This document is the program plan for the Effluent Treatment Facility (ETF) dangerous waste tank system integrity management. Corrosion rates and remaining life of the process equipment is estimated to support a planned replacement strategy that minimizes plant shutdowns. The data inputs for managing plant integrity include: Flowsheet chemistry – Concentrations of stainless steel corrosion threats (process chemistry and temperature) are assessed for both historic and future operating campaigns. Laboratory testing – The corrosion chemistry is simulated with laboratory work to estimate general corrosion rates and susceptibility to pitting or cracking. Integrity inspections – Data from ultrasonic testing, visual inspections, and leak checks are documented to assess past and current status of vessel integrity. ETF integrity program – The inspection frequency and protocol for future inspections are established in the context of prior findings and anticipated corrosion rates. Independent Qualified Registered Professional Engineer (IQRPE) assessments – Results from prior IQRPE reviews are referenced and summarized. Relevant integrity inspection data is provided or referenced for the next IQRPE assessment in fiscal year (FY) 2019. This integrity program plan provides an engineering approach to monitor corrosion rates on an ongoing basis and an evolving estimate of the remaining useful life for each process vessel in ETF. Preliminary estimates indicate that the Secondary Waste Receiving Tank B and Second Reverse Osmosis Feed Tank will likely require repair/replacement prior to the completion of the ETF mission. Replacement strategies and materials of construction are identified to support continued operation and future support of the Hanford Waste Treatment and Immobilization Plant. Figure ES-1. Integrity Activities SUMMARY
Reaction cylinders 0-43 gal/min < 43.3 gal/min Teflon-coated aluminum Design Infoa Set Valuesc Hydrogen peroxide decomposers 40–90 gal/min 85 lb/in.2 Outlet 100 lb/in.2 Inlet 160°F 175 gal/min combined 150 lb/in.2 gauge 180°F CS with ester lining Design Infoa Set Valuesc pH Adjustment Tank pH adjustment tank 0 lb/in.2 gauge 90–140°F 0 lb/in.2 gauge, 200°F 304/304L SS Design Infoa Set Valuesc pH adjustment tank pumps 100-120 gal/min 110-120 lb/in.2 gauge 90–140°F 150 lb/in.2, 140°F Operating Proceduree Set Valuesc Degasification Column Degasification inlet cooler 86–140°F 316L SS Training manuald Degasification vessel 86°F 175 gal/min, ±12 in. H2O at 100°F FRP Degasification transfer pumps 30 – 50 lb/in.2 gauge 86°F 175 gal/min, 45 lb/in.2 316 SS Design Infoa Operating Proceduree Reverse Osmosis System First RO feed tank 0 lb/in.2 gauge 50-90°F 0 lb/in.2 gauge, 120°F 304 SS Design Infoa Set Valuesc First stage RO feed pumps 250 – 300 lb/in.2 gauge gal/min 50-90°F 600 lb/in.2 gauge, 120°F SS Design Infoa Set Valuesc Operating Proceduree First stage membrane vessels array 1 100-270 lb/in.2 gauge Inlet 30-120 lb/in.2 gauge Brine <10 lb/in.2 gauge Permeate 70-120 gal/min Brine 60-90 gal/min Permeate 60-90°F 600 lb/in.2, 113°F Design Infoa Set Valuesc Operating Proceduree 290
First stage membrane vessels array 2 170-370 lb/in.2 gauge Inlet 100-325 lb/in.2 gauge Brine 15 lb/in.2 gauge Permeate 15-30 gal/min Brine 60-95 gal/min Permeate 60-90°F 600 lb/in.2, 113°F Design Infoa Set Valuesc First stage RO booster pumps 170-370 lb/in.2 gauge 75–200 gal/min 60-90°F 370 lb/in.2 gauge, 120°F, 200 gal/min SS Design Infoa Set Valuesc Second RO feed tank 0 lb/in.2 gauge 60-90°F 0 lb/in.2 gauge, 120°F 304 SS Design Infoa Set Valuesc Second stage RO feed pump 400-520 lb/in.2 gauge gal/min 600 lb/in.2 gauge, 120°F SS Design Infoa Set Valuesc Operating Proceduree Second stage RO skid 100-450 lb/in.2 Inlet 100-400 lb/in.2 Brine 50-80 lb/in.2 Permeate 15 gal/min Brine 135-150 gal/min Permeate 64-90°F 600 lb/in.2, 113°F, 70 gal/min Design Infoa Set Valuesc Polishers and Effluent pH Adjustment Tank Polisher column 70 lb/in.2 gauge Inlet 25-50 lb/in.2 gauge Outlet 20-100 gal/min 152 gal/min Design Infoa Set Valuesc Resin traps 20-45 lb/in.2 gauge Set Valuesc Effluent pH adjustment tank 0 lb/in.2 gauge 50-120°F 0 lb/in.2 gauge, 120°F 304 SS with CS saddle Design Infoa Set Valuesc Effluent pH adjustment tank pumps 70 – 90 lb/in.2 gauge 40-150 gal/min 50-120°F 175 gal/min Design Infoa Operating Procedured Set Valuesc 290
occasionally received parking lot runoff during rain/snow melt, plus sand and other debris blown into the sump. Both tanks were removed from service due to severe pitting damage, TK117 in 1998, and TK109 in 2007. Tank 109 was visually inspected on a one-year frequency before being taken out of service in 2007. Tank 117 has not been inspected on a defined periodicity, given discovered leaking in 1998, the tank was inspected to determine the cause of failure on May 18, 1998. The dates of previous inspections are: Load-In Tank 109 Load-In Tank 117 November 5, 1998 May 18, 1998 October 5, 2000 September 25, 2002 June 10, 2003 May 26, 2004 September 15, 2005 December 7, 2006 December 7, 2007 (see Figure A8) Visual inspection data is mostly available for Tank 109, which was visually inspected eight times prior to failure. Accumulation of sediment on tank floor, heaviest near drain. Rust stains coming from inlet opening in roof, running down tank wall. Moderate to severe pitting in tank wall, with numerous rust streaked pits and pits capped with corrosion product. Pit density heaviest in eastern half of tank. Rust stains from carbon steel contamination in grinding marks on tank wall. Load-In Tank 109 Showing Pits on Tank Wall (A); Capped Pits in Tank Wall (B); Sediment on Tank Floor (C); and Rust Colored Stains at Tank Inlet (D) on December 7, 2007. Figure A8. Load-In Tank 109 59A-TK-109 Tank Number: 2025ED-59A-TK-109 Report Number: 021240814-019 Date: 12/7/2007 Pitting corrosion is still active in this tank as of December 7, 2007 and is likely worsening this tank. TK109 has been removed from service and is currently in delayed closure.
RPP-59452, 2016, IQRPE Installation Assessment Report for the ETF Heat Exchanger Project, Rev. 0, Meier Architecture, Kennewick, Washington. RPP-PLAN-60485, 2015, Repair Plan, Rev. 0, Washington River Protection Solutions, LLC, Richland, Washington. RPP-RPT-61144, 2017, IQRPE Repair Assessment Report for the Effluent Treatment Facility Thin Film Dryer Hopper, Rev. 0, Meier Architecture, Kennewick, Washington. WAC 173303, “Dangerous Waste Regulations,” Washington Administrative Code, as amended.