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Title: Reliability centered maintenance pilot system implementation 241-AP-tank farm primary ventilation system final report

Abstract

When the Hanford Site Tank Farms' mission was safe storage of radioactive waste in underground storage tanks, maintenance activities focused on time-based preventive maintenance. Tank Farms' new mission to deliver waste to a vitrification plant where the waste will be processed into a form suitable for permanent storage requires a more efficient and proactive approach to maintenance. Systems must be maintained to ensure that they are operational and available to support waste feed delivery on schedule with a minimum of unplanned outages. This report describes the Reliability Centered Maintenance (RCM) pilot system that was implemented in the 241-AP Tank Farm Primary Ventilation System under PI-ORP-009 of the contract between the U.S. Department of Energy, Office of River Protection and CH2M HILL Hanford Group Inc. (CHG). The RCM analytical techniques focus on monitoring the condition of operating systems to predict equipment failures so that maintenance activities can be completed in time to prevent or mitigate unplanned equipment outages. This approach allows maintenance activities to be managed with minimal impact on plant operations. The pilot demonstration provided an opportunity for CHG staff-training in RCM principles and tailoring of the RCM approach to the Hanford Tank Farms' unique needs. This report details themore » implementation of RCM on a pilot system in Tank Farms.« less

Authors:
Publication Date:
Research Org.:
CHG (US)
Sponsoring Org.:
USDOE Office of Environmental Management (EM) (US)
OSTI Identifier:
807328
Report Number(s):
RPP-8736, Rev.0
TRN: US0301795
DOE Contract Number:
AC27-99RL14047
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 21 Sep 2001
Country of Publication:
United States
Language:
English
Subject:
12 MANAGEMENT OF RADIOACTIVE WASTES, AND NON-RADIOACTIVE WASTES FROM NUCLEAR FACILITIES; IMPLEMENTATION; MAINTENANCE; MONITORING; RADIOACTIVE WASTES; RELIABILITY; SCHEDULES; STORAGE; STORAGE FACILITIES; TANKS; UNDERGROUND STORAGE; VENTILATION SYSTEMS; VITRIFICATION; WASTES

Citation Formats

MOORE TL. Reliability centered maintenance pilot system implementation 241-AP-tank farm primary ventilation system final report. United States: N. p., 2001. Web. doi:10.2172/807328.
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MOORE TL. Reliability centered maintenance pilot system implementation 241-AP-tank farm primary ventilation system final report. United States. doi:10.2172/807328.
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MOORE TL. Fri . "Reliability centered maintenance pilot system implementation 241-AP-tank farm primary ventilation system final report". United States. doi:10.2172/807328. https://www.osti.gov/servlets/purl/807328.
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@article{osti_807328,
title = {Reliability centered maintenance pilot system implementation 241-AP-tank farm primary ventilation system final report},
author = {MOORE TL},
abstractNote = {When the Hanford Site Tank Farms' mission was safe storage of radioactive waste in underground storage tanks, maintenance activities focused on time-based preventive maintenance. Tank Farms' new mission to deliver waste to a vitrification plant where the waste will be processed into a form suitable for permanent storage requires a more efficient and proactive approach to maintenance. Systems must be maintained to ensure that they are operational and available to support waste feed delivery on schedule with a minimum of unplanned outages. This report describes the Reliability Centered Maintenance (RCM) pilot system that was implemented in the 241-AP Tank Farm Primary Ventilation System under PI-ORP-009 of the contract between the U.S. Department of Energy, Office of River Protection and CH2M HILL Hanford Group Inc. (CHG). The RCM analytical techniques focus on monitoring the condition of operating systems to predict equipment failures so that maintenance activities can be completed in time to prevent or mitigate unplanned equipment outages. This approach allows maintenance activities to be managed with minimal impact on plant operations. The pilot demonstration provided an opportunity for CHG staff-training in RCM principles and tailoring of the RCM approach to the Hanford Tank Farms' unique needs. This report details the implementation of RCM on a pilot system in Tank Farms.},
doi = {10.2172/807328},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Sep 21 00:00:00 EDT 2001},
month = {Fri Sep 21 00:00:00 EDT 2001}
}
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DOI:  10.2172/807328
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  • Critical component failures during delivery of waste feed from the Double Shell Tanks (DST) to the Waste Treatment Plant (WTP) have a significant potential to idle the WTP facilities. A recent Engineering Report' estimates that over $600,000 per day in associated costs would be incurred for delays for failure to deliver waste to the WTP. Reliability Centered Maintenance (RCM) Analysis is all about performing the correct maintenance, on the correct equipment, at the correct interval to ensure processes are available and reliable to meet company goals and regulatory constraints. In support of meeting these goals, RCM analysis was completed onmore » six Primary Ventilation Systems to evaluate the functional importance and value of the assets in order to establish objective, engineering based, and cost-effective maintenance strategies. These strategies, based on specific criteria, enable the selection of appropriate maintenance tasks to be performed at optimum interval, on maintenance worthy equipment. The RCM process also serves to establish the initial documented bases for component maintenance tasks.« less

  • ; ;
    Three sections of primary transfer pipeline removed from the 241-SY Tank Farm in Hanford's 200 West area, labeled as SN-285, SN-286, and SN-278, were analyzed for the presence and amount of corrosion and erosion on the inside surface of the transfer pipe. All three sections of pipe, ranging in length between 6 and 8 in., were received at the 222-S Laboratory still in the pipe-in-pipe assembly. The annular spaces were filled with urethane foam injected into the pipes for as low as reasonably achievable (ALARA) purposes. The 3-in. primary transfer pipes were first separated from the outer encasement, 6-in. pipes.more » The pipes were cut into small sections, or coupons, based upon the results of a non-destructive pipe wall thickness measurement which used an ultrasonic transducer. Following removal of the foam, the coupons were subjected to a series of analytical methods utilizing both optical microscopy and scanning electron microscopy to obtain erosion and corrosion information. The ultrasonic transducer analysis of the SN-285 primary pipe did not show any thinned locations in the pipe wall which were outside the expected range for the 3-in. schedule 40 pipe of 216 mils. A coupon was cut from the thinnest area on the pipe, and analysis of the inside surface, which was in contact with the tank waste, revealed a continuous layer of corrosion ~ 100 11m (4 mils) thick under a semi-continuous layer of tank waste residue ~ 20 11m (1 mil) thick. This residue layer was composed of an amorphous phase rich in chromium, magnesium, calcium, and chlorine. Small pits were detected throughout the inside pipe surface with depths up to ~ 50 11m (2 mils). Similarly, the SN-286 primary pipe did not show, by the ultrasonic transducer measurements, any thinned locations in the pipe wall which were outside the expected range for this pipe. Analysis of the coupon cut from the pipe section showed the presence of a tank waste layer containing sodium aluminate and phases rich in iron, calcium, and chromium. This layer was removed by a cleaning process that left a pipe surface continuous in iron oxide/hydroxide (corrosion) with pockets of aluminum oxide, possibly gibbsite. The corrosion layer was ~ 50 11m (2 mil) thick over non-continuous pits less than ~ 50 11m deep (2 mils). Small particles of aluminum oxide were also detected under the corrosion layer. The ultrasonic transducer analysis of SN-278, like the previous primary pipes, did not reveal any noticeable thinning of the pipe wall. Analysis of the coupon cut from the pipe showed that the inside surface had a layer of tank waste residue that was partially detached from the pipe wall. This layer was easily scraped from the surface and was composed of two separate layers. The underlying layer was ~ 350 11m (14 mils) thick and composed of a cementation of small aluminum oxide (probably gibbsite) particles. A thinner layer on top of the aluminum oxide layer was rich in carbon and chlorine. Scattered pitting was observed on the inside pipe surface with one pit as deep as 200 11m (8 mils).« less

  • ; ;
    This report provides the results of an extent of condition construction history review for the 241-AP tank farm. The construction history of the 241-AP tank farm has been reviewed to identify issues similar to those experienced during tank AY-102 construction. Those issues and others impacting integrity are discussed based on information found in available construction records, using tank AY-102 as the comparison benchmark. In the 241-AP tank farm, the sixth double-shell tank farm constructed, tank bottom flatness, refractory material quality, post-weld stress relieving, and primary tank bottom weld rejection were improved.