DISTRIBUTION SHEET To D i s t r i b u t i o n

From Page 1 of 1 N. G. Awadalla Date 04/19/95

N. G. Awadalla W. B. Barton L. E. Borneman C. W. Dunbar G. L. Dunford D. B. Engelman L. F. Ermold R. A. Fordham L. A. F o r t R. L. F r i t z C. D. G r ine r C. E. Jensen N. W. K i r c h J. L. Lee R. E. Lerch J . M. L i g h t M. A. McLaughlin C. A. Petersen R. E. Raymond A. B. Sidpara J. P. Sloughter F. 0. Strankman J. A. Swenson J. D. Thomson A. D. Toth A. M. Umek D. J. Washenfel d e r R. W. Winslow D. D. Wodrich R. D. Wojtasek Central F i 1 es OSTI (2)

Project Title/Work Order Mul t i -Funct ion Waste Tank F a c i l i t y , Phase Out Basis

R2-76 H5-27 R2-06 R1-30 57-81 R1-49 57-84 R2-76 54-54 B4-08 81-59 R1-30 R2- 11 R2-50 57-85 B4-08 B2-35 66-47 R2-54 57-54 H5-27 R2-50 H5-49 R2-76 57-54 57-81 H5-27 57-54 57-54 57-84 18-04 18-04

EDT No. ECN No. 623156

O S T I

Name

A-6000-135 (01/93) WEF067

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Attach. Only

DlSCLAlMER

Portions of this document may be illegible in electronic image products. Images ate produced from the best available original document.

I

cbc. ajOMPl€rE I 1

2. ECN Category (mark one)

Direct Revision [XI Change ECN Temporary ii Suppl menta 1

I 623156 I

3. Originator's Name, Organization, MSIN, 3a. USP Required? 4. Date and Telephone No.

N. G. Awadalla, 74460, R2-76, [I Yes [XI NO 04/20/95 373-9243

' 5. Project Title/No./Uork Order No. 6. EldgJSysJFac. No. 7. Approval Designator

ENGINEERING CHANGE NOTICE

c1 13 c3

I I ....................................... - _ -

Mu1 ti-Function Waste Tank N/A \/A Faci 1 i ty

8. Docunent Nunbers Changed by this ECN 9. Related ECN No(s). IO. Related PO No. (includes sheet no. and rev.)

Ila. Modification Work Ilb. Work Package No.

[] Yes (fill out Elk. N/A Ilb)

Ilc, Ild) [XI No (NA Elks. Ilb,

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Cog. Engineer Signature & Date Cog. Engineer Signature & Date

~~ ~~~

E a . Justification (mark one,- Criteria Change [XI Design Improvement [] Enviromental 11 Facility Deactivation [I As-Found [ I Facilitate Const [] Const. Error/Omission [] Design Error/Omission [I 13b. Justification Detai I s

~

Revisions made to incorporate missing information

14. Distribution (include name, MSIN, and no. o f copies) See attached.

RELEASE STAMP .I r

A-7900-013-2 (11/94) GEF095

A-7900-013-1

1. ECN (use no. from pg. 1) ENGINEERING CHANGE NOTICE Page 2 o f 2 623156

17. Schedule Impact (days)

CONSTRUCTION 4 4 rJ/*

[ I $ [ I $

15. Design 16. Cost Impact

ENGINEERING V e r i f i c a t i o n Required

Improvement 11 [ I Delay

[I $ [I $

Add i t i ona l

Savings

t h a t w i l l be a f f e c t e d by t h e change descr ibed i n Block 12.

Add i t i ona l

Savings [ I Yes

[ X I No 18. Change Impact Review: I n d i c a t e t h e r e l a t e d docunents (other than t h e engineer ing docunents i d e n t i f i e d on Side 1)

Enter t h e a f f e c t e d docunent nunber i n Block 19. SDDIDD

Functional Design Criteria

Operating Specification

Criticality Specification

Conceptual Design Report

Equipment Spec.

Const. Spec.

Procurement Spec.

Vendor Information

OM Manual

FSAWSAR

Safety Equipment List

Radiation Work Permit

Environmental Impact Statement

Environmental Report

Environmental Permit

SeismiclStress Analysis

StresslDesign Report

Interface Control Drawing

Calibration Procedure

Installation Procedure

Maintenance Procedure

Engineering Procedure

Operating Instruction

Operating Procedure

Operational Safety Requirement

IEFD Drawing

Cell Arrangement Drawing

Essential Material Specification

Fac. Proc. Samp. Schedule

Inspection Plan

Inventory Adjustment Request

El 11 11 [ I [ I [ I 11 . [ I [ I [ I [ I [ I [ I [ I [ I r i

[ I El [ I [ I [ I [I [ I [ I [ I [I [ I [ I [I [ I [ I r i

Tank Calibration Manual

Health Physics Procedure

Spares Multiple Unit Listing

Test ProcedureslSpecification

Component Index

ASME Coded Item

Human Factor Consideration

Computer Software

Electric Circuit Schedule

ICRS Procedure

Process Control ManuallPlan

Process Flow Chart

Purchase Requisition

Tickler File

CIA

[ I [ I [ I [ I [ I [ I [ I [ I [ I [ I [ I [ I [ I 11 [ I r i

L J L J 11 19. Other A f fec ted Docunents: (NOTE: Docunents l i s t e d below w i l l no t be rev i sed by t h i s ECN.) Signatures below

i n d i c a t e t h a t t he s ign ing organizat ion has been n o t i f i e d o f other a f f e c t e d docunents l i s t e d below. Docunent Nunber/Revision Docunent Nurber/Revision Docunent Nunber Revis ion

n/a

20. Approvals

OPERATIONS AND ENGINEERING Signature

Cog. Eng. khbP - Cog. Mgr.

QA

Safety

Environ.

I

Other

Date Signature ARCHITECT-ENGINEER

PE

QA

Safety

Design

Envi ron.

Other

DEPARTMENT OF ENERGY

Signature o r a Contro l Nunber t h a t t racks the Approval Signature

Date

ADDITIONAL

A-7900-013-3 (11/94) GEF096

RELEASE AUTHORIZATION

Document Number: WHC-SD-W236A-ER-021, REV. 1 ~~~

Document Title:

Release Date: A p r i l 20, 1995

Multi-Function Waste Tank F a c i l i t y Phase Out Basis

This document was reviewed following the procedures described in WHC-CM-3-4 and is:

APPROVED FOR PUBLIC RELEASE

WHC Information Release Administration Specialist:

A p r i l 20, 1995

TRADEMARK DISCLAIMER. name, trademark, manufacturer, or otherwise, does not necessarily constitute or inply its endorsement, recomnendation, or favoring by the United States Govermnt or any agency thereof or its contractors or subcontractors.

Reference herein to any specific comnercial product, process, or service by trade

This report has been reproduced from the best available copy. Available in paper copy and microfiche. Printed in the United States of America. Available to the U.S. Department of Energy and its contractors from:

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

3. N h e r

WHC-SD-W236A-ER-021 2. Title

Multi-Function Waste Tank Facility Phase Out Basis 5. Key Words

Mu1 ti -Funct i on Waste Tank Faci 1 i ty MWTF Phase Out Basis

4. Rev No.

1

I 1. Total Pages 4%

r Orsanization/Charse Code 74460/DPMTF

7. Abstract

Additional double-shell tank storage capacity is not needed until FY 2004 or later. The waste volume in the current baseline program can be managed within the existing tank capacity. However, this requires implementation of some risk management actions and significant investment in software and hardware to accomplish the actions necessary to maximize use of existing storage tank space.

RELEASE STAMP I 8-

A-6400-073 (08/94) WEF124

WHC-SD-W236A-ER-021 R e v i s i o n 1

Page i

MULTI - FUNCTION WASTE TANK FAC I L ITY PHASE OUT BASIS

TABLE OF CONTENTS

1.0 EXECUTIVE SUMMARY

2.0 BACKGROUND

3.0 SUMMARY CONCLUSION

4 .0 ASSUMPTIONS

5.0 OPERATIONAL WASTE VOLUME PROJECTIONS

6.0 IMPACTS

7.0 PLAN OF ACTION

8.0 PROJECT PHASE OUT ALTERNATIVES

9.0 REFERENCES

APPENDIX 1 BACKGROUND INFORMATION

APPENDIX 2 ASSUMPTIONS

APPENDIX 3 SPECIAL WASTE VOLUME PROJECTION I N SUPPORT OF THE MWTF CANCELLATION EVALUATION

DISCLAIMER

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 responsi- bility for the accuracy, completeness, or usefulness of any information. apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Refer- ence herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recom- mendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

DISTRIBUTION OF THIS DOCUMENT IS UNLIMITED 4 v

WHC-SD-W236A-ER-021 Revision 1

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1.0 EXECUTIVE SUMMARY

On January 13, 1995, Westinghouse Hanford Company (WHC) recommended to the U.S. Department of Energy, Richland Operations Office (RL) that Project W-236AY Multi-Function Waste Tank Facility (MWTF) , should be phased out (Reference 1). The most recent information shows that wastes in the Tank Waste Remediation System (TWRS) current baseline can be managed within the existing waste tank capacity through fiscal year (FY) 2003. Additional double-shell tank storage capacity is not needed until FY 2004, or later.

As the retrieval , pretreatment, and immobilization programs further mature during FY 1996-1998, as well as privatization initiatives, so will clarification of specific needs for additional waste storage capacity. Managing the present and projected wastes within the existing double-shell tank system requires accepting increased risk, and implementing several new waste management actions. The primary objective of these actions is to ensure that the projected waste volume will not exceed the available waste storage capacity. Additional funding will be required to implement these actions, because none of the actions are presently in the TWRS baseline. As a minimum, these funds are needed for the present FY (1995) and for each of the two following FYs (1996 and 1997). The level of funding for each o f these fiscal years will vary depending on the implementation schedule.

The basis for the recommendation centers around the most recently updated Operational Waste Volume Projections (OWVP) as shown in Appendix 3. The key factors considered in the projections include, but are not limited to, the following:

Active mixing pump mitigation of the flammable gas safety issue in tank 241-SY-101 with no passive mi tigation needed for the other flammable gas watch list tanks Reduced waste volume generation by the Hanford Site facilities Improved tank space use Elimination of the contingency space Capability to manage waste in 200 West Area without two new tanks No anticipated additional storage needs from TWRS privatization initiative Unlikely that any existing double-shell tank will leak during the next 10 years Increased waste inventory estimates due to increased single-shell tank porosity estimates Decreased waste volume reduction factors for evaporator operations Concentration of waste to the specific gravity operating limit in all future evaporator campaigns Waste segregation requirements are revised

This document contains further details that address the above basis.. In addition, risk management issues, description of waste management actions, and implementation plans are included. Consequences of this recommendation including impact on TWRS programs, TWRS integrated schedule, and the Hanford Federal Faci 1 i ty Agreement and Consent Order (Tri-Party Agreement) mil estones are also discussed.

WHC-SD-W236A-ER-021 Revision 1

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2.0 BACKGROUND

The Justification of Mission Need for the Multi-Waste Remediation Facility, which included the MWTF, was approved by the U.S. Department of Energy Under Secretary on January 19, 1993 as a line item Major System Acquisition project. The present MWTF scope includes six waste tanks to be used primarily for dilution and storage of waste from tanks such as tank 241-SY-101 with priority safety issues.

Since the inception of the project, progress in the waste tank safety program has concluded that waste mixing is a preferable alternative to dilution for tank 241-SY-101. Also, the Hanford Site facilities made significant progress in reducing their waste generation rates and projected demand on the existing waste tank capacity. the OWVP annual report and challenging its assumptions. Numerous new factors came together to affect the projections sufficiently so that the need for new waste storage capacity could no longer be demonstrated. (For details, see Appendix 1).

In late 1994, increased emphasis was placed on examining

3.0 SUMMARY CONCLUSION

Additional doubl e-she1 1 tank storage capacity is not needed unti 1 after FY 2004 or later. The waste volume in the current baseline program can be managed within the existing tank capacity. However, this requires implementing of some risk management actions and significant investment in software and hardware to accomplish the actions necessary to maximize use of existing storage tank space.

Adequate storage capacity can be obtained through several avenues. These include combining the existing neutralized current acid wastes (NCAW) and, separately, combining the neutralized cladding removal wastes (NCRW); designating the evaporator feed and receiver tanks as spare storage; and using the existing and new cross-site transfer lines.

4.0 ASSUMPTIONS

The successful implementation of several key waste management actions will be necessary to accommodate phasing out the MWTF project. for the success of these actions is the availability of adequate funding. major assumptions providing the basis for the recommendation to phase out the MWTF project are described in Appendix 2.

The fundamental need The

. .

WHC-SD-W236A-ER-021 Revision 1

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5.0 OPERATIONAL WASTE VOLUME PROJECTIONS

The OWVP i s a system simulator of the evaporator, the 28 double-shell t anks and t h e i r t r a n s f e r systems, and the i n p u t s and processes t h a t take place i n the system. under base case and a l te rna t ive 200 Area operational scenarios. The OWVP simulator accounts f o r the chemistry, mass, and evaporation of t h e waste, and the operational l o g i s t i c s necessary f o r the system t o operate and the segregation rules associated w i t h d i f fe ren t waste types.

I t s purpose is t o project tank space needs f o r storage of waste

The OWVP i s updated on an annual basis by September of each year. of the OWVP (Reference 3) was issued i n 1994, and was based on data available July 1994. A special review team updated the information of Revision 20 on January 4, 1995, which prompted new inquir ies i n t o the h i s t o r i c segregation rules and t h e p o s s i b i l i t y of managing tank wastes w i t h i n ex is t ing waste tanks. Further review of projection assumptions and possible i n i t i a t i v e s f o r reducing t a n k space requirements resulted i n a new special update of the projections.

The OWVP provides a current status and future projection of the waste volumes t o be generated and stored. Using this information, scenarios can be developed t o evaluate the impact of proposed actions on waste volumes. decisions may be developed f o r s t r a t e g i e s t o change the required waste volumes. generation can be evaluated for t h e i r e f f e c t on waste volume. located i n Appendix 3.

Revision 20

Key

Segregation of wastes, evaporator operations, and control of waste The OWVPs are

The r e s u l t s of the special OWVP are i l l u s t r a t e d i n Figure 1. labeled L947BC represents the base case projection shown i n OWVP, Revision 20. The dashed l i n e i s the planning base t h a t r e s u l t s from the changes i n waste management pract ices and updated information resul t ing from the studies discussed i n Appendix 1. The so l id l i n e indicates the incremental additional space savings available, i f a technical basis i s developed t h a t will allow concentration of the wastes t o h i s t o r i c leve ls without causing new watch l i s t tanks t o be created. The changes i n required storage volumes a r e influenced by the following fac tors .

The act ive mixing pump mitigation of the flammable gas tanks such as tanks 241-SY-101 and -103 can be safely mitigated without re t r ieva l and d i lu t ion and maintain s a f e storage. Other watch l is t tanks can be mitigated i n a s imilar manner. Therefore, no additional tank space f o r the mitigation o f these tanks is required. T h i s results i n a reduction of the number of required tanks by two.

The dotted l i n e

The reduction i n waste generated by the Hanford S i t e f a c i l i t i e s from waste minimization e f f o r t s reduces the need f o r additional tank space. The projected waste flows have been reduced from previous projections of 93 .O Kgal/month t o the range of 18.9 t o 34.6 Kgal/month.

W HC- SD- W 2 3 6A- E R- 0 2 1 Revision 1

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Changing the waste segregation practices of the past, such as combining similar wastes, results in additional reductions. Retrieval of some double- shell tank solids may be necessary during FY 1996-1998 to ensure that sufficient spare tank capacity is available. Combining two tanks containing NCRW into one tank would free up .98 Mgal of space. Combining two tanks containing NCAW into one tank would free up .98 Mgal of space.

Using the evaporator feed and receiver tanks (241-AW-102 and -106) for additional space may be necessary. This space is currently used for evaporator operation. This action would free up 0.72 Mgal of tank space for emergency use.

Additional space for operational flexibility in the 200 West Area tank farms could be provided if additional actions can be taken. the use of tanks in 241-SY tank farm. Tanks 241-SY-101 and -103 are flammable gas watch list tanks that prohibit the use of their unused capacity. 241-SY-102 is the current single staging point for 200 West Area transfers to 200 East Area. This tank has limited use due to questions concerning the compatibility of the transuranic (TRU) solids in the heel of the tank and organic wastes now stored in some of the single-shell tanks. compatibility issue will offer more flexibility in the ability to transfer the wastes in 200 West Area.

The primary issue is

Tank

Resolving the

The current projection of storage needs extends through FY 2004 when the retrieval , treatment, and immobil ization program will be initiated. Approximately seven years lead time is required to provide additional storage tanks, should they be needed. Consequently, a decision to add storage capacity can be delayed until 1997. This would allow time to provide additional storage capacity for the retrieval, treatment, and immobilization programs. In addition, annual evaluations and decisions on additional storage capacity are required by the M-46 Tri-Party Agreement milestones.

Revision 1 Page 5 WHC-SD-W236A-ER-021

I

44 -

36 :

32

28

24

20

16

12

8

4

0

Figure 1

L9503A (3/95 DOE SPECIAL) VS 7/94 BASE CASE LANTS ASSUMPTIONS 1 1 1 1 1 " ~ ' " " ' ~ ~ 1 " ' 1 1 1 I I I " ' ~ " " ). FAC. GEN. RATE - 18.9-34.6 Kgol /Month 'FL. TREATM. FACIL. - 3 / 9 6 (LERF & Evop Condoneotoe. ooncur ron t l y ) IK 101-SY & 103-SY - No Dllutlon. i T STABILIZATION - Compl. ond o f F Y 2000 (8.2 Mgol) i T SOLIDS - 0.2 Mgol (2004); 0.3 Mgal (2005); 1.75 Mgol (2008) JREX TCO - No Roetart; TCO 0.225 Mgol DN (FY 1994-97) IETREATMENT TANKS - 3 In F Y 2005; 4 In F Y 2 0 0 6 -TNK WASHING. - Conoo l ldo to 101-A2 & 102-A2 Sol lda - Conao l ldo to NCAW Supornoto. ? GRAVITY OF DSSF - 1.5 g/ml ONTINGENCY TANK - Nono

.-L 9 47 0C

WHC-SD-W236A-ER-021 Revision 1

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6.0 IMPACTS

Impact Manaqement

Implementing the recommendation t o phase out the MWTF project requires d i l i g e n t management of the waste volume, and e n t a i l s potential f inancial and programmatic impacts. systems engineering methodology and developing two tools : a risk management l i s t and an action logic chart .

The approach will be t o manage the impacts using a

I n i t i a l l y , a risk assessment will be performed a s p a r t of the decis ion/r isk analysis waste management action (see Section 7.0) . The known risks will be compiled i n t o a risk management l i s t as will any risks discovered during the assessment. The risk management l i s t will contain impacts, degree of risk, actions t o be taken t o reduce or mitigate the risk, and the responsible manager. The l i s t will be a l i v i n g document and will be managed as par t of the waste management action plan u n t i l the actions a re completed, and then managed as par t o f the OWVP process.

A functional f l o w chart will be prepared as par t of the plans f o r f a l l back p o s i t i o n s waste management action. (Section 7.0) t h a t includes a l l of the credible undesirable events t h a t could occur. The f low chart will be used as a guide1 ine i n se lect ing the appropriate predetermined contingency actions f o r immediate implementation i f required. The functional flow chart and risk management l i s t will be compared t o ensure t h a t a l l risks are appropriately considered . Impact Ident i f icat ion and Mitiqation Strateqv

This section will describe how WHC plans t o use the systems engineering too ls t o ident i fy and mitigate the impacts o f phasing o u t the MWTF project . From a systems engineering viewpoint, phasing out the MWTF project i s not a declaration t h a t no new tanks will ever be b u i l t . I t i s a statement t h a t unless a comprehensive, technically defensible position is established t h a t requires storage space beyond current capacity, no resources will be diverted for the purpose of building new waste tanks. "No new storage space" will serve as a constraint on the functions and interfaces both w i t h i n and outside of TWRS unless i t can be shown t h a t no other viable a l te rna t ive i s reasonably achi evabl e.

The f irst step will be t o modify the TWRS Functions and Requirements Waste Storage System conceptual architecture. The enabling assumption concerning double-shell tank storage space will be changed t o show the select ion of the a l te rna t ive t o consolidate waste by blending and concentration, without new double-shell tanks, i n place of the a l te rna t ive t o consolidate the tank waste and b u i l d new double-shell tanks. To accomplish this change, t h e requirements i n the s t o r e waste function will need t o be changed by removing the constraints which r e f e r t o the Tri-Party Agreement milestones about b u i l d i n g new tanks. Note t h a t the architectural selection will be retained as an enabling assumption u n t i l the ongoing s tudies have been accepted as complete required analyses. A t t h a t time, the s tudtes will become the ra t iona le f o r select ion and the architectural choice will no longer be based on an enabling

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assumption. The formal decis ion/r isk analyses, together with the updated waste volume projections, are expected t o meet a l l or a t l e a s t most of the needs for completing the required analyses.

The modified Waste Storage System conceptual archi tecture will then pass down a revised doubl e-shell t a n k ,storage capacity t o i t s daughter functions and archi tectures . The daughter functions and associated archi tectures are current ly i n development and will be par t of the Technical Requirements Specifications. The limits of this revised capacity will then be shared w i t h affected functions through controlled interfaces . T h i s will require affected functions t o consider conceptual archi tecture a l te rna t ives what allow the double-shell ' tank Waste Storage System t o s tay w i t h i n i t s capacity. negotiations will be used t o determine the optimal use of exis t ing capacity. The revised conceptual archi tecture is expected t o meet the needs and performance requirements of the Manage Tank Waste function. The needs and performance requirements of the Process Waste function are n o t well enough defined a t t h i s time t o make a defensible determination o f the adequacy o f the conceptual Waste Storage System fo r disposal purposes. affected Process Waste daughter functions determine t h e i r most cost-effective archi tecture a l te rna t ives require more storage space than is available, the issue of whether and when t o b u i l d new storage capacity will be ' revis i ted.

Interface

I f many of the

The Technical Requirements Specifications will then be used t o a l loca te requirements and constraints i n t o project Design. Requirements Documents. The Design Requirements Documents then become part of the projects ' design baselines, and i n t h i s way the design of a l l affected projects will r e f l e c t any constraint imposed by the decision t o n o t build any new tanks.

Expected Impacts on TWRS and Other S i t e Fac i l i t i e s

The TWRS integrated schedule was reviewed and the only impacts ident i f ied prior t o FY 2004 are discussed below. shou ld become be t te r defined and 'more impacts may be ident i f ied .

As th is .process evolves, the impacts

TWRS Systems Engineering

Impacts t o TWRS Systems Engineering are minimal. because the project technical basis'development i s proceeding well i n advance r e l a t i v e t o functional development.

TWRS Systems Engineering objectives include development of Design Requirements Documents (DRD) f o r projects t ha t evolve from the analysis, and t o perform a comparison of existing projects ' DRD-related a c t i v i t i e s t o insure program 1 eve1 traceabil i t y of requirements . Faci 1 i t i es Safety Board (DNFSB) has recommended ear ly systems engineering concentration on exis t ing project DRDs.

The Defense Nucl ear

TWRS i s currently committed t o delivery of a DRD f o r the MWTF project by September 1995. With the MWTF phase o u t , t ha t milestone would n o t be necessary. This commitment should be deleted from the TWRS baseline.

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Project W-058

The phasing o u t o f the MWTF project will require Project W-058 t o reincorporate p r o v i s i o n s for infrastructure needs 1 i ke a control room, diversion boxes, power, and water. These elements have been removed from the exis t ing project baseline. including the projected cost for reincorporation, i s i n development.

These impacts s h o u l d n o t a f fec t the Systems Engineering work for Project W-058 because the project spec i f ic DRD will focus on Manage Tank Waste requirements.

A detai led evaluation o f these impacts,

Projects W-211, I n i t i a l Tank Retrieval System, and W-151, Tank 241-AZ-101 Waste Retrieval System

These retr ieval-related projects will be minimally effected i f the necessary changes are directed w i t h i n an adequate timeframe. The only changes shou ld be which waste tanks are planned for re t r ieva l and the small design modifications t o s u p p o r t t h a t plan. o f the necessary waste management actions (Section 7.0) required t o s u p p o r t the MWTF project phase out. frame for the needed r e t r i e v a l s i s pushed forward.

These changes are par t

The impact could esca la te i f the time

Waste Generators

Waste generators both w i t h i n and outside TWRS have been successful i n reducing waste output. incorporated i n the OWVPs included w i t h i n this document. waste generators will most l i k e l y be related t o terminal cleanouts o f excess f a c i l i t i e s . For these future a c t i v i t i e s , such as decommissioning and decontamination, reducing the generated waste and continuation of waste minimization e f f o r t s . shou ld be followed. I f , however, available storage capacity is inadequate t o s u p p o r t the a c t i v i t i e s o f waste generators, a systems engineering approach will be applied t o determine the most cost-effective path forward.

The r e s u l t s of these e f f o r t s have already been Any.impact t o

TWRS Operations

TWRS Operations support will be required f o r the r e t r i e v a l s and t ransfers t h a t a re par t of the waste management actions (Section 7.0). Operational procedures, operational safety 1 imits, and the'operation safe ty document will require revision. Other safety basis documents may require revision as well. Suitable preparations must be made t o support these actions.

Waste Characterization Program

Sampling of tanks targeted t o increase space f o r waste will be required. The schedule established by the waste characterization program will require revision t o s u p p o r t the MWTF phase o u t . NCAW, NCRW, TRU, and complexant waste tanks will be required t o be characterized on an expedited schedul e.

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Milestone #

Tri-Partv Aqreement Milestones

Title Date Reason

Several Tri-Party Agreement milestones are directly affected by the project phase out as shown in Table 1.

Presently, strategies are being developed to negotiate potential changes to these milestones. Tri-Party Agreement notification 1 etters are being devel oped.

In addition, a Tri-Party Agreement Change Request and

TABLE 1

Tri-Party Agreement Milestones Affected by Project Phase Out

M-42-00

M-42-01

M-42-01-TO2

M-42-02

M-42-02-TO1

M-42-02-TO2

Directly Affected I

Provi de Addi t i onal Doubl e-Shell Capacity

Initiate "Hot" Operations of the MWTF 200W Area Tanks

12/31/1998

02/28/1998

Initiate Construction of the MWTF 200W Area Tanks

Complete Construction of the MWTF 200E Area Tanks

09/30/1994

09/30/1998

Initiate Construction of the MWTF 200E Area Tanks

Compl ete Detai 1 ed Design of the MWTF 200E Area Tanks

02/28/1995

01/31/1996

These milestones are the MWTF Tri-Party Agreement milestones directly affected by the ultimate path forward (page D-77, Tri-Party Agreement mi 1 estone document, see Reference 20)

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7.0 PLAN OF ACTION

Waste Manaqement Act ions

The pro jec ted waste volume inventory can be managed u n t i l FY 2004 o r l a t e r w i thout t he add i t i ona l double-shell tank storage capaci ty t h a t would have been provided by P ro jec t W-236A. Although t h i s p o s i t i o n i s t e c h n i c a l l y feas ib le , several waste management act ions are needed t o m i t i g a t e the p o t e n t i a l s h o r t f a l l o f storage capaci ty near the end o f t he decade (see Reference 1). The ac t ions are separated i n t o several categor ies. Several ac t ions r e q u i r e r e t r i e v a l operat ions and add i t iona l operat ional procedure 1 i m i t s . Other a c t i ons are techn ica l and requ i re the performance o f engineer ing eval ua t i ons t o v a l i d a t e operat ing l i m i t s . The remaining act ions, however, a re a combi na t i on o f both . These waste management act ions cons is t o f t he fo l low ing :

7.1 Consol idate the neu t ra l i zed cur ren t ac id waste (NCAW)

Neut ra l i zed cur ren t ac id waste i s p resent ly s tored i n t w o double-shel l tanks. Tank 241-AZ-101 contains 791 Kgal and tank 241-AZ-102 contains 434 Kgal o f t h i s type o f waste f o r a t o t a l o f 1,225 Kgal (Reference 4). Th is t o t a l volume can be concentrated t o a l low storage i n one tank. Therefore, combining NCAW i n t o one tank would f r e e up 980 Kgal o f space w i t h an estimated 500,000 BTU/hour heat load i n the r e s u l t i n g tank. This heat load may exceed cur ren t operat ing procedure 1 i m i t s . Both tanks conta in ing NCAW are designed f o r s i g n i f i c a n t l y h igher heat load than the an t i c ipa ted heat load r e s u l t i n g from combining the waste. However, recent operat ing procedures l i m i t s requ i re l o w e r s o l i d s load ing than the l e v e l t h a t may r e s u l t from waste consol idat ion. F e a s i b i l i t y evaluat ions and sa fe ty assessments w i l l be prepared before i n i t i a t i n g NCAW conso l ida t ion . I f double-shel l tank r e t r i e v a l i s appropriate, Pro jec t W-211, I n i t i a l Tank Re t r i eva l Systems, w i l l be rebasel ined t o accomplish t h i s ac t i on on a schedule cons is ten t w i t h the technica l basis o f t he pro jec ted waste volume inventory over the next decade.

7.2 Consol i d a t e the neut ra l i zed c ladding removal waste (NCRW)

S i m i l a r t o NCAW, NCRW i s s tored i n t w o double-shell tanks, 241-AW-103 and -105. Tank 241-AW-103 contains 487 Kgal o f so l ids , wh i l e tank 241-AW-105 conta ins 388 Kgal o f s o l i d s o f t h i s type o f waste f o r a t o t a l o f 875 Kgal (Reference 4). Combining NCRW i n t o one tank f rees an add i t i ona l tank. Another way o f p rov id ing add i t i ona l capaci ty i s t o s t o r e double-shel l s l u r r y feed (DSSF) on top o f NCRW. Pro jec t W-211, " I n i t i a l Tank Re t r i eva l Systems," has been i n i t i a t e d t o prov ide t h e c a p a b i l i t y t o mix, d i l u t e , and remove waste s tored i n 10 o f t he 28 double-shel l tanks. Tank 241-SY-101 was o r i g i n a l l y designated as the f i r s t tank t o be re t r i eved . P ro jec t management has recen t l y requested RL concurrence t o proceed w i t h T i t l e I design f o r tank 241-AW-105 as the f i r s t tank t o be r e t r i e v e d ins tead o f tank 241-SY-101, thus achieving the conso l ida t ion o f NCRW no l a t e r than FY 1998/1999, (Reference 5 ) . As s ta ted i n Reference 2, sa fe ty

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issues , characterization, and environmental documentation requirements will be performed concurrently with the design a c t i v i t i e s . . . I

7.3 Validate waste Specific Gravity numerical l imi t

Waste spec i f ic gravity and di lut ion r a t i o are two interdependent fac tors i n control l ing waste chemistry and avoiding a spec i f ic chemistry condition t h a t may r e su l t i n enhanced gas retention capab i l i t i e s within the waste. Investigations (Reference 6) show tha t a waste spec i f ic gravi ty l imi t of 1.35 would preclude gas retention charac te r i s t ics of the waste. Waste concentration t o spec i f ic gravity values higher than 1.35 may cause unacceptable gas retention capabi l i t i es followed by periodic episodic gas release events. However, higher waste spec i f ic gravity numbers may be found t o be acceptable a f t e r fur ther investigation. Waste volume projections are highly dependent on the degree a t which, the various types o f wastes are concentrated through the evaporator (Reference 7). Because o f the highly dependent re la t ionship, a validated technical basis fo r the waste spec i f ic gravity is needed. Development of t h i s technical basis would ensure close coup1 i n g between the evaporator performance and gas retention capabi l i t i es of the waste. technical basis includes consideration of process controls (e.g. , instrument e r ror bands) t o ensure tha t the spec i f ic gravi ty l imi t i s n o t exceeded. In t u r n , the technical basis would reduce the uncertaint ies i n the fu ture waste volume projections and val idate the numerical l imi t for acceptable waste spec i f ic gravity.

Part of t h i s

7.4 Evaluate evaporator feed and receiver tanks as spares

To account for a potential shor t fa l l in the exis t ing waste storage capacity the evaporator feed and receiver tanks may be considered as spares. Tanks 241-AW-102 and 241-AW-106 are the evaporator feed and receiver tanks respectively. Por t ions of these two tanks a re available t o s to re concentrated waste as long as the evaporator operations are required. emergency or upset condition (e.g., a postulated scenario where a flammable gas double-shell tank leaks). Evaporator operations, however, could n o t resume unt i l space in these two tanks is recovered. The objectives of this task are t o val idate the f e a s i b i l i t y o f t h i s action and ident i fy operational constraints .

These tanks could provide the required space capacity in an

7.5 Resolve complexant/transuranic (TRU) waste i n 200 West Area

Complexed waste was generated i n the 1970s from the B Plant s t ront ium recovery process and subsequently stored i n single-shell tanks in 200 West Area. area single-shell tanks is approximately 3.6 m i l l i o n gallons b u t may be as high as 4.4 m i l l i o n gallons. Approximately 40% of t h i s l i q u i d waste (1.4 mi l l i on gallons) may be considered complexant (Reference 8) . Tank 241-SY-102 i s the only double-shell tank i n 200 West Area designated as a staging tank t o t ransfer the pumped waste t o 200 East Area. The other two tanks, 241-SY-101 and -103 are bo th flammable gas watch l i s t tanks and could n o t readily be considered as staging tanks t o t r ans fe r the

Recent estimates indicate tha t the pumpable l i q u i d i n west

. *--. .-,- . . . .. .. . I_~- . ~ . . . ._ . . ._. -.. .... . . , .. r .. .

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waste f rom 200 West t o 200 East Area. d e t a i l s on tanks 241-SY-101 and -103 and the reasons f o r cons ider ing tank 241-SY-102 as the on ly ava i l ab le s tag ing tank i n 200 West Area.

Reference 8 provides add i t i ona l

To reduce the amount o f waste t h a t requ i res more c o s t l y d isposal opt ions, complexed waste and TRU wastes have been segregated. The waste segregat ion was a lso accomplished t o comply w i t h DOE Order 5820.2aY "Radioact ive Waste Management .I1 Add i t i ona l l y , waste evaporat ion o f t he combined complexant and noncomplexant wastes may r e s u l t i n a s i g n i f i c a n t l y t h i ck , viscous s l u r r y a f f e c t i n g the r e s u l t i n g volume reduc t ion f a c t o r and the waste volume p ro jec t i ons (Reference 8). The ob jec t i ves o f t h i s waste management ac t i on are t o : 200 West Area sing1 e-shel l tanks w i thout compati b i l i t y concerns; 2) develop add i t i ona l in fo rmat ion requ i red t o evaluate c o m p a t i b i l i t y issues o f complexed and/or TRU wastes w i t h i n the context o f t he on ly s tag ing tank i n 200 West Area (241-SY-102); 3) i d e n t i f y waste management ac t ions t o reso lve t h i s issue (these act ions may range f r o m c leaning and r e t r i e v i n g the TRU waste i n tank 241-SY-102 t o s imply us ing i t as a s tag ing tank i n i t s present cond i t ion) ; and 4) develop an emergency pumping and i n t e r i m s t a b i l i z a t i o n plans f o r t he 200 West Area s ing le - s h e l l tanks w i t h c o m p a t i b i l i t y issues. Some tanks have no t been sampled, t he samples cha rac te r i z ing the waste must be obtained through the cha rac te r i za t i on program on a tank-by-tank basis.

1) i d e n t i f y t he

The new 200 West Area tanks would no t be operat ional i n t ime t o support r e s o l u t i o n o f t h i s issue s ince they would not be ava i l ab le p r i o r t o FY 1999.

7.6 T r i -Party Agreement M i 1 estones Negoti a t i ons

Several T r i -Par ty Agreement mi lestones are d i r e c t l y a f fec ted as a r e s u l t o f t he p r o j e c t phase out (see Table 1).

A nego t ia t i on team cons is t i ng o f RL and WHC personnel i s being assembled t o begin negot ia t ions w i t h the Tr i -Par ty Agreement stakeholders. add i t ion , a s i m i l a r team i s being assembled t o d iscuss p r o j e c t close-out issues w i t h the p u b l i c and o ther stakeholders.

I n

Technical and admin is t ra t i ve e f f o r t s are being planned t o p rov ide the above teams w i t h the t o o l s and in fo rmat ion f o r t i m e l y completion o f t he T r i -Pa r t y Agreement negot ia t ions. I n addi t ion, t h i s in fo rmat ion can be used t o accurate ly respond t o issues ra i sed by the p u b l i c and o ther stakeholders.

7.7 Perform a formal Decis ion/Risk Analys is

The o b j e c t i v e o f t h i s ac t i on i s t o perform a formal d e c i s i o n / r i s k ana lys is i n accordance w i t h establ ished Hanford Systems Engineering p r i n c i p l e s and procedures. The dec i s ion / r i sk analys is w i l l address the o v e r a l l impact o f t he MWTF p r o j e c t phase out recommendation. These impacts w i l l encompass a l l o f TWRS programs inc lud ing, bu t not l i m i t e d t o , d isposal , r e t r i e v a l , p r i va t . i za t i on i n i t i a t i v e s , storage, and

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pretreatment (Reference 9) . appropriate t o develop action plans when needed t o mitigate risks.

Decision analyses will be used as

7.8 Perform OWVP Contingency Space Analysis

In Reference 1, the waste volume projections summary was based on Revision 20 of WHC o f f i c i a l waste volume projection document (Reference 3 ) . This summary, however, included several updates t o the waste volume as given i n Reference 3.

Examples of these updates discussed i n the fo l lowing sections:

7.8.1 - Continue t o act ively mitigate Tank 241-SY-101 via the intermit tent operation of the mixer pump. Selection of act ive mitigation technique in l i e u of passive mitigation ( d i l u t i o n ) resulted in a reduction of waste volume projection of 1.0 mi l l i on gallons. Additionally, tank 103-SY may n o t require passive mitigation as well, and the r e su l t s will be an additional reduction of 1.0 m i l l i o n gal 1 ons.

7.8.2 - Eliminate the one contingency tank space i n calculat ing the waste volume projection. the double-shell tank storage system of an additional 1.0 mi l l i on gal 1 ons .

This action resulted i n a reduced demand on

Further d e t a i l s on the updates t o the waste volume projections are out1 ined i n Reference 1.

One objective of t h i s action i s t o analyze and invest igate the va l id i ty of this action and assess the impact of n o t having the contingency space i n the OWVP calculations.

7.9 Additional Costs t o Project 'W-058, Cross-Site Transfer System

Project W-058, Rep1 acement Cross-Site Transfer System, has been in i t i a t ed t o replace the aging t ransfer pipe l ines . This project and the new tanks project have been integrated i n order t o reduce overall cost . The integrat ion of these two projects have been achieved by sharing common purpose f a c i l i t i e s , such as power and control rooms. MWTF project , the new cross-s i te t ransfer system scope will be revised t o provide these needed services independently o f the MWTF project . Therefore, the purpose o f this action is t o perform a detai led estimate fo r the required additional costs t h a t must be added t o the baseline cost of the. cross-s i te t ransfer system.

By phasing o u t the

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7.10 Develop Plans f o r Fall Back Positions

W i t h i n this waste management action, ident i f icat ion and evaluation of a l te rna t ive and f a l l back options will be addressed using t h e decision/ risk analyses. These options may be necessary should a shortage i n waste tank storage capacity occur w i t h i n the next 10 years. These options will be developed i n a generic format and ye t i n suf f ic ien t detail t o enhance mitigating the risks associated w i t h potential waste storage shor t fa l l i n the future .

8.0 PROJECT PHASE OUT ALTERNATIVES

Project phase out scenarios are presently i n preparation. One o f these scenarios will consider rapid project ramp down w i t h l i t t l e or no consideration f o r the a b i l i t y t o r e s t a r t . Another scenario will consider the completion of the design packages, or a portion thereof, before ramping down. Cost and s t a f f i n g requirements necessary t o orderly phase out the project will vary, depending on the selected phase out scenario. MWTF demobilization planning are presently available i n a d r a f t form i n Reference 10.

Details regarding the

9.0 REFERENCES

1. Let ter , W . T. Alumkal, WHC, t o T. R. Sheridan, R L , "Multi-Function Waste Tank Fac i l i ty Decision Paper," #9550111, dated January 13, 1995.

2. Letter, M. A. Payne, WHC, t o R . F. Christensen, R L , "Current Plans f o r Hydrogen Mitigation Program," #9551009, dated February 24, 1995.

3. WHC-SD-WM-ER-029, Revision 20, "Operational Waste Volume Projection," September 1994.

4. WHC-EP-0182-82, Revision 82, "Waste Tank Summary f o r Month Ending January 31, 1995," March 1995.

5.

6.

Letter , M. A. Cahill , WHC, t o B. L. Nicoll, R L , "Continuing Project 94L-EWW-211, I n i t i a l Tank Retrieval Systems," #9551250, dated March 15, 1995.

PNL-10417, "An Assessment of the Dilution Required t o Mitigate the Hanford Tank 241-SY-101, I' February 1995.

7. WHC-SD-WM-TI-690, Revision 0, "Waste Volume Reduction Factors f o r Potential 242-A Evaporator Feed, I' Apri l 1995.

8. Internal Memo, D. A. Reynolds t o A. M. Umek, "Options f o r Pumping Complexed Waste i n 200 West Area," #71330-95-001, dated March 14, 1995.

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9. Letter, J. E. Kinzer, RL, to President, WHC, "Multi-Function Waste Tank Facil ity - Project W-236A Decision Paper, I' #95-TOP-027, dated March 17, 1995.

10. DRAFT, "Project W-236A Multi-Function Waste Tank Facility Demobilization Plan," March 1995.

11. WHC-SD-W236A-ER-01lY Revision 0, "Position Paper, Need for Additional Waste Storage Capacity and Recommended Path Forward for Project W-236AY MWTF," September 26, 1994.

12. WHC-SD-ES-012, Revision 0, "MWTF Path Forward Engineering Analysis Technical Task 3.3 Single-Shell Tank Liquid Contents," April 1995.

13. WHC-SD-W236A-015, Revision 0, "Waste Segregation Analysis for Saltwell Pumping in the 200 West Area," April 1995.

14. WHC-SD-W236A-ES-014, Revision 0, "Multi-Function Waste Tank Facility Path Forward Engineering Analysis Technical Task 3.6, Estimate of Operations Risk in the 200 West Area," April 1995.

15. WHC-SD-W236A-ES-013, Revision 0, "Passive Versus Active Mitigation Cost Analysis," April 1995.

16. WHC-SD-W236A-ES-01lY Revision 0, "Retrieval Sequence," April 1995.

17. Operational Waste Volume Projects Work Group, "Doubl e-She1 1 Tank Inventory and Available Space," Revision 0, December 27, 1994.

18. Multi-Function Waste Remediation Facility, Justification of Mission Need,

19. WHC-SD-WM-ER-432, Revision 0, "Life Management of 28 Double-Shell Tanks,"

January 14, 1993.

April 1995.

20. 89-10, Revision 3, "Hanford Federal Facility Agreement and Consent Order Fourth Amendment, I' January 1994.

21. Letter, A Hon to T. R. Sheridan, "Operational Waste Volume Projections - Current Data," January 4, 1995.

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APPENDIX 1 BACKGROUND I N FORMAT I ON

Existinq S ta tus

In March, 1995, a Path Forward Task Team was formed t o address necessary actions involved with the RL/WHC recommendation t o phase out the MWTF project . This team comprises representatives from several TWRS organizations whose e f f o r t s a r e crucial i n resolving the issues necessary for an order ly phase o u t . The primary team objectives a re to :

Develop a c l e a r technical basis for the project phase out Ident i fy the Tri-Party Agreement milestones affected by the tanks deci si on Define what i s required for, and begin the negotiation o f , changes t o the Tri-Party Agreement milestones Develop a detai led MWTF project phase o u t plan Plan and implement Waste Management Actions necessary t o s u p p o r t the tanks decision Define the impact of the project phase o u t on other TWRS programs

Pro.iect Hi s t o r y

1990- 1993

In 1990, the MWTF was i n i t i a t e d t o provide additional storage capacity th rough the design and construction of four new, double-shell one-mill ion-gallon tanks. This capacity was required t o suppor t continued tank farm operation, pretreatment, and disposal. The project was validated i n 1991 as a 1993 Major System Acquisition with a scope of fou r tanks (and suppor t f a c i l i t i e s ) a t an estimated cos t of $435M. The scheduled completion date was 1999. Conceptual Design was completed i n 1992.

Milestones were established in the Tri-Party Agreement under the M-31 s e r i e s t o complete up t o four tanks by 1999. received t o achieve maximum acceleration of the MWTF, and t o a l so reduce scope associated with the s u p p o r t of pretreatment and the High-Level Waste Vi tri f i cat ion Project .

In December of 1992, d i rec t ion was

In February 1993, the revised Jus t i f i ca t ion of Mission Need (JMN) (Reference 18) provided the basis for the additional four s torage tanks. The primary purposes o f these tanks a re d i lu t ion and storage of waste from tanks with p r i o r i t y sa fe ty issues such as Tank 241-SY-101.

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Subsequent t o this direct ion, additional storage capacity needs w h i c h exceeded the proposed four new tanks was ident i f ied. The additional needs, p l u s concerns for operational f l e x i b i l i t y i n the 200 West Area, led t o a presentation i n March 1993 t o the U.S. Department o f Energy-Headquarters (DOE- H Q ) , Director of Environmental Waste Management (John Tseng). T h i s presentation proposed adding two tanks i n 200 West Area, accelerating these two tanks t o a 1998 completion, and reducing costs of the project through a s e r i e s of specified a c t i v i t i e s t o maintain a t o t a l project cost of $435M f o r a l l six tanks.

A Baseline Change Proposal was prepared t o document these changes, and direct ion t o proceed on the six-tank concept was received from RL i n September 1993. Following the concurrence w i t h the six-tank concept, a change request t o modify the Tri-Party Agreement milestones was i n i t i a t e d . request was rol led i n t o the overall renegotiation o f the Tri-Party Agreement, and resulted i n the current milestones established under the M-42 s e r i e s .

T h i s change

The project scope a t th i s time was six tanks, scheduled t o be complete i n 1999, w i t h an estimated Total Project Cost of $413M.

September 1994 P o s i t i o n

Reviews a t th i s time raised several issues regarding the mission, scope, and schedule of the MWTF. The decision t o build new tanks, and i f so how many, must address several factors , such as operational risk and needs, the amount of waste t h a t the s i t e will generate i n the future , safety, a v a i l a b i l i t y of exis t ing double-shell tanks, and impact on other projects. Operational risk and f l e x i b i l i t y must be managed such t h a t any ident i f ied risk is reduced as soon as practicable, and additional needed tank capacity must be made avail able t o s u p p o r t operations. The retr ieval of waste from single-shell tanks and watch l i s t tanks will require subsequent storage i n a double-shell tank, and therefore, will add t o the t o t a l amount o f waste t h a t must be stored. The aging condition of the exis t ing 28 double-shell tanks becomes s igni f icant as time passes. Also, other projects depend on Project W-236A (e.g. , integration and use of common u t i l i t i e s , systems, and s u p p o r t f a c i l i t i e s ) .

Based on the above, a new path forward was developed (Reference 11) which recommended t h a t two new tanks were needed for safe waste storage i n the 200 West Area, and they s h o u l d be constructed as soon as practicable. I t was also recommended t h a t the design shou ld continue f o r the tanks i n the 200 East Area w i t h a decision made by September 1995 on whether t o construct them. The construction o f the cross-site t ransfer 1 ine should proceed as scheduled.

To implement this new path forward, the following s teps were recommended:

Revise W-236A and other project baselines as required.

Complete the Environmental Impact Statement; revise the scope as necessary.

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Complete systems engineering t o va l ida te the need and requirements fo r the MWTF, Cross-Site Transfer Line, and t h e i r technical bases by September 1995. The work includes: - Obtaining approval of the Functions and Requirements Document from the

U.S. Department of Energy (DOE). - Developing the Technical Requirements Base1 ine and obtain approval from the DOE. - Developing a Design Requirements Document (DRD) f o r MWTF.

- Comparing the MWTF DRD w i t h the ex is t ing Functional Design Cr i t e r i a . - Performing necessary t rade studies. (These t r ade studies evolved i n t o

the 10 technical tasks discussed below).

Eight technical tasks were ident i f ied as par t of a comprehensive s t ra tegy t o provide a firm technical foundation f o r t he MWTF recommendation (Reference 11). A l l of the eight tasks and r e s u l t s a re summarized a t t he end of this appendix.

November 1994 OWVP Work GrouD

A j o i n t work group was formed i n November 1994, consis t ing of DOE, WHC and Ecology representat ives , t o review Revision 20 of the OWVP repor t (Reference 3 ) . The group focused management 'a t tent ion on waste segregation rules and o ther assumptions b u i l t i n to the inventory management s t ruc ture . The work group issued a special report on January 4, 1995 (Reference 17). The project ions displayed i n the report showed t h a t projected Hanford wastes could be handled without new waste tanks, i f cer ta in compensatory act ions were taken t o maximize t h e use o f avai lable tank space. T h i s included consideration of the success of mixing pump mitigation of t he waste tank SY-101 flammable gas issue and a pending safe ty program conclusion t h a t ac t ive mit igat ion current ly has l e s s uncertainty than passive mitigation by d i lu t ion .

Januarv 1995 Recommendation

TWRS was asked t o reassess the need f o r additional double-shell s torage space due t o funding l imi ta t ions f o r FY 1995 and outyears. project ions, risk associated w i t h not having additional tanks i n FY 1999 and beyond, and waste management a1 te rna t ives were cons'idered i n this assessment. Based .on this assessment, WHC recommended t o RL t h a t the MWTF Project be phased out (see Reference 1 ) . T h i s phase o u t should be done i n such a way t h a t t he pro jec t team can be reassembled and construction completed on the two 200 West area tanks f i v e years a f t e r a project r e s t a r t decision i s reached, i f necessary.

Current waste volume

Although management of the waste volume i s technical ly f eas ib l e , this decision places some f inanc ia l , programmatic, and safe ty risks on TWRS (see Reference 1 ) . Appendix 2.

Key assumptions leading t o this decision a r e provided i n

A comparison of ex is t ing waste volume capacity r e l a t i v e t o the waste tank volume requirements indicate t h a t the waste volume will overtake the space avai lable i n 1999 (see Reference 1 ) . Therefore, waste managements act ions a re necessary t o accommodate current waste volume projections (see Section 7.0).

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March 1995 RL Concurrence

On March 17, 1995, RL concurred w i t h the WHC recommendation (Reference 9) by responding t h a t recent changes and analyses indicate t h a t double-shell tank storage capacity is n o t needed u n t i l a t l e a s t FY 2004. The waste volume i n the current baseline program can be managed w i t h i n the exis t ing tank capacity u n t i l then, b u t w i t h higher risks. RL directed WHC t o proceed w i t h the actions described i n Reference 1 and t o address the comments i n attachment 2 of the RL Let ter (Reference 9). R L also requested an action plan and change request t o implement the recommended actions. make preparations for negotiation of changes t o affected Tri-Party Agreement m i 1 estones.

In addition, R L d i rected WHC t o

Technical Task Summaries

Optimum Safe D i l u t i o n Ratio and Specific Gravity

The d i lu t ion r a t i o t o prevent gas retention and allow waste t r a n s f e r t o 200 East Area was determined t o be 1:l. gravity limit was determined t o be approximately 1.35 for evaporator operation. Laboratory t e s t s t o val idate d i l u t i o n r a t i o will be conducted by July 1995.

The minimum safe spec i f ic

See Reference 6.

Evaporator System Performance

The volume of s lur ry needing storage a t a spec i f ic gravity (SpG) o f 1.35 i s 6.04 Mgal . T h i s compares w i t h the upper bound of 5.44 Mgal of s lur ry indicated i n OWVP Revision 20 a t the DSSF s lur ry l imit (approximately a 1.5 SpG). shell tanks is realized because o f the evaporator endpoint change from DSSF t o a 1.35 SpG l imi t .

A net increase of s lur ry volume needing storage i n the double-

Reference 7 includes waste volume reduction fac tors by stream; for s lur ry conditions o f 1 .2 SpG, 1.35 SpG, and DSSF (approximately 1.5 SpG). Operating uncertainties including instrument accuracy are addressed. P1 anned and actual waste volume reduction fac tors a re shown f o r h i s t o r i c 242-A campaigns . Si ngl e-She1 1 Tank Liquid Contents

Liquid t o be pumped f o r s tab i l iza t ion of single-shell tanks i s 4.3 Mgal i n 200 West Area and 1.8 Mgal i n 200 East Area. T h i s i s 2.0 Mgal more than the amount shown i n the OWVP, Revision 20.

F l u s h water will a lso require interim double-shell tank storage o f 1.6 Mgal of water u n t i l volume reduction through the evaporator can be accompl i shed.

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Appendix 1 - Page 5

A review of pumping records back t o the 1970s shows t h a t t yp ica l ly more l iqu id was pumped from tanks than would be predicted by sa1,tcake porosity ( i n t e r s t i t i a l l i q u i d ) . The pure sal tcake porosity does n o t account for l iqu id found i n pockets or layers . A calculat ion was developed t o account for l i q u i d found i n pockets o r layers , using a "projection porosity". The data show the projection porosity of the sa l tcake i n single-shell tanks t o be on an average around .63 (see Reference 12).

Waste Segregation Analysis

Current estimates of waste ye t t o be pumped i n 200 West Area a re 4.3 Mgal. Up t o 1.4 Mgal may be complexed waste. The only double-shell tank farm in the 200 West Area is the 241-SY farm. Two of the tanks in t h a t farm, 241-SY-101 and -103 are on the flammable gas watch l is t . T h i s makes i t impractical t o be considered for receipt of t he pumped waste. T h i s leaves 241-SY-102 as the only double-shell tank t h a t can receive waste in the 200 West Area. 241-SY-102 contains a layer of sludge i n t he bottom which i s highly TRU. Current ru les , as ou t l ined in the Waste Compati b i 1 i t y Program P1 an, prohi b i t commi ngl i ng compl exed waste and TRU waste. The current s t ra tegy is t o pump waste t h a t can be commingled in to 241-SY-102. Additional s tudies are being planned t o decide o n t he best course o f action for the complexed waste i n the 200 West Area. Reference 13.

See

Life Management o f Existing Double-Shell Tanks

A remaining-1 i f e assessment indicated t h a t the double-shell tanks and t h e i r associated waste t r ans fe r pipelines shou ld be able t o maintain t h e i r i n t eg r i ty for the next 10-years. T h i s is based on t h e assumption t h a t normal operational controls and limits are n o t exceeded and t h a t adequate, periodic inspections and additional reinforced concrete analyses do n o t reveal any unexpected weaknesses. Avail ab1 e analyses do n o t thoroughly address e i t h e r concrete creep e f f ec t s or thermal-cycl ing e f f ec t s .

Some double-shell tanks appear t o be more sens i t ive t o stress-corrosion cracking than the others. This means t h a t any future in-tank waste processing i n those sens i t ive tanks must have adequate chemical corrosion inh ib i t ion controls maintained a t a l l times; inspections a re necessary t o see i f any aggravated crack growth-to- 1 eakage damage could be occurring .

i n addition per iodic l i n e r

Constrictions e x i s t i n some f a c i l i t i e s i n t h a t only one o r two pipel ines feed these s i t e s ; t r a n s f e r un t i l repa i r o r replacement of l i ne . See Reference 19.

a. single- o r double-failure would preclude waste

Estimate of Operational Risk

There i s a probabj l i ty of experiencing d i f f i c u l t i e s i n operating the 200 West Area tank farm i n t he next ten years. There is a high probabi l i ty of encountering d i f f i c u l t y i n managing leaking single-shell tanks containing complexed or noncomplexed waste i n the near term.

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Appendix 1 - P.age 6

Other major observations follow: 1) In general, operating t h e 200 West Area tank farm successfully i s highly dependent on operabi l i ty o f the present cross-s i te t r ans fe r 1 ine, 2) waste volumes projections are inherently uncertain and can eas i ly vary between p l u s or minus 3 Mgal, and (3 building two new 200 West Area million-gallon tanks increases our a b i l i t y t o manage contingencies and unplanned events

Reference 14 highlights several paths in to the future and quant i f ies the r i sks and impacts for r i s k management consideration.

Cost of Passive Versus Active Mitigation

Without consideration of waste storage costs , passive mitigation appears t o be s l i g h t l y more cost e f fec t ive than act ive mitigation. cost advantage may change when waste storage costs are considered. d e t a i l s see Reference 15.

However, t h i s For

Waste Retrieval Sequence

Reference 16 documents the waste re t r ieva l study. the decision t o phase o u t the MWTF project will n o t have a s ign i f i can t impact on the re t r ieva l sequence.

The study found t h a t

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Appendix 2 - Page 1

APPENDIX 2 ASSUMPTIONS

The decision t o phase out the MWTF project is based on the following assumptions:

1. Wastes i n NCAW tanks can be consolidated.

Combining NCAW in to one tank frees up nearly .98 Mgal w i t h an estimated heat load of 500,000 BTU/hour, possibly exceeding the current operating limits. current operati ng p l ans requi re 1 ower sol i d s 1 oadi ng . The tanks were designed f o r s ign i f icant ly higher heat loads but

2.

3.

Wastes i n NCRW tanks can be consolidated.

Combining the NCRW so l ids in to one tank o r s tor ing concentrated DSSF on top of NCRW will provide .98 Mgal additional tank capacity. The capabi l i ty t o t ransfer NCRW so l ids does not exist a t this time. Capital upgrades would be required t o provide this capabi l i ty .

Active mitigation of flammable gas watch l i s t tanks is acceptable.

The ongoing ac t ive mitigation of 241-SY-101 and the contingency plan f o r i n s t a l l a t i o n of mixer pumps i n 241-SY-103 and 241-AW-101 i f required, must continue t o be an acceptable mitigation action f o r this sa fe ty issue (Reference 2). No passive mitigation by d i lu t ion of any hydrogen safe ty issue will be required.

4. The evaporator operating tanks can be used f o r spare capacity.

Tanks 241-AW-102 and -106, used t o support the 242-A Evaporator operations, a re the feed and receiver tanks. A.portion of the feed and the receiver tanks i s avai lable t o s to re concentrated waste material as 1 ong a s evaporator operations a re required.

These tanks could provide additional emergency capacity f o r s i t ua t ions such a s a flammable gas double-shell t a n k leak. The negative effect of this is no evaporator operations would be allowed u n t i l the tank space i s made avai 1 ab1 e.

5. The waste incompatibil i ty issue f o r tank 241-SY-102 will be resolved allowing the pumping of complexant single-shell tank l iqu ids .

Complexed waste l iqu id is considered incompatible wi- th the high t ransuranic sludge i n 241-SY-102 because i t may dissolve t h e t ransuranics . I f the complexed waste 1 iquid dissolved the t ransuranics i t would increase disposal cos ts and could lead t o processing problems i n the evaporator. Waste sampling and an engineering study a r e required t o determine which single-shell tanks contain complexed waste and evaluate the options f o r handling the complexed waste. Any tanks determined t o be complexed should first be evaluated f o r dissolut ion of t ransuranics from

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Appendix 2 - Page 2

241-SY-102 sol ids, and detrimental crystal behavior and high viscosity resulting from evaporation. Then the engineering study should evaluate the options and associated impacts for handling the complexed waste. These include complexed waste which does not dissolve the transuranics, accepting increased operating costs and risks from complexed waste which does dissolve the transuranics, and cleaning out 241-SY-102 before transferring any compl exed waste. strategy will increase the capability of using 241-SY-102 for waste collection and transfers.

Determination of a compl exant hand1 i ng

6. .

The existing cross-site transfer lines are adequate to transfer wastes from 200 West Area to 200 East Area until the replacement transfer line is operational in 1998.

Two of the original six cross-site transfer lines built in the 1950's remain in service. The two remaining lines will be tested this year for leaks. These lines are required to transfer 241-SY-102 waste as well as the single-shell tank pumpable liquid waste.

Waste management actions for reducing TWRS risk will be deemed adequate by the Tri-Party Agreement negotiating parties.

An agreement with the Washington State Department of Ecology, U.S. Environmental Protection Agency, and U.S. Department of Energy to eliminate the construction of additional tanks and to accept an increased level of programmatic risk is required to complete the shutdown of the MWTF project. reducing TWRS risk will be deemed adequate by the negotiating parties.

7.

It is assumed that the waste management actions for

8. No double-shell tank problems will occur that limit their use.

The life management activities for the double-shell tank waste storage system will ensure an adequate remaining life (minimum 10 years) for the double-shell tanks with no problems limiting their use. Any unexpected problems with the existing double-shell tanks could significantly increase the programmatic risk.

Adequate storage capacity will continue to exist in the 200 East Area.

Any actions needed to ensure adequate storage space in the 200 East Area to accept 200 West Area tank farm waste will be implemented. continued operation of the 242-A Evaporator to reduce waste volumes and the potential use of the evaporator operating tanks as spare capacity are included in this assumption.

9.

The

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Appendix 3 - Page 1

APPENDIX 3 SPECIAL WASTE VOLUME PROJECTION

IN SUPPORT OF THE MWTF CANCELLATION EVALUATION

Operational Waste Volume Projection, Revision 20 was issued i n September 1994 (Reference 3) . t o assess a l te rna t ive scenarios f o r operating the tank farms, w i t h special emphasis on operating without constructing new tanks a t least through 2004. Reference 9 requested a special long range waste volume projection t h a t would incorporate the l a t e s t f a c i l i t y waste generation ra tes , d r a f t information provided by the MWTF p a t h forward tasks and many of the space saving actions proposed i n Reference 1. This l e t t e r presents the operational planning basis and graphics f o r the special waste volume projection completed i n response t o this request.

Since i t s issue, studies (Reference 1, 21) have been conducted

The Waste Volume Projection (WVP) system is a complex system simulation which was developed t o a s s i s t i n managing the tank farms and identifying i f new tanks were needed. I t was re l ied heavily upon during the evaporator outage t o a s s i s t i n managing the generation and receipt of waste so t h a t avai lable space was not exceeded.

The WVP system simulates the evaporator operation, the 28 double-shell t a n k s , and the associated t r a n s f e r systems. chemistry, mass, volume and operational l o g i s t i c s t o evaluate various operational scenarios. Although any simulation is dependent upon the correctness of the i n p u t information, this projection i s based upon the best estimates o f waste generation and composition provided by the waste generators. The special WVP has shown t h a t i t is possible t o manage the double-shell tanks i n such a way as t o not require the construction of any new double-shell tanks before 2006. A spec i f ic s e t o f actions i s ident f i e d which will allow this t o be done. These a re discussed i n the discussion of planning basis section below.

I t takes into account the e f f e c t s of

Attachment 1 presents an executive summary of the operational p l a n n i n g basis f o r DOE Special Projection L9503A. f o r the July 1994 Baseline Case (L947BC) has been included. Plans t h a t have been changed between the projections have been shaded.

Attachment 2 presents a detai led operational planning matrix comparing the plans used i n DOE Special Projection L9503A w i t h those used f o r the J u l y 1994 Baseline Case. F l u s h fac tors and Waste Volume Reduction Factors (WVRFs) have been included i n the table .

For comparison purposes, the basis used

Attachment 3 i s the standard long range projection graphic f o r this special projection depicting tank needs through 2006. Tank needs a re shown.for both the 1.35 (estimated) and 1.5 spec i f ic gravity end points for evaporation.

-I-

-

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Appendix 3 - Page 2

Attachment 4 is a bar graph showing waste inventory and available space for d i f fe ren t waste categories. This presentation of the information was used i n Reference 21 and has been found t o increase understanding of the d e t a i l s o f space usage. graphic explaining inventory changes.

Attachment 5 i s a spreadsheet t h a t attempts t o summarize the waste additions, evaporations, and losses t h a t occur during this projection. T h i s spreadsheet attempts t o approximate the waste changes on an annual basis even though these changes may be occurring a t the end of a f i sca l year (FY).

Numerical annotations and notes have been included w i t h th i s

Attachment 6 i s a tabular representation o f space usage s imilar t o Table 2 of Reference I .

Discussion Planninq Basis. Major planning changes are discussed below:

1. Combination o f Dart ia l lv f u l l separate NCAW and NCRW tanks.

The in-tank washing scenario used i n this projection assumed t h a t the NCAW solids from Tanks 241-AZ-101 (35 Kgal o f so l ids ) and 241-AZ-102 (102-AZ) (95 Kgal o f sol ids) would be combined into Tank 102-AZ a f t e r i n - tank washing of the sol ids had been completed (FY 1999). supernates and washes were assumed t o be concentrated and combined i n t o Tank 241-AY-101.

The NCAW

The PFP TRU (Pi) solids i n Tank 241-SY-102 (143 Kgal PT); the NCRW solids from Tank 103-AW (487 Kgal PD); and the NCRW sol ids from Tank 241-AW-105 (388 Kgal PD) were a l l consolidated into Tank 241-AW-103 d u r i n g FY 1999. Tank 241-AW-103 contained 1018 Kgal of sol ids a f t e r the combinations had been compl eted which could compl ica te sol i d s re t r ieva l .

2. Mitiqation o f Watch List Tanks.

Active mitigation o f Tank 241-SY-101 was continued th rough FY 2006. addition, i t was assumed t h a t passive mitigation of other watch l i s t f l ammabl e gas doubl e-shell tanks woul d n o t be necessary.

In

3. Spare Space.

Operational space i n Tanks 241-AW-102 and 241-AW-106 was used t o provide 0.72 Mgal o f the required 2 Mgal of spare space s t a r t i n g in FY 1999. This action was taken t o decrease tank space needs. require t h a t special procedures be written t o make cer ta in t h a t the required volume was being maintained and t h a t proper sequence of operations would allow this space t o be used should a leak occur i n a doubl e-shell tank.

This action would

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Appendix 3 - Page 3

4. Use of Tank 241-SY-102 for pumpins complexed SWL.

Current SWL pumping practices require tha t a double-shell tank be avai lable for receiving the l iquid wastes pumped o u t o f single-shell tanks. tanks located i n the 200 West Area be used as a receiver tank. Two of the tanks in 200 West Area (Tanks 241-SY-101 and -103) are on the f l ammabl e gas watch 1 i s t and therefore cannot receive waste additions. This means t h a t a l l SWL pumped i n the 200 West Area will be routed through’ Tank 241-SY-102.

SWL pumping i n the 200 West Area requires t h a t one of the three

Tank 241-SY-102 contains a sludge layer of PT solids. complexed SWL t o Tank 241-SY-102 with the PT solids i n the bottom should n o t present a problem. However, complexed wastes and TRU solids have been segregated both t o minimize the expense o f disposal and t o comply with DOE Order 5820.2A. This required the solids i n Tank 241-SY-102 be removed from the tank prior t o pumping of complexed SWL i n the 200 West Area (see item 1 f o r additional information). Questions about the r e l i a b i l i t y and/or plugging of current t ransfer l i nes and the long-lead time required for re t r ieva l projects would delay the re t r ieva l of the sol ids u n t i l December 1998. After consulting w i t h re t r ieva l organizations, this projection assumed t h a t the re t r ieva l o f s o l i d s i n Tank 241-SY-102 would s t a r t in December 1998 and be completed i n one month using the new cross-s i te t ransfer l i ne . The pumping of complexed SWL was s ta r ted i n January 1999. T h i s date allows a l l SWL t o be completed by the end of FY 2000. WHC is investigating accelerating 241-SY-102 re t r ieva l and a l te rna t ive methods of dealing w i t h the 200 West Area SWL including sampling of the liquors t o confirm t h e i r c l a s s i f i ca t ion , relaxing of the segregation ru les , and i n i t i a t i n g t r ans fe r s from smaller available tanks. t o advance the completion of SWL pumping as much as possible. doing we are confident t h a t SWL pumping can be completed before the end of FY 1999.

Pumping non-

The purpose of these s tudies i s By so

5. Cross-si t e t ransfer 1 ines.

Per the request for this projection, cross-s i te transport of wastes from 200 West Area t o 200 East Area is assumed t o be available.

6. Continqencv space.

A t the request of DOE and WHC upper management, previous operational waste volume projections have added one tank of contingency space in the long range portion (1999 on) t o account for any inaccuracies i n waste generation r a t e s or i n .the determination of WVRFs. The contingency tank has been removed (References 1 and 9) from this projection.

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Appendix 3 - Page 4

7.

8.

9.

SWL Volumes.

Based on preliminary information from the MWTF Path Forward Task Studies, this projection assumed that 6.2 Mgal (previously 3.6 Mgal) of single- shell tank wastes would be pumped from 1995-2000. this waste was assumed to be complexed resulting in 2.6 Mgal of complexed SWL (previously 0.5 Mgal). The newly revised WVRFs (to DSSF) was 55 for non-complexed SWL and 10 for complexed SWL. The revised WVRF for non- complexed SWL is based on an estimated SWL content in Tank 101-AN and needs to be verified in the future when more single-shell tanks have been characterized.

Approximately 42% of

Facilitv Generation Rates.

The total facility generation rate used in this projection varied from approximately 18.9 to 34.6 Kgal/month (previously 93 Kgal/month for the July 1994 Baseline Case).

Prel iminarv Multi-Function Waste Tank Facil itv (MWTF) Path Forward Task.

Preliminary information obtained from the MWTF Path Forward Tasks were included in these projections. The most significant of these items were increased SWL pumping volumes (see item 7) and new WVRFs (new values are included for appropriate waste streams in Attachment 2).

10. Privatization.

TWRS Program privatization concepts are not included in this study. However, it is currently believed to have no negative impact.

11. Pretreatment.

At the time this projection was started, final information had not been received designating which tanks of waste would be pretreated first. This projection assumed that pretreatment would begin with wastes that were at the desired 5 M Na concentration. space faster since the.feed doesn't require dilution prior t o pretreatment. FY 2005.

Using this logic frees up tank

Tanks 241-AN-106 and 241-AP-105 were pretreated in

Next the wastes in Tanks 241-AW-101, 241-AN-104, and 241-AN-105 were pretreated in FY 2006 to decrease the flammable gas watch list waste inventory. 6 Mgal/Yr (5 M Na feed) pretreatment rate since these tanks will require some dilution:

Pretreating these wastes in 2006 is compatible with a

Tank

241-AW-101 241-AN-104 241-AN-105

I n v e n t o r.v - (Kqal 1 1127 1060 1127

Concentration Na, M -10. 7.85

.. 7.85

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Appendix 3 - Page 5

As i n the Ju ly 94 Baseline Case projection, i t was assumed t h a t one Low Level Waste (LLW) receipt t a n k and one High Level Waste (HLW) receipt tank would be required i n FY 2005. An additional LLW rece ip t tank was added i n FY 2006.

12. Sinale-Shell Tank Solids Retrieval.

The amount of so l id s re t r ieved i n FY 2004 and 2005 was the same a s t h a t used i n the Ju ly 1994 Baseline Case projection: 0.2 Mgal o f so l id s i n 2004 and 0.3 Mgal of sol i d s i n 2005. The amount of sol i d s re t r ieved i n 2006 had t o be reduced t o 1.0 Mgal t o reduce double shell tank need t o the ava i lab le 28 double shell tanks.

Discussion of Pro.iection Results

The graphic shown i n Attachment 3 indicates t h a t tank space needs can be managed w i t h i n the avai lable tank space provided the consolidation of NCAW tanks and NCRW tanks can be completed as outlined i n item 1 above. the lead time f o r re t r ieva l systems t o allow consolidation of t h e waste and the needs o f interim s t ab i l i za t ion , there is a p i n c h point i n 1999 which will have t o be c lose ly managed.

As current ly modeled, a l l four aging waste tanks a re f i l l e d with high-heat wastes during 1997 and 1998. T h i s leaves us without a spare tank f o r high- heat wastes i n the event of a leak i n one of these tanks. We are exploring possible scenarios which will allow us t o avoid this condition and believe t h a t a number of solut ions can be developed which will lower this.risk.

Because of

This projection was completed before the MWTF special s tud ies had been f ina l ized and was completed . w i t h preliminary information. I t is l i k e l y t h a t planning changes will occur before the OWVP, Rev. 21 projection i s completed:

1.

2.

The WVRF f o r non-complexed SWL provided on 3/14/95 was 55. I t is l i k e l y t h a t this value will be changed t o 47. space requirement by approximately a t h i r d of a tank by-the end of 2000.

The r e t r i eva l of Tank 241-SY-102 so l id s was completed i n December 1998. I t i s possible t h a t this da te could be pushed forward if funds were avai 1 ab1 e.

This would increase our tank

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Appendix 3 - Page 6

Table 1. Summary Comparing the 7/94 Baseline and DOE Special Projection Cases F a c i l i t y or Project I Baseline Case (L947BC) - Plans I DOE Special Case (L9503A) - Plans

vaporator Restart

I Effluent Treatment F a c i l i t y Startup

ingle-shell tank Porosity Compl exed SUL , Volume Pumped

Stabi

Kga 1

- l i z a - , t ion

97; Tank 102-AY

gal (0.8 Total) in FY 2004; 1 (1.2 Total) in FY 2005

1 (0.8 Total) in FY 2004; 1 (1.2 Total) in FY 2005

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Appendix 3 - Page 7

Attachment 2 Table 2. Operational Planning Matrix

Comparison o f 7/94 OWVP Baseline Case & DOE Special Projection ( A l l * Years are F i sca l Years)

7/94 OWVP DOE Special Base1 i ne L9503A

Case Case F a c i l i t v Generations

I To ta l L i m i t , Kgal/mo 93 18.9-34.6

PUREX Monthly Rate, Kgal /mo TCO Scheduled TCO Vol ume, Kgal Flush f o r TCO

0 0

400 dDSSF 225 DN 1994-1997 1994-1997

10% 10% WVRF f o r TCO ( t o DSSF) 65 99

- UO, F a c i l i t y Monthly Rate, Kgal /mo 0 0

B P lan t Monthly Rate, Kgal /mo 23 5 (1995-2001)

0.5 (2002-2028) 0%

Monthly Rate, Kgal /mo N/A Flush f o r misc. waste 5% WVRF f o r misc. waste ( t o DSSF) 91.5 99 TCO Scheduled 1997-2001 1997-2001 TCO Volume, Kgal DN 562 . 450 Flush f o r TCO 5% 10% WVRF f o r TCO ( t o DSSF) 91.5 99

S P lan t Monthly Rate, Kgal /mo 18 1.7 t o 2.5 Flush f o r misc. waste 6% 22% WVRF f o r misc. waste ( t o DSSF) 98 99

T P lan t Monthly Rate, Kgal /mo 15 . 0.13 t o 15 Flush f o r misc. waste 6% 22% WVRF f o r misc. waste ( t o DSSF) 97 99

100 Area Monthly Rate, Kgal/mo

TCO Scheduled TCO Volume, Kgal

100-K Basin Cleanout . TCO Scheduled TCO Volume, Kgal

105-F & 105-H Basin To ta l in 1995-96, Kgal

Flush f o r ALL 100 Area Waste WVRF for ALL TCO waste ( t o DSSF)

100-N

.....................

.....................

......................

0

1995-1999 571 DSSF

None 0

225

44% 97

0

1995-1996 1500 DN

1998 530

225

44% 99

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Appendix 3 - Page 8

Table 2. Operational Planning Matr ix Comparison o f the 7/94 OWVP Baseline Case & DOE Special Projection

300 Area Monthly Rate, Kqal /mo - - . Flush f o r misc. waste WVRF f o r misc. waste ( t o DSSF)

400 Area Monthly Rate, Kgal /mo Flush f o r misc. waste WVRF f o r misc. waste

WSCF Monthly Rate, Kgal /mo

Tank Farms Monthly Rate, Kgal/mo WVRF f o r f lushes ( t o DSSF)

(continued)

7/74 OWVP Base1 i ne

Case

5 44% 98

1 44% 98

0.7

30 99

S o l i d Waste Mixed Waste Trench 31 Leachate Monthly Rate, Kgal /mo - . WVRF ( t o DSSF)

Tank 107-AN Caust ic Add i t i on One Time Add i t i on i n 1995, Kgal

S a l t Well L i a u i d PumPinq Tota l Volume remaining, Mgal West Area Receiver S t a r t Complexed SWL i n 200W Compl e t i on , FY Meets TPA Mi lestones Tota l D i l u t e Complexed SWL, Mgal Po ros i t y (apparent) Flush f o r SWL Pumping WVRF f o r non-complexed ( t o DSSF) WVRF f o r complexed ( t o DSSF)

S i nq l e-She1 1 Tank Sol i d s Tank 106-C Re t r i eva l SST Waste Re t r i eva l Demo Tank Farm Closure s t a r t Re t r i eva l D i l u t i o n Rat io Vol. r e t r i e v e d i n 2004(Mgal) Vol . r e t r i e v e d i n 2005 (Mgal ) Meets TPA M i l estones No. SSTs Retr ieved S1 udge Retr ieved (Mgal )

0 95

50

3.6 Tank 103-SY

1995 2000 Yes

0.5 35% 10% 32 14

1997 2003 2018 3 : l

Yes 149

0.2 0.3

12.2

DOE Special L9503A

Case

1.6 44% 94

0.5 44% 94

0.0

10 99

0 99

50

6.2 Tank 102-SY

1999 2000

No

6 5% 2 5% 55 10

2.6

1997 2003 2018 3 : l

Yes 149

0.2 0.3

12.2

W HC- SD- W 23 6A- E R- 0 2 1 Revision 1

Appendix 3 - Page 9

Table 2. 'Operational Planning Matrix Comparison o f the 7/94 OWVP Baseline Case & DOE Special Projection

(continued) .

7/94 OWVP Base1 ine

Case

Low Level Waste (LLW) Pretreatment Facil itv Includes New Evaporator Yes Start Construction(mo/yr) 11/1998 Constr. compl ete(mo/yr) 12/2003 Hot Start 12/2004 Complete processing(mo/yr) 12/2028

2020 DSSF/SST

TWRS completion date Starting Feed

Sal tcake Rate( 12/2004-6/2007) ,Mgal /yr 6 LLW Feed Tank (filled) 1 LLW Receipt Tanks; 2005 1 LLW Receipt Tanks; 2006 on 2 HLW Receipt Tanks; 2005 on 1 Saltcake Retrieved (Mgal) 23.4

LLW Vitrification Facility Start Construction (mo/yr) 12/1997 Constr. compl ete(mo/yr) 12/2003 Hot Start 06/2005 Complete vitrification 12/2028 Characterization time

Rate (6/2005-6/2007) , Mgal /yr 6 Vol. vitrified 2005, Mgal 2

per tank 0.5 year

In-Tank Washi nq Start 11/1994 Scenario # Case 2 Basic description Combine washed

i nati on. sol ids. of sol ids comb- 101-AZ & 102-AZ

DOE Special L9503A

Case

Yes 11/1998 12/2003 12/2004 12/2028

2020 DSSF/SST Sal tcake

6 1 1 2 1

23.4

1211997 12/2003 06/2005 12/2028

0.5 year 6 2

9/1995 Case 2

Combine washed

solids. . 101-AZ & 102-AZ

Hiqh Level Waste (HLW) Pretreatment (Enhanced Sludge Washing) Start Construction(mo/yr) 06/2001 06/2001 . - - Hot Start (enh. sludge wash) 0612008 0612008 Compl ete processing 12/2028 1212028

Start Construction(mo/yr) 06/2002 06/2002 Constr. compl ete(mo/yr) 12/2007 12/2007 Hot Start 12/2009 12/2009 Complete vitrification 12/2028 12/2028 Characterization time

HLW Vitrification Facility

per tank 1.5 years 1.5 years Production rate (metric ton/day) 20 . 20

WHC-SD-W236A-ER-021 Revision 1

Appendix 3 - Page 10

Table 2. Operational Planning Matrix Comparison of the 7/94 OWVP Baseline & DOE Special Projection

(continued)

PFP S t a b i l i z a t i o n S t a r t Volume, Kgal F1 ush WVRF

Evaporator Next Outage Date Evaporation Product Evaporation Limit (g/ml) LERF capaci ty (Mgal ) Gal. condensate/gal . WVR Yearly evaporation of DN ( i .e . , maintain currency)

S t a r t d a t e (mo/yr) Liauid Effluent Treatment Facil i t v

Rate TO E

Watch Lis t /Safetv 101-SY Dilution & 103-SY Dilution &

date da te

SDareIContinqencv Space Spare Space, Mgal Use Operat'ional space i n 106-AW

Contingency space, Mgal as p a r t of spare space

-date

Waste Seqreqation Loss o f Waste Segregation Store DSSF on NCRW s o l i d s Segregate Compl exed wastes

Loss of DST %ace Number Tanks Removed

from Service Date Tank Removed

New DST Construction New West Area Tanks Date Constructed New East Area Tanks Date Constructed

7/94 OWVP Base1 i ne

Case

1998 on

6% 561

63

>2005 DSSF

13

Yes

1.52

1.3

06/1995

150 gpm 70 %

1:l (1998) 1:l (2000)

2.28

No

(1999 on)

No No

Yes

1.14

None N/A

2 2/98

4 12/98

DOE Special L9503A

Case

1995-2006 70 22% 81

>2005 dDSSF

13

Yes

1.35 (estimated)

1.3

03/1996 (requested TPA change; not o f f i c i a l ye t )

150 gpm 70 %

None None

2.28

Yes (0.72 Mgal) None

N/A

No No

Yes

None N/A

None . N/A

None N/A

WHC-SD-W236A-ER-02 1 Revision 1

Appendix 3 - Page 11

Table 2. Operational Planning Matrix Comparison o f the 7/94 OWVP Baseline & DOE Special Projection

(continued)

7/94 OWVP Base1 i ne Case

DST Retrieval Retrieval o f 102-SY solids to allow

compl exed SWL pumping None

solids in 103-AW & 105-AW None Consolidation o f NCRW

DOE Special L9503A Case

Yes (12/1998)

Yes (9/1999)

Attachment 3

Revision 1 Page 12 - Appendix 3 WHC-SD-W236A-ER-021

4-4

4-0

36

32

28

24

20

L9503A (3/95 DOE SPECIAL) VS 7/94 BASE CASE .

4 -

0 .

- l l l l I l l l ~ l r - - h I I I I I I l l 'LANTS ASSUMPTIONS

- 1 r I I I I l I I I ' . . . 0. FAC. GEN. RATE FFL. TREATM. FACIL. - 3/06 (LERF & Evop Condonrator, concurrently) tIK 101-SY & 103-SY - No Dllutlon. ST STABlLlZATlON ST SOLIDS UREX TCO RETREATMENT TANKS - 3 In FY 2005; 4 In FY 2008 I-TNK WAStllNO

P GRAVITY OF OSSF ONTINQENCY TANK - None

- 18.9-34.6 Kgol/Month

- Compl. ond o f FY 2000 (8.2 Mgol) - 0.2 Mgol (2004); 0.3 Mgol ( 2 0 0 5 ) ; 1.75 Mgol (2008) - No Rrr ta r t ; TCO 0.225 Ugal ON (FY 1094-97)

- Conrolldote 101-Az & 102-At Solldr - Conrolldote NCAW Supernotor - 1.5 g/ml ./LO 4 7 BC

.... .*.. . . . .*' .*. ,L9503A 0 1.35 Sp 0

. . . . . . . . e

' a ' . . . . . . . . . . . . . . . ' . . , . . t-

81 83 85 87 89 91 93 95 97 99 .01 03 05 07 09 11 13 15

Fiscal Year L9503A

. .. ‘I’ . .I... . ;eb= Y L . . .. .

Attachment 4

0 SPACE

N ON

3 SPACE

DSSF

3 SPACE

3 SSTS

3 SPACE

a oc

3 SPACE

a NCAW

SPACE

El CP

0 SPACf

0 BAW

0 SPACl

111 2AW

0 SPACl

UI PT

0 SPACl

a NCRM

SPACE

cc

0 SPACE

EaWL

. .. . . . Revision1 Appendix 3 - Page 13 WHC-SD-W236A-ER-021

Tank Inventory ana Space I I I I I I I I I I I I I I I I I I I I I

L U

26

24

22

20

18

16

u) 2d C

Y-

o L 14

E 12 0 4

3 z IO

8

6

4

2

0

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

1

WHC-SD-W236A-ER-021 Revis ion 1

Appendix 3 - Page 14

General I n fo rma t ion f o r "Tank Inventorv and Space" Gra~hic--L9503A

This bar c h a r t graphic i s meant t o show t h e increase and decrease i n t h e var ious waste categor ies o r waste types f o r DOE Special P r o j e c t i o n L9503A. Tank space needs f o r " in- tank washing" have been included. Spare and pretreatment r e c e i p t tanks are n o t shown. Beginning i n 1999, a p o r t i o n o f t he evaporator operat ional space maintained i n tanks 241-AW-102 and -106 w i l l a lso be considered as spare space t o decrease tank space needs. D i l u t i o n o f tanks 241-SY-101 and -103 are n o t inc luded i n t h i s p r o j e c t i o n through FY 2006. Levels o f D i l u t e Noncomplexed waste (DN) i n t h e d i l u t e r e c e i v e r and evaporator tanks w i l l va ry w i t h t ime. .The bar f o r each year dep ic t s t h e tank space needs f o r t h e end o f t h a t f i sca1 ,yea r .

Numbered Comments f o r "Tank Inventorv and Space" Graphic

1.

2.

3.

4.

5.

6.

"Watch L i s t " t ank i nven to r ies are constant f r o m 1995-2005. It i s assumed t h a t complexed s a l t w e l l l i q u i d pumping i n 200 West Area would be added t o Tank 241-SY-102 a f t e r t h e PT s o l i d s were r e t r i e v e d (see note 9).

Space above NCRW s o l i d s i s r o u t i n e l y used t o s t o r e DN waste. c l a r i t y , t h e graph shows t h i s DN i nven to ry i n w i t h t h e o the r DN i nven to ry toward t h e top o f t he graph. space shown i n t h e NCRW group t o t h a t shown i n t h e DN group).

Space above PT s o l i d s i s used t o s t o r e DN waste, (see note 2).

I n 1994 t h e r e i s a step change i n t h e space i n t h e Concentrated Phosphate (CP) group ( t w o tanks). I n 1993 the CP waste occupies p a r t o f t w o tanks. I n 1994 t h e ma te r ia l i s combined so t h a t it occupies on ly one tank; t h e space f r e e d i s then added t o t h e DSSF group i n 1994. This represents a t r a n s f e r o f a small amount o f CP waste from tank 241-AN-106 t o tank 241-AP-102. I n 1994, tank 241-AN-106 was used t o s t o r e DSSF.

For

( i .e. , t o ascer ta in " f r e e " space, add t h e

The DSSF group shows increases i n a v a i l a b l e space over t ime (e.g., 1994). When a DSSF tank becomes f u l l , a new tank must be added, which obv ious ly has empty space i n it. This i s shown g r a p h i c a l l y year-to-year w i t h step increases i n t h e number o f DSSF tanks and v a r i a t i o n s i n t h e a v a i l a b l e space shown i n t h e group. Increase i n DSSF volumes occur due t o s a l t w e l l 1 i q u i d (SWL) , evaporated d i l u t e wastes, and terminal c leanout (TCO) wastes.

I n 1996 t h e r e i s an increase i n space above t h e d i l u t e complexed (DC) waste inventory . Th is r e s u l t s from pumping t h e DC waste from tank 241-AY-101 (980 Kgal) t o tank 241-AP-103 (1140 Kgal), thus c r e a t i n g more n e t headspace. Reduction i n t h e DC waste i nven to ry i n 1996 i s caused by an evaporation. 241-AP-103. P r o j e c t i o n L9503A inc luded approximately 2.1 Mgal o f a d d i t i o n a l complexed SWL as compared t o t h e previous p r o j e c t i o n f o r t h e J u l y 1994 OWVP.

Evaporation i s necessary t o prevent o v e r f i l l o f t ank

WHC-SD-W236A-ER-021 Revision 1

Appendix 3 - Page 15

7. The increase i n NCAW inventory and tank needs s t a r t i n g i n 1996 were caused by in-tank washing of the NCAW solids. The f ina l result of the operations were completed by the end of FY 1999 and included: -- Washed NCAW so l ids from tanks 241-AZ-101 and -102 were combined in to

t a n k 241-AZ-102. - NCAW supernates and washes were evaporated and combined in to tank

- Tank 241-AZ-101 was "freed up" by the'end of FY 1999 and used as aging spare space/di 1 Ute receiver. .

Increase i n NCAW inventory i n 1997 r e s u l t s from the re t r ieva l of t a n k 241-C-106 so l ids t o tank 241-AY-102. These a re high-heat s o l i d s t h a t have been added t o the NCAW waste category (must be stored i n aging waste tanks, e.g., tank 241-AY-102).

241-AY-101.

8.

9. The PT solids from tank 241-SY-102 were cross-site t ransferred t o tank 241-AW-103 beginning December 1998. Therefore, the PT waste category and space a r e eliminated by the end of FY 1999.

10. NCRW s o l i d s from tank 241-AW-105 were retr ieved t o tank 241-AW-103 i n FY 1999. This resulted i n a decrease i n NCRW tanks by one tank by the end of FY 1999. the s o l i d s i n tanks 241-AW-103, 241-AW-105, and 241-SY-102 have been consol i dated.

Tank 241-AW-103 would contain 1018 Kgal o f s o l i d s a f t e r

11. Retrieval of single-shell tank solids was s ta r ted i n FY 2004 i n TX tank farm. I n i t i a l single-shell tank so l ids will be stored i n tank 241-SY-102.

12. The increase i n stored DN i n 2005 caused by re t r ieva l of single-shell tank s o l i d s w i t h 3 : l re t r ieva l water; some of re t r ieva l water i s being stored pr ior t o evaporation.

13. Decrease i n DSSF inventory i n 2005 r e s u l t s from pretreatment and v i t r i f i c a t i o n of 2 Mgal of DSSF.

14. Decrease i n watch l i s t inventory and tank needs i n 2006 results from pretreatment and v i t r i f i c a t i o n of 3.3 Mgal of DSSF from the watch l i s t category (tanks 241-AW-101 , 241-AN-104, and 241-AN-105).

15. Years 2000-2004 appear nearly constant i n DSSF and DN inventory and t o t a l waste inventory. faci 1 i t y terminal cl eanouts have been completed. Only nominal vol umes o f very d i l u t e waste a re being received, which is reduced by the evaporator w i t h l i t t l e generation of DSSF.

By the end of FY 2000, a l l SWL pumping and Hanford

16. Increase i n DC inventory caused by pumping of complexed SWL i n 200 West Area a f t e r the s o l i d s h a v e been moved out of tank 241-SY-102 (December 1998).

__ . . . . .,, ~ .... . ,.. .. , _*_ , . . ".. 1 ,-. . I , , . ... ... .,. ~. , . - ." - ,_rr7 .-

FISCAL YEAR----->

BASELINE SPACE UTIL STARTING INVENTORY SPARE SPACE CONTINGENCY SPACE WATCH LIST TANK SPACE AVAIL. SEGREGATED SPACE AVAIL. PRIORITY/OPERATIONAL AVAIL. MISC. HEADSPACE AVAIL.

NEW WASTE ADDITIONS PUREX MISC. U03 B PLANT s PLANT T PLANT 300 AREA 400 AREA WSCF TANK FARM (LINE, ALC) EVAPORATOR FLUSHES PFP LAB W/ SOLIDS TK 101-SY DILN/RETRVAL

TK 106-C SOLIDS RETRVAL PUREX TCO (94-97) W/ FLUSH B PLANT TCO (97-2001) W/ FLUSH lOON TCO (95-99) W/ FLUSH PFP STABILIZATION SWL PUMPING W/O FLUSH IN-TANK WASHING OF 101-AZ SST SOLIDS RETRVAL 100 AREA FBH 107-AN CAUSTIC FAC.GEN.+SWL+x-site FLUSHES

TK 103-SY DILN/RETRVAL

NEW WASTE ADDITIONS TOTAL TOTAL WASTE BEFORE EVAP YEARLY CALC WVR FROM ABOVE CUM CALC WVR FROM ABOVE

*** ACTUAL EVAP WVR ******* *** CUM ACTUAL EVAP WVR *** **PRETREATMENT/VITRIF LOSS***

NET INVENTORY CHANGE

END OF YEAR INVENTORY

TOTAL CAPACITY

9/30/93

25507 2280

673 1038 1174 194

25507

31280 28.0

9/30/9:

9/30/94

22992 2280

0 726 605 1641. 66

22992

22992

28310 25.4

9/30/94

1995

22992 2280

0 726 584 2183

0 0 60 20 28

19.2 6 0

120 70 6 0 0 0

124.3 0

1241.2 0 99 0 0

112 50 95

2050.7

25042.

-4790 -4790

0

-2739.

20252.

26025. 23.4 1995

1996

20252. 2280

0 726

2094.7 2117

0 0

60 25 37

19.2 6 0

120 70 6 0 0 0

124.3 0

1241.2 0

1432 0 0

112 0

432 3684.7

23937.

-3820 -8610

0

-135.2

20117.

27335. 24.5 1996

1997

20117. 2280

0 726

1557.5 2087

0 0

60 30 47

19.2 6 0

120 70 7 0 0

800 0 99 0 0

1500 0 0 0 0

452 3210.2

23327.

-1600 -10210

0

1610.2

21727.

28378. 25.5 1997

1998

21727. 2280

0 726 1405 2251

0 0

60 30 49

19.2 6 0

120 70 7 0 0 0 0 99 0 0

1428 0 0 0 0

4 34 2322.2

24049.

-1670 -11880

0

652.2

22379.

29041. 26.0 1998

1999

22379. 2280

0 726

581.75 2548

0 0

60 30 68

19.2 6 0

120 70 7 0 0 0 0

99 0 0

1265 1000

0 0 0

397 3141.2

25521.

-2230 -14110

0

911.2

23291.

29426. 26.4 1999

2000

23291. 2280

0 726 447 2891

0 0

60 30 89

19.2 6 0

120 70 7 0 0 0 0 99 0 0

513 0 0 0 0

214 1227.2

24518.

-1450 -15560

0

-222.8

23068.

29412. 26.4 2000

2001

23068. 2280

0 726 447 1878

0 0 60 30 112

19.2 6 0

120 70 6 0 0 0 0 99 0 0 0 0 0 0 0 91

613.2

23681.

-550 -16110

0

63.2

23131.

28462. 25.5 2001

2002

23131. 2280

0 726 447 1854

0 0 5

30 135 19.2

6 0

120 70 6 0 0 0 0 0 0 0 0 0 0 0 0 96

487.2

23618.

-440 -16550

0

47.2

23178.

28485. 25.5 2002

2003

23178. 2280

0 726 447 1799

0 0 5

30 180 19.2

6 0

120 70 6 0 0 0 0 0 0 0 0 0 0 0 0

106 542.2

23720.

-480 -17030

0

62.2

23240.

28492. 25.6 2003

2004

23240. 2280

0 726 447 1399

0 0 5 30 180

19.2 6 0

120 70 6 0 0 0 0 0 0 0 0 0

800 0 0

106 1342.2

24583.

-840 -17870

0

502.2

23743.

28595. 25.6 2004

2005

23743. 2280

0 726 447 3630

0 0 5

30 180

19.2 6 0

120 70 6 0 0 0 0 0 0 0 0 0

1200 0 0

106 1742.2

25485.

-960 -18830 -2000

782.2

24525.

29608. 26.5 2005

2006

24525. 2280

0 726 447 3630

0 0 5

30 180

19.2 6 0

120 70 6 0 0 0 0 0 0 0 0 0

4000 0 0

106 4542.2

29067.

-2900 -21730 -3314

1642.2

26167.

29936. 26.8 2006

WHC-SD-W236A-ER-021 Revision 1

Appendix 3 - Page 17

WASTE TYPE AND NEEDS

Concentrated Waste

Supernate Liquid Waste from Site Generators

200W Receiver Tank 241-AW-102 and 241-AW-106 Evaporator Support

Spares

S1 udge Washing Demo

Impact of Evaporator Limits (Specific Gravity of 1.35 versus 1.5)

Impact of Higher Single- Shell Tank Liquid (Porosity of 0.45 versus 0.35)

Segregated Space **

Attachment 6

FISCAL YEAR 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005

14.8 15.2 16.1 17.5 18.3 17.9 18.0 18.1 18.1 18.2 18.7 17.1 9.1 5.8 4.8 5.0 4.9 5.0 4.8 4.8 4.8 4.8 4.8 6.5

*** *** *** *** . *** *** *** *** *** 1.2 1.2

2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3

2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 *** *** *** *** *** *** *** *** ***

*** *** *** 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

*** *** *** 0.0 0.2 0.3 0.6 0.8 1.0 1.1 1.1 1.1 1.1 1.1 1.1

*** *** *** *** *** *** *** *** *** *** *** ***

, 9

Passive Mitigation 241-SY-101 and 241-SY-103

TOTAL * * ** ***

NO PASSIVE MITIGATION

31.20 29.40 28.90 30.00 30.90 30.40 30.40 30.50 30.50 30.60 31.10 31.20

WASTE TANK VQkUME REQUIREMENTS IN MlhhlQNS QF GALLONS

28 double-shell tanks provide 31.28 million gallons of capacity Additional cost for hardware, safety analyses, and other impacts will be incurred Included with concentrated waste Val ues.