Introduction - Hanford Site



Effluent Treatment Facility Filtration System Scaled TestingProject No. Pall Cartridge Filter Test Plan – ETF Fouling SimulantDocument No. RPP-PLAN-63468PREPARED BYWashington River Protection Solutions, LLCRevision: A Status: Initial DraftAugust 6th, 2019Quality Level: QL-3TABLE OF CONTENTS TOC \o "2-4" \h \z \t "Heading 1,1" 1.0Introduction PAGEREF _Toc15547378 \h 12.0Test Objectives PAGEREF _Toc15547379 \h 22.1Success Criteria PAGEREF _Toc15547380 \h 23.0Methodology PAGEREF _Toc15547381 \h 33.1Tests PAGEREF _Toc15547382 \h 33.2Test Systems PAGEREF _Toc15547383 \h 33.3Test Procedures/Run Sheets PAGEREF _Toc15547384 \h 33.4Data Collection PAGEREF _Toc15547385 \h 43.4.1Data Types PAGEREF _Toc15547386 \h 43.4.2Instrumentation PAGEREF _Toc15547387 \h 43.4.3Data Acquisition System PAGEREF _Toc15547388 \h 43.4.4Sampling PAGEREF _Toc15547389 \h 43.4.5Data Control, Storage, and Archival PAGEREF _Toc15547390 \h 53.5Personnel Qualifications PAGEREF _Toc15547391 \h 53.6Evaluation PAGEREF _Toc15547392 \h 53.7Safety PAGEREF _Toc15547393 \h 53.8Test Report PAGEREF _Toc15547394 \h 63.8.1Test Run Letter Memoranda PAGEREF _Toc15547395 \h 63.8.2Test Report PAGEREF _Toc15547396 \h 64.0Configuration Management PAGEREF _Toc15547397 \h 74.1Test Documents and Records PAGEREF _Toc15547398 \h 74.2Change Control PAGEREF _Toc15547399 \h 74.3Nonconformance Control PAGEREF _Toc15547400 \h 74.4Review and Approval PAGEREF _Toc15547401 \h 75.0Environmental Management PAGEREF _Toc15547402 \h 85.1Chemical Management PAGEREF _Toc15547403 \h 85.2Waste Management PAGEREF _Toc15547404 \h 86.0Issues, Risks, and Assumptions PAGEREF _Toc15547405 \h 96.1Issues PAGEREF _Toc15547406 \h 96.2Risks PAGEREF _Toc15547407 \h 96.2.1Equipment Malfunctions and Failures PAGEREF _Toc15547408 \h 96.3Assumptions PAGEREF _Toc15547409 \h 97.0Schedule PAGEREF _Toc15547410 \h 108.0Roles and Responsibilities PAGEREF _Toc15547411 \h 118.1Test Director PAGEREF _Toc15547412 \h 118.2Test Lead PAGEREF _Toc15547413 \h 118.3Test Operators PAGEREF _Toc15547414 \h 118.4Quality Assurance PAGEREF _Toc15547415 \h 119.0Definitions PAGEREF _Toc15547416 \h 1210.0References PAGEREF _Toc15547417 \h 13Appendix A ETF Fouling Simulant Recipe…………………………………………………………………..17LIST OF FIGURESNoneLIST OF TABLES TOC \c "Table" Table 31: Anticipated Training for ETF Filtration Testing PAGEREF _Toc15547418 \h 5Table 41. Planned Test Documents and Records PAGEREF _Toc15547419 \h 7LIST OF ACRONYMSCFFCross Flow FilterDFLAWDirect-Feed Low Activity WasteETFEffluent Treatment FacilityFFTFilter Feed TankLAWlow-activity wasteM&TEmeasuring and test equipmentTMPtransmembrane pressure VSEPVibratory Shear Enhanced ProcessWACWashington Adminstrative CodeWRPSWashington River Protection Solutions, LLCIntroduction Washington River Protection Solutions, WRPS, operates the Effluent Treatment Facility (ETF) within the Hanford Site. ETF is essential to the Hanford waste treatment mission plan as it serves the role of receiving, treating, and disposing of liquid effluents from various on-site processes. ETF’s main processes consists of organic contaminants removal/destruction, suspended solids removal, evaporation, concentration, condensation, and drying. Specifically, filtration to remove organic contaminants and solids from liquid effluents is critical for sustaining ETF’s throughput. Anticipation of colloidal and microbiological components clogging the filter has garnered significant interest due to the adverse ramifications arising from irreversible filter fouling with the current dead end filtration technology being utilized in ETF (RPP-RPT-61362). With ETF plant upgrades in progress to support the increased capacity of DFLAW operations, evaluating alternatives to the current filtration technology used in the main treatment train is necessary in order to select a path forward aimed at minimizing filter plugging and plant shutdown. The aim of this test plan, using the existing ETF Pall cartridge filter, is to provide baseline data against which to compare the performance of the VSEP and Spintek systems (covered in separate test plans). The subcontractor is responsible for procuring the Pall filter and building a simple test loop to meet the needs of this test plan.All testing will be run using a filter fouling simulant as defined in Appendix A.Test ObjectivesOverarching technical objectives of performing the pilot scale testing are: To provide basline data using the ETF fouling simulant. This data includes volume of simulant filtered and filter differential pressure against time.Success Criteria1) Cartridge filter shows an increasing differential pressure as simulant is fed through it, and volume of simulant filtered has been recorded.MethodologyTestsTesting scope comprises of a single test run where simulant feed is fed to a single full size cartridge filter in a once through configuration at a flowrate of 5gpm. The test will stop when the filter differential pressure reaches 50 psid. Following this testing, the test skid will be installed at ETF, or a test facility able to accept real basin water ,and real basin water run through to act as a baseline for the testing activities on real basin water feed. That testing will be the subject of a different test plan. Test SystemsAll testing contained in this test plan will be performed at the subcontractor’s facility. The test system should comprise a feed tank, pump, cartridge filter, filtrate receipt tank and necessary instrumentation and valves. The test item is a 1 micron rating Pall Corporation Poly Fine? cartridge filter, part number ARD-1-30UN-DOE in an appropriate housing. The filter cartridge has a surface area of just less than 1.5 sq.ft. and ETF operations shows the filters to be fouled after processing 1800 gals/sq.ft surface area, so it is anticipated that ~2500 gallons of simulant feed will be required for this test. Test Procedures/Run SheetsThe subcontractor will develop test run sheets and any required procedures consistent with the objectives and success criteria presented in this plan. The test run sheets will be reviewed and approved by the buyer prior to the start of testing. Test run sheets will include or address the following (at a minimum):Purpose and scope of testingCompletion of prerequisitesAvailability of tools and materials including personal protective equipment and measuring and test equipmentChange controlSequential and non-sequential test stepsVerification, witness, or hold pointsCollection of samplesAcceptance criteriaConfiguration of the system as testedA test log to document test evolutions, problems, important observations, etc.Preservation and control of test data recorded electronically and manually (i.e. round sheets). Data CollectionData TypesThe ETF Pilot Scale FiltrationTesting project collects both qualitative and quantitative data. Qualitative data consists of data that cannot be reasonably collected using measuring and test equipment. Examples of qualitative data include, but are not limited to:Visual observationsPhotographs Video recordingsQuantitative data consists of data collected using measuring and test equipment. Examples of quantitative data include, but are not limited to:ConcentrationDimensionsFluid flowPressureTemperatureTest data should be collected, recorded and controlled in accordance with the requirements of ISO9001:2015. InstrumentationReserved.Data Acquisition SystemReserved. SamplingSamples of feed and filtrate will be collected at three times during the test runs. Analysis will be limited to TSS, particle size distribution and pH. Samples collected during testing will consist of grab samples taken either directly from totes and tanks or indirectly through designated sample collection valves on piping. Samples will be collected, labeled, stored, and shipped in wide-mouth Nalgene bottles or laboratory-supplied sample kits. Sample kits supplied by the analytical laboratory will be preferentially used when available. Each sampling event will collect a primary sample and a duplicate sample. Sample volumes will be a minimum of 500 mL.Samples will be labeled sequentially with a unique identifier traceable to the test procedure/run sheet and logged in the sample log. Primary samples will be designated as “A” samples. Duplicate samples will be designated as “B” samples and archived. Unique sample identifiers will be of the form:ETF-PILOT FILT-RunSheet#-XXXXX-A (for primary samples), andETF-PILOT FILT-RunSheet#-XXXXX-B (for duplicate samples)Chain of custody forms will track shipments of samples to the designated laboratory for analysis. Samples submitted for analysis will be transported to the designated laboratory in project-specific coolers. Storage, transportation, analysis and disposal of samples follows laboratory procedure once custody of the samples is transferred to the laboratory. Undissolved solids analysis will be performed by EPA standard method 180.1. Data Control, Storage, and ArchivalData, both electronic (if any) and hardcopy, will be controlled to prevent inadvertent loss or damage. Electronic data will be backed up to an external storage device at a minimum of once per day. Both electronic and hard copy data will be submitted to document control for storage and archival upon completion of a test run.Personnel QualificationsPrior to commencing testing, WRPS and any subcontractors will ensure test personnel complete requisite training. Training consists of two primary categories: training to ensure completion of test objectives and success criteria during execution and facility-specific training to ensure safe, compliant conduct of operations. Commensurate with the scope, complexity, and nature of activities to be performed, test personnel will complete training for the items identified in REF _Ref319921918 \h Table 31. Methods of training include, but are not limited to, classroom sessions, on-the-job training, or a combination of methods.Table STYLEREF 1 \s 3 SEQ Table \* ARABIC \s 1 1: Anticipated Training for ETF Filtration TestingTest ExecutionFacility-SpecificTest PlanEmergency ResponseTest Run sheet(s)Waste ManagementTest Control and Change ControlChemical Spill ResponseSamplingLock Out / Tag Out *Personal Protective Equipment* Personnel with lock out / tag out training will be determined by the test facility owner.The Test Director and Test Lead will be qualified based on training and experience. EvaluationEngineers and technical staff from WRPS will evaluate the test results and data to ensure that test equipment performs satisfactorily. The contractor issued test report will document the results of the evaluation.SafetyThe testing subcontractor will perform testing under the safety requirements of the subcontractor facility. Testing will comply with regulatory requirements and the following federal and state regulations:10 CFR 851, Worker Safety and Health Program29 CFR 1910, Occupational Safety and Health StandardsRCW 49.17, Washington Industrial Safety and Health ActAnd the following Washington Administrative Code requirements:Washington Administrative Code 173-303, Dangerous Waste RegulationsWashington Administrative Code 173-400, General Regulations for Air Pollution SourcesTesting will be conducted in accordance with industrial health and safety practices to meet applicable state and federal regulations. Oversight of safety practices related to testing activities may be performed by WRPS personnel. All personnel on the Test Team shall immediately bring any personnel safety concerns to the attention of the Test Director for immediate resolution.Test ReportTest Run Letter MemorandaLetter memorandum documenting preliminary results of test runs will be issued within 8 days of completion of test run. The content of the letter memorandum will include or address the following:Test run conditions (i.e., run sheet targets and achieved conditions)Performance of key unit operations Key observations from testing, andIdentification of success criteria achieved. Test ReportThe subcontractor will issue a test report following receipt of analytical sample results and analysis of process data. The test report will include or address the following:Test configuration(s)Test methods,Test results including summarized data for both measured and analyzed parameters,Test exceptions,System performance evaluation,Conclusions,Recommendations, andAppendices.Appendices to the test report will include or address the following:Raw data collected during testing,Drawings (i.e., as-built P&IDs) depicting the test configuration,Analytical results from sample analysis in as-reported form, and Completed test run sheets and test log noting observations on system behavior during processing.Configuration ManagementTest Documents and RecordsDocuments and records to be generated during and in support of testing are identified in REF _Ref319919757 \h Table 41. Flagged items will be maintained at the operator control area while testing. Additional documents and records that arise in support of testing will be maintained in an appropriate location as defined by the content of the item.Table 41. Planned Test Documents and RecordsItemItemTest PlanData Acquisition Files (if any) *Test Platform Controlled Drawing Package*Sample Logs*Test Procedure(s)/Run Sheets*Test Logs*Round Sheets*Test Exceptions*Calibration Records of M&TE*Test Run Letter MemorandaTraining RecordsTest Report* Maintained at the operator control area while testing. M&TE: measuring and test equipment Change ControlIf during testing, deviations to the approved test equipment configuration are encountered, or if changes to the test sequence or execution of test steps become necessary, the Test Director and WRPS shall be notified before testing progresses any further. Agreed changes should be documented in the test log in sufficient detail that the test could be recreated if necessary.Nonconformance ControlSection not applicableReview and ApprovalQualified personnel will review and approve test run sheets, revisions, substantive changes, letter reports, and test reports before issuance.Environmental ManagementThe testing will operate under the environmental management program of the subcontractor test facility. The environmental management program, which is compliant with applicable local and state regulations, addresses chemical management and waste management.Chemical ManagementTest chemicals, including cleaning chemicals, shall be stored and managed in accordance with the facility environmental management program. Waste ManagementWaste storage and disposal shall be managed in accordance with the facility environmental management program. Issues, Risks, and AssumptionsIssuesNo significant issues have been identified to date.RisksEquipment Malfunctions and FailuresDuring operations, it is possible for equipment to malfunction and/or fail. Malfunctions/failures, if they occur, will be documented in the test log along with the corrective action. AssumptionsNo significant assumptions have been identified to date.ScheduleReservedRoles and ResponsibilitiesTest DirectorThe Test Director reports to the WRPS project engineer and has responsibility for the following:Oversees execution of all phases of testingPlans, monitors, and controls the testing activities and tasksLeads, guides, and monitors the analysis, design, implementation and execution of testsSchedules tests for execution and monitors, measures, controls, and reports on the test progress and the test results, managing changes to the test documents and compensating, as needed, to adjust to evolving conditionsEnsures completion of prerequisites and resolution of safety- or technical-related issues before the start or resumption of testingEnsures collection of required test dataCoordinates and approves, in conjunction with the project engineer, substantive changes to approved test run sheetsEnsures test evolutions, problems, and important observations are documented in the test logPrepares summary reports on test status during test execution.Test LeadThe Test Lead(s) report to the Test Director and have responsibility for the following:Directs execution of all phases of testing in accordance with test plan and test run sheetsVerifies completion of prerequisites and assists with resolution of safety- or technical-related issues before the start or resumption of testingProvides technical guidance to the Test Director on test evolutionsReviews substantive changes to approved test run sheetsEvaluates test data against acceptance criteria.Test OperatorsTest operators report to the Test Lead(s) and have responsibility for the following:Operate the test systems in accordance with the safety requirements of the test facility, training, issued test run sheets and manufacturer instructions under the guidance of the Test Director and the direction of the Test Lead(s).Immediately bring any personnel safety or technical concerns to the attention of the Test Lead(s) and Test Director for resolution.Quality AssuranceQA personnel have responsibility for the following:Assure project deliverables meet QA requirements in accordance with approved procedures prior to release to the clientDefinitionsReserved.ReferencesSOW - Provision of Test Facility and Test Operator Personnel for Pilot Scale Filter TestingAPPENDIX A – ETF FOULING SIMULANT RECIPEThe final simulant formulation and method of preparation is currently under development, however the following tables shows the draft recipe to help in planning activities.ETF Simulant Stock CompoundsNameWater Solubility (Mol/L)Quantity (Mol/L)Aluminum Chloride (AlCl3)5.242E+003.245E-06Ammonium Chloride (NH4Cl)5.552E+004.476E-04Calcium Chloride (CaCl2)6.712E+005.530E-04Sodium Phosphate (Na2PO4)3.947E-023.65E-06Magnesium Sulfate (MgSO4)2.160E+001.451E-03Iron(III) Chloride (FeCl3)4.587E+006.509E-07Ortho Silicic Acid (H4SiO4)1.249E-034.974E-04Potassium Chloride (KCl)3.192E+002.353E-04Sodium Nitrate (NaNO3)1.084E+013.089E-03Sodium Nitrite (NaNO2)1.181E+017.746E-06Sodium Bromide (NaB)1.127E+012.464E-06Sodium Flouride (NaF)1.005E+008.661E-06Sodium Bicarbonate (NaHCO3)8.214E-012.226E-03Target Bulk Properties for ETF simulantBulk ParameterEstimated ValueUnitpH7.8pHSpecific Conductivity1,050uS/cmAlkalinity135.7mg/LTotal Dissolved Solids738.1mg/LTotal Suspended Solids39.0mg/LTotal Organic Carbon0.0mg/L ................
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