TRITIUM CONCENTRATIONS ‘IN ‘EFFLUENT WATER (pCi/1)

Walnut Creek

Date Pond A-1 — Pond B-4 _ Pond C-1 at_Indiana
8/22/74 os 4200 1200 * 3000
8/27/74 - 1400 3503 , 6000
8/28/74 - 634 625 2332
8/29/74 - 788 504 2401
8/30/74 - . 1180 _ 4125 1575
9/01/74 1512 1164 * 3136
9/02/74 2165 579 803 1834
9/03/74 — 1193 1296 (2042) 537 2228
9/04/74 5520 * 3568 552
9/05/74 * * 1606 *
9/06/74 2374 * * 1730
9/07/74 * * * x
9/08/74 * * * *
9/09/74 * * * *
9/10/74 1382 6374 * 2092
9/11/74 1063 962 513 2427
9/12/74 1986 1952 623 6186
9/13/74 1479 692 . * . 1362

¢ ) Replicate Sample
* <MDA


TRITIUM SMEAR SURVEYS

BUILDINGS 776-177 : °
DATE BLDG/ROOM BOX OR SYSTEM PL/SMEAR (MAX. )
9-05-74 T16-15h* 206-499 Molten salt 5,560
. ' inside box
9-06-74 116-205 205 Plenum - cold side < 100
T16-206 206 Plenum = cold side < 100
TIT-452 206-532 top of box < 100
206-536 < 100
' 206-538 < 100
255-043 < 100
206-542 < 100
206-543 . < 100
253-022 ye 163
253-026 . < 100
253-027 < 100
206-524 j < 200
206-517 < 100
206-522 < 100
206-523 < 100
206-524 < 100
206-525 < 100
203-663 < 200 ©
206-527 | < 100
206-528 < 100
206-530 L < 100
117-430 206-427 inside box 2h, 400
206-408 | 379 ,000
! | 206-448 . 123,000



SPECIAL ASSEMBLY - DRYBOX SMEARS

APPENDIX VIII


-6-

BOX OR SYSTEM

DATE BLDG/ROOM Pi/SMEAR (MAX. )
9-11-Th TT1-430 Box 373 82,400
Line 373-372 30,900
Box 372 141,000
Line 372-371 21,800
Box 371 8,130
371 Weights N 800
371 Scale > 157,000
371 Carriers 4,220
371 Balance 2,680
Line 371-370 64,700
Box. 370 57,100
“Line 370-367 29,900
Box 368 16,800
Box 367 25,400
Box 369 23,000
L Line 16,200
TT1-452 Floor at J-2h 460
. Floor at K-2k 4TO
Floor at L-2h 640
Floor at M-2h 780
Floor at K-25 560
tL Floor at J-25 : 950
TT1-430 Line 314 59 ,500
Box 329 560
Box 330 1,240
Box 331 2,080
Box 332 2,360



€

BUILDINGS 776 AND 777 VENTILATION OPERATIONS

8/02/74 “Checked out the control room "master" speed
controls for supply and exhaust fans.

Required speed changes on most major fans.

v 8/03/74 Completed steam outage at "C" pit. Welded
fittings into the high pressure condensate
* line to permit the discharge of condensate
from the 300 psi line into the 776 to 771
condensate line. (Not yet in service).

. Installed check valves in the preheat coil
condensate lines from systems 4, 6 and 2.

Overhauled the west reducing station.

This shutdown allowed all the 776/777 ven-
tilation systems to go to almost atmospheric
humidity. The inerted systems were the
only ventilation systems not affected.

~ 8/06/74 Booster #1 was curtailed for construction
‘ work, .
The final. stage of plenum 206 was tested
and the plenum is alright for service.

The Booster #1 curtailment was to install
a fitting on the second floor booster
ductwork to provide a method of using a
portable exhauster to assist in the forth-
coming shutdown.

8/07/74 The Booster #1 load which was temporarily
: handled by the GBDA exhaust plenum 205 was
switched into the new booster type exhaust
~ : plenum 206. Construction cut one day off

, their scheduled downtime.

Air is being pulled through the zone #2
ductwork and the supply plenum to cool the
oversized 205 exhaust fan and prevent excessive
negative on the GBDA boxes.


“URINE ANALYSIS

Tritium analysis are randomly performed on. 10% of our normal
Pu/Am urine samples. From these data, a baseline will be
established to indicate trends, If they exist. Specific tri-
tium analysis will continue to be made on employees working

In areas showing increased concentrations. Tritium urinalysis
results displaying total body exposures exceeding 1 mrem/week
will be accounted to the employées radiation exposure record
and appropriate actions taken when indicated.

Tritium urinalysis results, pertinent to the latest occurrence
are tabulated below, together with preliminary background data:

Identifications Area pci H3/2
998 777 - 15740 + 6100
869 777 25610 + 6100
510 777. 32320 + 6170
012 ‘ 777 21600 + 5800
548 777 22370 + 5800
680 777 15730 + 5640
801 707 13700 + 5370
180 779 24000
4hg 779 14000
112 707 17000

- Non Occupational - Denver 470

004 123 630 + 580


DATE BLDG/ROOM
9-06-74 “TTT=430
ad
9-06-74 776 Roof
TTT-43T
T1T-463
_
9-09-74 116-205
- T16-206
TTT-430
T11-452
TTT-430

~2-

BOX OR SYSTEM

Pi/SMEAR (MAX. )

206-452
206-454
206-456
206-457
E.B. Welder.
206-46h
206-4h2
206-369
206-438
206-370
206-362

Penthouse

Al

A-2

A-3

A-5

Conveyor line
A-T

* 205 Plenum (hot side)

206 Plenum (hot side)
Unit 36403/21410
Carrier 516

Unit 36403/21403
Carrier 545

Hydride Beaker

Unit 36403/21410
Unit 36403/2140

inside box

4,800

6,300
19, 800
88,700
353,000
13,400
105,000
12,900

3,880
20,800
42,800

_ < 200
110,000
4,800
9,400
1,200.
7,900
7,700

211,000
1,230,000
520
85,600

. 1,200
13,200
249 ,000
1,320

480


vipaw anne wu AOU UY

*

BOOSTER

ZONE I DEAD

ZONE 2 "BY BOXES & HOODS RM. 424
GRIT BLAST & HOOH) RM. 418
VACUUM PUMPS & HOODS RM. 416

ZONE 3 SUPER DRY DOWN DRAFT EXHAUST RM. 432
DEVELOPMENT COATING INERT EXHAUST
RM. 463
DISASSEMBLY LATHES RN. 430

NO. I 7

PLENUM
206

* PLENUM
204

ZONE 4 ‘SPECIAL ASSEMBLY DOWN DRAFT ROOMS
RM, 452
Be MACHINING HOODS RM. 452

’ ZONE 5 INERT SURVEILLANCE EXHAUST RM. 475

ZONE 6 SPECIAL ASSEMBLY SLOVE BOX LINE
RM. 452

SIZE REDUCTION RM, 146
INCINERATOR = -RM.-135

~ BOOSTER
NO. 2

INERT
201

MOLTON SALT RM. 15400. J3
FOUNDRY LINE RM. 135:

ZONE I SOUTH MACHINING LINE RM. 134°

ZONE 4 DEVELOPMENT MACHINING LINE RM. I3T

. PLENUM
205

GBDA
EXHAUST °

ZONE 2 INSPECTION GLOVE BOX AREA RM. 430

ZONE 3 - INSPECTION GLOVE BOX & DEVELOPMENT

COATING RM. 430 & 437

" REF. DRAWINGS NO. 13941-1 *
33941-2
3945-3


ROOM AIR SAMPLER - ROOM 452
SPECIAL ASSEMBLY - BUILDING 777

Sample 3 . 3
Date Volume/m' pCi/Sample pCi/m

5-31 5.94 56,000 . 9427.6
6-04 5.94 72,000 e121,2
6-03 5.94. 121,000 ; 20370.3
6-06 5.94 35,000 5892.2
6-05 5.94 98,000 16498.3
6-13 5.94 32,000 5387.2
6-12 6.15 "28,000 4552.8
6-11... 6.15 76,000 12357.7
6-10 6.37 89,000 13971.7
6-07 6.15 © 67,000 10894.3
6-20 5.52 24,000 4347.8
6-19 6.15 28,000 . 4552.8
6-18 6.57 "2,900 441.0
6-17 4,67 27,000 5781.5
6-14 6.15 42,000 6829.2
6-25 5.09 23,000 4518.6
6-24 6.37 Lost -
6-21 6.15 Lost --

7-01 6.37 22,000 3453.6
6-28 2.76 12,000 4347.8
6-27 6.15 33,000 5365.8
6-26 6.15 28,000 4552.8
7-05 5.94 23,000 3872.0
7-03 5.94 18,000 3030.3
7-02 6.37 25,000 3925.0
7-09 6.15 16,000 2601.6
7-10 . 6.15 28,000 4552.8
7-16 5.09 107, 000 21021.6
7-15 6.15 36,000 5854.0
7-18 6.15 31,000 5040.6
7-17 5.94 25,000 4208.7
7-23 5.94 6,000 1010.1
7-19 6.37 31,000 | 4866.5

7-22 6.37 31, 000 4866.5
.


*

TRITIUM CONCENTRATIONS IN AMBIENT AIR (pCi/m?)

On Site
Date

8/09-8/23/74
8/16-8/23/74
8/23-8/29/74
8/23-8/29/74
8/29-9/05/74
8/20-9/05/74

Off Site

8/16-8/23/74
8/23-8/29/74

M. R. Boss
9/20/74

S-80 (Pond A-1)
8-22 (Gate 12)
S-80

§-22

S80

S-22

Vol (m?) pei 3yyn3

20 1.4

10 1.1
8.9 5.1
8.9 <2.3
8.9 <MDA
8.9 _ <MDA

10 <1.4
8.9


AUTHORIZATION TO SHIP SS MATERIALS

o

APPENDIX V


TRITIUM URINANALYSIS
@e

_ APPENDIX III


Sample

Date ‘ Volume/m? pCi/Sample pei/m®
7-26 - 6.37 16, 000 2511.7
7-25 4,25 9,000 2117.6
7-24 6.15 19,000 . 3089.4
7-31 5.97 11, 000 1842.5
7-29 6.37 ; 11,000 1726.8
7-30 4,94 17,000 3441.0
8-01 5.73 13,000 2268.7
8-06 «5.08 6,000 1178.8
8-02 6.37 ~ 16,000 2511.7
8-07 6.37 4,000 . 627.9
8-09 * 6.37 8,000 -1256.0
8-08 6.15 .11, 000 1790.0
8-09 6.37 8,000 1235.9
8-13 6.37 | 9,000 1413.0
8-12 6.15 | 8,000 1300.8
8-15 6.37 <MDA

8-16 6.37 23,000 3611.0
8-19 6.15 15, 000 2439.0
8-20 6.37 20,000 3139.7
8-21 6.37 21,000 3296.7
8-22 "6,15 Lost --
8-23 6.15 18,000 2926.8
8-26 5.09 | 45,000 8840.0
8-27 6.15 19,000 3089.4
8-28 5.95 29,000 4873.9
8-29 5.52 22,000 3985.5
8-30 6.37 240 x 10° 37676609.0
9-03 6.37 7 x 10° 1098901.1
9-04 6.37 54,000 8477.2
9-05 5.09 26,000 5108.0
9-06 - Lost ; --
9-09 5.94 18,000 3030.3
9-10 6.37 20,000 3139.7
9-11 5.52 16,000 2898.5
9-13 6.15 29,000 4715.4
9-16 5,52 13,000 2355.1

9-17 20,3 33,000 1625.6


-5-

9/09/74 Health Physics entered plenums 205 and 206 .
to get samples for investigation.

#4 exhaust fan was put into operation. All
exhaust fans have now had the belt guards
revised to meet OSHA.

All supply systems now operable.

9/11/74 The special assembly glovebox dryer system
was removed from service to gather silica jel
samples. Back in service on the p.m. shift.

Samples were collected from the GBDA and
S-1, S-3/7, S-4 and S-8 Kathabar systems.

Experienced an upset on the Inert system.
Apparently it was caused by air lock leakage.

The data logger was repaired and returned to
service. It was necessary to replace the
analog digital converter board.


*

During the period August 23- 25 and August 30-September 2 excessive

humidity caused the. dry air systems (205,206) to contain

considerably more moisture than is normally present in these

effluents. A steam supply outage caused dryer shutdown ‘on

August 24 and the dryer capacity was deliberately reduced on

August 27 to conserve energy. Unseasonable rains, occurring at

this time, also aggravated the abnormally higher humidity.

; oe

Tritium contamination residing in glovebox lines, exhaust and

supply plenums could not be discounted as being contributory

to the increased contamination observed in other lines and

effluent exhaust. The releases were undoubtedly the result of

any one or more of the conditions cited. Additionally, analysis

of various drying agents reveal the presence of contamination

and illustrate that room air supplies are contaminated to some
extent. ‘

RECOMMENDATIONS

As the result of past experiences, recommendations for improving
the overall tritium handling program can be made. Some appear
fundamental or even trivial, but more importantly, all are
feasible and easily implemented.

1. Expedite the surveillance required to characterize the
tritium contamination levels known to exist in areas of
Buildings 776/777, 707, 771, and 774. In the absence of
complete information regarding the residual activity, it
becomes increasingly more difficult to specifically
determine the extent and location of additional tritium
contamination entering the Rocky Flats Plant from
incoming shipments.


8-02
8-05
8-07
8-09

812.

81h
8-16
819
821
823
8-26
828
8-30
9-03

9-04

to

to

to

to

to

to

to

to

to

to

to

to

to

to

to

8-05
8-07
8-09
8-12
Bib
8-16
8-19
8-21
8-23
8-26
8-28
8-30
9-03
9-04

9-06

‘TRITIUM SAMPLING RESULTS IN AUGUST

Concentrations in pei /m> (Multiply by 197}

TRA
1,972
4,460
4,ohg
2,455

. 59335

4,181
2,086
6,602

Lost
3,260
4,03h
3,183
1, bho
7,010

728b

362. 171-205
7 657
89 13

< Det 2,488

< Det 1,363
< Det 1,158

TH Lost

135 Lost
Lost < Det
< Det Lost
< Det < Det

5,911 139
cE) 1,182
1S 148,000

< Det

< Det 3,862

Integrated value for period

9-04 to 9-06

1,305

2 to obtain uci /m2)
T1-206 TIT Spec Assy = Fm Air TTB
2,268 3 2,512 20,700
1,179 3 628 23,000
1,789 3 1,256 20,700
1,300 3 1,413 18,400
° Lost. ~ 25,300
Beg 3 3,611 23,000
3 2,439 23,000
3,240 25,300
3,297 3 Lost 30,000
2,927 ; 8,841 27,600
3,100 ; 4, 87% 25,300
3,986 ; 25,300
86 31.7 x 10° (8-30) ., 723,000
"2,020 aa x 10° 877 ~2h,000
(9-03) (9-04) »
2,326 4,081 (9-05)
3,42


. . : . a CLASSIFICATION
i Cae Toe UNCLASSIFIED

OOW CHEMICAL COMPANY U.S.A.

: ; ROCKY FLATS DIVISION aN
peo GaLDEN, coLeRuo “fee Lr - ey) i

AUTHOR! ZATION To SHIP $s MATERIALS

Oare__June 19, 1974 . : No, - 1993
SHIPPER : o CO, : . ii
STATION Battelle, Pacific Northwest Laboratory ris___| HyA : r

Aboress, P.O. Box 999 i : . i
, Richland, Washington 99352 _ “
Requesteo Suiprinc Dare Ready to shin: awaiting approval :

Hl

i

. - i

SIGNATURE OF AUTHORIZED REPRESENTATIVE _ i i

i|

. - 4

ts GENERAL MATERIAL DESCRIPTION x . 4
hho SS Material (CHemicat Etemenr) Plutonium Gross Quanyiry_301 grams j
on Puysicat Description___Pu metal - unalloyed ° i I
be | CHemicar DESCRIPTION, a Puy 4

: Princieac tweurtties___ Normal for weapons grade Py < i.
\ MATERIAL ORIGINATION (PLEASE CHECK) RF; Ait: arnco;,  [KJenwi; | |

: LASL; LLL; OrweR,

, , : foe | oO 5

i MATERIAL HISTORY . . re : . ty 4
2 HAS THE MATERIAL BCEN EXPOSED TO ANY OTHER RADIONUCLIDES, SUCH 43-F1S810N ProoucTs, OTHER acrimocs, ap
| . TAITOUM, ETC.? (Yes or No). NO a i . i

Ir Ves, OESCAIBE IN DETAIL THE CONDITIONS IN WHICH THE MATERIAL was ‘Exroseo ON A SEPARATE Succ. ed
HAS THE MATERIAL COME IN CONTACT WITH ANY MAZAROOUS MATERIAL on -yridendo “Umusuan, PRocessine on H

restst (Yes on No)__NQ |

UF VES, OESCRIGE IN DETAIL THE HAZARDOUS MATERIAL PROCESSING OR TESTS ON A SEPARATE SHECT.
WHAT 18 THE rorM oF THE waTeRiac?_ Metal piece C past

Stanature of SHipeca's TecHNicaL REPRESENTATIVE, = not “available for signature
i
! 1 i
METHOD OF PACKAGING Ve 4
Oursioe Container Tyec_AEC-AL-USA 5332 BF - Approx. No. One. :
Iusioe Container Tree__RF Pump down can Approx. No.___One

OrHer Container Inronmation_Evacuated and refilled with high purity gas.
Hazanos Inctuoine Secci at Paccautions_Open pump down can_on down grate table

4 a t
DOw RECEIVING APPROVAL : . L he ‘ .
Revieweo For Process ComPaTiBiLiTy, _ bfoy fry
pomorigee TecWareal REPRESENTATIVE:

: se ATE
: . APPROVED FOR SHIPMENT .ON, ops [ok By, _ fa tof ¥

AuTHORIzE6 SS REPRESENTATIVE DATE

“ CLASSIFICATION
RF-43940 (10473) : UNCLASSIFIED

DestRoY PREVIOUS. 1SSUC



PLENUM
206

PLENUM en

204

* BOOSTER
NO. 2

j
nN
: PLENUM
205

os)

CLD DUYOIEK.NU. 2 LUAU IU FLENUM Z£U0 AUL. /,19/4

ZONE I

ZONE 2

ZONE 3

(TeMPoRARY)

ZONE 4

ZONE 5
ZONE 6

as ae

D

HOS

DEAD

"BY BOXES & HOODS RM. 424
GRIT BLAST & HOOD RM. 418
VACUUM PUMPS & HOODS RM. 416

SUPER DRY DOWN DRAFT EXHAUST FM. 432
DEVELOPMENT COATING INERT EXHAUST
RM. 463 .

DISASSEMBLY LATHES RM. 430

SPECIAL ASSEMBLY DOEN DRAFT RCOMS
RM. 452

Be MACHINING HOODS RM, 452

INERT SURVEILLANCE EXHAUST RM. 475

SPECIAL ASSEMBLY GLOVE BOX LINE .
RM. 452 °

{ SIZE REDUCTION RM. 146
[INCINERATOR RM. 135.

MOLTON SALT RM. 154
FOUNDRY LINE RM, 139:

| ZONE I SOUTH MACHINING LINE RM. 134°
ZONE 4 DEVELOPMENT MACHINING LINE RM. 131
ZONE 2 INSPECTION GLOVE BOX AREA RM. 430 |
ZONE 3 INSPECTION GLOVE BOX & DEVELOPMENT -
Li COATING RM. 430 § 437

REF. DRAWINGS NO.- 13941-I 4

13941-2
13941-3


GBDA EXIAUST TO Booker NO. I MAY 14,1973

BOOSTER
NO. I

*

ZONE I DEAD °
ZONE 2 "BY BOXES § HOODS RM. 424
GRIT BLAST & HOOD RM. 418
VACUUM PUMPS-§ HOODS RM. 416

ZONE 3 SUPER DRY DOWN DRAFT: EXHAUST RM. 432
DEVELOPMENT COATING INERT EXHAUST
RM. 463
DISASSEMBLY LATHES 2M. 430

NO. 2

VERT

er

5
Nov

aS

- BOOSTER | a

ZONE 4 SPECIAL ASSEMBLY DOWN DRAFT ROOMS
RM. 452
. Be MACHINING HOODS RM. 452

ZONE .S .INERT SURVEILLANCE EXHAUST RM. 475

| ZONE 6 SPECIAL ASSEMBLY GLOVE BOX LINE

RM. 452

SIZE RELUCTION RM. 146
INCINERATOR RM. 135

MOLTON SALT RM. 154
FOUNDRY LINE RM. 135}.

ZONE I SOUTH MACHINING LINE RM. 134

ZONE 4 DEVELOPMENT MACHINING LINE RM. I31

ZONE 2° INSPECTION GLOVE BOX AREA RM. 430

ZONE 3 INSPECTION GLOVE BOX § DEVELOPMENT

-COATING RM. 430 & 437

REF. DRAWINGS NO. 1394I-I-
: _ 13941-2
1394-3


ENVIRONMENTAL SAMPLE RESULTS
e

APPENDIX II


ZONE I DEAD

ZONE 2 ."B' BOXES & HOODS 8M. -424
GRIT BLAST & HOGD RM. 418°
VACUUM PUMPS § HOODS RM. 416

ZONE 3 SUPER DRY DOWN DRAFT EXHAUST TM, 432
DEVELOPMENT COATING INERT EXHAUST .

RM, 463 ;
; . | DISASSEMBLY LATHES RM. 430
-ZONE 4 SPECIAL ASSEMBLY DOWN DRAFT ROOMS
; . RM, 452
PLENUM . Be MACHINING HOODS RM. 452
206 ZONE 5 INERT SURVEILLANCE EXHAUST RM. 475
ZONE 6 SPECIAL ASSEMBLY GLOVE BOX LINE -
RM. 4520
. tee . , .
PLENUM ; SIZE RECUCTION RM. 146 te
204 — INCINERATOR RM. 13S ~fivin Sen
. inn a MOLTON £ALT RM. 154 _
RaeR FOUNDRY LINE RM. I3HE
ZONE I SOUTH MACHINING LINE RM. I34.
INERT _J . ZONE 4 DEVELOPMENT MACHINING LINE RM, I3I
201 + der —
. ZONE 2 INSPECTION GLOVE BOX AREA RM. 430
PLENUM =
205 _ "ZONE 3 INSPECTION GLOVE BOX & DEVELO?MENT

COATING RM. 430 & 437

REF. DRMWINGS NO. 3941-1
13941-2
13941-3


ITEMS REMOVED FROM SPECIAL ASSEMBLY LINE
o

APPENDIX IV


TRITIUM RELEASE ~ CIRCA 1974

ECR 317311-105
°

December 13, 1974

M. RK. Boss
F. D.Hobbs

Environmental Control

Distribution : . KWIC Index

R. D. Forest Contamination
M. A. Thompson/ EMF Surveillance
G. J. Werkema Tritium

IRF (Record) Ventilation


DATE. BLDG/ROCM
9-11-Th TT6-4h0 -
116-432

-8-

BOX_OR SYSTEM

Pi /SMEAR (MAX.)

Floor

Floor K-20
Floor H-19
Floor H-20
Floor K-19

#1 System Kathene
#4 System Kathene
#3/7 System Kathene
#8 System Kathene
GBDA System Kathene

e
2,000

500
1,460
T10
520

160,000 = ome
400,000 = 0.8

450,000 = «4

140,000 = 0%

400,000 = 0.7
a

BB me


10.

11.

12,

13.

‘production buildings Inakes the acquisition of liquid

*
The increased emphasis on routine tritium monitoring in the

scintillation counters desirable in the supporting
laboratories. °

Since Rocky Flats has agreed to accept materials slightly
contaminated with tritium, the routine tritium urinanalysis

program should be continued with periodic data evaluation.
4a

Install continuous tritium monitoring instrumentation in

those operations having a release potential. (Specifically,
the special assembly areas of Building 777.)

Develop procedures and provide facilities for decontaminating
shipping containers and other equipment. There appears to

be a significant cost savings involved in doing this.
‘

The reduction of dryer capacity in building air supply
systems to save energy is of dubious value. This practice
should be eliminated until the benefits become more obvious.


With the exception of retirement pits, recycle plutonium
buttons, and oralloy tomponents, all other incoming
shipments of SS material must be evaluated for tritium
contamination, e

The tritium detection program should be expanded to
include individual pressure vessels and other shipping
containers. This program, in its present form, heavily
relies on ‘administrative controls to prevent the shipment
of tritium-contaminated SS material to the Rocky. Flats
Plant. Historically, it is known that SS materials have
been shipped to Rocky Flats in containers contaminated
with tritiun.

Expedite the construction of the tritium surveillance
area planned for Room 431, Building 777.

‘
Expand the overall surveillance program to include
non-SS materials shipped to Rocky Flats from other
USAEC contractors. :

Standardize the collection, flow rates and apparatus
in those samples used for tritium analysis.

Cross-contaminated sampling apparatus, resulting in the
loss of data, points to the extreme care that must be
exercised to obtain valid sample results.

All containers used in shipping SS materials should be
physically identified by number. These container numbers
should likewise appear on the authorization for shipment
(Form RF-43940, see Appendix V). This additional
information would be invaluable in documenting the history
and usage of these containers.


DATE BLDG/ROOM
9-10-74 T1430
e
‘
i L

116 - Size Reduction

T16-201

oh

BOX_OR SYSTEX

Line 589-462
Box 462 °
Box 466 -
Line 462-452
Line 356-357
Line 357-316
Box 316

line 316 E
line 316 W
Line Box 360
Box 360

Line 360-361
Box 362
Line 361-362
Box 362

Line 362-328
line 364
Line 440
Line 328
line 325 E
line 325
Conveyor to 443
Box 166

Box 515

Box 163

Box 161

_ Box 505

Filters
Floor
Floor

PL/SMEAR (MAX)

eo
20,600
17,500
10,200
6,4h0
160,000
318,000
13,000
413,000
182,000
28,420
45,600
160,000
120,000
_ 226,000
121,000
163,000
725,000
138,000 .
73,900
T4, 100
24,900
255,000
18,000
15,200
221,000
6,480
25200

9,760
< 500
1,200


TRITIUM SAMPLING RESULTS IN AUGUST

APPENDIX VI


ns

yan r4 ae log

Resiven _ Mh inten

cern sed), b

Me mae HARD ,1477-81-

Responsible Individual ~
Intended Use?

a8 190
“ SWL 2ST WG

Asal

if
2 A
a
ut



GB0A To PLENUM 205 FEB: 11,1974
. . e

BOOSTER
NO. I

PLENUM
206

* PLENUM”

ZONE I

ZONE 2

ZONE 3

ZONE 4

ZONE 5
ZONE 6

L.

204

* BOOSTER

NO. 2

INERT
201

PLENUM
205

GEDA —
EXHAUST

—
ZONE I

ZONE 4

ZONE 2

ZONE 3

‘DEAD

““'B" BOXES § HOODS RM. 424

GRIT BLAST §& HOOD RM. 418
VACUUM PUMPS & HOODS RM. 416

SUPER DRY DOWN DRAFT EXHAUST RM. 432
DEVELOPMENT COATING INERT EXHAUST
RM. 463

DISASSEMBLY LATHES RM. 430

SPECIAL ASSEMBLY DOKN DRAFT ROOMS
RM, 452

Be MACHINING HOODS RM. 452

INERT SURVEILLANCE EXHAUST RM. 475

SPECIAL ASSEMBLY GLOVE BOX LINE -
RM. 452 cot .

{SIZE REDUCTION RM. 146
INCINERATOR = RM, 135

MOLTON SALT REL i154
FOUNDRY LINE R¥. 135

SOUTH HACHINING LINE RM. 134°
DEVELOPMENT MACHINING LINE RM. I3I
INSPECTION GLOVE BOX AREA RM. 430

INSPECTION GLOVE BOX § DEVELOPMENT
COATING RM. 430 & 437

REF. DRAWINGS NO. 3941-1

13941-2
13941-3


Date

8/09/74 (0.18")
9/02/74 (0.40")
9/12/74 (0.15")

Locations

T-4
T-5
T-8
T-10
T-50
T-51

*. <MDA

M. R. Boss
9/20/74

TRITIUM RAINOUT (pCi/1)

T-4 T-5 T-8 T-10 T-50 T-51
1886 1267 515 * 1246 3043
1390 749 1037 * 46322 1219
* * * * * 523

eo

North of Building 771 at fence
East of Building 771 at fence

East of fence

East of Building 444

Northeast of Building 995 at fence
East of Building 776/777


DATE BLDG/ROOM
 g-0l-Th T11/452
a -
9-05-74 TIT/452
9-10-71 TTT/452
i} L

H2e.

BOX NO.

206-512
206-510
206-507
206-505
206-504
206-529

206-531.
Conveyor belt
206-532 °

206-530

206-542
206-548

206-541
206-531

pCi /SMEAR

(MAX. )

2,870,000
1,060,000
6,590 ,000
4,240,000
1,640,000
488,000
-4Ok ,000

10,200,000

339,000
122,000

91,400
300,000

2,260,000
5590 ,000


TRITIUM SMEAR SURVEY
o

APPENDIX IX


- . CLASSIFICATION =

. UNCLASSIFIED
OW CHEMICAL COMPANY U.S.A. Se an
ROCKY FLATS DIVISION , as
GOLDEN, COLORADO
eb cu Repro 223)
AUTHORIZATION TO SHIP SS MATERIALS |
. . . : . of aoe
oare__dune 24, 1974 oo No. . 1204
SHIPPER : . |
STATION battelle, Pacific Northwest Laboratory. , ris HYA-

Avoress__P.0. Box 999

Richiand, WA 99352"

Requesteo SuipPinG Dare, About July 15, TST

SIGNATURE OF AUTNORIZE£0 REPRESENTATIVE

GENERAL MATERIAL DESCRIPTION
SS Marcarac (CHemicat Evcment), Plutonium

Puvsicat Description Pu metal - unalloved

Gross ‘buanrity 12_grams

CuemicaL Descri Prion,

Pu
Principat Impurities Normal for this grade of Pu

LASL; LLG;- Orner,

MarertaL ORIGINATION (PLEASE CHECK) Ht. Bit Fost (ewe: i

MATERIAL HISTORY.

HAS THE MATERIAL BEEN EXPOSEO TO ANY OTHER RADIONUCLIDES, SUCH AS FISSION provucts, OTHER acrimipes,

TRiTbUM, ETC.? (Yes or No). No.

ir YES, DESCRIBE IN DETAIL THE CONDITIONS IN WHICH THE MATERIAL was ‘exrosto ON A SEPARATE SHEET.

Has THE MATERIAL COME 18 CONTACT WITH ANY HAZAROOUS MATERIAL OR ‘unverdone” UNUSUAL PROCESSING OR

tests? (Yes or No). No”

|.

IF YES, DESCRIBE IN DETAIL THE HAZARDOUS WATER) Ai “PROCESSING OR TESTS ON A SEPARATE swcer.

WHAT 18 THE FORM OF THE MATER! AL?_

Stanarure of SHipper's TECHNICAL REPRESENTATIVE __

METHOD OF PACKAGING : uae
Qutste Container Tyee AEC -AL-USA 5332 BF APPROX. NO.

]_- not available for signature

One

Instoe Container Tyec__RF Pump down can Aprox. No.

One

Orucr Container Inrormation_evacuated & refilled with high purity gas.

Hazaros inccuoine Secciac Precautions None

"Note" This item is a sample from and will be ‘shipped in the same container with the

Jtem described in request No. 203.
DOW RECEIVING APPROVAL

Dow RECEWVING

Reviewco FoR Process CompatiBiLity,

AUTHORIZED TECHNICAL REPRESENTATIVE

Approveo ror SHIPMENT, ON, Wh cl By, .
. AUTHORIZCO SS REPRESENTATIVE

CLASSIFICATION

LLUNCLASSIFIED

RF-43940 (10-73)

Destroy PREVIOUS ISSUE

plaboy

7

\
i
i

Oate

ate



Elevated room air samples were collected in an area immediately
adjacent to the downdraft reom in which the shipping containers
were opened. However, the validity of the elevated room air
samples could. not be absolutely confirmed due to a suspected
cross-contaminated sampling apparatus.

The other portion of the investigation centered around the
possibility of residual contamination from the July 1973
incident, and proved to” be complex due to the extensive
modification of Building 776/777 exhaust systems in recent
months. These modifications eliminated the existing glovebox
dry air'‘systems and booster-type systems one and two. These
systems were replaced by four distinct exhaust ventilation
systems, During the course of these modifications, a myriad

of construction and operational upset conditions were
experienced. These upset conditions generally include excessive
positive/negative glovebox pressures, excessive leakage between
exhaust systems as the result of cross-connections, temporary
ducting connections between systems to obtain air balance or
cooling within a system and excessive building humidity. A
chronology of the ventilation operations thought to be
“pertinent is included as Appendix I.

Construction modification to the effluent ventilation system
is shown in the accompanying diagrams. Two new exhaust plenums
were constructed in 1974, As shown, System 205 was placed in
service in February 1974 and exhausted the dry air glovebox
system in Building 776. At this time, exhausted air from the
special assembly room was diverted, via temporary ductwork,

to System 205 and this condition persisted until early August
when Plenum 206 was completed. This temporary connection
between 205 and 206 explains the tritium contamination found
in both systems.


DATE BLDG/ROOM BOX OR SYSTEM Pi/SMEAR (MAY. )
9-211-Th TTT-430 Box 334 * 2,880
Line 307-324 4,960
Line 308 8,200
Box 318 2,360
Box 314 28,800
Box 324 67,700
Box 312 20,900
Box 323 7,360
Box 311 74,900
Box 321 23, 300
Line 321-320 23,900
Box 320 3,280
Box 309 1,720
Box 206-447 _ 226,000
176-250 Plenum Floor < 100
L Plenum Fan < 100
116-252 Plenum Floor 465
L Plenum Filter 1,636
116-S-8 Plenum Filter < 100
L Plenum deep beds < 100
* 116-S-7 Plenum Filter “< 100
tL Plenum Floor < 100
TT6-S-4 Plenum Filter < 100
116-252 Plenum Floor 3,625

~

Plenum Filter

3,603


DATE.

9-12-74

BLDG/ROOM.

+ TTI-430

L

TT1-43T
TT1-463

T1T-43T
L

“1171-452

” 716-Booster II

-5~ -

: ° :
BOX OR SYSTEM Pi /SMEAR (MAX. )

Box 447 31,300
Box 431 13,800
Box 432 4,2h0
Box 4hs5 18,200
Box 443 2,680
Box hhh 472,000
Box 434 8h , 800
Box 4h3 120,000
Box 435 167,000
Box 4h2 145,000
Box 436 96,400
Box 437 117,000
Box 438 _ 46,300
Box 439 32,000
Box 366 7,840
Box 365 12,300
N. Conveyor - 46,300
Box A-4 20,300
Box A-6 5,640
252-082 9,040
Silica Jel dwyer ~ seeth (my) << 100: 136 mans
Filters “y60
Floor < 100


8/07/74

8/09/74
8/12/74.
8/14/74
8/16/74

through
8/18/74

8/23/74

-2-

At this time the 205 plenum was connected
to loads handled by the original GBDA
exhaust plenum and the 206 plenum was |
connected to loads handled by the original
Booster #1 plenum.

A meeting was held to schedule the shutdown

for the inert tie-in and the GBDA start up.
e

The GBDA controls were prepared for start

up.
Went into shut down conditions for inerting.

Construction worked overtime and completed
the shutdown work.

The GBDA system was put into service followed
by the Inert system.

‘
Excessive leakage between the Inert system and
the GBDA system caused trouble. A cross
connection was located Saturday, August 17,
1974.

The GBDA system could not be operated in
fully automatic condition because the. leakage
through the vortex vanes more than equals

the amount of supply that can be forced into
the system.

The temporary supply duct from GBDA zone #3
to the super dry intake was put into service
and the super dry room was worked down to a
minus 36°F dewpoint for the Killdeer project.

Decontaminated the top of plenum 205 and the
GBDA zone #3 safety disk. The supply line
is hot and when the safety-disk lifts there
is a contamination potential. The safety
disks will be removed.


9/02/74

9/03/74

9/04/74

9/05/74

9/06/74

9/07/74
9/09/74

~4-

Had a data logger on control room negative.
The building negative was alright.

Kathabar representative was here to check
out S-S Kathabar. S-S was operated at
high fan speed with Kathabar in operation.

#1 exhaust fan in high speed.

. :
S-5 back on slow speed, Kathabar off: #1
exhaust fan back to medium speed,

4:00 p.m. - Attempted to put #3 main exhuast
fan on. Could not start it.

5:55 p.m. - #4 main exhaust shut down on
overheat. Put #1 and #2 exhaust fans on
high speed. : ,

9:04 p.m. - #4 exhaust on the line in medium
speed, #1 and #2 exhaust fans in medium
speed.

11:04 p.m. - Data logger failed. It was
out of service until September 11, 1974.

Exhaust fan #3 back in service. Problem had
been caused by a mislabeled control circuit
breaker.

Shut down #5 and #8 Kathabars, The #4 main
exhaust fan was down for cleaning.

Health Physics checked plenums 205 and 206
for tritium.

S-9 shut down for painters.
S-4 Kathabar off. Not needed.

DOP tested the S-3 supply system HEPA filter
bank. .


©

persons in the vicinity of the Rocky Flats Plant were not exposed
to tritium levels above normal background... The fact that the
incident did occur indicates the possibility of future incidents,
possibly of greater magnitude, and the need for improved, diligent
monitoring to preclude receipt of unknown contamination from
other USAEC sites.

DISCUSSION

Immediately upon indication of elevated tritium concentrations in
effluent air from Building 776/777, an investigation of the causes
was initiated. The possibility of the receipt and processing of
a tritium-contaminated shipment or buildup of residual contami-
nation from the July 1973 tritium incident were both considered.

It was learned that elevated room air concentrations of tritium
were detected in the special assembly area of Building 776/777,
although these elevated concentrations could not be related
specifically to the time period of the effluent air releases.
It was further learned that two separate sealed shipping containers
were opened in the special assembly downdraft room on August 29.
These containers had been received from BNWL on July 17, 1974.
One contained parts, while the other contained samples from the
parts. Following verification of weights, the samples were

‘ immediately repackaged for shipment to Lawrence Livermore
Laboratories on September 4, 1974. The parts were subsequently
placed in the production stream for recycle.

Tritium analysis of the shipping vessel containing the samples
showed 1.33 x 108 pCi tritium/smear, while the vessel containing
the parts showed 1.16 x 104 pCi tritium/smear. The fact that
the container with small samples of the part had the highest
contamination level indicates the pressure vessels, and not the
material contained in the vessels, were contaminated.


SMEARS IN DRYBOXES IN SPECIAL ASSEMBLY

. . pCi /SMEAR
DATE BLDG/ROOM . BOX NO. (Max. )
8-29-74 T1T/452 206-548 2,515,000
T1452 . 206-542 Possibly lost
206-513 Possibly lost
“206-512 ‘ Possibly lost
253-030. Possibly lost
024-029 Pass thru Possibly lost
253-029 Possibly lost
253-028 Possibly lost
253-027 "887,000
‘ 206-531 14,400,000
8-30-74 111/452 253-024 11,000,000
! o 253-023 2,380,000
H 253-022 2,500,000
206-525 1,770,000
206-524 502,000
206-522 ; 210,900,000
L L .
9-03-74 . TT1/452 206-542 39,600,000
i . 206-538 7,890 ,000
| : 206-537 | 71930 000
: 206-536 154,000
253-032 231,000
206-527 644,000

Lo : L 206-528 1,420,000


ITEMS REMOVED FROM SPECIAL ASSEMBLY LINE

s

DATE ITEM DISPOSITION »Ci/SMEAR
8/2 30923-5987 Molten Salt 776 8000
; DDH-118 Module J Bldg 707 1700
DDH-120 Module J Bldg 707 1000
DDH-122 , Module J Bldg 707 6000
DDH-129. _ Module J Bldg 707 8000
8/5 U-602-3231 " Serap 900
U-602-3219 Scrap 300
53037-6500 ‘Scrap 600
53049-10170 Scrap 5000
8/6 U-622-6039 , Offsite Shipment 2000
U-622-6080 Offsite Shipment 8000
8/13 U-203-6693 Recycle 3000
8/14 U-206-7215 Molten Salt 776 7000
DDH-108 Module J Bldg 707 7702
30923-1823 Molten Salt 776 6619
U-202-8126 Scrap 4000
11404-18903 Scrap 547
11803-19801 Scrap 1119
11402-18903 Scrap 2310
Can Sampling Fixture Prod. Surv. 779 1216
8/20. Coupons, 27 ea. Pu Met, 779 7000
8/14 U-206-7215 Scrap, Recycle 7000
8/20 30501-4214 Scrap 3000
30501-3503 Scrap 4000
TAB-1-C-31202 Vault 707 9963
8/23 U-204-6699 Scrap, Recycle 5000
8/14 U-203-6693 Scrap, Recycle 3000
8/20 Coupons, 4 ea, Pu Met, 771 1260

MRB: 9/24/74

°


! TRITIUM RELEASE - CIRCA 1974
; M._R. Boss, F. D. Hobbs

During the period August 30 to September 4, 1974, approximately
1.3 Ci of tritium was released via air effluents from Building
776/777, Subsequent sampling confirms that tritium concentra-
tions returned to normal levels after September 4,

Three possible causes of this incident were considered. One;
the release may have been the result of buildup and subsequent
release of residual tritium from the July 1973 tritium incident.
Two; it may have been caused by a recent receipt of tritiumn-
contaminated materials. Three; a combination of circumstances,
involving both residual buildup and additional source material.

Regardless of the cause of this release, there was no significant
elevation in ambient air or water tritium concentrations. There
was only a single rainwater sample collected during this time
period in which a detectable increase in tritium concentration
above backgreund was detected. Independent analysis by the
Colorado Department of Health confirms these findings. Also,
specific tritium urinanalysis on operating personnel who may
have been exposed indicates no measurable increases.

SUMMARY AND CONCLUSIONS

The specific cause of the tritium release could not be absolutely
determined. One possible source was a sealed shipping container

in which samples’ were received from Battelle Northwest Laboratories
(BNWL). "However, tritium contamination residing in glovebox

lines, exhaust and supply plenums from the previous major tritium
incident in 1973; cannot be totally discounted as the cause or

at least being contributory. One significant fact relating to

the recent tritium incident remains that no operating personnel
received an exposure as indicated by urinanalysis. Also,

.

! vi-


ROOM AIR SAMPLES - SPECIAL ASSEMBLY

APPENDIX VII


DATE BLDG/ROOM
9-10-74 TT1-452
TTT-430
[.

BOX OR SYSTEM

_ OL1 on floor 206-536

206-400 -' inside box
206-399
206-ho9
206-398
206=426
206-408
206-397
206-396
206-427.
206-405
206-40
206-395
206-129
206-448
206-430
206-447

Box 454

Line 454-452
Box 452

Line 452-451
Box 451

Line 454-456
Box 456

Line 456-457
Box 457

Box 458

Box 459

Box 059

Line 457-589
Box 589

Pi /SMEAR (MAX)

< 100
16,200
47,500

149 ,000
92,300
7,6h0
46,600
35,200,
10,300
62,800
Th, 800
221,000
27,700

6,960
15,100
12,000

7,680

5,840
- 3,960

4,960
32,700
69,100

1,120

920

6,040
32,500

8,720
244,000
231,000
338,000
123,000


co


o

BUILDING 776 AND 777 VENTILATION OPERATIONS

APPENDIX I


8/23/74 The outside air intake of supply system #5
was found to be hot. (Decontaminated Monday, *
August 26, 1974).

The Inert system area #2 supply line was shut
down so construction could make some corrections
to the system,

8/24/74 : Steam shutdown to install check valves in the

condensate lines-of the remaining supply system
preheat coils. ,

This shutdown allowed all ventilation systems
except the Inert systems to go to atmospheric
humidity. .

8/26/74 ‘The Killdeer project is completed.
The S-5 system was started up.

' .
8/27/74 Started cutting back on dehumidification and
power consumption in Buildings 776 and 777. |

Completed the filter plenum fire detection
tests. Several small faults were noted and
repair requests were issued.

Completed the bimonthly safety checks.
DOP tested the S-S supply HEPA filter bank.

Filter Technicians started the decontamination
of the Booster #2 filter plenum.

The cut back on dehumidification was excessive
and the following day Supply Systems #1, #4,
#7 and #8 Kathabars were returned to service
to partially dry out the building.

8/31/74 Cleaned exhaust fans. This required shutting
down the individual main exhaust fans and
increasing the flow carried by the other
three.