contentschprc.hanford.gov/files.cfm/prc-srp-00060,_rev_0,_functional... · contents 1.0 general ......

PRC-SRP-00060, Rev. 0

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Contents

1.0 General Overview ..............................................................................................................1 1.1 Introduction ..............................................................................................................2 1.2 Operating Environment ............................................................................................4

1.2.1 The 324 Radiochemical Engineering Complex ...........................................4 1.2.2 Mockup Location .......................................................................................13

1.3 Environmental Conditions .....................................................................................15 1.4 Nuclear Safety ........................................................................................................16 1.5 Preparation for Operations (Out of scope for contractor) ......................................16 1.6 Installation of Equipment (Out of scope for contractor) ........................................16 1.7 Buyer Furnished Equipment ..................................................................................17 1.8 Operations Plan ......................................................................................................17 1.9 Equipment Disposition...........................................................................................17

2.0 Functional Design Criteria ..............................................................................................17 2.1 Functional Requirements .......................................................................................17

2.1.1 General Functional Requirements ..............................................................17 The FSS is required to perform the following functions: ......................................17 2.1.2 Fail-Safe Condition Requirements .............................................................18

2.2 Interface Requirements ..........................................................................................18 2.2.1 Interfaces with the 324 REC Facility .........................................................18 2.2.2 Interfaces with the Mockup Location ........................................................21 2.2.3 Cameras & Lighting ...................................................................................22

2.3 Electrical Requirements .........................................................................................22 2.4 Mechanical Requirements ......................................................................................22 2.5 Radiological Requirements ....................................................................................22 2.6 Nuclear Safety Requirements ................................................................................23 2.7 Fire Protection Requirements ................................................................................23 2.8 Quality Assurance Requirements ...........................................................................23

3.0 References .........................................................................................................................24

Figures

Figure 1: Floor Saw System (FSS) ..................................................................................................1 Figure 2: 324 Building General Arrangement .................................................................................2 Figure 3: General Arrangement of REC Cells A, B, C, D, and Connecting Airlock ......................3 Figure 4: B-Cell Floor Dimensions (H-3-20160) ............................................................................6 Figure 5: B-Cell After Grouting ......................................................................................................6 Figure 6: Airlock, A-Cell, B-Cell, and C-Cell Configuration .........................................................8


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Figure 7: Isometric View of the REC Cells and Operating Galleries ............................................10 Figure 8: Auxiliary Hook (Crosby S-320AN 7 Ton #1022430) and Shackle (Crosby G-

209 1018570) ............................................................................................................11 Figure 9: REC Cranes ....................................................................................................................12 Figure 10: Mockup for 324 Building B-Cell and Airlock Exterior ...............................................14 Figure 11: Interior of Mockup .......................................................................................................14 Figure 12: Interior of B-Cell Mockup ...........................................................................................15 Figure 13: Mockup Overhead View ..............................................................................................15 Figure 14: MSM in B-Cell (looking west, one of six shown) (REF. H-3-300262, Sheet 9) .........19 Figure 15: Example of 324 B-Cell Master Slave Manipulator ......................................................20 Figure 16: Sketch of 324 B-Cell MSM gripper fingers. ................................................................21

Tables

Table 1. REC Crane Summary .......................................................................................................11 Table 2: REC Hot Cell Combustible Loading Limits ....................................................................23


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Terms

CHA Cask Handling Area CHPRC CH2M HILL Plateau Remediation Company DOE U.S. Department of Energy ERDF Environmental Restoration Disposal Facility FSS Floor Saw System FSF Floor Saw Frame MSM Master Slave Manipulator NRTL National Recognized Testing Laboratory REA Remote Excavator Arm REC Radiochemical Engineering Complex SSC Structures, Systems and Components


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1.0 General Overview The purpose of this Functional Requirements Document (FRD) is to establish the functional criteria for the Floor Saw System (FSS), see Figure 1. This system will operate in the 324 Radiochemical Engineering Complex (REC) B-Cell on the Hanford site, Richland, Washington. The FSS shall segment the B-Cell floor remotely without requiring maintenance, repairs or blade replacement. The system shall include the hardware, components and controls required to remotely cut the B-Cell floor in preparation for floor and soil removal.

The system shall use a modified Diamond Technology, Inc. (DTI) AK-400 Wall Saw mounted in a special frame. The system shall include an integrated control system, umbilical deployment system and water cooling system.

The FSS will be used in conjunction with several other Structures, Systems and Components (SSC) including the upper Remote Excavator Arms (REA) and Transfer Mechanism.

A detailed description of the FSS may be found in the design report narrative for the floor saw, PRC-SRP-00024, Design Report Narrative For The Floor Saw, KUR-1782F-RPT-026 R0 (300-296 Soil Remediation Project). This document was generated as part of an early design effort, may not contain current information, and is provided for reference only.

Figure 1: Floor Saw System (FSS)


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1.1 Introduction

The 324 Building is a non-reactor Category 2 Nuclear Facility located in the 300 Area of the U.S. Department of Energy (DOE) Hanford Site. The 324 Building was constructed from 1963 to 1966 to support materials and chemical process research and development activities ranging from laboratory / bench-scale studies to full engineering-scale pilot plant demonstrations with radioactive materials. The 324 Building is comprised of multiple floors and includes a shielded metallurgical facility, REC cells (A, B, C, and D), low level canyon, tank vault, cold canyon, cask handling area (CHA), maintenance shops, laboratory area, administrative offices, and building support systems. A general plan view of the 1st floor in the 324 Building is shown in Figure 2: 324 Building General Arrangement. Figure 3 shows a general arrangement of the REC Cells within the 324 Building. The cells, tank vault, and building support systems are currently operational with the remaining areas decommissioned. The cold shop and cold canyon structure have been removed.

Figure 2: 324 Building General Arrangement


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Figure 3: General Arrangement of REC Cells A, B, C, D, and Connecting Airlock

Records indicate that in October 1986 a concentrated, liquid waste stream containing cesium-137 (137Cs) and strontium-90 (90Sr) was spilled onto the floor of B-Cell. Unknown quantities of water were used immediately after the spill, and at various other times following the spill, to wash items contained in the B-Cell. A breach in the B-Cell sump was discovered during deactivation and stabilization activities. Exposure rates and temperature measurements were made to provide an estimates of the nature and extent of the soil contamination underneath B-Cell. Exposure rates in excess of 10,000 R/hr. have been detected. The peaks in the measured exposure rates approximately underlie the locations of the expansion joints in the B-Cell floor. The current interpretation is that the leak from the B-Cell sump spread laterally along a felt liner between the floating B-Cell central slab and the cell wall foundation that extends under the floor area.

The selected technical approach for soil removal beneath the B-Cell is to first remove the debris and about 6-inches of grout on the B-Cell floor. The floor will be remotely sliced up with a diamond tipped saw, then demolished and remotely excavated with the REA exposing the underlying contaminated soil. Structural modifications will be performed to support the B-Cell prior to retrieving contaminated soil. Additional facility modifications will also be performed to support installation of the remote excavation equipment.

The existing B-Cell concrete floor with stainless steel liner and embeds will be removed. Next, soil underlying each of the B-Cell walls is sequentially, remotely excavated. The excavation beneath each of the B-Cell walls is started at the expansion joint, where the most highly radioactive soil exists, and is removed horizontally and vertically to a maximum depth of 10-ft. The excavation beneath each of the cell walls is anticipated to extend approximately 2 to 3-ft. on either side of the expansion joint in the B-Cell floor, which is 20-inches from the cell wall. The shielded probe collimator system will be used to verify the highly radioactive soil has been removed from the excavation beneath each of the cell walls.

After soil is excavated from beneath each of the B-Cell walls, grout is added to fill the excavated area and provide structural stability before excavating beneath the next B-Cell wall. Following


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excavating soil beneath the B-Cell walls, other highly radioactive soil is remotely excavated as necessary to enable future open air remediation of the remaining contaminated soil, which will be performed under a separate project.

The more highly contaminated soil and debris will be placed in A-Cell, C-Cell and D-Cell in the REC and grouted in place. If the total volume of contaminated material exceeds available facility hot cell space, the excess material will be packaged in waste boxes, grout added to fill the void space and the waste boxes transported to the Environmental Restoration Disposal Facility (ERDF) located at the Hanford site.

After completing remote excavation of the soil beneath B-Cell, a separate project will completely fill each of the cells with grout, then cut the cells into monoliths and removed the monoliths to the ERDF for disposal.

1.2 Operating Environment

The FSS will be operating on the floor of the B-Cell. This highly radioactive area precludes any hands-on operations, thus all activities are performed remotely. A general layout of the B-Cell, relative to the other cells, is shown in Figure 5.

Before being deployed at the 324 REC, the FSS will first be installed at the non-radioactive Mockup location. At this ‘proving-ground’ location, equipment will be tested and operators will be trained in preparation for the radioactive environment of the 324 REC B-Cell and Airlock areas. The equipment used at the Mockup location will also serve as backup equipment to the equipment built for use at the REC.

1.2.1 The 324 Radiochemical Engineering Complex

The 324 REC s a multistory steel structure housing an array of processing cells, hot cells, and associated SSCs. Regarding the project, the focus areas contain four hot cells, an adjoining Airlock, the CHA, and operating gallery. The REC hot cells are labeled A thru D. The 324 Building is a climate-controlled area that will fluctuate between 60°F and 90°F. The FSS does not interact with C and D cells and thus they are not discussed here.

The equipment installed in the 324 Building will be subjected to radioactive dose. Measured and calculated radiological conditions are documented in PRC-SRP-00009, 300-296 Soil Remediation Project Radiation Material Evaluation.

Dose rates will increase in A-Cell, C-Cell, and D-Cell as a result of placing into these cells debris and/or waste bins containing soil excavated from beneath B-Cell. However, the dose rates calculated for B-Cell after floor removal and during primary zone soil excavation are expected to be bounding.

There are also several cranes within the REC that service the cells, Airlock and CHA as shown in Figure 9: REC Cranes.


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1.2.1.1 A-Cell

The interior of A-Cell is 9ft-3in. (north-south) by 21ft (east-west) and extends from 0ft to 29ft above grade. The cell floor and walls are lined with stainless steel to the 10ft-4in. elevation. A-Cell is surrounded on three sides by operating galleries on the first, second and third floors.

1.2.1.2 B-Cell

The interior of the B-Cell is 22ft (north-south) by 25ft (east-west). B-Cell is 10ft below grade and extends 20.5ft above grade. The floor and walls (up to 17ft-2in. elevation) are lined with stainless steel. B-Cell is surrounded on three sides by operating galleries on the first and second floors and on two sides by an operating gallery at the basement level.

1. The B-Cell interior measures 25ft (east – west) by 22ft (north - south) and extents from (-) 10ft to +20ft-6in. elevation. See Figure 4 for dimensional details. See drawings H-3-20160 and H-3-20214 detail 261 for original construction drawings.

2. Walls are 5ft- 4in. thick. Reference drawing H-3-20160.

3. The sloped B-Cell floor and walls are lined with 11 gauge stainless steel sheeting to an elevation of 17ft-2in. (H-3-20273).

4. A 3in. deep sloped trench along the east wall in the B-Cell floor leads to a 2ft by 2ft sump trough in the northeast corner (H-3-20195).

5. A ½in. wide expansion joint filled with sealing compound or mastic circumscribes a concrete slab from the wall footer inset at a distance of 20 inches from the wall. See drawing H-3-20195 for additional detail.

6. The B-Cell door dimensions are 17ft-2in high by 6ft-6in wide (H-3-20240). It is divided vertically in two sections. The door sections must be operated in sequence with the top being opened first and closed last. The air-operated B-Cell door latches, opens and closes reliably but has not had any preventive maintenance.

7. The B-Cell is considered a High Contamination and Very High Radiation Area with no personnel access.

8. B-Cell contains three (3) sets of Central Research Laboratories Model F MSMs on the north, south, and west sides accessed from the gallery at ground level.

9. Due to the high radiation within B-Cell the B-Cell shield door must be closed to conduct personnel access within the Airlock or to open the Airlock shield door.

10. The B-Cell currently has 6 inches (nominal) of grout on the floor with embedded debris (Figure 7).

11. The B-Cell Floor consists of an 11 gauge stainless steel liner, 1in x 1in x ¼ in stainless steel angles embedded in a 6-inch thick concrete slab with further embedded, 6-in. center-to-center welded wire fabric reinforcement and cobblestone underneath. Reference H-3-20195 for slab thickness. Reference H-3-20273 for floor liner details.


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Figure 4: B-Cell Floor Dimensions (H-3-20160)

Figure 5: B-Cell After Grouting


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1.2.1.3 Airlock

Adjoining the REC cells on the east side is an Airlock. The Airlock is at the 0ft elevation and extends 29ft above ground level. The cell floor and walls are lined with stainless steel to the 17ft-2in. elevation. The Airlock is surrounded on three sides the REC cells and on the east side by the CHA.

1. The Airlock internal dimensions are 21ft-6in (east – west) by 22ft (north-south) by 33ft (elevation) (H-3-20160 and H-3-20214 detail 261). The Airlock floor is at the 0ft elevation. The Airlock slopes toward a trench running north/south in front of the B-Cell Door. The Airlock floor and walls to the 17ft-2in elevation are lined with 11 gauge stainless steel sheeting.

2. The Airlock shield door dimensions are 18ft high by 6ft-6in. wide (H-3-20241 detail 32). The door opens, closes and latches properly.

3. Three cranes can access the Airlock: the A/D crane, the B-Cell crane and the A-Cell crane. The A/D crane has full access to the Airlock while the B & C-Cell cranes are limited.

4. Shield walls at the operating faces of the REC cells and Airlock are 4ft to 5ft-4in thick concrete elsewhere adjoining the operating galleries, and 4ft-6in thick adjacent the Airlock. There are three oil-filled glass viewing windows on the first floor of B-Cell; one window located at each of the north, south and west operating gallery walls. Figure 6 and Figure 7 show this general layout.

5. The Airlock’s only outside access is from the CHA and this door is normally closed. From the Airlock area, the REC cells may be accessed. All REC cell doors must be closed before personnel entry into the Airlock.


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Note: Remote excavator arm locations are outlined in red. D-Cell is above C-Cell but it not shown in this illustration

Figure 6: Airlock, A-Cell, B-Cell, and C-Cell Configuration

1.2.1.4 Cask Handling Area

1. The CHA dimensions are approx. 59ft-4in (north - south) by 24ft-6in (east - west) in the area serviced by the CHA crane (H-3-300262 sheet 6, revision 2 and H-3-300262, sheet 7, revision 2).

2. A Truck Lock area adjoins the CHA on the north with dimensions are approx. 30ft (north – south) and 15ft-9in (east – west). The CHA and Truck Lock are separated by door #176 which is 25ft-11in high by 10ft wide (H-3-20171). The Truck Lock has a roll-up door #106 on the north face having an opening elevation of 15ft-11.5in (H-3-300262, sheet 1, revision 4 and H-3-300262 sheet 3) by 12ft wide (H-3-20173).

3. A 30 ton overhead bridge crane (also equipped with a 5-ton crane) is available for use within the CHA but does not travel into the Airlock or other cells. The CHA crane travels 87ft in total, servicing both the CHA and the Truck Lock area (H-3-300262, sheet 7, revision 2). The CHA crane minimum pick point and maximum lift height elevations are 23ft-0in and 24ft-0in per H-3-300262, sheet 7.


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4. An Air Technical Industries model RBC-20000-SPBW Reverse Boom Crane (RBC) with maximum extended lift capacity of 10,000 lbs., is available in the CHA. The RBC has a maximum lift height of 128 inches when the boom is retracted and 170 inches when the boom is extended. The RBC floor to hook height is 5 inches with the boom extended / lowered and 29 inches with the boom retracted /lowered. The maximum reach of the RBC is 82 inches beyond the wheels1.

5. The Airlock Rail System is a rolling cart that travels along a rail between the CHA and the Airlock. It has a capacity of 30 tons and can hold items up to a width of 5 feet. Reference airlock rail system drawing H-3-317731, Sheets 1 and 2.

6. The CHA is considered a Radiological Controlled Area. Reference DOE-STD-1098-2008, DOE Standard Radiological Control, for additional details on radiation area designations.

1.2.1.5 Operating Gallery

1. The operating gallery surrounds the REC Cells on three sides at ground, second floor and basement levels. The floor plans can be found in drawing H-3-20190 (basement), H-3-20160 (ground), and H-3-20166 (second floor).

2. Two windows are available for viewing the B-Cell on the south and west sides at ground level. The viewing window on the north side is non-functional.

3. B-Cell MSMs are operated from the gallery.

4. Certain portions of the floor saw, such as the controls and VFDs will be staged in, or installed from, the gallery.

5. Equipment routing through doors and around obstacles in the gallery will need to be verified.

6. The gallery is considered a Radiation Control Area.

1 Air Technical Industries website accessed 7-24-2017; http://www.airtechnical.com/product/reversible-boom-crane/


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Figure 7: Isometric View of the REC Cells and Operating Galleries


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1.2.1.6 Cranes, Hoisting and Rigging

1. The typical crane hook configuration includes an auxiliary Crosby hook (PN: S=320AN 7 Ton #1022430) and shackle (PN: G-209 #1018570) but may employ any site approved hook configuration. See Figure 8: Auxiliary Hook (Crosby S-320AN 7 Ton #1022430) and Shackle (Crosby G-209 1018570) for an illustration of the configuration.

Figure 8: Auxiliary Hook (Crosby S-320AN 7 Ton #1022430) and Shackle (Crosby G-209 1018570)

2. The Airlock will be used to stage equipment including the REAs, Transfer Mechanism, REA tools, waste bins, Floor Saw and other equipment thus floor space will be a significant consideration when designing equipment.

3. The Airlock is considered a Radiation Area and High Contamination Area with limited personnel access.

324 Facility (REC) crane capacities are listed in

Table 1. REC Crane Summary while general plan view range of motion is shown in Figure 9.

Table 1. REC Crane Summary

Location Crane Name Current Cap. (Orig.) Tons

High Hook Position

Special Features Access

B-Cell 10-Ton Bridge

10-Ton 5.75 (10) 17-ft. 6-inch

3-Ton 3 16-ft. 10-inch

Rotating Boom Hoist

½ -10 to +27-ft. Attached to 3-Ton Trolley

Airlock/ D Crane

A-D Crane 5 29-ft. Highest Elev. Use to service B-Crane

A-Crane (Same rail as A-D)

A-Crane 5 29-ft. Use to service B-Crane


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Location Crane Name Current Cap. (Orig.) Tons

High Hook Position

Special Features Access

C-Cell C-Crane 2 11-ft. 11-inch

Cask Handling CHA Crane 30 24-ft.

Figure 9: REC Cranes


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1.2.2 Mockup Location

The FSS will first be deployed in the Mockup B-Cell location and a subsequent FSS will later be deployed at the 324 Facility. The Mockup is located at 2325 Horn Rapids Road in Richland, Washington. The Mockup area is constructed to allow full scale testing and training on remote operations required for the remote soil excavation activities associated with the 324 Building REC. The Mockup area will be used to demonstrate and troubleshoot equipment prior to deployment in the REC. See Figure 10, Figure 11, Figure 12, and Figure 13 for sketches of the Mockup.

The features of the Mockup include the following:

1. A full-scale simulation of the B-Cell and Airlock areas

2. Simulates the B-Cell stainless steel lined floor: Mockup cell floor is 11 gauge stainless steel lined concrete floor with 6-in. center-to-center #3 welded wire fabric reinforcement and embedded stainless steel angle.

3. Duplicates B-Cell concrete walls from the -10 ft to the +5 ft elevations.

4. Drywall with metal stud framing to simulate B-Cell walls from the +5 ft to the +14 ft-6 in. elevations.

5. A single overhead 10-ton crane to simulate the B-Cell crane.

6. The testing area is enclosed in a temporary fabric-covered area with a footprint of approximately 80 by 100 ft.

7. An electrical connection panel will be available in the Mockup gallery near the FSS controller enclosure. A 480/277/240VAC, 3Ph, 40 Amp supply will be provided. A 120 VAC, 1Ph, 20 Amp circuit will also be available. Camera control and monitoring stations will be similar to those at the REC.


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Figure 10: Mockup for 324 Building B-Cell and Airlock Exterior

Figure 11: Interior of Mockup


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Figure 12: Interior of B-Cell Mockup

Figure 13: Mockup Overhead View

1.3 Environmental Conditions

The environmental conditions for all operations are as follows:

1. REC Galleries, Airlock, and CHA: Climate controlled, 60°F to 90°F.

2. B-Cell Operating temperatures: 80°F to 95°F.

3. Mockup Fabric-Covered Location (outside ambient air): -23°F to 113°F

4. The Mockup fabric shell provides significant defused daylight inside and protects the inside environment from wind and precipitation.


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1.4 Nuclear Safety

The 324 Building is a Hazard Cat 2 Nuclear Facility.

Based on CHPRC-02981, 324 Building Safety Equipment List (Formerly WCH-199, Rev. 3) three systems are identified as Safety Class:

1. REC hot cells, wall, and ceilings (not including window, doors, penetrations and components mounted to the hot cell walls).

2. 324 Building Roof and Exterior walls surrounding the areas of the building ventilated by the Zone II system (not including windows, doors and penetrations).

3. Stack EP-324-01-S, fan housing and ducts connecting the building to the stack.

A single system is identified as Safety Significant; the last stage of the HEPA filters in the Zone 1 and II ventilation systems.

The equipment being installed is neither Safety Significant nor a Safety Class system. They are neither a part of, nor do they directly affect the building safety systems.

1.5 Preparation for Operations (Out of scope for contractor)

The area will be prepared and ready for installation of the FSS:

1. The upper REA and Transfer Mechanism will already be installed.

2. Utility (water, electrical) connections in the gallery will be in place. CH2MHILL Plateau Remediation Company (CHPRC) shall supply the locations of connections at a later date.

3. Gallery floor space will be identified and cleared for installation of ancillary control and operations (water cooling) equipment.

4. Remote camera and lighting system along with audio will be in place and available to use during FSS installation and operation.

1.6 Installation of Equipment (Out of scope for contractor)

The FSS will be transported into the facility through the Truck Loading Bay and staged in the CHA at both the Mockup and the REC. At the Mockup, the single 10-ton crane will be used to do all the equipment handling. In the REC the FSS will be transported into the Airlock using an Airlock Rail System and then into B-Cell using the 5.75 ton B-Cell crane. The FSS Control System and Saw Motor Water Cooling System enclosures will be transported into the gallery and positioned for operation on the South side of B-Cell. The utilities enter the B-Cell gallery near just above the floor level and east of the operator window.


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1.7 Buyer Furnished Equipment

The Buyer has built and tested a prototype floor saw and it will be available upon request of the contractor. This consists of the FSS frame unit assembly, the control system, and additional blades. It does not include a saw motor water cooling system.

1.8 Operations Plan

The FSS will be operated from the gallery using direct line of site through the south B-Cell window and/or using the remote vision system (camera and lighting system). The floor saw will be positioned using the 3 ton or 5.75 ton B-Cell cranes.

1.9 Equipment Disposition

If the FSS does not last the duration for the project, then it will be replaced. The equipment installed in the REC cells will be abandoned in place at the end of the project. The Floor Saw will be cut into segments, placed in A-Cell and grouted in place. Equipment installed in the gallery areas of the 324 Building will be left for later demolition activities. The FSS delivered to the Mockup for testing and evaluation is intended to become the back-up saw for the 324 REC, should that one fail.

The cables for the floor saw in the contaminated area of the REC will be abandoned in place.

2.0 Functional Design Criteria The FSS shall cut the B-Cell floor into segments. It shall do this by cutting through the stainless steel floor liner, stainless steel angle reinforcements under the liner, and to a depth of at least 4”. This must be accomplished with no maintenance or repair of the FSS.

2.1 Functional Requirements

2.1.1 General Functional Requirements

The FSS is required to perform the following functions:

1. Cut minimum of 3300 in-ft of B-Cell floor. 2. The FSS shall accommodate remote operations including installation, relocation, and

removal. 3. The saw shall cut between 2 and 8 inches deep into the B-Cell floor, through 11 gauge

stainless steel (SS) liner, embedded 1in x 1in x ¼ in stainless steel angles, wire mesh, and concrete.

4. The FSS shall operate reliably in a radioactively contaminated environment subject to loose debris and water wash-downs for a minimum 6-month operation.

5. The system shall provide blade cooling water that also serves to mitigate dust. 6. The system shall include a recirculating cooling water system for motor cooling. 7. The frame system shall not move (from its own weight) during cutting operations.


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8. The saw system shall have a shroud to maintain a wet environment for the blade. 9. The saw shroud shall have a skirt to maintain a wet environment and contain sparks. 10. Provide non-electronic positional indication for blade depth and carriage position. 11. Operate in a manual mode upon any automatic mode failure. 12. The saw and control system shall be vendor-integrated to meet the power, sensing,

control, and user interfaces required in the Performance Specification. 13. The controller shall be provided with a hand-held pendant featuring a display that

includes critical parameters. The pendant shall also include at a minimum, the controls specified in the performance specification, PRC-SRP-00066.

14. The floor saw frame shall be designed to allow ease of being cut into three segments using the REA hydraulic shear tool, Caterpillar®2 S305 Hydraulic Demolition Shear, to assist removal from B-Cell and placement into A-Cell. Each segment must have a Below-The-Hook Lifting Device for use with the B-Cell and A-Cell cranes.

15. Complete unit and three (3) individual segments shall have crane pick points. 16. Minimize B-Cell water addition from blade cooling water by limiting flow range from

9gph to 20ghp. 17. The system shall include an umbilical management system to prevent tangling and

pinching of electrical and water lines.

2.1.2 Fail-Safe Condition Requirements

1. Floor saw must shut off in the event of a loss of power. 2. Any electrical system protection devices, such as fuses, breakers, or surge protectors,

must be located on the Gallery side of the cables, cords, or wiring. 3. Control software must have “safe mode” shutdown and recovery features in case of

power surge, loss, and recovery.

2.2 Interface Requirements

The FSS shall interface with SSCs in the Mockup and the 324 REC Facility.

2.2.1 Interfaces with the 324 REC Facility

1. Gallery – Controls shall be placed in the Gallery within 10ft of penetrations BS011-08, shown on drawing H-3-317768, on the south wall of the B-Cell, next to the window. Power and control wiring shall go through one of these penetrations.

2. Utilities –

a. 324 Facility power: Electrical power will be available from within the gallery where connections are made.

b. 324 Facility water supply: a 1 inch, Sch. 40, FNPT carbon steel connection, supply line with a minimum pressure of 80psig and a maximum pressure of 125psig will be available.

2Caterpillar is a registered trademark of Caterpillar Inc., 100 N.E. Adams Street, Peoria, IL


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3. Cranes – FSS must have a hoisting and rigging pick point on it that will allow it to be picked with the existing facility crane hooks, including the following cranes: 30T Cask Handing Area, 5T Airlock, 5.75T B-Cell and 3T B-Cell.

4. MSM’s – Any component intended to be grasped by the MSM must accommodate existing grippers. Sketches of the MSM and Grippers are shown in Figure 14, 15, and 16, below.

5. Airlock Rail System – The FSS must fit onto the cart in the CHA, see cart drawing H-3-317729, and be able to pass through the door into the airlock.

6. A-Cell – Disposal of the floor saw into the A-Cell must accommodate planned cell debris, dams, and crane handling capabilities.

7. B-Cell Floor – This includes the floor and approximately 4 inches of rubble left on the floor after grout demolishment.

8. Transfer Mechanism – The FSS must be installed, operated, and removed with the Transfer Mechanism in place. The transfer mechanism sits on the B-Cell door threshold. Refer to preliminary transfer mechanism drawings, H-3-318008, H-3-318009 and H-3-318010 for information. Note that the latter is not the final design. The final dimensions must be confirmed with CHPRC prior to design completion of the floor saw.

Figure 14: MSM in B-Cell (looking west, one of six shown) (REF. H-3-300262, Sheet 9)

Swing Radius 57” to 129” -20° to +90° (Horiz.) Swing


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Figure 15: Example of 324 B-Cell Master Slave Manipulator


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Figure 16: Sketch of 324 B-Cell MSM gripper fingers.

2.2.2 Interfaces with the Mockup Location

1. Utilities –

a. Mockup Electrical: Power will be available from within the Mockup where connections are made.

b. Mockup water source is from the City of Richland sanitary water supply. The 300-296 Water Delivery System will store and pump water from the City of Richland to the floor saw system. The water delivery system connection will consist of a 1 inch, Sch. 40, FNPT end. The maximum pressure will be 110 psig.

2. Crane – A single 10-ton bridge crane will be used for all lifting operations.

3. MSM’s –MSM’s will be installed at the Mockup similar to those of the 324 REC.

4. Transfer Mechanism – The FSS must be installed, operated, and removed with the Transfer Mechanism in place. The transfer mechanism sits on the B-Cell door threshold. Refer to preliminary transfer mechanism drawings, H-3-318008, H-3-318009 and H-3-318010 for information. Note that the latter is not the final design. The final dimensions must be confirmed with CHPRC prior to design completion of the floor saw.


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2.2.3 Cameras & Lighting

Cameras and lighting will be provided at both the Mockup and B-Cell for assisting with remote crane and positioning operations. Controls and views of the camera system are completely independent of the FSS.

2.3 Electrical Requirements

Electrical requirements for the FSS are listed below.

1. Electrical equipment must comply with NFPA 70, National Electrical Code.

2. Electrical equipment and devices (including material, fittings, devices, appliances, fixtures, apparatus, and the like, used as a part, or in connection with, an electrical installation) for which there is a National Recognized Testing Lab (NRTL) listing category, shall be listed, labeled, and recognized by an organization currently recognized by Occupational Safety and Health Administration.

3. Once the FSS is in B-Cell, an umbilical (composed of power and control wires and a water hose) shall be used to run from the floor saw up to a penetration, where the cables shall be hooked by an operator using a tool from the Gallery side and pulled through the B-Cell wall, using ALARA principles to protect workers from radiation exposure.

4. The power supply and control cords shall be equipped with straight plugs (or CHPRC Engineering approved alternatives) that can be connected to the floor saw by MSMs. The power supply, and control wiring if necessary, shall have male plugs for connecting to receptacles in the Gallery and female ends at the floor saw connection.

5. The FSS system shall operate on 480V, 240V, and/or 120V systems.

2.4 Mechanical Requirements

1. The FSS must operate within the geometric constraints of the environment.

2. Equipment must be capable of handling the loads and stresses of installation and operations and disposal (including off-normal events).

3. Equipment must be capable of handling the loads and stresses (von Mises) of operations using a minimum allowable yield stress design (safety) factor of 2. More detail is given in the performance specification, PRC-SRP-00066, section 6.10.1, Design Loads.

2.5 Radiological Requirements

The equipment shall be designed to withstand the radiological dose rates calculated in the material evaluation, PRC-SRP-00009. Note that PRC-SRP-00009 includes an assumed duration

NFPA 70, National Electrical Code, is a registered trademark of the National Fire Protection Association, Quincy, Massachusetts.


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of 133 days before the floor saw is removed from service. The Contractor shall use a duration of 6 months (180 days) instead of the duration included in PRC-SRP-00009.

The FSS will be remotely installed and operated. However, installation of the floor saw connections through the penetrations has the potential to exposure workers to a high dose rate of radiation. To what extent is possible, the equipment must incorporate shielding and confinement along with engineered controls to provide radiological protection to the worker during installation and operation. Administrative controls should be used as little as reasonably possible.

2.6 Nuclear Safety Requirements

This equipment to be designed is for General Service. The equipment being installed is neither Safety Significant nor a Safety Class system. They are neither a part of, nor do they directly affect, the building safety systems.

2.7 Fire Protection Requirements

The combustible materials within the REC Cells and near the oil-filled cell windows shall meet the limits shown in Table 2 from CHPRC-02984, Building Fire Hazards Analysis (Formerly WCH-361, Rev. 2) Section 10.2. These combustible loading limits were developed to ensure the quantities of combustible materials present are insufficient to result in flashover conditions, insufficient to result in failure of oil-filled hot cell windows, and insufficient to result in filter plugging, which would cause an unfiltered release of radioactive material into the atmosphere.

Table 2: REC Hot Cell Combustible Loading Limits

Location Baseline

(Plastic Equivalence)

Combustible load in each cells and airlock 380 kg (836 lb.)

Within 0.91 m (3 ft) of oil-filled cell windows 13.8 kg (30.4 lb.)

A calculation has been prepared for the design provided by CHPRC that analyzes the planned combustible loading within the REC Cells and galleries and complies with the combustible loading limits (KUR-1782F-CALC-M020, Equipment Combustible Loading).

If the contractor deviates from the design provided by CHPRC, the contractor shall calculate the plastic equivalence combustible material for the system design in accordance with procedure 324-PRO-OP-53669, Hot Cell Combustible Material Inventory.

Contractor is encouraged to use materials that reduce the combustible material inventory while ensuring system meets performance requirements.

2.8 Quality Assurance Requirements

Quality Assurance Level 3.


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3.0 References

The referenced documentation for the 300-296 Remote Soil Excavation Project was prepared under the Washington Closure Hanford (WCH) River Corridor Closure Project contract with the U.S. Department of Energy, Richland Operations Office (contract no. DE-AC06-05RL14655). The 300-296 Remote Soil Excavation Project work scope and the associated documentation was transitioned to CHPRC in 2016. CHPRC has not reviewed and is not responsible for the content within the documentation prepared under the WCH contract. The documentation is provided for information only. Prospective contractor may not rely on the referenced documents as a representation of the conditions likely to be encountered when performing work under this solicitation. Each prospective contractor retains sole and complete responsibility for providing goods and/or services in compliance with the statement of work and specifications without regard to aforementioned documents.

Documents prepared under the WCH contract include:

KUR-1782F-CALC-M020, Rev. 0, Equipment Combustible Loading, Kurion, Richland, WA

The following documents have been prepared by CHPRC:

324-PRO-OP-53669, Hot Cell Combustible Material Inventory, CH2M Hill Plateau Remediation Company, Richland, Washington

CHPRC-02981, 324 Building Safety Equipment List, Rev. 0, 2016, CH2M Hill Plateau Remediation Company, Richland, Washington

CHPRC-02984, 324 Building Fire Hazards Analysis Rev. 1, 2016 (Formerly WCH-361, Rev. 3), CH2M Hill Plateau Remediation Company, Richland, Washington

DOE-STD-1098-2008, Radiological Control, Change Notice 1, 2009, US Department of Energy, Washington, D.C.

H-3-20160, Arch Floor Plan Elevation 0ft-0In Area 3, Rev. 3, 1989, Pacific Northwest Laboratories, Richland, WA

H-3-20166, Architectural Floor Plan El 11ft-6in Area 3, Rev. 3, 1989, Pacific National Laboratories, Richland, WA

H-3-20173, Architectural Door Details, Rev. 1, 1966, Vitro, Richland, WA

H-3-20190, Architectural Floor Plan El (-) 10ft-0in. Area 3, Rev. 1, 1966, Vitro, Richland, WA

H-3-20195, Structural Concrete Foundation & Basement Plan Area 3, Rev. 1, 1966, Vitro, Richland, WA

H-3-20214, Structural Concrete Hot Pilot Cells, Area 3, Rev. 6, 1983, Pacific Northwest Laboratories, Richland, WA

H-3-20240, Hot Pilot Cells Crane and Shield Doors to Low Bay Cell, Rev. 1, 1966, Vitro, Richland, WA


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H-3-20241, Hot Pilot Cells Crane and Shield Doors Air Lock, Pyro, and Mech. Cell, Rev. 1, 1966, Vitro, Richland, WA

H-3-20273, SST Liner Details Hot Pilot Cells & Hot MET, Cells, 1966, Rev. 2, Vitro, Richland, WA

H-3-300262, sheet 1, SCW Loading System Facility Drawing Building Plan at El. 0ft-0in., Rev. 4, 2015, Washington Closure Hanford, Richland, WA

H-3-300262, sheet 3, SCW Loading System Facility Drawing Plan, Cask Handling Area, Rev. 0, 1993, Pacific Northwest Laboratories, Richland, WA

H-3-300262, sheet 6, Facility Drawings Cell Area Building El. at Sect A-A, Rev. 2, 2015, Washington Closure Hanford, Richland, WA

H-3-300262, sheet 7, SCW Loading System Facility Drawing Building El. at Sect B-B, Rev. 2, 2015, Washington Closure Hanford, Richland, WA

H-3-300262, Sheet 9, Facility Drawings Cell Area El at Sect D-D, Rev. 2, 2015, Washington Closure Hanford, Richland, Washington

H-3-317729, Air Lock Track Cart Assembly, Rev. 0, 2016, CH2M Hill Plateau Remediation Company, Richland, Washington

H-3-317731, Sheets 1 and 2, Airlock Tracks Installation Plan, Rev. 0, 2017, CH2M Hill Plateau Remediation Company, Richland, Washington

H-3-317768 Sheet 1, Structural Elevation at Gridline B Looking South, Rev. 1, 2017, CH2M Hill Plateau Remediation Company, Richland, Washington

H-3-318008, Sheets 1 and 2, Machine Transfer Mechanism Assembly and Details, Rev. 0, 2017, Kurion, Richland, Washington

H-3-318009, Sheets 1-10, Machine Transfer Mechanism Frame Assembly and Details, Rev. 0, 2017, Kurion, Richland, Washington

H-3-318010 Sheets 1-9, Machine Transfer Mechanism Cart Assembly and Details, Rev. 0, 2017, Kurion, Richland, Washington

PRC-SRP-00009, 300-296 Soil Remediation Project Material Evaluation, Rev. 0, 2016, CH2M Hill Plateau Remediation Company, Richland, Washington

PRC-SRP-00024, Design Report Narrative for the Floor Saw, Rev. 0, 2016 (Formerly KUR-1782F-RPT-026 Rev.0), CH2M Hill Plateau Remediation Company, Richland, Washington

PRC-SRP-00058, Functions and Requirements Document 300-296 Soil Removal Project Transfer Mechanism System, Rev. 0, 2017, CH2M Hill Plateau Remediation Company, Richland, Washington

PRC-SRP-00066, Performance Specification 300-296 Soil Removal Project Floor Saw System, Rev. 0, 2017, CH2M Hill Plateau Remediation Company, Richland, Washington