John Duda
U.S. DOE-FETC
D&D Focus Area
P.O. Box 880
Morgantown, WV 26507

Shannon Saget
U.S. DOE-RL
EESB3230 Q Avenue
Richland, WA 99352

Kenneth M. Kasper, CHP
Waste Policy Institute
1224 Pineview Drive
Morgantown, WV 26505

The technical performance and cost-effectiveness of innovative and improved technologies are being comprehensively evaluated through a demonstration program developed and managed by the Department of Energy's (DOE’s) Deactivation & Decommissioning Focus Area (DDFA). Interim Safe Store of the C Reactor, a high-profile facility deactivation project at DOE's Hanford site, is host to technology demonstration efforts designed to evaluate at least 20 innovative technologies. Results of the technology demonstrations are reported throughout the DOE complex and to deactivation and decommissioning (D&D) firms, stakeholders, and others, to facilitate implementation and deployment of superior technologies. Widespread deployment of improved technologies will significantly contribute to the reduction of costs and risks associated with D&D operations. The C Reactor demonstration project has proven itself to be effective, as evidenced by the adoption of several alternative technologies as the new baselines at Hanford, at other DOE sites, and by commercial nuclear utilities.

DOE's Office of Environmental Management (EM) is responsible for the cleanup of radioactive and hazardous wastes at contaminated sites and facilities throughout the department's nuclear weapons complex (complex). Within EM, the Office of Science and Technology (OST) manages a research, development, and demonstration program aimed at advancing environmental restoration and waste management technologies, which are integrated with regulatory drivers to reduce risks and cleanup costs. OST identified major problem areas on which to focus its activities and subsequently implemented focus areas to address these problems. One of these focus areas is the DDFA, which addresses the challenges associated with deactivating and decommissioning over 7,000 contaminated structures.

The DDFA's mission is to develop, demonstrate, and facilitate the deployment of technologies and systems to solve customer-identified needs for deactivation and decommissioning of DOE's radiologically contaminated surplus facilities. One goal of the DDFA is to provide the capabilities to cost-effectively deactivate and decommission up to 90% of the surplus facilities by the end of fiscal year 2002. In a broader sense, the DDFA seeks to improve project baselines through improved commercial and newly developed technologies so that cleanup costs are reduced. The DDFA's approach to cost reduction includes "buying" rather than making, demonstrating rather than developing, and developing technologies to fill technology gaps.

To effect immediate cost reductions, much of the DDFA's recent strategy has been directed towards technology demonstrations with follow-on deployments. This strategy has led to the creation of the focus area’s Large-Scale Demonstration Program. Large-Scale Demonstration Projects (LSDPs) critically assess the cost and performance of a suite of alternative technologies alongside corresponding baselines under actual field conditions. These LSDPs are fully integrated within an operating organization's project; thus demonstrated technologies that prove to be superior are implemented and truly assist in reaching the end state for a given facility. Mr. Bossart and Mr. Kasper have provided a comprehensive treatise of the LSDP concept.¹

The DDFA currently manages three LSDPs and the startup of several additional LSDPs is currently under way. One current LSDP, and the topic of this paper, is the C Reactor project at the Hanford Site in southeastern Washington State. A succinct description of the C Reactor Interim Safe Store LSDP is provided in the next section. Ms. Saget, et al.², provides a more complete discussion of the baseline project.²

The C Reactor is one of eight surplus production reactors at the Hanford Site. The facility is located on the south bank of the Columbia River. Cleanup at Hanford continues, just as it does throughout the complex, but with significant emphasis on facilities located along the Columbia River corridor. To that end, the interim safe storage (ISS) of the reactor block at C Reactor, incorporating the demonstration and deployment of innovative technologies, has commenced. The ISS at C Reactor will serve as a model for future D&D of the seven remaining reactor facilities at Hanford and for similar facilities throughout the complex, for example, the five reactors at DOE's Savannah River Site.

The total cost for decommissioning the eight reactors has been estimated to be more than $600 million as referenced in the project's conceptual design report. After considerable debate, it was determined that a more manageable, interim approach to complete removal of the reactor facilities would be to decontaminate and remove surrounding facilities and portions of the C Reactor structure, and then to place the reactor core into a safe configuration pending future removal and disposal. Objectives of the ISS project include

• Safe store the reactor core for up to 75 years.
• Actions cannot preclude future D&D goals.
• Potential risk to site employees is reduced.
• Minimize releases to the environment.
• Reduce inspection and surveillance costs.
• Reduce maintenance costs.

Information available in the detailed design report indicates that the cost for ISS of Hanford's surplus reactor facilities totals $136 million. Just under $25 million of this total is for ISS of the C Reactor. It is expected that with successful demonstration of technologies at C Reactor and with sitewide adoption of those technologies with superior performance, the cost of ISS for the remaining reactors can be reduced by one-fifth to one-third, to about $20 to $16 million each.

At C Reactor, innovative technologies in the areas of characterization, health and safety, decontamination, stabilization, demolition, and waste processing have been identified and have been or will be demonstrated. A minimum of 20 new and emerging technologies will be demonstrated in the project.

Field work at C Reactor commenced in FY97 and is scheduled to be complete in about 21 months. At writing, 12 of at least 20 technology demonstrations have been completed. The site is committed that ISS be accompanied by intensive use of new technologies to lower costs, accelerate schedules, and reduce worker exposure. In concert, these benefits will assist the site in meeting 2006 Plan objectives, Tri-Party Agreement Milestones, and Hanford Site Technology Coordination Group (STCG) needs. Hanford stakeholders strongly support the project and the continuation of the reactor ISS concept.

As previously noted, the C Reactor at Hanford is one project within the DDFA's Large-Scale Demonstration Program portfolio. Selection LSDPs is based on the following criteria:

• LSDPs should prove the significant benefits of using a suite of improved technologies compared to the baselines
• Technology demonstrations should be conducted at a scale that is convincing to problem holders all across the complex and at commercial facilities
• LSDPs should assist DOE operations offices in accomplishing their D&D projects
• LSDPs should have a significant visible impact or skyline change
• Each LSDP should be managed by an Integrating Contractor Team, which is discussed later.

The LSDPs are structured as comprehensive actions in that the DDFA seeks to facilitate the implementation and deployment of technologies which, through field demonstrations, are shown to be superior. To that end, each LSDP develops a communication plan to convey results to problem holders, technology developers, D&D firms, stakeholders, regulators, and other interested parties. To convey detailed cost and performance results, an Innovative Technology Summary Report (ITSR) is developed for each technology demonstrated in a LSDP. These reports, commonly referred to as "green books," assist decision-makers in determining whether a demonstrated technology merits deployment at their site. Additional discussion of ITSRs is provided in a later section of this paper.

An Integrating Contractor Team (ICT) has been assembled for each of the DDFA's LSDPs; the team plays a key role in implementing each LSDP. In general, the ICT manages the technology demonstration aspects of each project. Typically, representatives from three or more D&D firms compose the ICT, in addition to the site’s management contractor. Other professionals are included on ICTs on a case-by-case basis to appropriately represent other programs and projects within DOE. This representation ensures that the entire DOE weapons complex, not just the particular project associated with the LSDP, benefits from the demonstrations of innovative technology. For example, since the Savannah River Site has five production reactors that remain to be decommissioned, it has been a solid contributor to the C Reactor ICT.

Figure 1 shows the members of the C Reactor ICT. AEA Technology (AEA), through an international agreement with the DOE, participates on the C Reactor team. AEA's contributions include the continual canvassing of the European community for new technologies, thus allowing the project to benefit from global technological advancements.

 
Fig. 1. C Reactor Interim Safe Storage Integrating Contractor Team

Responsibilities of the ICT include determining the appropriateness of a given technology demonstration, discussing and approving demonstration scope, and reviewing and reporting demonstration results. The breadth and diversity of the ICT provides balanced project management and ready access to an expanded knowledge base of D&D technologies and challenges. The C Reactor ICT meets monthly via video conferencing, in addition to meeting in person at the Hanford site every fourth month. ICT actions/interactions are not limited to the scheduled meetings, but occur continually using e-mail, phone, or fax.

An additional benefit of employing a team concept is that it allows for "technology sharing" both on and off site. ICT member’s direct knowledge of demonstration results facilitates use of improved technologies at other DOE sites and at commercial nuclear facilities. Through ICT participation and implementation of an effective communication process, information permeates to other D&D firms so that alternative technologies that show superior performance and lower cost are incorporated into a firm’s toolbox.

As previously stated, the DDFA is participating in a DOE Operations Office project, which must gain regulatory acceptance. Stakeholder concerns are also considered. Both the U.S. Environmental Protection Agency and the Washington State Department of Ecology are members of the ICT and as such have firsthand knowledge of the innovative technologies being demonstrated. Given the nature of D&D, regulatory issues, which require extensive investigation and permitting, are not generally applicable to the technologies being demonstrated at C Reactor. Where regulatory issues do exist, they are disclosed to potential users in ITSRs.

The C Reactor project team maintains a constant dialog with Hanford's STCG D&D subgroup. As a result, STCG issues are often addressed in real time. Basically, it is in the best interest of the project to keep stakeholders fully informed so that support for widespread deployment of successful technologies can be gained. The following section, which addresses communication, provides further discussion of stakeholder interaction.

As do all LSDPs, the C Reactor LSDP has in place a far-reaching communication plan. A responsibility of the DDFA is to convey technology performance data throughout the DOE complex and beyond to commercial utilities, regulators, stakeholders, technology vendors, D&D firms, financiers, and others. To communicate effectively, several techniques are employed. These techniques include written reports, focus group presentations, conference presentations, news releases, site tours, and an open house. An open house was held October 8, 1997 at the Hanford Site to provide a forum for technology providers and problem holders to exchange ideas and other information on new and emerging technologies, especially technologies demonstrated in the DDFA's LSDPs. Figure 2 illustrates the C Reactor LSDP communication strategy.

 
Fig. 2. C Reactor LSDP Communication Strategy

Electronic communication methods are extensively utilized by the project. A homepage exists on the World Wide Web at www.bhi-erc.com. Innovative technology fact sheets and ITSRs are available at this address. The project team has also established links with other electronic information systems to effect the widest possible dissemination of demonstration results. The C Reactor LSDP is linked to EarthVision at www.earthvision.net, and to the Global Network of Environment & Technology at www.gnet.org. Basic information for the more than 200 initially screened technologies is also available via a technology information system being developed by the Hemispheric Center for Environmental Technology at Florida International University. Figure 3 shows the process flow for the C Reactor LSDP.

 
Fig. 3. Process Flow for the C Rector LSDP

Through an interagency agreement, the DDFA has engaged the U.S. Army Corps of Engineers (Corps) to analyze the costs associated with the innovative technologies demonstrated (and corresponding baselines) at the LSDPs. The Corps was selected by DDFA because of its knowledge and considerable experience in cost estimating and analysis, experience that includes EM-specific analysis. Furthermore, use of the Corps provides an independent, consistent, and comprehensive cost evaluation of data that decision-makers and D&D firms can use with confidence.

At C Reactor, the Corps actively participates in all ICT activities to ensure that cost issues are adequately considered all through the technology selection and demonstration process. Subsequent to technology selection, the Corps maintains an active role by participating in requirements analysis, data quality objectives, and readiness reviews, and is frequently on site during each demonstration to ensure a quality process. Soon after each technology demonstration is completed, the Corps evaluates the cost effectiveness of each innovative technology, along with its corresponding baseline technology or process. Cost results are reported in Section 5 of the ITSR, with detailed cost information provided as an appendix.

As part of the C Reactor LSDP, 12 technologies have been demonstrated thus far. Information about the technology demonstrations is provided below.

LARADS is based on the integration of an auto-tracking laser system used to conduct civil surveys with a radiological detection system. Position data and radiological survey information is taken, sent from detector to receiving station, and then combined into electronic files to provide clear, detailed, and accurate surveys. Reports can be graphical, with color-coded radiological levels overlaid on CAD drawings or on photographs. LARADS is replacing the baseline technology of handwritten radiological survey reports created after survey is completed using hand-drawn area sketches

LARADS Benefits

• Clear, concise, and comprehensive radiological surveys
• Accurate correlation of contamination level to contamination location (within 2 cm.)
• Data logged electronically not reproduced from memory

LARADS is being implemented at C Reactor to characterize and free-release over 15,000 ft² of walls and floors. In addition, it will be used on the remaining ISS projects for Hanford’s other reactor facilities and for survey work at several facilities including Hanford's processing facilities (canyons).

MITUS completely replaces site power for D&D projects in conjunction with other needed services. After seven electrical safety accidents in a year, Hanford sought a system to provide safe temporary power. MITUS routes power to various parts of the facility via orange armored cables. These orange feeds terminate at up to 20 specially designed kiosks. The kiosks supply a variety of power voltages (110, 220, and 480 V), three-way communication capabilities and paging, emergency egress lighting, and a multilevel alarm system. The three alarm conditions are medical (blue), alert (yellow), and evacuation (red). Any alarm can be triggered from any kiosk; every alarm signal also notifies the central alarm station. The modular design of MITUS allows for quick setup and tear down and movement to another facility. The baseline technology for MITUS is to upgrade and use existing facility power in addition to separate communication and emergency functions. MITUS is being implemented at C Reactor to provide electrical power and communication requirements. In addition, it will be used on remaining ISS projects for Hanford's seven reactor facilities and will be used on future canyon D&D projects at Hanford.

MITUS Benefits

• Allows all existing facility power feeds to be deenergized eliminating unknown electrical hazards
• Electrical safety is enhanced
• Emergency alert requirements are provided
• Communication functions improve overall project efficiency
• Savings on remaining seven reactor projects at Hanford alone estimated at $ 4.2 million

The SCM/SIMS is a motorized characterization and data analysis system for surveying contaminated floor and wall surfaces. A position-sensitive gas-proportional counter (PSPC) takes 400 radiation measurements in an area of a single square meter. Survey data and sample location are logged electronically as well as displayed on an LCD screen for the operator. The data from each survey is analyzed by the SIMS to obtain visual representations of the surfaces surveyed, to generate a data report detailing the actual numerical results, and to overlay the data into a CAD drawing. At C Reactor, the system was shown to be a versatile platform for a contamination measurement including the application of the PSPC for alpha and beta-gamma contamination. This technology is being implemented at C Reactor to release several areas of the structure. The following facilities chose to employ the use of the SCM/SIMS (shown in Figure 4 below) after its demonstration at C Reactor:

• Oak Ridge Institute of Science and Education¾ independent verification measurements of equipment and facilities for both the DOE (including K-25 Site) and U.S. Nuclear Regulatory Commission
• BONUS research reactor facility in Puerto Rico¾ characterization release survey of 42,000 ft² of floors and walls
• 108-F Facility at Hanford¾ characterization survey detected the presence of plutonium in this facility which was previously thought to be "clean"
• DOE's INEEL Air Support Building¾ over 127,000 ft² was surveyed in 2 weeks of on-site effort under harsh environmental conditions
• Building 301, Hot Cell facilities at ANL¾ characterization survey where rooms measured averaged 100,000 dpm/100 cm² with peaks greater than 10 million dpm/100 cm²
• Connecticut Yankee Nuclear Power Station¾ survey performed on exterior paved surfaces and parts of the turbine building where over 260,000 ft² were surveyed and nine previously unidentified contaminated locations were identified

In addition, the STCGs have identified the SCM/SIMS technology as having a high probability of meeting identified needs at Savannah River Site's Heavy Water Components Test Reactor Project and at several environmental restoration projects at Sandia National Laboratory.

SCM/SIMS Benefits

• Surveys are 3 (alpha) to 7 (beta/gamma) times faster than baseline
• Data analysis and reporting 5 to 10 times faster than manual surveys
• Overall cost savings of 30% using SCM/SIMS
• Estimated $183K savings per production reactor

STREAM is a multimedia database designed to enhance project productivity and safety using icons and "point and click" technology to navigate through the "virtual facility" or topics of interest. A variety of tabs and folders are used to enter or retrieve information. The STREAM Reference Library provides a multilevel, free-form relational database structure for storing numerous reference documents, engineering information, equipment operations data, photographs, videos, maps, and numerous other pieces of information valuable to the project. STREAM provides a tool to improve day-to-day work performance and management tracking. The baseline technology associated with STREAM is the use of multiple databases and management tracking tools. STREAM is being implemented at C Reactor to provide three major support functions: visual imaging capabilities, a reference library, and waste management tracking and reporting. It will be used on remaining ISS projects for Hanford's seven reactor facilities and will be used to support the decommissioning of the Heavy Water Components Test Reactor at the Savannah River Site. In addition, the STREAM system is being deployed to support clean up work at the Chernobyl disaster site.

STREAM Benefits

• Improved worker safety
• Labor and dose savings
• Savings on remaining seven reactor projects at Hanford alone estimated at $2.1 million

The Gamma Ray Imaging (GRI) System is a building contamination survey system used to remotely measure the surface contamination/exposure levels of walls, floors, and ceilings. The GRI system consists of a detector head containing a gamma scanner, video camera, and laser range finder mounted on a scanning pan and tilt unit. The unit can be deployed from a remote workstation via cables. All radiological readings are stored in a database which then constructs two-dimensional color surface, contour, or log plots of the contamination overlaid on a video picture of the area and recorded on a video cassette recorder. The GRI system was demonstrated in the C Reactor fuel storage basin to remotely measure basin walls and floors for both cesium-137 and cobalt-60. The GRI system was not implemented at C Reactor because there were no additional areas requiring characterization upon completion of the demonstration. However, based on the demonstration, the GRI technology was deployed to support the following projects:

• Hanford's B Plant (canyon facility) for facility characterization activities
• Unit One at the Peach Bottom Atomic Power Station in Aberdeen, Pennsylvania, for detection of cesium-137 and cobalt-60 in primary cooling piping and in the fuel transfer basin
• Rocky Flats Environmental Technology Sites in Denver, Colorado in Building 371 for the identification of plutonium-239 in glovebox ducting and ports

GRI System Benefits:

• Remote operation reduces worker exposure by limiting "hands-on" measurement in radiation areas
• Clear, concise visual report representation of radiation levels and accurate location of contamination

Several additional technologies have been demonstrated during the C Reactor LSDP. Analyses are ongoing to determine if these technologies exhibit significant improvements over baseline technologies:

Self-Contained Pipe-Cutting Shears¾ This is a totally self-contained hydraulic shear effective at quickly cutting small piping or conduit. In addition to making the cut, it crimps the end helping to seal in contamination.

Heat-Stress Monitoring System ¾ The hot summer climate of Eastern Washington was a perfect place to evaluate the Heat-Stress Monitoring System. The Heat-Stress Monitor remotely analyzes a worker’s physiological state through a series of sensors for core temperature (ear canal), skin temperature, heart rate, and motion. Associated software polls the sensors several times per minute and alerts the work crew supervisor or safety personnel of parameters that could indicate that a person is under undue stress. The worker can then be removed from the work area to prevent an adverse reaction such as heat stress or heat stroke.

Sealed-Seam Sack Suits ¾ This technology demonstration involved the evaluation of several coveralls made from special synthetic materials. These materials are designed to protect personnel from radiological and chemical hazards while allowing warm, moist air to escape keeping the worker cooler and more comfortable.

Wireless Remote Monitoring System (WRM-Plus) ¾ The WRM-Plus is a local- and remote-reading dose measurement device that has increased sensitivity to help eliminate the use of antenna cabling and line extension amplifiers devices. Containment monitoring can be performed without elaborate antenna networking saving both dose and manpower during setup and teardown of the WRM-Plus system.

RESRAD-BUILD ¾ This is one of the RESRAD computer programs developed by Argonne National Laboratory designed for pathway analysis. RESRAD-BUILD calculates exposures to individuals occupying a structure contaminated with radioactivity. The Record of Decision (ROD) for C Reactor requires that the site satisfy residential use standards at closure. The application of RESRAD-BUILD at C Reactor would allow the project to evaluate the extent of decontamination required to meet the criteria established in the ROD and demonstrate compliance with the ROD at closure. The benefits of this application are waste reduction (minimizes the extent and amount of decontamination required) and minimized project costs (reduced labor and disposal costs).

2-D Linear Motion System ¾ This is a versatile tool that uses cabling and motorized take-up reels to accurately position and maneuver various devices such as radiation monitors and decontamination tools, on walls.

Concrete Shaver¾ The Concrete Shaver is a self-propelled, electric-powered, diamond concrete shaving machine that can cleanly remove concrete surfaces within extremely accurate depth tolerances. It is suitable for use on flat or slightly curved walls and floors. Preliminary demonstration data showed that, among other positive attributes, the device has a better production rate and depth control than the baseline scabbling technology.

Future Demonstrations¾ The C Reactor LSDP is planning to demonstrate at least eight additional technologies, for a total of 20, before the project terminates during fiscal year 1998. Areas targeted for demonstration include large-bore pipe cutting, structural steel decontamination, thick concrete cutting, surface decontamination, and reactor stabilization.

The C Reactor LSDP is expanding the suite of technologies available for DOE cleanup activities. This work includes D&D of 13 surplus production reactors around the complex and up to 7,000 contaminated legacy facilities. Beyond the DOE, commercial test and power reactors are expected to benefit from the project, through the involvement of D&D firms, international collaborators, and the extensive communication avenues employed by the project.

Commercial technology providers, owners of innovative technologies, benefit by gaining additional understanding of the DOE cleanup and technology development programs and how they can lead to potential market opportunities. For D&D firms, quantitative cost and performance data are widely disclosed so that these firms can determine whether or not to integrate new technology systems into their product and service lines.

Through the implementation of the C Reactor LDSP, a suite of innovative technologies has been identified and demonstrated alongside baseline operations within a highly visible D&D project, the C Reactor ISS. The cost and technical performance of innovative technologies will be fully assessed compared to baseline operations and demonstration results will be widely communicated. Most importantly, DOE operations offices and their contractors are implementing and deploying improved technologies and systems that translate into accelerated schedules, reduced risk, and lower cleanup costs.

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