1 2. To: (Receiving Organization) SNF K Basins Projects SNF/K Basins Projects 5. Proj./Prog./Dept./Div.: Page 1 of 1 ~JDT 161 593 JUJJ 6 199 GINEERING DATA TRANSMITTAL *4+q 3. From: (Originating Organization) SNF K Basins Projects Jeremy B. Crystal 6. Cog. Engr.: (AI (CI (D) Sheet Rev. Itern (B) DocurnentlDrawing No. No. No. No. 11. Receiver Remarks: (E) Tie or Description of Data Transmitted 1 WHC-SD-SNF-TC-004 0 Development Test Procedure for High Pressure Water Jet System I I 1 I I I I .. . 2. Release 5. Post-RevieW 3. Information 6. D i s t (Receipt Acknow. Requimd) I -. -. -. - see WHC-CM-3-5, :ae.l2.71 .e KEY 2. Appmved wlcomment 3. Disapproved wlcomment 5. Reviewed wlcomment 6. Receipt acknowledac 4. Related EDT No.: SlGl (See Approval Designator for mquimd signahrms) (GI '(HI "' N/A 7. Purchase Order No.: (GI (HI N/A High Pressure Water Jet 3051300 9. Equip./Conponent No.: 10. System/Bldg./FaciLity: 12. Major Assm. Dug. No.: N/A 13. Permit/Permit Application No.: N/A 14. Required Response Date: 5/24/95 Approval Reason On'gl- Receir Desig- for nator nator Trans- DisDo- Dl~o- I V. Reason for Transmittal (GI I Disposition (H) ?i (I) Approval Designator In I I 1.ADDmVal 4.ReviEW I 1. Approved 4. Reviewed nolcomment E. S. Q. D or NIA I IJI Name IK) Signature IL) Data (MI MSlN I (J) Name IK) Signature IUDate (MI MSlN I Re* I Disp. D. S. Takasurni Authorized Representative Date r J. 8. Crystal Slanature of EDT Goinator I for Receiving Organization D. S. Takasurni Cognizant Manager Date Disapproved n/comnents ED-7400-172-2 (04/94) GEF097 857400-172-1 (07191)
Transcript
1
2. To: (Receiving Organization)
SNF K Basins Projects
SNF/K Basins Projects 5. Proj./Prog./Dept./Div.:
Page 1 of 1 ~JDT 161 593 JUJJ 6 199 GINEERING DATA TRANSMITTAL
1 WHC-SD-SNF-TC-004 0 Development Test Procedure for High Pressure Water Jet System
I I 1 I
I I I
.. . 2. Release 5. Post-RevieW 3. Information 6. D i s t (Receipt Acknow. Requimd) I
-. -. -. - see WHC-CM-3-5, :ae.l2.71
.e KEY
2. Appmved wlcomment 3. Disapproved wlcomment
5. Reviewed wlcomment 6. Receipt acknowledac
4. Related EDT No.:
SlGl (See Approval Designator for mquimd signahrms)
(GI '(HI "'
N/A 7. Purchase Order No.:
(GI (HI
N/A
High Pressure Water Jet
3051300
9. Equip./Conponent No.:
10. System/Bldg./FaciLity:
12. Major Assm. Dug. No.:
N/A 13. Permit/Permit Appl icat ion No.:
N/A 14. Required Response Date:
5/24/95
Approval Reason On'gl- Receir Desig- for nator nator Trans- DisDo- D l ~ o -
I V.
Reason for Transmittal (GI I Disposition (H) ?i ( I ) Approval Designator In I I 1.ADDmVal 4.ReviEW I 1. Approved 4. Reviewed nolcomment E. S. Q. D or NIA
I
IJI Name IK) Signature IL) Data (MI MSlN I (J) Name IK) Signature IUDate (MI MSlN I Re* I Disp.
D. S. Takasurni
Authorized Representative Date
r J. 8. Crystal
Slanature of EDT Goinator I for Receiving Organization
D. S. Takasurni
Cognizant Manager Date Disapproved n/comnents
ED-7400-172-2 (04/94) GEF097
857400-172-1 (07191)
DISCLAIMER
Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.
RELEASE AUTHORIZATION
Document Number: WHC-SD-SNF-TC-004, REV 0
Document Title: Development Test Procedure High Pressure Water Jet System
Release Date: 6/5/95
This document was reviewed following the procedures described in WHC-CM-3-4 and is:
APPROVED FOR PUBLIC RELEASE
WHC Information Release Administration Specialist:
June 5, 1995
TRADEMARK DISCLAIMER. name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recomnendation, or favoring by the United States Goverrment or any agency thereof or its contractors or subcontractors.
This report has been reproduced from the best available copy. Available in paper copy and microfiche. Printed in the Uniied State3 of America. Available to the U.S. Department of Energy and its contractors from:
Reference herein to any specific c&rciat product, process, or service by trade
U.S. Department of Energy Office of Scientific and Technical Information (OSTI) P.O. Box 62 Oak Ridge, TN 37831 Telephone: (615) 576-8401
Available to the public from: U.S. Department of Comnerce National Technical Information Service (NTIS) 5285 Port Royal Road Springfield, VA 22161 Telephone: (703) 487-4650
A-6001-400.2 (09/94) WEF256
SUPPORTING DOCUMENT 2. Title
Devel opment Test Procedure High Pressure Water J e t
a e u e \ o v m e d +es+, d;fh q f e s s q r i u l a i e v j e 4 ,
System 5. Key Words
I 1. Total Pages 16
3. Ntmber 4. Rev No.
WHC-SD-SNF-TC-004 0
6. Author . Name: J. B. Crystal
I Organization/Charge Code 2GOOO/LD24C
7. Abstract
Test procedure for developmental testing of High Pressure Water J e t System.
9.1 O u a l i f i c a t i o n s / T r a i n i n q . . . . . . . . . . . . . . . . . . . 9.2 R e s p o n s i b i l i t i e s . . . . . . . . . . . . . . . . . . . . . .
11.1 S a f e t y Meet ing . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 S a f e t y Walk Down . . . . . . . . . . . . . . . . . . . . . . . 11.3 Water J e t F i x t u r e C o n f i q u r a t i o n . . . . . . . . . . . . . . .
HIGH PRESSURE WATER JET SYSTEM DEVELOPMENT' TEST PROCEDURE.
1.0 TEST ITEM IDENTIFICATION
Development testing will be performed on the water j e t cleaning f ixture t o determine the most effective arrangement of water j e t nozzles t o remove contamination from the surfaces o f canisters and other debris.
The following debris may be stained w i t h dye t o simulate surface contaminates: Mark 0, Mark I , and Mark I1 Fuel Storage Canisters (both s ta inless steel and aluminum), pipe o f various size, ( s tee l , stainless, carbon steel and aluminum). Carbon steel and stainless steel plate, channel , angle, I-beam and other surfaces, specifically based on the Scientific Ecology Group (SEG) inventory and observations of debris within the basin.
NOTE: The dye t o b e used i s SLIDE @ Thin -L ine Layout B l u e
2.0 GENERAL DESCRIPTION
The overall objective of the development t e s t i s t o develop and demonstrate a combined system. 'Thi s i ncl udes 'associ ated t o o l s and equipment t o perform cleaning of canisters and other debris i n the 105 K East ( K E ) Basin. The development tes t ing shall achieve optimum reduction i n . the level o f contamination/dose ra te on debris, prior t o removal from the basin and packaging for disposal. Repetitive tests may be necessary t o achieve proper configuration and process control steps for the operations procedure for use a t K Basins.
This development t e s t procedure will define the performance tes t ing of the High Pressure Water J e t System (HPWJS,) f ixture(s). T h i s procedure will provi.de guide1 ines and instructions t o control and evaluate the most effective arrangement o f water j e t s for removing the contaminated surface 1 ayer from canisters and other debris presently identified in the KE Basin. Additionally', the desired resul t will be t o deliver t o K Basins a thoroughly tested and proven method for under water decontamination and dose reduction.
2.1 TEST OBJECTIVES
Uti1 izing the HPWJS connected ' t o specially designed water j e t f ixture head (s) .: 0 C1 ean surfaces of canisters coated w i t h simulated contamination ensure the
most safe and eff ic ient process. -
e Demonstrate a simulated controlled radiological environment for the decontamination of cani s te rs , equipment and mi scel 1 aneous materi a1 s under water with mini,mal water surface disturbance.
1
SLIDE is a Registered Trademark o f Percy Arms, Inc.
0 Demonstrate the best- combination of nozzle configuration, water pressure, water f low ra te and cleaning speed t o clean canisters.
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0
0
0
Complete the testing o f a l l variables and combinations of variables i n the most effective and safe manner while maintaining complete development t e s t records.
Demonstrate the configuration of associated support t o o l s and equipment required t o perform decontamination and dose reduction tasks a t the K Basins for the Debris Removal Program.
Develop an operations work procedure for the implementation of this process a t the K Basins (consistent w i t h the development t e s t report) .
Based on t e s t report concl usi ons , devel op the necessary t r a i ni ng documents required t o t ra in and qualify support personnel i n the safe and eff ic ient performance o f t h i s process.
2.2 TEST METHOD
The t e s t shall be performed under water within a mocked up controlled radiological environment t o sirnulateanormal work conditions a t the KE Basin.
The development t e s t will be repeated as many times as necessary t o reach the expected resul ts o f removing most o f the simulated contamination (dye coating) from the t e s t items i n an effective and ef f ic ien t manner.
3.0 TEST CONDITION LIMITS
Personnel involved in these t e s t s shall use, wear and employ required safety equipment and practices during the operation o f the HPWJS and associated t o o l s and equipment. Protective equipment shall be provided for the eyes, ears, face, head and’ feet .
A t the s t a r t o f each sh i f t and before s tar t ing the HPWJS, the Safety Checklist (Attachment A) will be completed by the SEG Technical Advisor a f te r a wal kdown of the system is completed to’ ensure and verify that t o o l s and equipment are safe t o operate.
Only trained and qualified personnel shall start up and operate the HPWJS. During testing, SEG personnel shall be present and provide overall technical direction for the se t up o f f ixtures and associated hardware. (See Section 9.0 for responsibil i t ies)
The simulated coating material c r i t e r i a i s that’98% of the surfaces be coated with dye t o simulate the contdminated surface.
2
WHC-SD-SNF-TC-004, Rev. 0
3.1 FIXTURE DESIGN CRITERIA
The f ix ture design shall include the following features:
0
0
0
As Low As Reasonably Achievable (ALARA), engineered in to the process.
Minimize handling of items t o be cleaned. ’
Minimize the moving parts o f the special wands and water j e t f ix ture heads.
Ease o f operation by the operators.
Ease o f maintenance; and rep1 acement of degraded nozzl es.
Minimize cleaning time fo r each canister.
4.0 INSTRUMENTS AND CALIBRATION
Pressure gauges are calibrated by the vendor prior t o shipping. No other calibration is required.
5.0 FACILITIES, EQUIPMENT AND MATERIALS
5.1 FACILITIES
The test basin i n the 305 Cold Test Faci l i ty and the tank i n the ten t located outside a t the east end o f the building will be u t i l i zed f o r the test program. .
5.2 EQUIPMENT
The HPWJS will provide water a t the desired pressures and flow ra tes . The system can provide up t o 15,000 psi water, w i t h f l o w r a t e up t o 15 gpm. The water j e t s k i d will be located outside of the building on the south east corner. Electrical service t o the s k i d .will be provided by a portabl e diesel generator u n i t , connected d i rec t ly t o the motor control panel and grounded t o a building ground. Feed water will 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 auxiliary feed pump. Electrical service t o the feed pump. will be provided via a control panel from the 480 vol t , 3 phase out le t near the t e s t basin. The high pressure hose will be run t o and be discharged e i the r t o one o f the tanks i n the ten t or the t e s t basin through a control valve t o the f ixtures and/or heads. Bypass water and drains will be routed back t o the t e s t basin.
3
WHC-SD-SNF-TC-004, Rev. 0
A work s ta t ion will be set up i n the t e s t basin on the south s ide hand r a i l w i t h i n the 305 Cold Test Facil i ty. The item t o be cleaned will be placed into the t e s t basin and a HPWJS w i t h varying discharge pressures and f l o w ra tes will be directed a t the surfaces t o be cleaned through nozzles on the underwater j e t f ixtures. An assortment of tools and equipment will be ut i l ized t o l i f t , hold, place. and manipulate items under water during the .cleaning ac t iv i t ies . Additionally, a work s ta t ion may be set u p . i n the t en t located on the east side of the 305 f a c i l i t y t o perform simulated cleaning of items i n one of the tanks.
6.0 OPERATION PROCEDURE
The HPWJS opeyating procedure and/or vendor manuals shall be used for operation of the HPWJS i n support of these t e s t ac t iv i t ies .
6.1 A Job Hazard Analysis (JHA) form specific t o these tests will be required i n accordance w i t h WHC-CM-4-3, Standard A-3. Existing JHAs may be appl icable.
6.2 Applicable JHAs and Material Safety Data Sheets (MSDS) shall be posted or’ located i n t h e 3 e s t f a c i l i t y test area.
6.3 Test area personnel shall observe safety precautions outlined i n the JHA and MSDS.
7.0 MAINTENANCE AND FAILURES .
Use only products intended for high pressure water j e t t i ng . DO NOT use damaged items. Inspect c o n d i t i o n o f a l l parts prior t o use. Immediately inform t e s t supervision of any water or o i l leakages. Failure t o do so may r e su l t i n equipment damage.
A logbook will be kept by the operator o f the HPWJS concerning a l l breakdowns, repairs , or leaks. The logbook will be located a t or near the u n i t , reviewed and in i t i a l ed each day by the SEG Technical Advisor t o ensure proper maintenance i s performed.
0 Do not a l t e r products. Products should be used only as‘intended.
4
WHC-SD-SNF-TC-004, Rev. 0
0
0
0
0
0
0
Do n o t touch water'coming from weep holes on f i t t i n g s and parts with bare hands o r t r y t o s t o p the leakage by plugging the holes. .Water coming from the weep holes ' i s a t high pressure and will cause injury by penetrating the skin.
Check condition of a l l high pressure threads. Use Teflon tape only on low pressure pipe and f i t t i n g s male threads before connection. Do n o t l e t tape overlap and block end of tub ing . Use "Never Seize" thread lubricant on high pressure pipe and f i t t i ngs . Be sure there i s a minimum engagement o f four threads. Do n o t use pipe wrenches on high pressure pipe or f i t t i n g s . Any protective shielding removed from high pressure t u b i n g and hoses during servicing must be replaced when servicing i s complete. Failure t o replace shielding may resul t in serious injury t o personnel o r damage t o the equipment.
Prior t o water j e t cleaning, operate pump a t low flow and low pressure (500 psi) t o flush debris from system before attaching nozzle. Stop pump and relieve all. pressure i f adjustments are needed. I f properly working, ins ta l l nozzle and slowly increase flow and pressure u n t i l operating pressure i s reached.
Only t r a i ned personnel should perform maintenance or repair .
In case of freezing conditions, drain water from a l l components.
8.0 TEST DATA
The t e s t data recorded for each item cleaned shall include:
Water Pressure Water Flow Rates Area Cleaned
Fixture. Configuration ' Time Required
8.1 TEST GOAL
The t e s t goal i s t o remove a t l eas t 80% of the dye from the canister and other debris piece simulated.
5
WHC-SD-SNFLTC-004, Rev. 0
9.0 PERSONNEL REQUIREMENTS
9 .1 Oualifications/Training
Personnel performing these tests shall be trained and' qual if i ed by. the HPWJS vendor representative or a vendor cert.ified person for the safe start up, operation'and shutdown of the HPWJS. Training records shall be maintained in the project files for those who have received training on operation of the HPWJS.
9.2
9.2.1 Test Techni ci an
Resuonsi bi 1 i ti es
The Test Techni ci an (305 Faci 1 i ty Technician) i s responsi bl e for performing the physical hands. on manipulation of tools, equipment and general faci 1 i ty support.
9.2.2 WHC Test Enqineer
The WHC Test Engineer is responsible for ensuring that the test is performed per the development test procedure. He shall review each of the Test Data Sheets verifying the recorded information and write a test report summary and recommend final design of fixture and associated support equipment.
9.2.3 SEG Techni cal Advi sor
The SEG Technical Advisor(s) are responsible for the overall. coordination of the special fixtures and equipment including interfacing with equipment vendors for SEG procured equipm,ent. One of the major responsibilities is to ensure proper equipment set up and safety of operation. Prior to each test run they shall perform the walk down of the system and complete the initial input to the Safety Check1 ist (Attachment A) and.Development Test Data Sheet (Attachment B).
The SEG Technical Advisors are certified trainers and will provide equipment training to test technicians and designated Operations personnel who perform testing.
10.0 WITNESSES
Witnessing requirements for the development testing (only by the 305 Facility Test Technician (WHC Person)), shall be indicated by sign offs on the Development Test Data Sheet (Attachment B) .
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WHC-SD-SNF-TC-004, Rev. 0
11.0 TEST EXECUTION
11.1 Safety Meeting
A pre-job safety meeting will be conducted w i t h t e s t personnel prior t o s tar t ing acceptance testing .
11.2 Safety Walk Down
A Pre-test safety walk down will be performed by the SEG Technical Advisor and the 305 Facili ty Test Technician prior t o s t a r t i ng and running each t e s t configuration.
11.3 Water Jet Fixture Confiquration
The water j e t f ixture shall be developed from the t e s t configuration a f t e r the development t e s t goal i s achieved.
11.3.1 Purpose
This tes t ing shall be documented by recording development t e s t da ta . The steps may be reordered t o provide the most eff ic ient process. The Development Test Data Sheets (Attachment B) will be ut i l ized t o record specif ic t e s t information. The water, j e t fixture/heads and associated suppor t equipment configuratidns shall be recorded for each t e s t using a single l i ne sketch. The water pressures and water flows for each t e s t configuration along with nozzde size, type and arrangement shall. be rec.orded. Manifolds, control valve type and hose arrangement will also be included and recorded in the sketch.
11.4 Scope
Develop the most eff ic ient configuration o f f ixtures for cleaning the simulated surface contamination under water. The tes t ing is t o be performed on each of the debris type o f materials identified w i t h varied configurations .of the water j e t f ixtures and heads. _ .
11.5 Set UP
The operations procedure for the HPWJS shall be uti l ized in conjunction with t h i s t e s t procedure. This skid mounted pump system provides water a t various pressures and flow rates. The high pressure hose will be connected through a manifold t o two foot control valves. High pressure hose/pipe will be connected.to the underwater j e t f ixtures from the f o o t control Val ves ..
Special handling t o o l s and equipment will be’ used for positioning and manipulating of the debris t o and through the cleaning water j e t f ixture . These f ixtures may be supported from the hand r a i l of the t e s t basin. A crane o r j i b may be’used t o manipulate the large items (canis ters) .
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WHC-SD-SNFLTC-004, Rev. 0
12.0 TEST STEPS
12.1 Connect hoses and place the water jet fixture into the test basin.
12.2 Place the test .material into the test basin.
12.3 Start-up the HPWJS following the detailed steps in the HPWJS Operations Procedure.
12.4 Control flow to the fixture by operating the foot control valve(s).
12.5 Position and manipulate the test material and/or the cleaning fixture to clean until the surface of the material appears to be clean with at least 80% of the dye .coating removed;
12.6 Time the cleaning duration and count the number of passes.
12.7 Remove item from the water and'inspect.
12.8 Document level of "decontamination" on the Test Data Sheet as a percentage of paint/dye removed from the surface of the debris test item.
12.9 Repeat steps 11.2.1 through 11.'2.8 as necessary.
. ..
13.0 DISPOSITION OF TEST ITEM
Save for reuse in future testing.
14.0 DATA SHEETS
Data will be recorded on the Development Test Data Sheet. An SEG Technical Advisor is responsible for initially filling out the Test Data Sheet. It is the responsibility of the SEG Technical Advisor t o maintain the test records and a daily shift log of development test activities.
A Test Data Sheet Index Log (Attachment C) shall also be maintained by the SEG Technical Advisor starting with number 001. Test data shall be forwarded to the WHC Project Engineer for storage and control of official release as deemed necessary. .
WHC-SD-SNF-TC-004, Rev. 0
ATTACHMENT A
SAFETY CHECKLIST
A- 1
WHC-SD-SNF-TC-004, Rev. 0
* SAFETY CHECK LIST * Tes t Log Number. FOR
HIGH PRESSURE WATER JETTING SYSTEM
SEG Technical Advi s o r : ( p r i n t )
DATE: TIME: INSPECTION PERFORMED BY SIGNATURE:
YES NO 1.
2.
Has the Pre Job b r i e f i n g been completed?
Are personnel t r a i n e d and q u a l i f i e d t o opera te t h e HPWJS?
3 .
4.
Is personnel safety equipment avai 1 ab1 e a t t h e . j o b site?
Have t h e work area and t h e s k i d area been roped o f f with proper s i g n s posted?
5. Have precaut ions been taken t o p r o t e c t electrical equipment?
6 . Is the area c l ea red o f t r i p p i n g hazards?
Is the ope ra t ing pressure of t h e f i t t i n g s g r e a t e r than t h e planned tes t pressure.? (max test pressure is 15,000 psi)
Are a l l hoses, l ances , guns and f o o t cont ro l valves rated f o r the maximum opera t ing pressure?
7.
8.
9. Are a l l f i t t i n g s , hoses, lances, guns and f o o t cont ro l Val ves i r good .working condi t i on?
Is t h e feed water purnp$roperly placed i n t h e basin and connected t o t h e pump s k i d and has i t been f lushed?
t Lo= 10.
11. Have t h e Fi 1 ter and. Y-strainer been checked f o r cl eanl iness and i n good opera t ing condi t ion? - -
A-2
WHC-SD-SNF-TC-004, Rev. 0
NO YES 12. Are the skid drains, cooling water and dump water
properly routed?
Are the safety shrouds on guns, .valves and hoses?
Conf i rm el ectri cal service connecti ons are proper1 y connected and power from the Portable Generator is avai 1 ab1 e?
13.
14.
15. Has the high pressure hoses been f lushed and all air removed prior t o nozzle being installed? -
16.
17.
Is the cooling water t o the plungers- operating properly?
Has the oil level been checked on the sight glass for the power end?
18. Has the Pressure Regulator been charged with nitrogen t o the desired operating pressure?
Has hookup, i ncl udi ng pi pes, hoses and connections , been pressure tested with water a t the maximum operating pressure?
19.
20.
21.
Is the dump pressure regulator drain line connected properly?
Has Job site been examined for environmental considerations, with action as appropriate?
Are a1 1 control systems operational? 22.
REMARKS :
A-3
WHC-SD-SNF-TC-004, Rev. 0
ATTACHMENT B
DEVELOPMENT TEST DATA SHEET
B- 1
WHC-SD-SNF-TC-004, Rev. 0
DEVELOPMENT TEST DATA SHEET
HIGH PRESSURE WATER JET SYSTEM Test Log Number
SAFETY WALK DOWN COMPLETED /I Si gnature of SEG Technical Advi sor
Date Ti me Test Engineer .. Test Techni ci an Test Item Materi a1 Type Water Jet fixture^ Nozzle Size and Type Control Val ve Conf i gurati on
Pressure PS! F1 ow 9.p.m. Cl eaning Time minutes Number of Passes
Remarks On C l eanness
Other Remarks
Single Line Sketch of Fixture and Control Valve Arrangement
Sign Offs I 'si gnature 1 Date
Witness ( i f required)
Test Technician (305 Bldg.) II I
SEG Technical Advi sor
B-2
WHC-SD-SNF-TC-004, Rev. 0
ATTACHMENT C * DEVELOPMENT TEST DATA SHEET INDEX LOG * Test Log Number
00 1
002
003
004
005
006
007
008
009
010
01 1
012
0 13
014
015
016
017
018
Date II Test Engineer
II . : II
c- 1
DISCLAIMER I
This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their . employees. makes any warranty, express or implied, or assumes any legal liability or nsponsi- f bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or ; process disclosed, or represents that its we would not infringe privately owned rights. Refer- ,, cnce herein to any sptcific commercial product, process, or service by trade name, trademark, * manufacturer, or otherwise does not n d l y constitute or imply its endorsement, rccom- mendation, or favoring by the United States Government or any agency' thereof. The views and opinions of authors expressed hcrcin do not ntcessarily state or reflect those of the United States Government or any agency thereof.
