.

A special head and nozzle insert style is available that do not use npt threads. .Instead a straight thread with O-ring seal is employed. This design is rated for 20.000 psi working pressure as an alternative to the standard 1/4 npt design. Please refer to Section 4.0 Parts list for the part number and name.


NOTE: It is recommended that all operating personnel be familiar with the for the use of IlY

d Pie-nt", which is published by the Water Jet Technology Associatlon. .

.::...

.. . .. ... .. . . .. . . . . . .~

Operations with the RJV3 Rotary Head can be potentially dangerous if caution is not exercised prior to and during tool use. Please read and follow all of these instructions.

3.1 Only competent and trained persons should operate this equipment.

3.2 Do not exceed the maximum operating pressure specified for any component In a system.

3.3

3 . 4

3.5

3.6

3.7

3.8

3.9

This equipment should always be used with an operator controlled dump mechanism to release the high pressure water.

The immediate work area should be marked off to keep out untrained persons.

All personnel in the area should wear eye protection, and other protective clothing in accordance with specific conditions.

The t w l should be securely supported. Strong back thrust is created by waterjets and these forces can become unbalanced if a nozzle should become plugged.

Inspect the equipment for visible signs of deterioration, damage, or improper assembly. Do not operate until repaired. Make sure all threaded connections are tight and leak free.

Check to see that all control functions work properly before going to high pressure.

If it is necessary to have a person work near the cleaning jets, then it is this person who should have control of the pressure dump mechanism.

. -. . : i . .

'"X"" indicates jet angle of head. ! I i

"P" indicates 1/4 npt port ~ I I "K" indicates O-ring seal

I ""X" indicates orifice size of nozzle.

11951 I 1 I


&4 TROUBLESHOOTING GUIDg

SYMPTOM

Leaks out weep holes

Seals wear out too quickly

PROBLEM

1. Worn H.P. Seal 2. Worn seat 3. Worn inlet nut

1. Worn out seat

2. Rough shaft finish

3. Shaft ID worn

Water found in viscous fluid 1. Operated with H.P. seal leaking badly

2. Worn shaft seal

Shaft won't rotate

Head spins too fast

Shaft wobbles

1. Not enough jet torque

2. Bad bearings 3. Internal damage 4. Clamped in rotor area

1. Too much power for head design

2. Low or empty on viscous fluid

3. Water in viscous fluid

1. Bearings are worn 2. Shaft is worn

SOLUTION

1. Replace seal (12) 2. Replace seat (11) 3. Repair or replace nut (02)

1. Replace if smaller than .308 diameter.

2. Polish shaft ID with clean 600 grit paper or replace.

3. Replace if larger than .318 0.

1. Replace seal (1 2)

2. Replace seal (10)

1. Test by hand, if ok check nozzle/head chart

2. Replace bearing (07 8 09) 3. Inspect and repair 4. Move clamp

1. Reduce power or correct head design

2. Refill viscous fluid

3. Clean and refill

1. Replace bearing (07 & 09) 2. Replace bearings and

shaft (01)


7.0 LlMlTED WARRANTY

StoneAge, Inc. warrants to the extent herein provided the products of its own manufacture against defects in material and workmanship under normal use and service for which the products were designed for a period of six (6) months after shipment from the factory. If such products should fail through defect in workmanship or material and specific written notice of failure is made within six (6) months after date of shipment from the factory, StoneAge. Inc. will either repair or replace any such items, F.O.B. its factory without charge. StoneAge, Inc. shall not be liable for expense incurred in repairs or alterations made outside the factory without the proper and prior authorization. StoneAge, Inc. shall have the option of requiring the return of the defective products to its factory, with transportation charges prepaid, to establish the claim. StoneAge, Inc. shall in no event be held liable for damages or delay resulting from or arising out of defective products nor for consequential damages or otherwise except for repair or replacement of items of defective material or workmanship asforesaid.

THIS WARRANTY IS EXPRESSLY IN LIEU OF AUOTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABlUPl AND FmESS FOR USE AND NElTHER ASSUMES.NORA~~~ANYPERSONTOASSUMEKHISTONEAGEINC. ANYOTHER UABILITY IN CONNECTION WITH THE SALE OF ITS PRODUCTS. THIS WARRANTY SHALL NOT APPLY TO PRODUCTS OR ANY PARTS THEREOF WHICH HAM: BEEN SUBJECT TO ACCIDENT, NEGLIGENCE. ALTERATION, ABUSE, OR MISUSE. STONEAGE, INC. MAKES NO W A R W WHATSOEVER IN RESPECT TO ACCESSORIES. PARTS OR PRODUCTS NOT MANUFACTURED BY STONEAGE, INC.

, . . . . .

PRODUCT NAME: L-451500 WHC-SO-SNF-ATR-010, REV. 0 PAGE 111-21

111. INGREDIENTS

% - 100

MATERIAL

IV. FIRE AND EXPLOSION HAZARD DATA

FLASH WINT(t.n mnhodls)): > W F Pemkv.Msnm8 Cloud Cup ASTM D 93

FLAMMABLE LIMITS IN AIR LOWER. N e t d n n m m d . % bv volunn: U r n : Not d n ~ m n d .

UNUSUAL FIRE AND - EXPLOSION HAZARDS: M a m s n d m.y poduca flomno RN hazard.

PKIDUCT NAME: L-45/500 WHC-SD-SNF-ATR-010, REV. 0 PAOE 111-23

Swcrtund ArneMrnems an0 Reaurnonzarion Act of 1986 (SARA1 Tine 111 r.Qyrn ubmrwon ot umud r o o o m ot rdoum ot tone c k m ~ m rhm aooon In 04 CFA 372 (tor SARA 3131. This tlrlomuoon mum bo insluam In d MSOSs um a n cwtw .nd bambum tor mi. m-d.

Canponma pmmm in m s producc n s loud when c W r w r s r.oomng undr mo -10 an: .... NONE .... Toxic Substances Comml Act (TSCAl STATUS:

Tho mngrmwna of ma oroauct arm on tho TSCA inwmow.

STATE RIGHT-TOXNOW

CALIFORNIA Propomon 65 Thh produrn eonmm 110 I d * of Umtod .ubnwn. wkoh tho sur0 of W t o m o h a bund to CM. ouvmr. brat dotam or o d m Rploduco~ ham. wkoh w d d m u m s urnno undn tk. Rmno.

MASSAWUSEITS Rigm-Tc-Unow. Subnmcs bm ( M U Harmw. S u b n m o n and Exmomnu~v Humuow Submsmw on tm MSL nwm D. d.nUfkd w h m pmmm 'n ProduOD.

Comwmnu p m u n in tks ormuoz m e I d wmcn d rvwtn mwrnng umu mo nmm m: .... NONE .... PENNSYLVANIA RigM.r*Know. Harudws Submmcm IJm Wwmoua Subnsnon and Soom.) Hummoum Subsrwncr on ma U m mum be IdMORm wmn prmsont In produco.

Componnt. omom in zhm prooust n Imw w'Kn could r w n rwomna u n d r tho mauo m n : .... NONE .... -

CALIFORNIA SCAQMD RULE 403.1 VOC'S: V d d o Orguro Conwownu (VOC'al - S u b m w n mm Y.WT w w w r o of - > 0.5 mnHg m 101'C (zlS.z'~L

T h m produet eormrm 0.00 ghtw VOC'a and 0.00 onmr VOC'r ( I n s wmor and m x a v ~ convw110.~.

OTHER REGULATORY INFORMATION EPA Hazard Caugonn: Nom

mmon contun i homn #a curnm as of tho d m of cma Wan.) Smisw O m Shut . Simm rho us0 of a s m i o m o n om mo ~ ~ n d i t t o m ot mm US. of mo owauct a n noc undor tM conuol ot O S Sp.a&an. 11 IS mo u n f s obbgmton to amurmns thm condioonm ot mato umm ot 1h0 product. REVlSa SHSnONS:

Soenon IX PRODUCT: 01080 F NUMBER: 502'1.00

- i


SERVICE BULLETIN 3QmuQrM IQQS

Improved Seat Design for BJV, SG, RJV3

A recent design change has been made to the high pressure seat used in several models of swivels. The change is to use a carbide seat instead of brass. This change will be effective with swivels shipped begining in January 1995. The carbide seat offers several advantages over brass. It is harder, smoother, and keeps an edge longer. The carbide seat is more expensive than the brass, but it will pay for itself quickly. High pressure seals will last longer running against the carbide seat.

1. The new seat design is completely interchangeable with the earlier brass style. No changes are required other than to swap the brass out for the new carbide style.

2. The benefits to this design change are; longer lasting Seal life and less maintenance.

3. The new Carbide seat will come standard in the BJV, SG-P8, SG-P12, SG- A12, and RJV3.

4. All service kits for the swivels affected will have the carbide seat included, begining in January also.

5. seats will continue to be used in the BJV-M, SG-P12-M, and RJV.

Q!dhL

BJ 11 Seat, Brass RJ 11-K Seat, Brass

New Part

BJ 11-C Seat, Carbide RJ 11-KC Seat, Carbide

Please consult StoneAge or your distributor if you have any questions.

54 GIRARD ST. 0 BOX 2907 DURANGO. CO 81302 (303) 259-2869

C'

~~~C-SD-SNF-ATR-OIO, REV. 0 I J I - Z h

SERVICE BULLETUV

Improved Design for RJV .. C" v,

A reca t design change has been made to the RJV Swivel to eliminate the bleed port in the body. This Ciange was effective with swive! seriai number 1465. The port is not needed with the new shaft seal lip direction (as described in RW Service Builetin, April 1993). Earlier models had the seal lip oriented in a way that trapped the viscous fluid and a bleed port was necessary to assemble the Unit The new design will have any excess fluid from "filling, push past the lip and spill out the Wee? ports.

1. The new body design is completely interchangeable with the earlier body styie y o changes' are required other than to have the shaft lip seal fadng M visc~us can

2. effectively smaller diameter.

I:..... ,. ... . pwh past. . . , .. ..

The bendits to this design change are; less parts, easier filling procedure, and an

3. the need for a plug s a w .

Eal i er model bodies can be modified by hlling the port with epoxy to eliminate

Please consult Stone4ge or your distributor if you have any questions.

54 GIRARD ST. BOX 2907 DURANGO. CO 81302 (303) 259-2869


APPENDIX IV

ORIGINAL ACCEPTANCE TEST PROCEDURE

I V - 1

\ I 4 5 1 5 \

2. To: (Receiving Orsmiration)

SNF K Basins Projects 5. Proi./Prog./Dapt./Div.:

NHC-SD-SNF-ATR-010, REV. 0

._ 3. From: ( D r i s i n t i n g Orgnirntion) 4. Relatad EDT No.:

SNF K Basins Projects N/A 6. Cog. Engr.: 7. Purchase D&r No.:

SNF/K Basins Projects

Please review for approval.

Jeremy B. Crystal 8. Originator Ramark:

N/A 9. Ewip./Colpmnt No.:

, High Pressure Water Jet 10. fy.tcr/BLdg./Faci L i ty:

I I I 21. DOE APPROVAL ( i f required)

[I Approved Lk: 11 Approved w i c n n n t s

[I Disapproved ulc-ts

C t r l . No. 20.

D. s. T*..”d 0. $. T.k.sumi &hr S k N t “ W 01 €01 O N Amh0ttzb.d R.pn*mnt.tin O N b a n h u n M.n.0.r ON 0 rio i n n o r lor R.c.iv*lp Ommkulon

11. Receiver Rwrks:

BO-7400-172-2 (04/94) CEFG97

305/300

N/A 13. P e n i t / P e m i t Application No.:

N/A

12. Major ASYI. ~ u g . NO.:

14. Rewired Rnporse Date:

r'.'L-~3-S,~F-ATR-010, REV. 0 I'J-5

1 .... -..-.__ SUPPORTING DOCUMEN r

2. T i t l e

Acceptance Test Procedure for High Pressure Water Jet System

High Pressure Water Jet Operation Procedure ATP

5. K e y Uords

3. N-r 4. Rev No.

WHC-SO-SNF-ATP-010

6. Author

)IN: JB Crystal k/%f

OrganizatimlCharge code 2GOOO/LD24C

Jet.

- a. RELEASE S T W

A-6600-073 (081%) YEF126

WHC-SD-SNF-ATR-010, REV. 0 IV-6

WHC-S/ -010, Rev. 0

Table o f Contents

1.0 TEST ITEM IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 2.0 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.0TESTOBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 DESIGN CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . 2 3.2 ACCEPTANCE TEST CRITERION FOR DECONTAMINATION . . . . . . . . . 2 3.3 TEST METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4.0 TEST CONDITION LIMITS . . . . . . . . . . . . . . . . . . . . . . . . 2

5.0 INSTRUMENTS AND CALIBRATION . . . . . . . . . . . . . . . . . . . . . 3

6.0 FACILITIES, EQUIPMENT AND MATERIALS . . . . . . . . . . . . . . . . . 3 6.1 FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6.2 EQUIPMENT SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . 4 6.3 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7.0 OPERATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 4

8.0 MAINTENANCE AND FAILURES . . . . . . . . . . . . . . . . . . . . . . 5

9.0 ACCEPTANCE TEST DATA . . . . . . . . . . . . . . . . . . . . . . . . 6

10.0 PERSONNEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . 6 r a i n i n q . . . . . . . . . . . . . . . . . . . 6

6 10.1 g u a l i f i c a t i o n s / T 10.2 P e s o o n s i b i l l t i e s . . . . . . . . . . . . . . . . . . . . . .

10.2.1 Test Technician . . . . . . . . . . . . . . . . . . . 6 10.2.2 WHC Test Ena ineer . . . . . . . . . . . . . . . . . . 6 10.2.3 SEG Technical Advisor . . . . . . . . . . . . . . . . 6 10.2.4 g u a l i t v Assu rance . . . . . . . . . . . . . . . . . . . 6

. .

11.0 TEST EXECUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 11.1 Safetv Meetinq . . . . . . . . . . . . . . . . . . . . . . . . 7

Walk Down . . . . . . . . . . . . . . . . . . . . . . . 7 7

11.2 Safetv 11.3 Water J e t F i x tu re Conf iaurat i o n . . . . . . . . . . . . . . . 11.4 Test Conduct . . . . . . . . . . . . . . . . . . . . . . . . 7 11.5 Set UO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 11.6 ScoDe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

12.0 TEST STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

13.0 DISPOSITION OF DEBRIS ITEM . . . . . . . . . . . . . . . . . . . . . 8

14.0 ACCEPTANCE DATA SHEETS . . . . . . . . . . . . . . . . . . . . . . . 8

ATTACHMENT A - SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . A-1

ATTACHMENT B - ACCEPTANCE TEST DATA SHEET . . . . . . . . . . . . . . . . B-1

ATTACHMENT C - ACCEPTANCE TEST DATA SHEET INDEX LOG . . . . . . . . . . . C-1

/-

P-010, Rev. 0 . WHC-SD-SNF-ATR-010, 1v-9 REV. 0

Only t ra ined and q u a l i f i e d personnel sha l l start-up and operate the HPWJS. During these tests , SEG personnel shal l be present and provide ove ra l l technica l d i r e c t i o n f o r the set up o f cleaning f i x t u r e and associated hardware.

coated w i t h dye t o simulate the contaminated surface.

(See Section 10.2 f o r r e s p o n s i b i l i t i e s )

The simulated coating mater ia l c r i t e r i a i s t h a t 98% o f the surfaces be

5.0 INSTRUMENTS AN0 CALIBRATION

Pressure gauges are ca l ib ra ted by the vendor p r i o r t o shipping. No other c a l i b r a t i o n i s required.

6.0 FACILITIES, EQUIPRENT AND HATERIALS

6.1 FACILITIES

acceptance t e s t program. The 305 Cold Test F a c i l t t y t e s t basin w i l l be u t i l i z e d f o r the

The HPWJS w i l l provide water a t the desired pressures and f low ra te . The system can provide up t o 15,000 p s i w i th a f low r a t e o f up t o 15 gpm. The water j e t sk id w i l l be located outside o f t he 305 bu i l d ing on the south east corner. E l e c t r i c a l service t o t h e sk id w i l l be provided by a por tab le d iesel generator u n i t connected d i r e c t l y t o the motor contro l panel and grounded t o a b u i l d i n g ground. Feed water w i l l be pumped from the t e s t basin t o the water j e t pump through a 2 inch PVC l i n e from an a u x i l i a r y feed pump. E l e c t r i c a l serv ice t o the feed pump w i l l be provided v i a a cont ro l panel f r o m the 480 vo l t , 3 phase o u t l e t near the t e s t basin. The high pressure hose w i l l be run t o and be discharged through d contro l valve and the f i x t u r e s and/or heads t o the t e s t basin. Bypass water and drains w i l l be routed back t o the basin.

A work s ta t i on w i l l be set up i n the t e s t basin on the east s ide a t the

A h igh pressure water j e t nozzle w i th varying discharge pressures and 305 Cold Test F a c i l i t y . The i tem t o be cleaned w i l l be placed i n t o the t e s t basin. f l o w ra tes w i l l be d i rected a t the surfaces t o be cleaned through nozzles on the water j e t f i x t u r e s . An assortment o f t oo l s and equipment w i l l be u t i l i z e d t o l i f t, hold, place, pos i t i on and manipulate canis ters under water dur ing c leaning a c t i v i t i e s . Addi t ional ly , mockups o f the associated process equipment and t o o l s may be set up separately (mocked up) t o v e r i f y process f low and operab i l i t y .

Any one o f the fo l low ing type canis ters can be used f o r t he acceptance t e s t and sha l l be stained w i th dye t o simulate surface contaminates: Mark 0, Mark I , and Mark I1 Fuel Storage Canisters. Both a s ta in less s tee l and aluminum can is te r sha l l be tested.

NOTE: The dye to be used i s SLIDE Q Thin- l ine Layout Blue

.

W H C - S O - S v R e V . 0 WHC-SO-SNF-ATR-010, REV. 0 IV-12

9.0 ACCEPTANCE TEST DATA

The acceptance t e s t data sha l l 'be recorded f o r the ef fect iveness and r a t e o f surface area cleaned a t the associated f low and pressure f o r each o f the i d e n t i f i e d simulated tes ts per sect ion 11.0, Acceptance Test Execution.

10.0 PERSONNEL REQUIREHENTS

10.1 Oua l i f i ca t i ons lT r a in inq

Personnel performing these tes ts sha l l be t ra ined and q u a l i f i e d by the HWJS vendor representat ive o r a vendor c e r t i f i e d person f o r the safe s t a r t up, operation and shutdown o f the HPWJS.

10.2 ResDonsi b i 1 i t i es

10.2.1 Test Technician

The Test Technician (305 F a c i l i t y Technician) i s responsible f o r performing the physical hands on manipulation o f t o o l s and equipment and f o r general f a c i l i ty support.

10.2.2 &IC T e s t Enaineer

The Test Engineer i s responsible f o r ensuring tha t the t e s t i s performed per the Acceptance Test Procedure and sha l l sign o f f on the Test Data Sheets v e r i f y i n g t h a t the t e s t 'was performed, va l idated and acceptable.

10.2.3 SE6 Technical Advi sor

The SEG Technical Advisor(s) are responsible f o r the overa l l coord inat ion o f the special f i x tu res and equipment inc lud ing i n t e r f a c i n g w i t h equipment vendors f o r SEG procured equipment. A major r o l e i s t o ensure proper equipment set up and safe operation. P r i o r t o the acceptance t e s t he sha l l perform the Safety Checkl ist (Attachment A) o f the system and complete the i n i t i a l input t o the Acceptance Test Data Sheet (Attachment B) .

10.2.4 Q u a l i t y Assurance

Witnessing by q u a l i t y assurance/qual i t y cont ro l (qA/QC) personnel sha l l be .required f o r the val idated t e s t resu l ts ; and sha l l be ind icated by s ign o f f s on Attachment B, Acceptance Test Data Sheet.

TEST CONTROL COPY

/ W H C - S O - F l O , Rev. 0

11.0 TEST. EXECUTION

11.1 Safety Meetinq


A pre-job safety meeting w i l l be conducted w i th t e s t personnel p r i o r t o s t a r t i n g acceptance test ing.

11.2 Safetv Walk D O W

A Pre-test safety walk down w i l l be performed by the SEG Technical Advisor p r i o r t o s t a r t i n g the acceptance tes t .

11.3 Water J e t F i x tu re Conf i aur a t i o n

The water j e t f i x t u r e design i s the r e s u l t o f the development tes t i ng . Any adjustments and/or changes t o the f i x t u r e dur ing the acceptance t e s t i n g sha l l be noted on an “as-bu i l t ” drawing t o i d e n t i f y the f i n a l acceptance t e s t conf igurat ion.

11.4 Test Conduct

Test ing sha l l be documented by recording acceptance t e s t data. The Acceptance Test Data Sheet (Attachment 6) w i l l be u t i l i z e d t o record spec i f i c t e s t information. The water j e t f i x t u r e and associated support equipment conf igurat ions w i l l be tested f o r process f low and compa t ib i l i t y w i th in ter faces. The water pressures and f lows f o r the t e s t conf igurat ion along w i t h nozzle size, type and arrangement sha l l be recorded. Manifolds, cont ro l valve type and hose arrangement w i l l also be included and recorded i n a sketch o r an as-bu i l t drawing.

11.5 Set UR

The operations procedure f o r the HPWJS and/or vendor manual sha l l be u t i l i z e d i n conjunct ion w i th t h i s acceptance t e s t procedure. .This sk id mounted pump system provides water a t various pressures and f low ra tes . The h igh pressure hose w i l l be connected through a manifold t o 2 f o o t con t ro l valves. water j e t c leaning f i x t u r e s From the foo t cont ro l valves.

High pressure hose/pipe w i l l be connected t o the under

Special handling too l s and equipment w i l l be used f o r pos i t i on ing and manipulat ing the canis ter through the cleaning j e t f i x t u r e . These f i x t u r e s may be supported f r o m the hand r a i l o f the t e s t basin. A crane o r j i b may be used t o manipulate the canisters.

11.6

Test the ef fect iveness o f f i x t u r e s conf igurat ion f o r cleaning the simulated surface contamination on a canis ter underwater. The t e s t w i l l be performed on a t l e a s t one o f both s ta in less s tee l and aluminum mater ia l type canis ters .

TEST CONTROL COPY


12.0 TEST STEPS

The following test steps require QA/QC validation on the Acceptance Test Data Sheet (Attachment 8) :

12.1

12.2

12.3

12.4

12.5

12.6

. 12.7

12.8

12.9

Connect hoses and place the water jet fixture into the test basin work station.

Place the pre-coated canister into the test basin work station holder.

Start-up the HPWJS following the detailed steps in the HPWJS Operation Procedure.

Set the water pressure at the skid and control water flow to the fixture by operating the foot control valve(s).

Position and manipulate the canister and/or the water jet fixture until the item appears to be clean.

Record time, number of passes and pressure and flow rate for each test.

Remove the cleaned canister from the water and inspect.

Document level of "decontaminafion" on the Acceptance Test Data Sheet (Attachment 8) percentage of paintldye removed from the surface of the canister. Acceptance i s removal of 80% o f the dye.

Repeat steps 12.1 through 12.8 as necessary for each of the canister material type acceptance tests.

13.0 DISPOSITION OF DEBRIS ITEM

Save for reuse in future testing.

14.0 ACCEPTANCE DATA SHEETS

Data will be recorded on the Test Data Sheet. An SEG Technical Advisor is responsible for initially filling out the Test Data Sheet. responsibility o f the WHC Test Engineer to maintain the test records and a daily shift log o f test activities.

the WHC Test Engineer starting with number 001.

It is the

A Test Data Sheet Index Log (Attachment C) shall also be maintained by

WHC-SD-SNF-ATR-010, REV. 0 0 IV-17

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Are the s k i d drains, coo l ing water and dump water p roper ly routed?

Are t h e sa fe ty shrouds on guns, valves and hoses?

Confirm e l e c t r t c a l serv ice connections are proper ly connected and power from t he Portable Generator i s

Have the h igh pressure hoses been f lushed and a l l a i r removed p r i o r t o nozzle being i n s t a l l e d ?

avai lab le? L

d

YES

JL J L

Is t he coo l ing water t o the plungers operating proper ly?

Has the o i l l eve l been checked on the s igh t glass f o r t h e power end?

Has the Pressure Regulator been charged w i t h n i t rogen t o the desired operat ing pressure?

Has hookup, inc lud ing pipes, hoses and connections, been pressure tes ted with water a t , t he maximum operat ing pressure?

Is the dump pressure regulator d ra in l i n e connected proper ly?

Has Job s i t e been examined f o r environmental considerations, w i t h ac t ion as appropriate?

Are a l l con t ro l systems operat ional?

REMARKS :

TEST CONTROL copy

WHC- SD- SN F- AT UHC-SD-SNF-ATR-010, REV. 0 1'4-18

ATTACHHENT B

ACCEPTANCE 'TEST DATA SHEET

/ WHC-SO-SNF-ATR-010. REV. 0

*

WHC-SD-SN-IO, Rev. 0 Iv-21

ACCEPTANCE TEST DATA SHEET Test Log Number - HIGH PRESSURE WATER JET SYSTEM .

SAFETY WALK DOWN COMPLETED and PREPARED BY:

Signature o f SEG T echni ca l Advi sop

(Print)

Date Time Test Engineer Test Technician Test Debris I tem Water J e t F i x tu re Conf igurat ion Numb e r Nozzle Size and Type Control Valve Conf igurat ion TEST DATA:

Materi a1 Type -

Pressure p s i Flow Rate 9.p.m. Cleaning Time minutes Number o f Passes

Test Objectives: Have the fo l l ow ing t e s t ob ject ives have been met?

* Clean surfaces with simulated contamination t o ensure sa fe ty and e f f i c i e n t decontamination process. - No - Yes

, *

*

Demonstrate a cont ro l led process for t he decontamination o f canisters, equipment, and miscellaneous mater ia ls underwater with minimal water surface disturbance. Yes - No - Demonstrate the best combination o f nozzle conf igurat ion, water pressure, water f low r a t e and cleaning speed t o c lean canis ters as i d e n t i f i e d dur ing t h e development

- No tes t ing . Yes - * Perform the acceptance t e s t i n g f o r the most e f f e c t i v e

combinations o f f i x t u r e s and nozzles as determined dur ing the development tes t ing . Yes - No -

Acceptance Test Cr i te r ion :

The fo l l ow ing acceptance t e s t c r i t e r i o n has been met?

Removal o f 80% o f the simulate (dye coating) from the debr is surface o f each o f the canisters. Yes

1. - No -

TEST CONTROL Gc .

WHC-SD-SNF-ATR-010, REV. 0 Rev. 0 Iv -22

Remarks on cleanness

Other Remarks

Single Line Sketch of Fixture and Control Valve Arrangement or Drawing Number I

iignatures IC Witness (When reauired) Date: #C Test Technician Date:

#C Test Engineer ' Date:

TEST CONTROL C c"'b'

WHC-SD-SNF-ATR-010, REV. 0 1’4-23

ACCEPTANCE TEST DATA SHEET Test Log Number - HIGH PRESSURE WATER JET SYSTEM .

SAFETY WALK DOWN COMPLETED and PREPARED BY:

Signature o f SEG T echni cal Advi sop

(Print)

Date Time Test- T e s t e c h n i c i a n Test Debris I tem Material Type Water J e t F ix tu re C- Nozzle Size and TvDe Control Valve Configuration TEST DATA: Pressure ps i Flow Rate 9.p.m. Cleaning Time minutes Number o f Passes

Test Objectives:

* Have the fo l lowing t e s t objectives have been met?

Clean surfaces with simulated contamination t o ensure safety and e f f i c i e n t decontamination process.

Demonstrate a contro l led process f o r the decontamination o f canisters, equipment, and miscellaneous materials underwater with minimal water surface disturbance. Yes

- No - Yes

*

- No - * Demonstrate the best combination o f nozzle configuration, water

pressure, water flow r a t e and cleaning speed t o clean canisters as i d e n t i f i e d during the development tes t i ng . Yes - No -

* Perform the acceptance tes t i ng f o r the most e f fec t i ve combinations o f f i x tu res and nozzles as determined during the development test ing. Yes - No -

Acceptance Test Criterion:

The fol lowing acceptance t e s t c r i t e r i o n has been met?

1. Removal of 80% o f the simulate (dye coating) from the debris surface o f each o f the canisters. Yes - No -

TEST CONTROL C;

WHC-SD-SNF- / -010, Rev. 0 WHC-SD-SNF-ATR-010, REV. 0 IV-24


Other Remarks

Single Line Sketch o f Fixture and Control Valve Arrangement o r Drawing Number X

ii matures IC Witness (When required) Date:

MC Test Technician Date:

MC Test Engineer Date:

WHC-SO-SNF-ATR-010, REV. 0 Rev. 0 IV-26

e


Other Remarks

Single Line Sketch o f Fixture and Control Valve Arrangement or Drawing Number t

iignatures IC Witness (When required) Date:

MC Test Technician Date: ~~

MC Test Engineer Date: