TFC-ENG-STD-25, Transfer Pumps - Hanford



Ownership MatrixUSQ # 18-1127-DTABLE OF CONTENTS TOC \o "1-2" \h \z 1.0PURPOSE AND SCOPE PAGEREF _Toc514060459 \h 22.0IMPLEMENTATION PAGEREF _Toc514060460 \h 23.0STANDARD PAGEREF _Toc514060461 \h 23.1Transfer Pumps - General PAGEREF _Toc514060462 \h 23.2Pump Maintainability PAGEREF _Toc514060463 \h 53.3Motors and Motor Control PAGEREF _Toc514060464 \h 53.4Pump Performance Analysis PAGEREF _Toc514060465 \h 63.5Transfer Pump Piping and Components PAGEREF _Toc514060466 \h 73.6Testing PAGEREF _Toc514060467 \h 83.7Utility Pumps PAGEREF _Toc514060468 \h 84.0DEFINITIONS PAGEREF _Toc514060469 \h 95.0SOURCES PAGEREF _Toc514060470 \h 95.1Requirements PAGEREF _Toc514060471 \h 95.2References PAGEREF _Toc514060472 \h 9TABLE OF ATTACHMENTS TOC \h \z \c "ATTACHMENT" ATTACHMENT A – PUMPS WITH A LIMITED MISSION PAGEREF _Toc514060473 \h 11PURPOSE AND SCOPE( REF _Ref514059149 \r \h 5.1.3)This standard applies to waste transfer pump design and installations in tank farms waste tanks and secondary containment structures. This standard implements requirements of RPP13033, “Tank Farms Documented Safety Analysis,” Chapter 4, Sections 4.4.1, “Waste Transfer Primary Piping Systems.” The technical basis for the requirements in this document and approved deviations can be found in RPP-RPT-28501, “Technical Basis for TFC-ENG-STD-25, Transfer Pumps.”This standard does not apply to engineered equipment outside of secondary containment structures, mixer pumps, booster pumps, saltwell jet eductor pumps, or pump instrumentation, or pumps for waste treatment systems.IMPLEMENTATION( REF _Ref514059166 \r \h 5.1.6)This standard is effective on the date shown in the header.All deviations to any requirements of this standard shall be requested from the standard document owner. Approved deviations shall be documented in the accompanying standard basis document RPP-RPT-28501.STANDARD( REF _Ref514059166 \r \h 5.1.6)Transfer pumps with a mission less than 18 months in duration may be exempted from certain requirements of this standard as identified in Attachment A. Transfer pumps with planned usage less than 6 months may be exempted from additional requirements of this standard as identified in Attachment A.Approval of the Engineering Discipline Lead – Mechanical shall be obtained for use of specific positive displacement pumps. When used, positive displacement pumps are exempted from specific requirements that are not applicable to this type of pump design.Exemptions from requirements in this standard shall be documented with the basis for the exemption in RPP-RPT-28501.Utility pumps that are used to transfer small volumes of waste (e.g., sump pumps used to remove residual waste or water heels) shall meet only Section 3.7 for the purpose of meeting the requirements of this standard.Transfer Pumps - GeneralDesign and ConstructionPump nomenclature, definitions, design, application, testing, operation, and maintenance shall be in accordance with the guidelines of the Hydraulic Institute Standards, as applicable. ( REF _Ref514059166 \r \h 5.1.6)Pumps shall be procured, designed, and constructed using the guidance of nationally-recognized pump standards, as applicable. Potentially applicable pump standards are identified in TFC-ENG-DESIGN-D-13.2. ( REF _Ref514059166 \r \h 5.1.6)Vendor information and vendor product files shall be evaluated for requirements and recommendations (i.e., handling, storage, installation, preventive maintenance, corrective maintenance, operation, item/component/system design, and testing) to determine which requirements and recommendations are necessary for the item/component/system to perform its intended function and to meet the applicable standards. The requirements and recommendations as determined by the evaluation shall be incorporated into applicable controlling documents and design media. The evaluation shall include justification for not incorporating any vendor requirements or recommendations. ( REF _Ref514059166 \r \h 5.1.6)The maximum unrelieved discharge pressure of the pump should not exceed the design pressure of the pump assembly discharge side pressure boundary components. If the design pressure can be exceeded, the pump shall incorporate an accessible pressure relieving device to protect pump components and downstream pressure boundary components from exceeding the design pressure of the lowest rated pressure boundary component. ( REF _Ref514059263 \r \h 5.1.2, REF _Ref514059166 \r \h 5.1.6)In addition to initial cost, transfer pump selection should consider life-cycle cost including costs of installation, support systems, maintenance, operation, removal, and disposal.Pump performance (e.g., head, flow, etc.) shall meet the system requirements for its mission. Expected operation should be at or near the pump best efficiency point. ( REF _Ref514059166 \r \h 5.1.6)Materials of construction shall be selected to withstand the transfer pump’s mission and installed environment. Aluminum, brass, bronze, and copper base materials, if used, shall not come into contact with the waste fluid. Non-metallic materials shall conform to the requirements of TFC-ENG-STD-34. ( REF _Ref514059166 \r \h 5.1.6)Transfer pump components below the riser flange shall be designed to fit within the riser and be capable of being removed from the tank. ( REF _Ref514059166 \r \h 5.1.6)Centrifugal transfer pumps shall tolerate reverse rotation or shall be provided with an anti-reverse rotation device if reverse rotation is unacceptable. ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps shall be designed to be self-venting. This requirement is not be applicable to positive displacement pumps. ( REF _Ref514059166 \r \h 5.1.6)Sealing systems for transfer pump shafts extending into transfer pump pits shall be designed to preclude leakage into the pump pit. Pump designs with passive sealing systems that do not require active seals are preferred. ( REF _Ref514059166 \r \h 5.1.6)Transfer pump designs shall minimize the accumulation of solids where process lubricated bearings and mechanical seals are used. The pump should have the capability of flushing such areas. ( REF _Ref514059166 \r \h 5.1.6)Process lubricated bearings shall be abrasion-resistant (e.g., chrome-oxide surfaced stainless steel). ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps subject to impingement forces from mixer pumps shall be designed to withstand such loads. ( REF _Ref514059166 \r \h 5.1.6)For long line shaft pumps, the materials of construction shall be chosen to prevent differential thermal expansion of the individual pump components (i.e., shaft and column) from adversely affecting the performance of the pump over the maximum range of operating temperatures. Thermal expansion of accessory equipment (dilution piping, etc.) installed on the column of long line shaft pumps shall not bind or cause adverse column deflection. ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps shall have permanently installed lifting bails in accordance with drawing H-2-70001 or designed in accordance with the requirements of RPP-8360. Lifting points shall enable the fully assembled pump to be lifted from the horizontal to vertical position without damage. Secondary lifting points shall be identified on the pump column if required. Lifting bail and lifting attachment welds shall be magnetic particle or liquid penetrant tested. ( REF _Ref514059263 \r \h 5.1.2, REF _Ref514059166 \r \h 5.1.6)Pumps that require external lubrication sources should not be used. If used, specific approval of the Engineering Discipline Lead - Mechanical shall be obtained. ( REF _Ref514059166 \r \h 5.1.6)Identify engineering limitations and requirements that result from the design and incorporate into applicable controlling documents and design media. These limitations and requirements shall include, as a minimum, installation, testing, and on-site fabrication processes such as cleaning, welding, nondestructive examination, and parameters such as pressure, flow, speed, load limits (static and dynamic), travel limits, physical clearances, control and alarm settings, and environmental and thermal limits. ( REF _Ref514059635 \r \h 5.1.7)DecontaminationTransfer pumps shall be capable of being internally flushed with water to reduce contamination levels prior to and during pump removal, and to assure there is a clear path through the pump to allow drainage of free liquids. For positive displacement pumps, the pump shall be capable of being flushed by reverse rotation or other means. ( REF _Ref514059675 \r \h 5.1.1, REF _Ref514059166 \r \h 5.1.6)Design shall allow for easy washdown of external surfaces during removal. ( REF _Ref514059675 \r \h 5.1.1, REF _Ref514059166 \r \h 5.1.6)Transfer pumps shall be free draining. For positive displacement pumps, the pump shall be drainable by reverse rotation or other means. ( REF _Ref514059675 \r \h 5.1.1, REF _Ref514059166 \r \h 5.1.6)Transfer pump designs should simplify removal and packaging of contaminated pumps, and facilitate disposal in 8 foot or smaller lengths (for standard burial boxes).Identification and MarkingTransfer pumps shall be provided with a manufacturer’s nameplate securely attached at a readily visible location above the riser mounting plate. The nameplate should be stamped with the following information ( REF _Ref514059166 \r \h 5.1.6):Vendor’s size and model numberPump serial numberCapacityPumping headSpeedMaximum allowable working pressureTemperature, basis for maximum allowable working pressureMotor horsepower.The pump serial number shall be painted on the pump assembly in a readily visible location above the riser mounting plate as viewed from above. Lettering shall be black color on a yellow background. ( REF _Ref514059166 \r \h 5.1.6)The following areas of the pump shall be painted yellow for targeting ( REF _Ref514059166 \r \h 5.1.6):Nozzle kick platesA 1-1/2” band around the top side of dowel holesThe top portion of lifting bails.Pump MaintainabilityFirst-time use transfer pumps shall be procured requesting written maintenance recommendations of operational practices such as bumping and flushing after installation to maximize pump life. ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps shall be designed to require no routine “hands-on” maintenance requiring entry into secondary containment structures. ( REF _Ref514059675 \r \h 5.1.1, REF _Ref514059166 \r \h 5.1.6)Motors and Motor ControlGeneralElectric motors shall be rated to operate any point on the pump curve, and unless otherwise established, with a specific gravity of 1.5. ( REF _Ref514059166 \r \h 5.1.6)For pumps controlled by VFD: ( REF _Ref514059166 \r \h 5.1.6)Critical speed ranges shall be identified where unsuitable for continuous operation of the pump and drive motor assemblyVFD shall be configured to not operate continuously at, nor to pause acceleration or deceleration through, any critical speed range.Process indication shall include:RunningStoppedMotor amperage (a single representative phase).Process control shall include:Emergency stop/lockoutStartStop.A disconnect switch shall be provided as near as practicable to the pump location.Electrical motor overload protection for transfer pumps shall be adjustable.Motors Located in Secondary Containment StructuresWhere ignition source control requirements apply as classified in HNF-SD-WM-HC-017, motor design and installation shall meet the requirements of TFC-ENG-STD-45. ( REF _Ref514059863 \r \h 5.1.4)Motors located in transfer pump pits shall be provided with a manual pump shaft rotation device. ( REF _Ref514059166 \r \h 5.1.6)Motors Located Within the TankWhere ignition source control requirements apply as classified in HNF-SD-WM-HC-017, motor design and installation shall meet the requirements of TFC-ENG-STD-45. ( REF _Ref514059863 \r \h 5.1.4)Submersible motors shall be designed to prevent the ingress of waste into areas of the motor that are not drainable. ( REF _Ref514059675 \r \h 5.1.1)Submersible electric motors shall be designed to operate through the life of its mission in the temperature and radiation environment of the waste tank. ( REF _Ref514059166 \r \h 5.1.6)Pump Performance AnalysisUnmitigated pump performance parameters (i.e., head, flow, discharge pressure) for waste transfer pumps whose motors are controlled by variable frequency drives shall be determined assuming a failure of the variable frequency drive and other components (e.g., pressure relieving devices), and shall be based on the horsepower limitation of the motor. Pump operational parameters (e.g., pumped fluid temperature) shall be assumed to ensure that conservative unmitigated pump performance parameters are determined. Where possible, unmitigated pump performance parameters shall be expressed as pump curves, one pump curve assuming each of the pumped fluid specific gravities 1.0, 1.3, and the highest specific gravity (e.g., 1.5, 1.6) permitted. ( REF _Ref514059936 \r \h 5.1.5)Unmitigated pump performance parameters (i.e., head, flow, discharge pressure) for waste transfer pumps controlled by air or hydraulic motors shall be determined assuming failures of components (e.g., pressure control/compensating valves, pressure relieving devices) intended to limit the air, hydraulic, waste transfer piping pressure. Pump operational parameters (e.g., hydraulic fluid temperature and pressure, pumped fluid temperature) shall be assumed to ensure that conservative unmitigated pump performance parameters are determined. Where possible, unmitigated pump performance parameters shall be expressed as pump curves, one pump curve assuming each of the pumped fluid specific gravities 1.0, 1.3, and the highest specific gravity (e.g., 1.5, 1.6) permitted. ( REF _Ref514059936 \r \h 5.1.5)Unmitigated pump performance parameters (i.e., head, flow, discharge pressure) for positive displacement pumps shall be determined assuming failures of components (e.g., internal and external pressure relieving devices). Pump operational parameters (e.g., pumped fluid temperature) shall be assumed to ensure that conservative unmitigated pump performance parameters are determined. Where possible, unmitigated pump performance parameters shall be expressed as pump curves, one pump curve assuming each of the pumped fluid specific gravities 1.0, 1.3, and the highest specific gravity (e.g., 1.5, 1.6) permitted. ( REF _Ref514059936 \r \h 5.1.5)Evaluation methods and results shall be documented in a technical document such as a calculation (RPP-CALC-XXXXX) or report (RPP-RPT-XXXXX) and released per TFCENG-DESIGN-C-25 prior to operation of a new pump. If a calculation is not used, the document shall include the required sections as specified in Attachment A of TFC-ENG-DESIGN-C-10. ( REF _Ref514059166 \r \h 5.1.6)Transfer Pump Piping and ComponentsPiping, hose, fittings, and other non-pump pressure-containing components on the transfer pump assembly that are above the tank riser (such as discharge piping/hose, dilution lines, flush lines, etc.) shall meet the requirements contained in TFCENGSTD22 as applicable. ( REF _Ref514059263 \r \h 5.1.2, REF _Ref514059936 \r \h 5.1.5)Pump intake piping and/or hose relied upon to provide suction lift shall be designed to withstand the maximum vacuum condition and shall be resistant to kinking. Pump intake piping and/or hose relied upon to provide suction lift shall be designed to prevent suction vapor lock. ( REF _Ref514059166 \r \h 5.1.6)Changes in direction for flexible piping shall comply with the manufacturer’s minimum bend radius and twist requirements. ( REF _Ref514059166 \r \h 5.1.6)Float-type intake designs shall be analyzed to ensure buoyancy under all tank conditions. ( REF _Ref514059166 \r \h 5.1.6)Transfer pump accessory components (such as pressure relief devices and flush water valves) that may require maintenance or replacement shall not be located within the waste tank if failure of the component could jeopardize the future operability of the pump. ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps shall use Plutonium Uranium Extraction (PUREX) connectors or nozzles when connections are required to be remotely separable. Transfer pumps connected to hose–in-hose transfer lines (HIHTLs) shall use PUREX connectors or hose connectors compatible with the HIHTL connections. ( REF _Ref514059166 \r \h 5.1.6)Welding of transfer pump pressure-containing components shall be in accordance with ASME B31.3. ( REF _Ref514059263 \r \h 5.1.2)Welding of structural components shall conform to the AWS D1.1 for steel or AWS D1.6 for stainless steel. ( REF _Ref514059263 \r \h 5.1.2)Where ignition source control requirements apply as classified in HNF-SD-WM-HC-017, transfer pump design and installation shall meet the requirements of TFC-ENG-STD-45. ( REF _Ref514059863 \r \h 5.1.4)TestingTransfer pumps shall be tested for hydraulic and mechanical performance at the design point and full run-out in accordance with the Hydraulic Institute Standards (i.e., ANSI/HI 11.6 and ANSI/HI 14.6). ( REF _Ref514059166 \r \h 5.1.6)Each pump and motor assembly that will be controlled by a variable frequency drive shall be tested to identify speeds unsuitable for continuous operation (critical speeds) of the assembly up to a minimum of 110% of the rated speed of the pump. ( REF _Ref514059166 \r \h 5.1.6)New transfer pumps shall be subjected to a run-in test of at least 8 hours duration (24?hours is recommended) before installation in the waste tank. A run-in test consists of operating the fully-assembled pump at its design point (for a longer duration than a hydraulic performance test) to identify any time-dependent degradation in pump operation or performance. ( REF _Ref514059166 \r \h 5.1.6)Each part of the pump that contains liquid under pressure shall be hydrostatically tested in accordance with either the Hydraulic Institute Standards or the requirements of TFCENG-STD-22 as applicable. ( REF _Ref514059263 \r \h 5.1.2)For first-time use designs, it shall be demonstrated that the transfer pump assembly can be inserted into and removed from the tank riser without interference with the riser. Removal shall be demonstrated for predicted pump failure modes. ( REF _Ref514059166 \r \h 5.1.6)Transfer pumps stored longer than 1 year shall be subjected to a run-in test. ( REF _Ref514059166 \r \h 5.1.6)When variable frequency drives are used, speeds unsuitable for continuous operation (critical speeds) of the pump and motor assembly shall be verified to be locked out from operation. ( REF _Ref514059166 \r \h 5.1.6)Suction side piping and/or hose for transfer pumps relied upon to provide suction lift (e.g., flex-float adjustable intake, self-priming pumps) shall be tested to ensure pressure integrity (no air in-leakage). ( REF _Ref514059166 \r \h 5.1.6)Utility PumpsWaste transfer pumps that are used to transfer small volumes of waste (e.g., sump pumps used to remove residual waste or water heels) and meet the following:Where classified in HNF-SD-WM-HC-017, shall meet the requirements of TFC-ENG-STD-45. ( REF _Ref514059863 \r \h 5.1.4)Shall have a lifting point or device, and that point or device must be used to install or remove the pump. ( REF _Ref514059166 \r \h 5.1.6)Shall not produce a discharge pressure in excess of the lowest rated component of the transfer system. ( REF _Ref514059263 \r \h 5.1.2)Shall be approved by an NRTL. ( REF _Ref514059263 \r \h 5.1.2)Shall be used in accordance with the manufacturer’s recommendations. ( REF _Ref514059263 \r \h 5.1.2)DEFINITIONSTransfer pump. A device located within a tank farms waste tank that adds energy to the waste fluid to move it out of the tank. The fluid may be recirculated to the tank or moved to another tank through piping jumpers and transfer lines.Transfer pump pit. A waste transfer-associated structure (secondary containment) located above the waste tank that houses the transfer pump discharge assembly and connected waste transfer, flush, and dilution piping. The pump drive motor may also be located within this structure.Utility pump. A waste transfer pump that is used to transfer small volumes of waste (e.g., sump pumps used to remove residual waste or water heels) and meets the requirements of Section 3.7 of this standard.SOURCESRequirements10 CFR 835, “Occupational Radiation Protection.”10 CFR 851, “Worker Safety and Health Program.”DOE O 252.1A, “Technical Standards Program.”HNF-SD-WM-HC-017, “NFPA Flammable Vapor and Gas Hazard Classification for the Tank Farms.”RPP-13033, “Tank Farms Documented Safety Analysis.”RPP-RPT-28501, “Technical Basis for TFC-ENG-STD-25, Transfer Pumps.” TFC-PLN-02, “Quality Assurance Program Description.”ReferencesANSI/HI 11.6, “Rotodynamic Submersible Pump Test,” Hydraulic Institute Standards, Parsippany, New Jersey.ANSI/HI 14.6, “Rotodynamic Pumps for Hydraulic Performance Acceptance Tests,” Hydraulic Institute Standards, Parsippany, New Jersey.ASME B31.1, “Power Piping,” American Society of Mechanical Engineers, New York, New York.ASME B31.3, “Process Piping,” American Society of Mechanical Engineers, New York, New York.AWS D1.1, “Structural Welding Code – Steel,” American Welding Society, Miami, Florida.AWS D1.6, “Structural Welding Code – Stainless Steel,” American Welding Society, Miami, Florida.NFPA 70, “National Electrical Code,” National Fire Protection Association, Quincy, Mass.NEMA Standard MG-1, “Motors and Generators.”Hanford Drawings.H-2-70001, Sheet 1, “Lifting Bail Tank Farm Pump.”HNF-3218, “DST Transfer Pump History and Reliability Report.”RPP-8360, “Lifting Point Evaluation Process.”RPP-14541, “Jumper Fabrication and Testing Specification for Tank Farms.” RPP-RPT-42297, “Safety-Significant Waste Transfer Primary Piping Functions and Requirements Evaluation Document.”SD-WM-DGS-006, “Tank Farm Pump Critical Characteristic and Specification Guide.”TFC-ENG-DESIGN-C-10, “Engineering Calculations.”TFC-ENG-DESIGN-C-25, “Technical Document Control.”TFC-ENG-DESIGN-D-13.2, “Guidance for Applying Engineering Codes and Standards to Design.”TFCENGSTD22, “Piping, Jumpers, and Valves.”TFC-ENG-STD-34, “Standard for the Selection of Non-Metallic Materials in Contact with Tank Waste.”TFC-ENG-STD-45, “Design and Installations for Potentially Flammable Atmospheres.”ATTACHMENT A – PUMPS WITH A LIMITED MISSIONSelected requirements may be relaxed with Engineering Discipline Lead – Mechanical approval for pumps with a mission of less than 18 months.Maintenance requirementsPump/motor service lifeBearing requirementsLifting bail requirements, provided analysis verifies ability to install or remove the pump.Example: Pump used for SST retrieval.Additional requirements may be relaxed with Engineering Discipline Lead – Mechanical approval for pumps with planned usage less than 6 months.Run-in testsIdentification/marking requirementsPainting requirements.Example: Off-the-shelf pump used for 1-time pump-out of a catch tank. ................
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