tank side cesium removal system ap farm hydraulic ... · ap-106 riser 2 drop leg rpp-calc-62623...

A-6007-231 (REV 0)

RPP-CALC-62532

Revision 0

Tank Side Cesium Removal System AP Farm Hydraulic Transient Analysis

Prepared by

KW Dixon

Atkins Energy Federal EPC, Inc. (by ARES Corporation) for Washington River Protection

Solutions, LLC

Date Published

August 2019

Prepared for the U.S. Department of Energy

Office of River Protection

Contract No. DE-AC27-08RV14800

washington riverprotection solutions

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_______________ RPP-CALC-62532,_Rev._0 ________________

Page No.1 of28

CALCULATION COVER SHEET Date Rev. No.

Calculation No:____________________ 078906.18.01 -M-003

Project No. Project Title: Client:078906.18.01 Design of TSCR Upgrades IAtkinsTitle:

Tank Side Cesium Removal System AP Farm Hydraulic Transient AnalysisPurpose and Objective:

The purpose of this calculation is to evaluate the Tank Side Cesium Removal (TSCR) System piping andcomponents located in 241-AP Tank Farm (excluding the TSCR unit). Specifically, this analysis determines ifthe internal transient pressures and forces due to hydraulic transient loads are within the allowables of TheAmerican Society of Mechanical Engineers (ASME) B3 1.3 - 2016, Process Piping code. TFC-ENG-DESIGN-C-60, Preparation of Piping Analyses of Waste Transfer Systems, is used as the basis of evaluation. Thiscalculation also recommends abatement methods that should be implemented to mitigate or eliminateproblematic conditions which could result in excessive pressures and forces.

Rev. TotalPrepared By Checked By PM/TLNo. Pages _______ ______________________________ _______________________________ _____________________________

KW Dixon P.E. PM Dorsh, P.E. PM Dorsh, P.E.PrintName!

0 28 Sign:

_____ ______ Date: 08/05/2019 08/05/2019 08/05/2019

Revision Description (Revision Description/Affected Pages):

Initial release.

Print KW Dixon, P.E. PM Dorsh, P.E. PM Dorsh, P.E.

Name! 1.1 28 Sign:

___ ____ Date: _________________ Z3-/' ________________

Revision Description (Revision Description/Affected Pages):

Revised Design Input 2, Revised Section 3.1.1 relating to Tank Farm manual valve closures, Revised Section9.0 and added RPP-HOLD-57925.

Quality Assurance Procedure 3.1 Calculation Cover Sheet (08-15)

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________________ RPP-CALC-62532, Rev. 0

CALCULATION REVIEW CHECKLIST

Project No. Calculation No. Rev. No. Page No.

078906.18.01 078906.18.01-M-003 1 2 of 28

Items Checked Description of Resolution for Unacceptable Items____________________________________ Y N N/A ______________________________

1. Cover sheets properly completed. V ______ ________________________________________________

2. Calculation sheet headers complete with calculation

number, revision number, etc.

3. Calculation sheet contents are legible, accurate, and

complete per format.

4. Listed attachments included. V ______ ___________________________________________

5. Calculation objective clearly described. V ______ ________________________________________________

6. Criteria are suitable and properly referenced to task

specific documents.

7. Assumptions and input data, selected, described,

reasonable, and attached or referenced to task Vdocuments.

8. Calculation method identified and appropriate for the

design_activity. ______ ________________________________________________

9. Calculation results reasonable and correctly described

in results and conclusions.

10. Physical property calculations generated by CAD

software verified via hand calculations.

11. Computer program identified with version and

revision.

12. Computer input/output provided or referenced and

reasonable.

13. Computer run traceable to calculation (file #, etc.). V _____________________________________________

14. Computer input/output data and problem type within

validationlverification range of use.

15. Computer program validationlverification addressed. V _________________________________________

16. Computer operating system in use for calculation

preparation is the same as when the software was Vverified on machine.

Calculation Checking Method V Applicable Pages

1. Direct Step-by-Step Check V All.2. Reference Chart(s) or Book(s) Comparison

(Append_Documentation) _____________________________________________________

3. Alternate Calculation (pend Documentation)

Comments:

None.

Preparer (Print Name and Sign): Date:

KW Dixon, P.E. ii ? -23-/7Checker (Print Name and Sign): Date:

PM Dorsh, P.E. ,z 3-1 7Signatures obtained only after discrepancies are corrected and comments are resolved.

Quality Assurance Procedure 3.1 Calculation Review Checklist (10-17)

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RPP-CALC-62532, Rev. 0

CALCULATION SHEET

Project No. 078906.18.01 Calculation No. 078906.18.01-M-003 Rev. 1 Page No. 3 of 28

Title: Tank Side Cesium Removal System AP Farm Hydraulic Transient Analysis

Prepared By: KW Dixon, PE Date: 08/23/19 Checked By: PM Dorsh, PE Date: 08/23/19

Quality Assurance Procedure 3.1 Calculation Sheet (05-10)

TABLE OF CONTENTS

1.0 PURPOSE ....................................................................................................................................................5

2.0 BACKGROUND .........................................................................................................................................5

3.0 METHODOLOGY ......................................................................................................................................5

3.1 Transient Loads ......................................................................................................................................6 3.1.1 Transient Pressures ..........................................................................................................................7

3.1.2 Transient Forces ...............................................................................................................................8

4.0 DESIGN INPUTS ........................................................................................................................................9

5.0 ASSUMPTIONS ..........................................................................................................................................9

6.0 COMPUTER SOFTWARE .......................................................................................................................10

7.0 CALCULATIONS .....................................................................................................................................10 7.1 Pressure Magnitude ..............................................................................................................................10

7.1.1 Maximum Allowable Pressure Magnitude ....................................................................................10 7.1.2 Maximum Pressure Magnitude ......................................................................................................10

7.2 Pressure Differential ............................................................................................................................10 7.2.1 Maximum Allowable Pressure Differential ...................................................................................10

7.2.2 Maximum Pressure Differential .....................................................................................................11

8.0 RESULTS AND CONCLUSIONS............................................................................................................11

9.0 IDENTIFICATION OF RECOMMENDED ABATEMENT CONTROLS .............................................14

10.0 REFERENCES ..........................................................................................................................................15

Appendices

APPENDIX A

Transient Load Scenarios From RPP-CALC-62576

Tables

Table 3-1 TSCR Stress Calculations....................................................................................................................... 6 Table 8-1 Allowable Pressure Magnitude and Pressure Differential Summary ................................................... 12 Table 8-2 Summary of Appendix A Results ......................................................................................................... 13

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Acronyms

AFT Applied Flow Technology

AOV Air Operated Valve

ASME American Society of Mechanical Engineers

DCR Demand to Capacity Ratio

DLF Dynamic Load Factor

DSA Documented Safety Analysis

DST Double-shell Tank

FCV Flow Control Valve

HTF Hydraulic Transient Force

HIHTL Hose-In-Hose Transfer Line

IXC Ion Exchange Unit

lbf Pound Force

LAW Low Activity Waste

psid Pounds Per Square Inch Differential

SAC Specific Administrative Control

TFP Tank Farm Projects

TSCR Tank Side Cesium Removal

WRPS Washington River Protection Solutions

WTP Waste Treatment Plant

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1.0 PURPOSE

The purpose of this calculation is to evaluate the Tank Side Cesium Removal (TSCR) System piping and

components located in 241-AP Tank Farm (excluding the TSCR unit). Specifically, this analysis determines if

the internal transient pressures and forces due to hydraulic transient loads are within the allowables of The

American Society of Mechanical Engineers (ASME) B31.3 – 2016, Process Piping code. TFC-ENG-DESIGN-

C-60, Preparation of Piping Analyses of Waste Transfer Systems, is used as the basis of evaluation. This

calculation also recommends abatement methods that should be implemented to mitigate or eliminate

problematic conditions which could result in excessive pressures and forces.

2.0 BACKGROUND

Tank Farm Projects (TFP) has been tasked to execute the design and construction of the necessary upgrades to

the Tank Farms to allow the integration and operation of the TSCR Demonstration Project and Tank Farms for

the processing of tank waste. TSCR Upgrades will modify a subset of the double-shell tank (DST) system,

specifically three AP Tank Farm tanks; 241-AP-106, 241-AP-107, and 241-AP-108. TSCR Upgrades will

provide the infrastructure to transfer supernatant waste to TSCR and receive TSCR Low Activity Waste (LAW)

product, TSCR plant wash returns (filter backwash, ion exchange column caustic/water rinses and sump pump

liquids) and TSCR vent effluent. After completion of the TSCR upgrades and construction of the TSCR, the

capability will exist to treat tank waste to meet waste acceptance criteria for delivery to the Waste Treatment

Plant (WTP) LAW facility for vitrification.

3.0 METHODOLOGY

The goal of a transient analysis is to determine the flow transient loads that can occur in a system and should be

performed in one analysis. However, determining the stress in the piping due to the transient loads can be

performed in different evaluations. For the TSCR system, the transient loads are determined in

RPP-CALC-62576 while the evaluation of the stresses in both the general service and safety significant piping

occurs in numerous analyses. All general service piping is located outside of AP Farm in the TSCR unit. Safety

significant piping is located in both the TSCR unit and all AP Farm piping. The table below identifies the

numerous stress calculations within the TSCR system.

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Table 3-1 TSCR Stress Calculations

Transient Load

Calculation

Piping Location

Piping Class

Piping Evaluated Longitudinal

Stress Calculation

Internal Pressure (Hoop

Stress) Calculation

Drawing

RPP-CALC-62576

TSCR Unit

GS TSCR Unit Piping RPP-CALC-62577

RPP-CALC-62576

H-14-111270

SS HIHTL Connections RPP-CALC-62576 H-14-111280

IXC-150 Outlet Piping

RPP-CALC-63127 H-14-111255

RPP-CALC-62532

Tank Farm

SS

AP-106 Riser 2 Drop Leg

RPP-CALC-62623

RPP-CALC-62532

H-14-111344

AP-07F Pump Pit RPP-CALC-62624

H-14-111334 H-14-111335 H-14-111336 H-14-111340 H-14-111342 H-14-111365

AP-108 Riser 15 Drop Leg

RPP-CALC-62625 H-14-111346

All of the above stress calculations use the transient loads determined in RPP-CALC-62576 for determining the

piping stress due to impact loads as identified in ASME B31.3 para. 301.5.1 Impact Loads. Transient loads

create a circumferential stress (hoop stress) and axial stress (longitudinal stress) in piping. Specifically the

stress calculations above evaluate the longitudinal stress in the piping due to the transient loads. The hoop

stresses due to the transient loads are evaluated separately in RPP-CALC-62576 and this analysis. Note that this

analysis does not determine any additional transient loads. All transient loads are determined in RPP-CALC-

62576.

3.1 Transient Loads

Flow transient loads are defined as any load created by a device or condition which alters a system’s steady

state flowing or no flow condition. Flow transient loads can be divided into two categories 1) transient

pressures and 2) transient forces. The maximum allowable transient pressures are based on the system design

pressure and the occasional variances as allowed per ASME B31.3 para. 302.2.4. In order to bound the

evaluation of transient forces, the largest force produced from a transient event is determined. Conservatively

these loads are considered static and multiplied by a worst case dynamic load factor (DLF) of 2.0. This force is

then compared to the maximum allowable force determined in the stress calculations at the worst case

location(s) that generate the highest allowable Demand to Capacity Ratio (DCR) for longitudinal stress. If

DCRs are acceptable this method will avoid multiple force-time history stress analyses that are even more time

dependent and strenuous. If DCRs are not acceptable then force-time history outputs can be generated at worst

case elbows. The peak force output from these plots will be determined and again multiplied by a worst case

DLF of 2.0. This new typically lower force is again compared to the maximum allowable force determined in

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the stress calculations at the worst case location(s) that generate the highest allowable DCR for longitudinal

stress. If DCRs do not pass again then the force-time history plots will be input into a dynamic stress analysis. If

stresses are still not acceptable then abatement methods or redesign is required.

3.1.1 Transient Pressures

Transient pressures are created by a device or condition which alters a system’s steady state flowing or no flow

condition. Transient pressures within the TSCR System are determined for numerous scenarios in RPP-CALC-

62576. Although RPP-CALC-62576 was evaluating the TSCR unit, it contained both general service and safety

significant piping. Therefore, the procedures outlined in TFC-ENG-DESIGN-C-60 were used when

determining transient scenarios for evaluating the safety significant piping within the TSCR unit. Because of

this, no additional scenarios are considered in this evaluation for evaluating the safety significant piping in AP

Farm.

Based on RPP-CALC-62576, the scenarios which were applicable to evaluating the AP Farm piping are as

follows:

1. AP Farm Pump Trip

2. Automated Valve Operation:

a. Instant closure of flow control valve WP-FCV-306 located within the TSCR unit.

b. Instant closure of flow control valve WP-AOV-560 located within the TSCR unit.

c. Instant closure of a simulated valve within the TSCR unit on the drain line.

3. Manual Valve Operation:

a. AP Farm Manual Valves

b. TSCR Unit Manual Valves

4. Column Separation

Of the scenarios listed above, column separation was the only scenario which did not require detailed analysis

because it was shown to not be possible. All other scenarios listed above created transient pressures that would

travel into AP Farm through the various HIHTL lines going to and from the TSCR unit. Although there are

numerous automated valves in the TSCR unit, the valves identified above were selected as they were the valves

closest to the HIHTL connections that would create the bounding transient pressures in the safety significant

TSCR unit and AP Tank Farm piping.

By inspection, a Tank Farm manual valve closure during flowing conditions will exceed the maximum

allowable internal pressure of the PUREX connectors/nozzle (See Design Input 2). This is based on the

instantaneous closure of valves at similar flow velocities. [Therefore a safety-significant SSC and/or SAC is

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required to ensure Tank Farm manual valves are not operated during flowing conditions (see Assumptions).]

RPP-HOLD-57925.

TSCR manual valves are bounded by the analysis of automated valve instant closures. If an instant closure of

the automated TSCR valves is within compliance then manual TSCR valve closures will be considered

acceptable.

3.1.2 Transient Forces

Transient forces are created by a transient pressure wave as it travels through the piping at the speed of sound

within the fluid. As the pressure wave travels through the piping it subjects elbows to varying pressures

depending on the shape of the pressure wave. When the pressure at one elbow varies from the pressure at the

upstream and/or downstream elbow, a force imbalance exists. This force imbalance is applied to the piping and

pipe supports creating additional stress. The piping experiences an increase in longitudinal stress which must be

evaluated in a stress analysis. Calculation of Hydraulic Transient Forces (HTFs) can be very time consuming

due to the variety of possible transient events and the resulting large volume of output data. In addition, the

fluid transient modeling software, AFT Impulse which is used in RPP-CALC-62576, includes several

limitations that may impact the accuracy of these force calculations.

Based on the limitations of AFT Impulse, a more simplified approach is taken for determining transient forces.

The worst case transient force is more likely to occur at piping bends which have a large distance between an

adjacent elbow. The larger the distance the larger the pressure differential is likely to be. Using the formula

F=ΔP*A, where F is the transient force, ΔP is the maximum pressure difference between two elbows, and A is

the transverse internal area of the piping, a bounding transient force is determined. Conservatively assuming

the pressure wave has the shape of a step function from the maximum transient pressure to vapor pressure, a

bounding force is determined in Appendix A. These forces are then multiplied by a worst case DLF of 2.0 to

account for any stress amplification that could occur should the transient load duration occur over a similar

duration as a resonant period of the piping structure. These forces are then compared to the maximum allowable

transient forces determined in the stress analyses. The B31.3 stress calculations RPP-CALC-62623, RPP-

CALC-62624, and RPP-CALC-62625 determine the maximum flow transient load possible which results in the

maximum allowable longitudinal stress per ASME B31.3 code.

If the above simplified approach does not pass allowables, then force-time history plots will be generated from

AFT Impulse. Force-time history plots require two force pairs per elbow. One force pair is between the

evaluated elbow and the adjacent upstream elbow while the other force pair is between the evaluated elbow and

the adjacent downstream elbow. Each force pair is calculated in Impulse using the “Difference” force

calculation type. When more than two pipes are located between the elbow pairs the “Difference (3+ pipes)”

type is used. Each data point created in the force-time plot is the net force difference between the two elbows.

Positive force values correspond to a net force in the same direction as fluid flow, while a negative force value

corresponds to a net force in the opposite direction of flow. Once the resultant force magnitude is determined it

is again multiplied by a DLF of 2.0 to account for amplification due to resonance.

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4.0 DESIGN INPUTS

1. All AP Farm piping, components and Hose-In-Hose Transfer Lines (HIHTL) are classified as safety

significant per the Tank Farms Documented Safety Analysis (DSA) RPP-13033.

2. Tank Farm jumper hydrostatic test pressures are 600 psig per the AP07F jumper drawings identified in

Table 3-1. These jumpers include PUREX connectors/nozzles which are qualified to meet ASME B31.3

code with a design pressure of 400 psig in RPP-RPT-36800. A failure limit has not been determined for

the PUREX connectors/nozzles therefore the 600 psig hydrostatic test pressure will be used as the

maximum allowable internal pressure limit. Transient loads which exceed the 600 psig will require

implementation of a safety significant SSC and/or SAC to eliminate or mitigate the pressure within code

allowables.

3. [Maximum pressure magnitudes and pressure differentials shown in Appendix A are generated from the

AFT Impulse model used in RPP-CALC-62576. See RPP-CALC-62576 for all AFT Impulse inputs and

outputs.] RPP-HOLD-57906

4. The maximum allowable transient force from RPP-CALC-62623 is 350 lbf.



5.0 ASSUMPTIONS

1. RPP-HOLD-57906 is used throughout this analysis on the following inputs that need to be verified:

a. RPP-RPT-61220 Rev. 1:

i. TSCR Sequence Tables Appendix C – Modify all IXC Align Operations shall indicate

that valve WP-AOV-560 is verified open prior to closing valve WP-AOV-556.

ii. Section 5.2 Footnote – Add to footnote that WP-AOV-560 has minimum closure rate

from full open to close of 6 seconds.

b. H-14-111270 Sh. 1 Item 10 Rev. 2:

i. Update WP-PCV-557 as being a fail in place or fail open actuator.

c. If the above items are verified to be correct in the revisions identified then the analysis

performed in RPP-CALC-62576 is valid and RPP-HOLD-57906 can be removed.

2. RPP-HOLD-57925: It is assumed that one or more safety significant SSCs and/or SACs will be

implemented into the operating procedures or design to prevent the operation of manual tank farm

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valves during flowing conditions. Once a SSC and/or SAC are verified in the design or operating

procedures this hold can be removed.

3. Conservative assumptions not requiring verification are identified throughout the analysis.

6.0 COMPUTER SOFTWARE

Hand calculations were performed using PTC®1 Mathcad

®1 15.0. Results from Mathcad are checked directly

step-by-step.

7.0 CALCULATIONS

7.1 Pressure Magnitude

7.1.1 Maximum Allowable Pressure Magnitude

TFC-ENG-DESIGN-C-60 defines internal pressures due to sustained and occasional loads as safe when they do

not exceed the design pressure of any piping or components, including any variation in pressure allowable

under the terms of ASME B31.3, para. 302.2.4. For simplicity the maximum allowable sustained internal

pressure is conservatively based on the lowest system design pressure (rather than component design pressure)

of any section within the TSCR System. Per RPP-RPT-60603 Table 2-1 the lowest design pressure is 400 psig

at 180°F. This system design pressure will dictate the maximum allowable pressure magnitude that can occur in

any portion of the system. If this pressure is exceeded then allowable pressure variances per ASME B31.3, para.

302.2.4 will be considered. Note that the maximum allowable pressure differential determined below may

further limit the maximum allowable pressure magnitude of 400 psig due to the methodology of this analysis.

7.1.2 Maximum Pressure Magnitude

The maximum pressure magnitudes are calculated in RPP-CALC-62576 and shown in Appendix A for the

various scenarios evaluated.

7.2 Pressure Differential

7.2.1 Maximum Allowable Pressure Differential

Based on the limitations of AFT Impulse in the determination of transient forces discussed in Section 3.1.2, this

analysis will take a simplified conservative approach. Rather than determining transient forces at every elbow

in AP Farm, this analysis will determine the maximum transient differential pressure values based on the results

of AFT Impulse. This approach assumes that the shape of the transient pressure wave travels through the piping

with a shape similar to a step function. This is conservative because it allows for the maximum pressure

differential between adjacent elbows as the pressure wave travels through the piping. This maximum transient

differential pressure will then be compared to the calculated maximum allowable differential pressure

determined below. The maximum allowable differential pressure is calculated based on the maximum allowable

1 PTC and Mathcad are registered trademarks of PTC Inc., Needham, Massachusetts.

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transient force determined in the stress calculations. This transient force is converted into the maximum

allowable pressure differential based on the pipe diameter in which the pressures will occur.

The maximum allowable pressure differential is determined below.

If force-time outputs are determined then the maximum peak force value can be directly compared to the

maximum allowable transient force determined in the stress calculations.

7.2.2 Maximum Pressure Differential

The maximum pressure differentials are calculated in RPP-CALC-62576 and shown in Appendix A for the

various scenarios described in Section 3.1.

8.0 RESULTS AND CONCLUSIONS

The results of this analysis concluded that all transient events within the TSCR System do not cause transient

pressures or forces to exceed ASME B31.3 allowables in the AP Farm safety significant piping except for tank

farm manual valve closures. Because of this all manually operated AP Farm valves will require the

implementation of safety-significant support SSCs and/or SACs to mitigate or eliminate pressures/stresses to

within ASME B31.3 allowables. Once implemented, the SSCs and/or SACs can be credited for protecting the

safety-significant TSCR unit piping (see Assumptions). Manual operation of the manual TSCR valves is

acceptable since an instant closure of the automated valves is acceptable. See Table 8-1 and Table 8-2 for the

transient allowables and summary of Appendix A results respectively.

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Table 8-1 Allowable Pressure Magnitude and Pressure Differential Summary

rr3REN

Al Iowa ble

Transient Allowable DifferntialPiping

Transient Load Scenario PipingJHlHTL Evaluated Pressure <Reference Transient Pressure <ReferenceClassification

Magnitudet (psid)2

__________ ______________ ________________ (psig __________ _____________ __________

A3-106 Riser 2 Drop Leg 400 H-14-111344 104 Section 7.2.1

4Q0 H-14-111334

400 H-14-111335

400 H-14-11133AP-07F Pump Pit 37 Section 7.2.1

Safety Significant See Section 3.1 4QQ H-14-111340

400 H-14-111342

_______________________ 400 H-14-11135

AP-108 Riser 15 Drop Leg 400 H-14-11134 104 Section 7.2.1

_____________ ___________________ All HIHTL 425 RPP-14559 NA NA

1 - Allowable transient pressure due to design pressure (hoop stress}.

2- Allowable differentialtransient pressure due to transient forces (longitudinal stress).

3 - The internal pressure can exceed the design pressure by 20% provided all requirements of ASME p31.3 para. 302.2.4 are met.

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Table 8-2 Summary of Appendix A Results

Maximum Maximum Force-Maximum Maximum Force-

Analysis Section AFT Allowable Allowable Time AllowableTransient Pressure Differential time peak

Transient Initiator Section Evaluated Evaluated in Impulse Pressure Differential Pass? Peak PeakScenario Magnitude Pressure force

RPP-CALC-62576 Required 2 Magnitude Pressure Force Force (lbf)

(psug) (psid)2 pass?_________ __________ ______________________ ____________________ ______________ ________ __________ (psig) __________ (psid)1 (lbf) ________ ________

Feed Line Yes 176 400 72 37 No 20 125 Yes

Pump Trip AP Farm Pump Recirc Line4 Appendix Dl Yes 155 400 72 104 Yes - - -

___________ ________________________ Treated Effluent Line5 ________________ Yes 11 400 36 104 Yes - - -

Feed Line Yes 219 400 64 37 No 10 125 Yes

WP-FCV-306 Recirc Line4 Appendix El Yes 200 400 32 104 Yes - - -

SafetyAutomated ______________________

Treated Effluent Line5 ______________ Yes 25 400 64 104 Yes - - -

Significant 3Valve Feed Line Yes 234 400 84 37 No 43 125 Yes

loads 4 -

Operation WP-AOV-560 Recirc Line Appendix E2 Yes 215 400 84 104 Yes - - -

Treated Effluent Line5 Yes 36 400 86 104 Yes - - -

Simulated Valve Treated Effluent Line5 Appendix E3 Yes 204 400 70 104 Yes - - -

Manual AP Farm Manual Valves All Tank Farm SS NA No __________ __________ __________ __________ Yes ________ ________

Valve TSCR Unit Manual Valves All Tank Farm SS NA No __________ __________ __________ __________ Yes ________ ________

1- See able 8-1 tor allowable pressure magnitudes and ditterentials.

2- Values are calculated in RPP-CALC-62576 and graphed in Appendix A of this analysis.

3-Feed line includes AP-07F pump pit and feed HIHTL

4- Recirc line includes the recirculation HIHTL and the dropleg in AP-07F

5-Treated effluent line includes the treated effluent HIHTL and the drop leg in AP-106

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9.0 IDENTIFICATION OF RECOMMENDED ABATEMENT CONTROLS

Based on the conclusions of this analysis all manually operated tank farm valves in the scope of this analysis

will require the implementation of safety-significant support SSCs and/or SACs to mitigate or eliminate

pressures/stresses to within ASME B31.3 allowables. Once implemented, the SSCs and/or SACs can also be

credited in RPP-CALC-62576 for protecting general service and safety-significant TSCR unit piping. It is

recommended to implement SAC 5.8.5 from HNF-SD-WM-TSR-006 into the operating procedures of the

TSCR system.

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10.0 REFERENCES

1. ASME B31.3-2016, Process Piping, The American Society of Mechanical Engineers, New York, NY.

2. Crane, Technical Paper 410, Flow of Fluids Through Valve, Fittings, and Pipe, 2011, CRANE Co.,

Stamford, CN.

3. H-14-111255, Sheets 1-12, Rev. 1, TSCR IXC-150, Fabrication Assembly, Sequence Drawing,

AVANTech Inc.

4. H-14-111270, Sheets 1-36, Piping Process Enclosure Treated LAW, [Rev. 2]RPP-HOLD-57906,

AVANTech Inc.

5. H-14-111280, Sheet 11, Process Enclosure Frame Weldment, Rev. 0, AVANTech Inc.

6. H-14-111334, AP Farm TSCR Upgrades 241-AP-07F Jumper AP07F-WT-J-[P1-P2-(A)], Rev. 0, U.S.

Department of Energy, Richland, WA.

7. H-14-111335, AP Farm TSCR Upgrades 241-AP-07F Jumper AP07F-WT-EPDMJ-[C-D], Rev. 0, U.S.


8. H-14-111336, AP Farm TSCR Upgrades 241-AP-07F Dropleg Disch Notes and Parts List, Rev. 0, U.S.


9. H-14-111340, AP Farm TSCR Upgrades 241-AP-07F HIHTL Strbk Notes and Parts List, Rev. 0, U.S.


10. H-14-111342, AP Farm TSCR Upgrades 241-AP-07F Jumper AP07F-WT-EPDMJ-[A-B], Rev. 0, U.S.


11. H-14-111344, AP Farm TSCR Upgrades 241-AP-106 Riser 2 Dropleg Notes and Parts List, Rev. 0,

U.S. Department of Energy, Richland, WA.

12. H-14-111346, AP Farm TSCR Upgrades AP-108 Riser 15 Dropleg Notes and Parts List, Rev. 0, U.S.


13. H-14-111365, AP Farm TSCR Upgrades 241-AP Pump Dummy Notes and Parts List, Rev. 0, U.S.


14. HNF-SD-WM-TSR-006, Rev. 9, Tank Farms Technical Safety Requirements, Washington River

Protection Solutions, Richland, WA.

15. RPP-13033, Tank Farms Documented Safety Analysis, Rev. 7L, Washington River Protection Solutions,

LLC, Richland, Washington.

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16. RPP-14859, Specification for Hose-in-Hose Transfer Lines and Hose Jumpers, Rev. 14, Department of

Energy, Richland, WA.

17. RPP-CALC-62576, Tank Side Cesium Removal Unit Hydraulic Transient Analysis, Rev. 0, Department

of Energy, Richland, WA.

18. RPP-CALC-62577, ASME B31.3 Analysis of TSCR Process Piping, Rev. 0, Department of Energy,

Richland, WA.

19. RPP-CALC-62623, B31.3 Evaluation of Riser Adapter and Drop Leg Piping for 241-AP-106 Riser 2,

Rev. 0, Department of Energy, Richland, WA.

20. RPP-CALC-62624, B31.3 Evaluation of the Jumpers and Drop Leg Piping for 241-AP-07F Pump Pit,


21. RPP-CALC-62625, B31.3 Evaluation of Riser Adapter and Drop Leg Piping for 241-AP-108 Riser 15,


22. RPP-CALC-63127, Maximum Transient Load on the IXC-150 Outlet Piping, Rev. 0, Department of


23. RPP-SPEC-60603, Interface Management Agreement between TF Upgrades Project (Project #T1P190)

and the Tank Side Cesium Demonstration Project (Project #TD101), Rev. 2, U.S. Department of


24. TFC-ENG-DESIGN-C-60, 2017, Preparation of Piping Analyses for Waste Transfer Systems, Rev. A-3,

Washington River Protection Solutions, LLC, Richland, WA.

25. RPP-HOLD-57906, TSCR System Hydraulic Transient Analysis Hold, Washington River Protection

Solutions, LLC, Richland, WA.

26. RPP-HOLD-57925, TSCR System Manual Valve Closure Hold, Washington River Protection Solutions,

LLC, Richland, WA.

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APPENDIX A

TRANSIENT LOAD SCENARIOS FROM RPP-CALC-62576

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Scenario D1 (From RPP-CALC-62576)

Transient Event AP Farm Pump Trip

Model Path Clean, IXC-A>IXC-B

Section(s) Evaluated All AP Farm Piping

Pressure profile of treated effluent HIHTL and AP-106 Drop leg

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Pressure profile of feed and recirculation HIHTL, AP-07F pump pit, and recirculation drop leg

The above plot snapshot is taken at 0.3789 seconds. It illustrates that the maximum pressure differential

between two elbows 50 ft apart would be 36 psid. 50 ft is conservative since the all jumper and drop leg piping

sections are less than 10 ft.

36 psid

50ft

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Force-time history plot at worst case eblow on jumper AP-07F-WT-J-[P1-P2-(A)]

The peak transient forces in the above plot are approximately 5.5 lbf and 8 lbf. These forces act orthogonal to

each other at the evaluated elbow. When combined into the resultant force using the Root Mean Square (RMS)

and multiplying by a worst case dynamic load factor (DLF) of 2.0 to account for the maximum potential force

due to resonance amplification, the magnitude becomes:

2 ∗ √5.5𝑙𝑏𝑓2 + 8.0𝑙𝑏𝑓2 ≈ 20lbf

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Scenario E1 (From RPP-CALC-62576)

Transient Event Instant Closure of WP-FCV-306

Model Path Clean, IXC-A>IXC-B



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The peak transient forces in the above plot are approximately 2.5 lbf and 3.8 lbf. These forces act orthogonal to




2 ∗ √2.5𝑙𝑏𝑓2 + 3.8𝑙𝑏𝑓2 ≈ 10 lbf

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Transient Event Instant Closure of WP-AOV-560

Model Path Dirty, IXC-A>IXC-B>IXC-C




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The peak transient forces in the above plot are approximately 18 lbf and 12 lbf. These forces act orthogonal to




2 ∗ √18𝑙𝑏𝑓2 + 12𝑙𝑏𝑓2 ≈ 43 lbf

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Transient Event Instant Closure of Simulated Valve

Model Path Drain and Vent Model/Filter Blowdown/without sump pump


Max Pressure Diff. (psid) 35*2=70

Allowable Pressure Diff. (psid) 104

Maximum Pressure Magnitude (psig) 204

Allowable Pressure Magnitude (psig) 400

Pass? Yes

Pressure in Drain Line HIHTL and AP-108 Drop Leg

The pressure profile between J99 and J96 indicates the maximum pressure magnitude however, the profile

between these junctions is created from cavitation due to the elevation drop in the drop leg. Evaluation of the

event indicates the pressure increase is due to numerous vapor cavity collapses. These cavities are created due

to the low flow rate and drop in elevation from the drop leg inlet to outlet after the valve has closed. Impulse

cannot model open channel flow and also assumes that vapor cavities do not move. The pressure magnitude is

considered an absolute maximum even though unrealistic. The pressure differential within the HIHTL is not of

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concern. Only pressure differentials between the drop leg elbows and upstream or downstream elbows are. The

maximum pressure differential is conservatively determined from the 100ft location within the HIHTL to the

drop leg inlet. The pressure differential between these two points is a conservative maximum due to the long

distance between the elbows. The plot above is a snapshot at 0.1764 seconds. Due to isolation valves, all other

tank farm piping is isolated from pressure transients during this scenario.

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tank side cesium removal system ap farm hydraulic ... · ap-106 riser 2 drop leg rpp-calc-62623...

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