in 10 + . P :.. t. : "_" . . . * I OF ORNL P 2406 . i . < . . 1 .. > . 13 1 . ' . . . F45 MESO 136 340 EEE i ' . MICROCOPY RESOLUTION TEST CHART NATIONAL BUREAU OF STANDARDS -1963 . . . 1. .ORNL-P 2406CFSTI PRICES Conf. 661001-19 HC SLOJ M_50 SUMMARY DAML = AEE OFFIETAL ORNI - AEC - OFFICIAL Philosophy of Chemical Processing Equipment Design and Installation in the Transuranium Processing Plant* W. D. Burch, F. L. Peishel, and 0. 0. Yarbro Oak Ridge National Laboratory Oak Riäge, Tennessee The chemical processing of irradiated targets for recovery of large quantities of the highly alpha-active transuranic elements in the Trans- uranium Processing Plant (TRU) at Oak Ridge National Laboratory gas necessitated the development of unique methods of equipment design, fab- rication, and assembly. Methods were developed to meet the requirements of remote replacement or maintenance of all the process piping and equip- ment, both in manipulator-equipped cubicles, and in shielded cells accessible with long-handled tools operated through a containment shield. The acid chloride chemical environment dictated the use of tantalum and Zircaloy-2, materials that cannot be welded except in inert atmospheres. Simple : mechanical joints were developed to permit the field assembly of the piping system. A schedule that allowed only a short period of time for equipment installation after completion of the concrete cell bank also made desirable ::: the development of improved methods of assembling the complex components in TRU. Early in the project before the cell was built or the equipment designed, appropriate base lines were established that were used in design, construc- tion, and prefabrication. All the cell bank concrete openings and inserta d ou were located from these base lines. In addition, a grid system was installed *Research sponsored by the V. S. Atomic Energy Commission under contract with the Union Carbide Corporation. . wo ORMUL MEC-OFRAKCILALL ...-.. RELEASED FOR ANNOUNCEMENT IN NUCLEAR SCIENCE ABSTRACTS ORNL - AEC - OFFICIAL ORNL - AEC - OFFICIAL in each cell from the base lines, and all equipment was located from this grid. This grid was identical in all cells and equally spaced between cells. The base lines and grids are available for locating any new items that must register with existing equipment. In general, they were established to a tolerance of £1/32 in., which was also the tolerance on the location of various equipment mounts and joints of the prefabricated equipment. A cell grid was reproduced in the shops where prefabrication of piping or other components that had to be located with respect to the grid was being done. This assured that prefabricated components were correct. The first installation of prefabricated equipment consisted of items that are semipermanently fixed in place and that accurately locate the remorable components with respect to the grid system. This category included supports for tanks and piping assemblies, as well as some of the piping assemblies. The supports are fixed, and the piping assemblies are removable, but with difficulty. This portion of the work took about three . . . ... uco... : . . !1d to four months. • Following this, the prefabricated process tanks and piping in seven tenk pits and foui' cubicles were installed. This group included 36 process tanks, 8 equipment racks, and 750 units of prefabricated tubing. This installation, including the final leak checking, required only two months. The basic component in the fabrication of the chemical-processing equipment 18 & mechanical tube joint formed by a male- and a fema le-tapered surface held together witia o specially developed, remote lo cperable, one- screw clamo, appropriately called a TRU disconnect. These tapered surfaces are machined into a ferrule and attached to tubing by a rolling operation. BULL - MC-OFAKCIIALL (-01 SMU تنا- در بر دانi1: -3. . ORNI - ALE - OFFICIAL This joint provided the means for the attainment of a repid assembly of the chemical processing equipment and will permit remote replacement of compli- AN cated equipment in the future. LEGAL NOTICE Talo report was prepared as an account of Goverament spoarored work. Nellber ebe Uallad Suates, sor the Commission, sor Lay period acting on beball o. lbe Commission: A. Makes wynarranty or representation, exprenuod or lapiled, we respect to the accu. racy, completeness, or use twness of the information contained la this report, or that the use of way lolormation, appunaws, melbod, or process disclosed in this report may not lalringe printly owned rigble; or B. Assumes may llabillues with respect to the use of, or lur dariagos resulting from the use of any informitoa, appannu, method, or piocou disclosed in this report. As used in the above, "persoa acting on beball of the Commissioa" includes way oo- ployce or contractor of the Commission, or employer of such coatractor, to the extent that auch employee or contractor of the Commission, or employee of such contractor preparus, disnemlaales, or provides access to, way Information pursuant to employmeat or coatnici with the Commission, or no employment with such contractor. ت : 1 - ا در OM MC-OFFCO MAL باد دانi1: ORM * ATE = OFFICIAL PHILOSOPHY OF CHEMICAL PROCESSING EQUIPMENT DES IGN AND INSTALLATION IN THE TUNSURANIUM PROCESSING PIANI* ORNE = AEE = OFFISIAL . . . . . Oak Ridge National Laboratory Oak Ridge, Tennessee ABSTRACT : The chemical processing of the alpha-active transuranic elements in the Transuranium Processing Plant (TRU), a facility that must also provide gamma and neutron shielding, has necessitated the development of unique methods of equipmert fabrication and installation. These methods over. . came the problems encountered in tae use of hard-to-fabricate materials, such as Zircaloy and tantalum, and provided a system in which this equipe ment may be remotely replaced while maintaining alpha conta inment. shop-fabricated concurrently with the construction of the facility. The :.. methods used will allow this equipment to be removed later and to be . . L replaced by remote techniques. CHEMICAL PROCESSING EQUIPMENT DESIGN PHILOSOPHY The basic parameters for the design of the chemical processing equiprent to be installed in the Transuranium Processing Plant (TRU) were established during the initial design phases of the concrete-shielded cells and alpba . containment cubicles. These parameters were based on a process that was still under development. ORAL-MC-OFFROAAL *Research sponsored by the U. S. Atomic Energy Commission under contract with, the Union Carbide Corporation. . ..ORANEAEES-OFFICGLAL ORNI – AEC - OFFICIAL BRNE = AEE = OFFIEIAL The main-line chemical processing equipment and vulnerable operating equipment was located in manipulator-equipped cubicles. These cubicles are specially contained within surrounding shielded cells, and transfers into and out of them are to be made with equipment that will maintain alpha containment. All equipment in these cubicles will be removable, . . and the cubicles will be equipped to relocate replacement items remotely with a minimum of effort. With this information, a size for these cubicles was established: 7 ft wide by 7 ft deep by 8 ft 6 in. high. Four of the nine cubicles were designated for chemical processing... The surrounding cells are 7 ft wide by 18 ft long by 22 ft deep, and the portion of the cell behind and below the cubicles, designated the tank pits, contains the necessary process and storage tankage associated with a chemical process (see Fig. 1 in paper No. 8). They are sealed to maintain alpha containment and are accessible for maintenance or replacement of tanks through the top roof plugs, For maintenance the roof plugs are removed and ... & maintenance shield is installed to provide some gamma shielding, as well as to serve as an alpha-containment barrier as described elsewhere. Addi- tional gamma and neutron shielding will be supplied by flooding the cell - - - - - - with water to a level just below the piping connections on the item of equip- . . ~ , ment to be removed. . . . , 4 DETAILS OF DESIGN AND INSTALLATION - AUAW As the detailed conceptual design of process equipment proceeded, it became obvious that the location of some of the openings in the concrete B. F. Bottenfield et al., "Remote Maintenance Systems in the Transuranium Process Plant." ORHOLLALEC - OFFICIAL be . -3- BRNE = AEE = OFFICIAL between cells and between the well and outside would have to be located quite accurately. It was established that sleeves in the rear of the .. cell tank pits would have to be located to a :1/8-in. tolerance and that :: openings between cells and the recess for a large service plug for each ... cubicle, designated "J plug," would have to be located to a 41/4-in.. ..BRNE = AEE = OFFIEIA! tolerance with respect to a common point. . Design Base Line. The necessity for all the interconnected equipment to be replaceable remotely, as well as to fit together initially, established the need for a base line, or grid system, from which everything could be located. A primary base line established by the building designer was later used by .: the equipment designers and fabricators, as well as the equipment-install.tion contractor. The norty-south case line was the center line of cell 5; a ring welded to the intercell conveyor housing for locating the cubicle floor pan was set as the elevation base line; and the center line of the conveyor, which served all nine cubicles, was the east-west base line. These are the three reference base lines from which additional lines were accurately located with surveying Instruments to a £1/32-in. tolerance. This system of base. lines, shown in Fig. 1, also shows two grid bars, one on the east and one on the west wall of each cell tank pit, that were used to reference all items in a particular cell. These grid bars were used in design layouts, . de well as in the equipment fabrication and installation. They were installed after the building contractor had completed the structural portion of the building. The grid bars were located far enough inside the cell wall to vo vrriver ORRAL TALEC-COFFEGAL ------ Bottle Aff-effifcati 344-354-WXC TOP . :. . Fig. 1. Base Line Schematic Peishel - Philosophy of Design in TRU .............. .. ... .. 531 SUBICLE .... .. YA MI . W 3.. . . . .. . . .. CUBELES, . COCOYAN IS . w LAY . . . . PI? GR BARS . . TO AT . KEUNCLE . CUBICLES .. CUBICLE Z app. HEUSCLE L. CONVEYOR: PORT AING BASE LUE (TYPICAL) BASE LINE SCHEMATIC FIG. 1 8ẾNE = AEE =8FFLESAL og BNI ALEC DEBE . . ................. . COM . -4. 194744196 237-1998 : ORNL - AEC - OFFICIAL ensure that there would be no interference from the cell walls as long as . the tolerances in tbe drawing were adhered to in construction of the concrete walls. : : Equipment Installation Sequencing Installation of equipment was divided into two phases. In the first : phase, the main supports were located for the easily removable equipment that would be installed in group 2. Much of this first group of equipmeni can also be removed remotely if required. Also included in this group were ::::. the precast shielding plugs (which contain service lines for the process .. . equipment), the piping bund les between the cubicles and tank pits, end piping assemblies between the tank pits. These items might be described .. as the frame of a picture puzzle. The general arrangement of this equip- ment in a typical cell 18 depicted in Fig. 2. All the items in the tank pit were located from the grid bars that were mountea on the east and the west walls of the pits. These bars were: the first items installed and were located accurately (+1/3? in:) with reference to the previously established base lines associated with the conveyor housing and rings. These rings had automatically located the floor pan in each cubicle on mating machineå surfaces, and the location of . the cubicle to the pit line bundle was established from the rigid floor pan . assembly. The disconnect well on the cubicle end of this bundle was then . . used to locate the tracks for the equipment racks. The tracks were installed - - - - - - - - - - - ---------- BRNE = AE =8FFEIAL accurately with a jig; and the tracks were, in turn, used to locate everything else in the cubicle by means of another jig. Tous proper location of the cubicle equipment was assured. GORAN LAESCOPICAL 2 .DOC ::FIG:2 UP-I, EQUIPMENT ARRANGEMENT II 27 PORT RING CONVEYOR TANK SUPPORT ..... YO :::: MOOYO 02 YYYY 1 LITER . kn. . .LY . . . .' AXY . ism:1.4 isya . 2 . 122 8 ** . SS 1 :11 * 1 . * . R . ** * TWITT? . S OMsini .... 3 smiy say NASEMA : . ORTS TURIST .: . . . . onid HELSEA : INTER PIT N . . TOPS i. ..ii WI. 0 :41:3 . . 30109 WOW IN3Wdino3 . om 370NNA NI? *INU CUBICLE TO PIT . * NUA . . SEO . P . IN . Muina", (unid..) and 33AD3S 333189 CYSYID . . 13: : . * . . ...*.. . * .** . . . VI. . " 3 all . . 1 TRO ... .. . Siwand . 2 S S LO . PIT SER . KUI & Tava & AUTOS?T74- '18491ad DIBLIY QÜENIMUI anoso y B 1 sittitite GANG = 4€€ = OF CAL ORNL = AEE - OFFICIAL 1947348-38- ORNI = AIC - OFFICIAL The installation of this first group of prefabricated equipment required three to four months. Some of the prefabricated equipment before installation 18 picture, in Figs. 3 and 4. The second group of equipment consisted of 36 prefabricated proce86 tanis located in seven cell tank pits, 8 equipment racks located in four . cubicles, and the 750 jumper lines interconnecting the tanks and racks with other items previously installed. This equipment, which was pre- fabricated in the shop in jigs as pictured in Figs. 5 and 6, was „nstalled and leak-checked in only two monisis. The schematic arrangement of the equipment in one cell is shown in Fig. 7. ... :. : ..: NEW EQUIP-ENT AND FABRICATION METHODS TRU Disconnect. ' .ili... : In order to assemble the system, a large number of mechanical joints (more than 3000) were required. Each joint had to be capable of ready assembly by remote means, contain no organic gasket, and prove reliable for repeated assembży. Since a joint satisfying all these criteria was not available, one was developed for this program. The basic sealing surface design, as well as the means of clamping, was developed. The resulting TRU disconnect clamp, is shown in Fig, 8. The male and female ferrules clamped in this unit have been fabricated in various combinations of materials in 3/8-, 1/2-, and 3/4-in. tubing sizes. Special adaptations for 1/4-, 3/8-, and 1/2-in. pipe and 1/8- and 1/4-in. tubing have also been made to fit in this clamp. The configuration of a 3/8-in. male ferrule t'or tanta lum tubing 18 pictured in Fig. 9. 88N+ = REE-8FFIEIAL CRANI AFRIFICO MI BRNE = A LE = 8FIEIAŁ -EC-EFFFLAKE VIV: V + - a silliini V . - - C . min morsossomosoma + enginginema empre . . . . . . . 0 samenwonincasa OT .. .......... . 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AXX 4 11 10+ * : . .. ..... 0 2 ... .. .... . ...: .. ::.. . . . . 1 an ummam 2 DO. . $ I ... . . + . 2 C . . war Ali . " . . . 1 . SA .... . 2011 . WAT ... i Na stadionav immane . hinnanmiramanmark ad ottostansanasiasananvarandi . . 1 . + .. - - . an . . . . . jor area Peishel - Philosophy of Design in TRU Fig. 3. Cubicle Service Plug (J Plug) and Associated Piping LA . . 4 MO . 21" ' BANTECOFFRETAT Brela. 1986-8ft RALE 11 - . . Gwi - 1 1 * to 1 . . .. 11 .:- . + . . . BRNE - ALE=8EFIEIAŁ . C ORNI = AEE = OFFICIAL T . - T . 1 . . - 1 1 1 4 2 . 9 . . . - . 1 . . . 0 1 0 1 - ... Willi more C . re ready 1 . ! 1 - .measuw- 1 * 11 . 0 moment on a . . de . i SA . . companies and contacto Geowo.imagebame writes.com. m einem 23:36 " O iniha . . 0 S . . , 0 ... . . . . . I I . . 0 . 0 # X 400 . les ; . 1 VC . O w K . : ogramme is . . 3 r C 0 . . . 1 . 0 X . : ' C P i . . . . 11 . 13 13 . . 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WA .. 4 ' ... . **** ZVAO ii . . * ..1 . * . * We . . Hii nr. . ::. . . .... ** * . :: * .: ' . ** :.: ..: 333 .. * . . * . wiiiialinita!!!! . 1 * :: ., . WWV BANCA - ABBE OFFICIAL i Vindigungen anvio . . ... 27 $ : .... ..... Vitetiziatische . .: .... . C ', . - - WV818-338-4448 "OP "YU?33118-33*-19980 Fig. 7. Schematic Arrangement of All Equipment in One Cell : Peishel - Philosophy of Design in TRU PIT SERVICE - w 0 PLUG 11: . . . . . 1 . 1 . 12 2 TY UL X " . A . be . GY 2 DET GR @AR . C 21 7 VORT . . . . CUBICLE SERVICE PLUG PLUG) . . Temple A 7 w UL Share " . . . . . INTER PIT PLUG- NU H . CUBICLE TO PIT LINE BUNDLE - ..... - ... . EQUIPMENT RACK . 2 1 ...... * women are ..... 1 K . . * * 27 a . NO . . 1 . . . . . 03 . . CONVEYOR PORT . -PROCESS TANK SCHEMATIC ARRANGMENT OF GROUPS 162 EQUIPMENT ITEMS FIG. 7 ORN - AEC - OFFICIAL ORNI - A EC - OFFICIAL ORNI - AEC - OFFICIAL ORNL - AEC - OFFICIAL -* - - - . - - - - - - *-*- z MTK : . ORNI - AE ORNI - A OFFICIAL OFFICIAL . . ORNI - AEC - OFFICIAL ORNL - AEC - OFFICIAL Ecoteche - - - : - -ix-3--- --17 RT : ... ТОР LINE PROCESS LINE PROCESS ANCHOR CLAMP SINGLE BOLT DISCONNECT Peishel - Philosophy of Design In TRU F18. 8. TRU Disconnect Clamp and Ferrules . . . . . d . 2. . ORNL DWG 65-7835 QBALA46C-CoffISCALL · ONNI = AEE = OFFICIAL ВОР TOP Fig. 9. 3/8-in. Male Ferrule Pelsbol - Philosophy of Design In TRU BAMUL = AE = BEHELAL OKNI - AC - OFFICIAL O.R.N.L.. DWG. NO. 66-5031 . . o . STAINLESS STEEL TANTULUM for 180 he 379 -.980 . MALE FERRULE . Moo . .' .. ORIOS AEE - OFFICIAL ORNI - AEC - OFFICIAL The tapered joint was also adapted to a 2-in. size for a limited: mumber of joints in the waste headers by an in-line arrangement similar to a pipe union and a right-angle arrangement with a saddle clamp. These joints are more difficult to assemble but do allow the piping system they are in to be replaced, if necessary. The clamp and the ferrules were made as a mass production item. The clamps made of Hastelloy C and stainless steel cost $36.00 each. The price of the stainless-steel ferrules ranged from $3.50 to $8.00, depending on the size. Stainless steel and Zircaloy-2 units cost the same to fabricate. The TRU plant bas approximately 2800 of these joints Installed, with 24 different adaptations of the three basic sizes. Adaptation of Rolling Techidques The process of rolling tubes into tube sheets of a heat exchanger 18 highly developed. This process was adopted as the means of joining the machined disconnect ferrules to the process tubing to minimize the amount of welding. This was particularly important for Zircaloy-2 and tanta lum because of the requirements for completely inert atmospheres during welding, but most stainless steel ferrules were assembled similarly. These joints, which were required to leak less than 10° standard cc/sec, were individually tested (helium leak test). In the case of tantalum tubing, the female ferrule was formed by rolling and expanding the tube into a tapered stainless steel ferrule. The attachment of disconnect ferrules to tubing was the major use for the rolling operation. This rolling technique was also used extensively CORRLAEREOFICIAAL --7- ORNI - AEC - OFFICIAL BRNE = AE = BETEIAL to seal tantalum, Zircaloy-2, and stainless steel tubing in stainless steel tube sheets, which served as containment barriers between cell tank pits and between the cubicles and the tank pits. Nozzles in the beads of the process tanks were also installed in this fashion, thereby eliminating difficult welding operations. Diaphragm Pumps The need for a pump to transfer highly radioactive fluids that "Pizz" because of radiolytic gas formation resulted in the development of an air- vacuum-driven diaphragm pump. This pump circumvents the problemas of packling leaks and air locks in liquid-filled drive Unes, and, in addition, 18 self-priming. Alternating air pressure and vacuum motivate the diaphragm, which, coupled with the check valves on the liquid side, induce the pumping action. The pump 18 capable of an unprimed transfer of water at a suction Ulft of 20 ft, with a vacuum source of 23 in. Hg. The pump was designed with readily replaceable check-valve' assemblies and has disconnect connections similar to the other joints in the facility. . . . .. Diaphragm Valves A remotely controllid on-off diaphragm valve was developed for TRU to meet the requirements of small size and easy replacement. The valve, pictured in Fig. 10, is equipped with tapered female TRU disconnect ports for the three connections. The body parts, which will be wetted by the process fluids, are made of Zircaloy-2, and the diaphragm that serves as the valve plug 18. made of a 10% tungsten-tantalum alloy. CORALI AEREOFFROAAL CL OBNCALECOSEGELL JIU-JIU JITNO Tutu-33v NOU Why18-36=1878 Fig. 10. "TRU Valve Assembly CRML-DWG 65-13262 Peisael - Philosophy of Design of TRU SPRING SCREW (AISI420SS) - - - . ... : O TOTEC . - PISTON SEAL (GRAPHITE ASBESTOS! .. . -PISTON (AISI42055) -U-CUP (POLYURETHANE) DIAPHRAGM (TANTALUM 10W qui sont - O-RINGS (POLYURETHANE) TRU TYPE PROCESSING DISCONNECT PORTS PACKING (GRAPHITE ASBESTOS) WE . MAX. . . . DIAPHRAGM (TANTALUM IOW) a . 2. BODY (ZIRCALOY~2)- DIE KWD . vitch tilflumiin - TRU TYPE PROCESS CONNECTIONS NOTE: ALL OTHER PARTS ARE STAINLESS STEEL -- TRU TYPE AIR CONNECTION ALL DIMENSIONS ARE IN INCHES BODY (ZIRCALOY-2, GRADE RA-1) Manually Actuated TRU Processing Valve. Pneumatically Actuated TRU Processing Valve. ORANI AFEC-OFFCOML ORNI - AEC - OFFICIAL .. 5. - .. - ORNI = AEC = OFFICIAL - - . A small number of valves were also built with all parts to be wetted made -- * of the 10% tungsten-tantalum alloy. The valva bas been adapted to hand operation for a number of applications. ADVANTAGES OF THE TRU PHILOSOPHY The approach to equipment design, fabrication, and installation presented above proved to be workable. The system of locating everything in the cell bank from a grid established early in the program made much of the design fall into routine units. It also served as a quick and easy means of establishing the source of inadvertent errors during installation. The prefabrication of all the cell and cubicle equipment bad many advantages. The setting up of a cell mockup in a shop, as shown in Fig. 5, permitted easy access to all sides of the piping where there would be very confined spaces in the cell, and eliminated much of the time-consuming entry and egress from a deep cell accessible only from the top. The easy availability of shop equipment needed to perform the various fabrication operations also saved time. Craft interference was not a problem during fabrication as all pieces could be fabricated simultaneously, limited only by the manpower availability. Many items of equipment and entire equipment racks were tested for leaks, calibrated, and checked for operability prior to installation in the facility. Much of this work was concurrent with the construction of the building or with installation of the supports for this process equip- ment. The Critical Path Method was used to plan and schedule the many Alo ARCOmall ORNI - AEC - OFFICIAL pieces of, the "puzzle," and for the allocation of manpower to meet this schedule. THE MAJOR PROBLEMS . . . Many of the difficulties encountered involved achieving the #1/4-in. tolerance for the basic cell concrete. All supports were inset 1/4 in. from the nominal wall location ani shimmed to the correct location. Such a tolerance is probably not practical on massive concrete pours for an entire cell bank. Two locations of concrete openings for the cubicle . service plugs and two openings between cell tank pits required extensive chipping hamer work. A broader tolerance would bave alleviated some of this difficulty, but, even sc, 98% of the required sleeves were located accurately. Concrete self-drilling anchors were selected for attaching various supports and frames to concrete cell walls. These proved to be very difficult. to locate as accurately as needed. To simplify the attachment of items to walls, steel plates could be embedded in the concrete during cell construction and then these plates could be drilled and tapped. To do this, unfortunately, the equipment design needs to be well advanced before the cell drawings are completed, a situation not normally achievable. - - - - - - - - The removal of seals, plugs, and identification tags from prefabricated piping sections and other prefabricated items required more time 10 some instances than the actual Installation of the items. (Many items were stored for long periods of time and therefore had to be protected.) Preparation of the pieces for installation was very time-consuming, and manpower for this was not properly allocated. ORAVL--ACC-OFFICGAL -10- OWLE - AC - OFFICIAL REFERENCES 1. 0. 0. Yarbro, TRU Disconnect Ferrule and Clamp Details, ORNL-TM-1097 (May 1965). T. S. Mickey, Development of an Air-Operated, Metal-Diaphragm Pump for the Transuranium Processing Facility, ORNL-TM-995 (Oct. 16, 1964). W. D. Burch and C. 8. LaMaster, Critical Path Method for Scheduling the Transuranium Processing Plant: An Appraisal, ORNI-3925 (March 1966). 5 * BRNA AE- Offretu END . DATE FILMED 10/21 /66 ... .. 22