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Accession #: Dl9607181 1

Document #: SD-WM-PRS-013

TitlelDesc: [TWRS] LIFE MGMT AGING I T 1 995 ANNUAL REPORT

I (1) DocMent Nunber I I WHC-SD-WM-PRS-013

REV. 1 RECORD OF REVISION Page 1

L i f e Management/Aging 1995 Annual Report CHANGE CONTROL RECORD

C. E. Jensen K. V. Scatt 7/29/96

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A-7320-005 (08/91) UEF168

WHC-SD-WM-PRS-013 REV. 1

TWRS LIFE MANAGEMENTIAGING 1995 ANNUAL REPORT

1 .O INTRODUCTION

This report summarizes the activities and accomplishments during the 1995 fBcal year. The objective of the life management program is to ensure that the major waste management facilities at the Hanford site are able to safely meet the service demands of the Tank Waste Remediation System (TWRS) program over the life of the TWRS mission. Part of this program will develop material and structural integrity acceptance criteria for the systems, structures, and components (SSCs) that comprise the Hanford Waste Tank System facilities and assure that the SSCs are within these criteria.

The activities for the program include analyses, testing, and surveillance under several general task areas. This program will be conducted over the anticipated forty year period required to complete the TWRS mission.

The goal of the Life Management Program is to maximize the useful operating life of the DSTs and associated support systems including the transfer system and 242-A Evaporator. This goal is to be accomplished through management of degradation mechanisms associated with the various components.

Major End-Item Deliverables:

e e e e e e e e e e e e

DST Corrosion Monitoring Trade Study DST Prototype Corrosion Probe DST Corrosion Control Procedures DST Corrosion Control, 1st Tank Cathodic Protection Database DST Remaining Useful Life Estimate DST Corrosion Control, 2nd and 3rd Tanks DST Remaining Useful Life Estimate DST Corrosion Control, 4 through 14 Tanks DST Corrosion Monitoring System DST Remaining Useful Life Estimate Quantify DST Pitting Rates

12/95 6/96 9/96 9/96 9/96 9/96 9/97 9/97 9/98 9/98 9/98 9/01

2.0 FY 1995 DELNERABLES

2.1 Design Double Shell Tanks (DST) Crack Growth Rate Experiment (T2C-95-401)

An experimental procedure was written to define variables, number of samples, and experimental method necessary to develop DST crack growth rate data. This milestone

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2.9 Uniform Corrosion Report (WHC "Other" Milestone)

This activity was deleted from FY 1995 work scope to support MWTF Path Forward Task 3.8.

2.10 Life Management Annual Report (WHC "Other" Milestone)

This activity provides programmatic support to TWRS DSTs life extension tasks. This support includes the preparation of the life management annual program report which will document the status of the program tasks. The TWRS Life ManagemenUAging 1994 Annual Report, WHC-SD-WM-PRS-013, Rev. 0, was issued August 1994 and is presently being revised as TWRS Life ManagemendAging 1994 Annual Report, WHC-SD-WM-PRS-013, Rev. 1, September 1995.

2.1 1 Failure Mechanisms Report (WHC "Other" Milestone)

One of the first steps in the development of the life management program is the identification of potential failure mechanisms. The Failure Mechanisms Report reviewed the available literature for relevant failures and for evidence that suggested active mechanisms may be at work on TWRS components. Evidence from laboratory experiments, on-line monitoring, testing and surveillance, and analysis was evaluated. The most likely degradation or failure mechanisms have been identified in "Hanford Waste Tank System Degradation Mechanisms", WHC-SC-WM-ER-414, Rev. 0.

In most cases, more than one degradation mechanism is active on any given component. There is usually, however, a dominant mechanism driving the loss of component life expectancy. Localized pitting and concentration cell corrosion caused by the formation of localized regions of aggressive waste are the most threatening degradation mechanisms to the DSTs.

3.0 FISCAL YEAR 1995 CHRONOLOGY OF EVENTS

OCTOBER 1994

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Started work on FY 1995 activities. Canceled Technical Reports tasks to support Multifunction Waste Tank Facility (MWTF) Path Forward. Turned over of Transfer System Configuration Management Database. Prepared Low Hydroxide Concentration evaluations for 241-AY-101, 241-AP- 107, and 241-AP-108. Completed Letter Report: Corrosive Environment of SST Stabilization Transfer Line Heat Trace Conduits.

WHC-SD-WM-PRS-013 REV. 1

MAY 1995

Complete DST Pitting Test Plan. Letter Report: Use of A744 Stainless Steel in 241-SY-101. Issue FDC for Project W-430, 241-SY Tank Farm Cathodic Protection. Recommend deletion of cathodic protection for Project W-058, Cross-Site Transfer Line.

JUNE 1995

Initiated DST Pitting Experiments. Issued WHC-SD-WM-ER-414, Rev. 0, "Hanford Waste Tank System Degradation Mechanisms. Completed 1995 Annual Survey of West Tank Farms Cathodic Protection.

JULY 1995

Prepared Letter Report: Limiting SaltlMetal Interface Temperature Estimates for Storage of Cesium and Strontium Capsules in the Canister Storage Building.

AUGUST 1995

Prepared Letter Report: Total Corrosion Estimates for Cesium Chloride and Strontium Fluoride Capsules for 40-year and 80-year Storage in the Canister Storage Building. Supported TWRS Monthly Science & Engineering Technical Seminar: "Corrosion Issues" TWRS Engineering Reorganized, M&CE stays in Process Engineering. Completed Engineering Assessment of 241-AN Tank Farm Exhaust Duct. Completed Engineering Assessment of 241-SY Tank Farm Exhaust Duct. Evaluated of Corrosion Effects of 241-AY-101 Blending Options. Recommended removal of SN-276 transfer line from service. Hosted 15th Tank Structural Integrity Workshop, Richland, WA.

SEPTEMBER 1995

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Removed 2 year corrosion coupons form soil corrosion test site. Kicked-off trade study for DST corrosion monitoring strategy. Helium tested SL-120 transfer line. Coinpleted FY 1996 through FY 1998 Planning. Cathodic Protection article published in Materials Performance magazine.

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4.5 TESTING AND EXAMINATION

Degradation of the materials and structures of the SSCs is evaluated based on information provided from literature data, field examinations, laboratory testing, in-situ testing, or on-line testing. This task specifies the testing and examinations to collect information necessary to support degradation evaluation and to provide information on the condition of the materials and structures of the SSCs to support maintaining the structural and materials acceptance criteria throughout service life.

A dedicated program of remote Ultrasonic Examination (UT) for representative DSTs is planned under a separate cost account (1NlC31). Tank Farm ventilation ducting inspections for Project W-314 replacement were conducted in the 241-AN and 241-SY tank farms this year with positive results. The prototype corrosion probe discussed earlier also supports this task.

4.6 COMPONENT RELATIVE RISK ASSESSMENT

This task provides estimates of the failure frequencies of the SSCs, specifies the associated consequences and identifies the potentially life-limiting components. The estimates are made by probabalistic analyses for both leakage failure and structural failure categories and are used for screening and ranking of potential failure modes. The results of these analyses provide the means for a risk-based prioritization for the analysis, inspection, and testing activities. There were no significant activities supporting this task in FY 1995.

4.7 MITIGATION, UPGRADES AND RETIREMENT STRATEGY DEVELOPMENT

This task evaluates predicted service life verses the desired service life of tank farm SSCs, developed strategies for the mitigation of degradation mechanisms for those SSCs whose predicted service life is less than the desired service life, develops upgrade plans for those SSCs that do not presently meet or would not meet during future service the material and structural integrity acceptance criteria, and develops retirement strategies for those SSCs that do not meet the acceptance criteria. The primary focus of activities supporting this task in FY 1995 was improvements in the cathodic protection system for components of the transfer system.

5.0 HIGHLIGHTS

The highlights for the Fiscal year-to-date include items directly part of the Life ManagemedAging Program Plan and those activities that support this program.

5.1 PROTOTYPE CORROSION PROBE

In the area of corrosion control, design and installation of a prototype corrosion monitoring probe was accelerated by 12 months during this award fee period using qualified*C-l70

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5.7 HVAC DUCTING INSPECTIONS

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HVAC ducting scheduled for replacement in the 241-AN and 241-SY tank farms was inspected and determined to be acceptable for the remainder of the TWRS mission. Acceptance of these systems for continued use without replacement will provide significant cost savings to TWRS.

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5.8

An internet homepage with links to other materials and corrosion homepages around the world was created in FY 1995 and is expected to be posted on the internet with a Hanford external URL early in FY 1996.

MATERIALS & CORROSION ENGINEERING HOMEPAGE

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6.0 FY 1995 COST AND SCHEDULE PERFORMANCE

TOTAL

Total funds spent at the end of FY 1995 were $647.9K. The budgeted cost of work scheduled after first quarter scope reductions was $722.8K. With all FY 1995 work completed, this corresponds to a productivity challenge of 10.4%. (This performance summary is taken from the 10/2/95 cost run. Final end of year cost runs may add or subtract small amounts from the end of year total.)

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FY 1995 MILESTONE PERFORMANCE SUMMARY

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7.0 FUTURE PLANS

7.1 DST PITTING EXPERIMENTS

Pitting kinetics associated with DST steels and DST waste types are largely unquantified. Data exists in the form of 3 and 6 month experiments from multiple programs over the history of HLW storage at Hanford as well as other DOE sites. These pitting experiments are necessary to quantify expected pitting rates at various locations within DSTs., Once

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