System Design Description for Process Chilled Water (PCW)

DUF6-G-M-SDD-PCW REV. 4

ISSUING ORGANIZATION: ENGINEERING EFFECTIVE DATE: 12/19/2019

REQUIRED REVIEW DATE: 12/19/2022 PAGE 1 OF 33

PROCESS CHILLED WATER SYSTEM

U.S. Department of Energy Portsmouth/Paducah Project Office Portsmouth Site Paducah Site

FDU 6Depleted UraniumHexafluorideConversion Project

PROCESS CHILLED WATER SYSTEM PAGE 2 OF 34

DUF6-G-M-SDD-PCW, REV. 4

APPROVAL PAGE

Listed below are personnel responsible for the preparation, review, and approval of this plan. Signatures for each have been provided on DUF6 Form 4320, Document Review & Approval Form.

LEAD PREPARER Rick Spaulding, Portsmouth System Engineer

CONCURRED: Dustin Burkeen, Paducah System Engineer

APPROVERS: Matt Holland, Paducah Engineering Manager

Kirk Barlow, Design Authority

Jackie East, Nuclear Safety Manager

Scott Nicholson, Program Director I - ESH&QA

Adam Goldberg, Program Manager II - Chief Process Technical Officer

Fred Jackson, Program Director I - Chief Process Technical Officer/Chief Engineer/Deputy Project Manager Greg LeHew, Portsmouth Engineering Manager



REVISION LOG

Revision Effective Date Description of Change Pages

Affected

0 Initial issue. Issued for construction. All

1 06/01/07 Revised format and content to standardized template All

2 10/13/09 Update to match system as-built configuration All

3 05/02/16 3 Year Periodic Review All

4 12/19/19 1. Removal of References to BWXT/BWCS 2. Revised as needed 3. 3 Year Periodic Review

ALL



TABLE OF CONTENTS

LIST OF FIGURES ....................................................................................................................... 5

1 INTRODUCTION ............................................................................................................... 6 1.1 System Identification ............................................................................................. 6 1.2 Limitations of this SDD .......................................................................................... 6 1.3 Ownership of this SDD .......................................................................................... 6 1.4 Definitions/Glossary .............................................................................................. 7 1.5 Acronyms .............................................................................................................. 9

2 GENERAL OVERVIEW ................................................................................................... 11 2.1 System Functions ................................................................................................ 11

2.1.1 Primary Process Chilled Water System Functions .................................. 11 2.1.2 Safety Functions ...................................................................................... 11

2.2 System Classification .......................................................................................... 11 2.3 Basic Operational Overview ................................................................................ 11

3 REQUIREMENTS AND BASES ...................................................................................... 13 3.1 General Requirements ........................................................................................ 13

3.1.1 System Functional Requirements ............................................................ 13 3.1.2 Subsystem and Major Components ......................................................... 13 3.1.3 Boundaries and Interfaces ....................................................................... 13 3.1.4 Codes, Standards, and Regulations ........................................................ 13 3.1.5 Operability................................................................................................ 14

3.2 Special Requirements ......................................................................................... 14 3.2.1 Radiation and Other Hazards .................................................................. 14 3.2.2 ALARA ..................................................................................................... 14 3.2.3 Nuclear Criticality Safety .......................................................................... 14 3.2.4 Industrial Hazards .................................................................................... 14 3.2.5 Operating Environment and Natural Phenomena .................................... 15 3.2.6 Human Interface Requirements ............................................................... 15 3.2.7 Specific Commitments ............................................................................. 15

3.3 Engineering Disciplinary Requirements............................................................... 15 3.3.1 Civil and Structural ................................................................................... 15 3.3.2 Mechanical and Materials ........................................................................ 16 3.3.3 Piping Stress Analysis & Support Requirements ..................................... 18 3.3.4 Piping Welding Requirements ................................................................. 19 3.3.5 Pressure Vessel Analysis Requirements ................................................. 19 3.3.6 Chemical and Process ............................................................................. 20 3.3.7 Electrical Power ....................................................................................... 20 3.3.8 Instrumentation and Control .................................................................... 22 3.3.9 Computer Hardware and Software .......................................................... 22 3.3.10 Fire Protection ......................................................................................... 22

3.4 Testing and Maintenance Requirements ............................................................. 22 3.4.1 Testability................................................................................................. 22



3.4.2 TSR-Required Surveillances ................................................................... 22 3.4.3 Non-TSR Inspections and Testing ........................................................... 22 3.4.4 Maintenance ............................................................................................ 22

3.5 Other Requirements ............................................................................................ 23 3.5.1 Security .................................................................................................... 23 3.5.2 Special Installation Requirements ........................................................... 23 3.5.3 Reliability, Availability, and Preferred Failure Modes ............................... 23 3.5.4 Quality Assurance.................................................................................... 23 3.5.5 Miscellaneous .......................................................................................... 23

4 SYSTEM DESCRIPTION ................................................................................................ 24 4.1 Configuration Information .................................................................................... 24

4.1.1 Description of System, Subsystems, and Major Components ................. 24 4.1.2 Boundaries and Interfaces ....................................................................... 24 4.1.3 Physical Location and Layout .................................................................. 25 4.1.4 Principles of Operation ............................................................................ 25 4.1.5 System Reliability Features ..................................................................... 26 4.1.6 System Control Features ......................................................................... 26

4.2 Operations ........................................................................................................... 27 4.2.1 Initial Configuration (Pre-Startup) ............................................................ 27 4.2.2 System Startup ........................................................................................ 28 4.2.3 Normal Operations ................................................................................... 28 4.2.4 Off-Normal Operations ............................................................................. 28 4.2.5 System Shutdown .................................................................................... 29 4.2.6 Safety Management Programs and Administrative Controls ................... 29

4.3 Testing and Maintenance .................................................................................... 29 4.3.1 Temporary Configurations ....................................................................... 29 4.3.2 TSR-Required Surveillances ................................................................... 29 4.3.3 Non-TSR Inspections and Testing ........................................................... 29 4.3.4 Maintenance ............................................................................................ 29

Attachment A, Source Documents .................................................................................. 31 Attachment B, System Drawings ..................................................................................... 32 Attachment C, System Procedures ................................................................................. 33 Attachment D, Other Design Output Documents ............................................................ 34

LIST OF FIGURES

Figure 1, Simplified System Diagram of PCW System ............................................................... 12



1 INTRODUCTION

1.1 SYSTEM IDENTIFICATION

This System Design Description (SDD) covers the Process Chilled Water (PCW) System components, functions, and requirements. This system interfaces with the Closed Cooling Water (CCW) System as well as the Process Off-Gas Scrubber (POS) System and the Hydrofluoric Acid Recovery (HFR) System.

1.2 LIMITATIONS OF THIS SDD

This SDD does not cover civil/structural, fire suppression, or interfacing system requirements.

1.3 OWNERSHIP OF THIS SDD

The owner of this SDD is the System Engineer. The System Engineer is responsible for making changes to the technical content of the SDD.



1.4 DEFINITIONS/GLOSSARY



Term Definition Hydrofluoric Acid (HF) Hydrofluoric acid is a severe respiratory irritant, and in solution,

causes severe and painful burns of the skin.

Integrated Control System (ICS)

The Integrated Control System is the network of software and hardware components used to monitor and operate the process. ICS consists of the basic process control system (BPCS) and independent safety system (ISS).

Intelligent Motor Control Center (MCC)

A standard MCC that has individual compartments factory-wired with control system interface modules. These modules transmit most starter and motor data to the BPCS and allow for connection of external control interlocks.

Operator Workstation (OWS)

An operator interface consisting of a display system and keyboard with a communication link to the ICS. The OWS provides the operator interface required for start-up, shutdown and for general plant control and monitoring.

Performance Category (PC)

A classification using a graded approach in which structures, systems, or components in a category are designed to ensure similar levels of protection (i.e., meet the same performance goal and damage consequences) during natural phenomena hazard events.

Production Support A component or system that is not a major contributor to defense in depth and/or worker safety but is a major contributor to facility production as determined from hazard analysis.

Safety Significant A component or system whose preventative or mitigative function is a major contributor to defense in depth (i.e., prevention of uncontrolled material release) and/or worker safety as determined from hazard analysis (DOE-STD-3009-94).

Standard Operating Procedure (SOP)

A Standard Operating Procedure is a document that identifies the actions and safeguards that must be taken to perform a task.



Technical Safety Requirement (TSR)

The limits, controls, and related actions that establish the specific parameters and requisite actions for the safe operation of a nuclear facility and include, as appropriate for the work and the hazards identified in the documented safety analysis for the facility: Safety limits, operating limits, surveillance requirements, administrative and management controls, use and application provisions, and design features, as well as a bases appendix.

1.5 ACRONYMS

Acronym Definition AISC American Institute of Steel Construction ALARA As Low as Reasonably Achievable ARI Air Conditioning and Refrigeration Institute ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers ASME American Society of Mechanical Engineers BOP Balance of Plant BPCS Basic Process Control System BPVS Boiler and Pressure Vessel Code CCR Central Control Room CCW Closed Cooling Water System CFR Code of Federal Regulations DOE U.S. Department of Energy Acronym Definition DOE O DOE Order DSA Documented Safety AnalysisDUF6 Depleted Uranium Hexafluoride GSN General Support, non-configured GTAW Gas Tungsten Arc Welding HF Hydrofluoric Acid HFR HF Recovery System HFS HF Storage System hp Horsepower Hz Hertz/cycles per second IAS Instrument Air System ICS Integrated Control System ISS Independent Safety System



KOH Potassium Hydroxide MCC Motor Control Center NEMA National Electrical Manufacturers Association OWS Operator Workstation P&ID Piping and Instrumentation Diagram PCW Processed Chilled Water PES Plant Electrical System POS Process Off-Gas System PPE Personal Protective Equipment RAM Reliability, Availability, and Maintainability SDD System Design Description SMAW Shielded Metal Arc Welding SNM Special Nuclear Material SOP Standard Operating Procedure TSR Technical Safety Requirement WRC Welding Research Council



2 GENERAL OVERVIEW

2.1 SYSTEM FUNCTIONS

2.1.1 Primary Process Chilled Water System Functions

The PCW System provides chilled water (Portsmouth - 50% propylene glycol/water mix, Paducah - 20% propylene glycol/water mix) to various systems in the Conversion Building. The system utilizes the CCW System to cool and remove heat from the process chillers. The process chillers provide cooling water, which is a mix of propylene glycol and water, to both the POS and the HFR System.

2.1.2 Safety Functions

There are no safety functions associated with the PCW system.

2.2 SYSTEM CLASSIFICATION

The PCW System has been defined as General Support, non-configured (GSN). There are no Safety Significant or Safety Class components in the PCW; all components are General Support. This is described in the Documented Safety Analyses (DUF6-C-DSA-001 / DUF6-X-DSA-001).

There are no Technical Safety Requirements (TSRs) defined for the PCW System in the Technical Safety Requirements for the DUF6 Conversion Facility documents (DUF6-C-TSR-002 / DUF6-X-TSR-002).

2.3 BASIC OPERATIONAL OVERVIEW

A combination of propylene glycol and water, herein referred to as water, is pumped into the evaporator side of the process chillers where it is cooled. The water is then distributed to the de-ionized water scrubber heat exchangers and the KOH scrubber condensers. The water then flows to the suction side of the pumps and is re-circulated through the entire system. Water from the CCW system enters the condenser side of the process chillers where it removes excess heat.



A simplified system diagram is shown in Figure 1, Simplified System Diagram of PCW System.

PCW Compressio

n Tank

KOH Scrubber Condensers

DIW Scrubber Heat Exchangers

Air Separator

Evaporator Condenser

Process Chiller

Evaporator Condenser

Process Chiller

CCW Supply

CCW Return

PCW Pu

PCW Pu

Figure 1, Simplified System Diagram of PCW System



3 REQUIREMENTS AND BASES

3.1 GENERAL REQUIREMENTS

3.1.1 System Functional Requirements

3.1.1.1 Requirement: The PCW System shall provide cooling for the following systems:

• HFR System (heat exchangers for the de-ionized water scrubbers)

• POS (KOH Scrubber Condensers)

Basis: The PCW System shall be capable of removing the maximum heat rejected from the systems identified above in order to support the conversion process.

3.1.2 Subsystem and Major Components

3.1.2.1 Requirement: Equipment for both sites will be sized based on the Paducah, KY site.

Basis: The Paducah system’s requirements are used for both sites in order to utilize identical equipment for both sites and to facilitate future expansion of the Portsmouth, OH site.

3.1.2.2 Requirement: Two pumps, each with 100% capacity, will be used to recirculate the water.

Basis: Two pumps are used for redundancy purposes.

3.1.2.3 Requirement: Two process chillers, each with 100% capacity (388,000 Btu/hr) shall be used.

Basis: Two chillers are used for redundancy purposes. The capacity is determined based on the heat rejection requirements of the systems being served.

3.1.3 Boundaries and Interfaces

See Section 4.1.2.

3.1.4 Codes, Standards, and Regulations

The editions of the Codes and Standards shall be those in effect on August 2002, unless otherwise indicated.

3.1.4.1 Requirement: Air Conditioning and Refrigeration Institute (ARI)

• ARI 410, Forced Circulation, Air Cooling and Air Heating Coils

• ARI 550/590, Water Chilling Packages Using the Vapor Compression Cycle



3.1.4.2 Requirement: American Institute of Steel Construction (AISC), Manual of Steel Construction, Allowable Stress Design, Ninth Edition

3.1.4.3 Requirement: American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE), ASHRAE 15, Safety Standard for Refrigeration Systems

3.1.4.4 Requirement: American Society of Mechanical Engineers (ASME), ASME B31.3, Process Piping and ASME B31.9 Building Services Piping

3.1.4.5 Requirement: ASME Boiler and Pressure Vessel Code (BPVC), Section VIII

3.1.4.6 Requirement: Hydraulic Institute Standards

3.1.4.7 Requirement: National Electrical Manufacturers Association (NEMA), NEMA Motors and Generators, Revision 1

3.1.4.8 Requirement: Welding Research Council (WRC), WRC Bulletin 107, “Local Stresses in Spherical and Cylindrical Shells due to External Loading”

3.1.4.9 Requirement: WRC Bulletin 297, “Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles - Supplement to WRC Bulletin 107”

3.1.5 Operability

The PCW is not the subject of any TSRs that require it to be operable. At least one process chiller and one process chilled water pump must be in operation in order to deliver cooling water to process systems.

3.2 SPECIAL REQUIREMENTS

3.2.1 Radiation and Other Hazards

There are no radiation or other hazards associated with the PCW System.

3.2.2 ALARA

The PCW System contains no radiological hazards; therefore, the As Low as Reasonably Achievable (ALARA) concept is not applicable.

3.2.3 Nuclear Criticality Safety

Nuclear Criticality Safety requirements are not identified since the Safety Management Program Descriptions for the DUF6 Conversion Project (DUF6-U-SMP-005) has certified that the nuclear criticality accident is not credible.

3.2.4 Industrial Hazards

Propylene Glycol is used as an anti-freeze due to the cold temperatures required for the process equipment. Propylene Glycol is used in lieu of other chemicals, due to its non-toxic properties.



The refrigerant used is R-22,. This refrigerant poses a low health hazard. However, R-22 is listed as a Class II Controlled Substance in the EPA ozone depleting substances regulations 40 CFR 82 Subpart F. Owners, Operators, and/or service personnel must comply with the regulation. R-22 will be banned from production starting January 2, 2020.

Any vents or relief valves are positioned and vented to a location close to doors, vents, or window. The vents are kept a minimum of fifteen feet above the ground level.

3.2.5 Operating Environment and Natural Phenomena

Refer to DUF6-C-G-NPH-001 for Paducah, KY and DUF6-X-G-NPH-001 for Portsmouth, OH site-specific Natural Phenomena Hazards mitigation.

3.2.6 Human Interface Requirements

The operator’s primary interface for all process functions will be the Operator Work Station (OWS). The OWS will provide the operator with access to all the facility process and Balance of Plant (BOP) systems for control, data acquisition, communications, logging, trending and alarming. Alarm indication at the OWS will be composed of a visual indication on the monitor, as well as a local visual and audible indication adjacent to the OWS. In general, all alarms can be acknowledged at the OWS by the operator.

The PCW requires operator involvement to manually setup the Process Chillers, operate valves for the chiller and the closed cooling water.

Specific alarm instrumentation, alarm conditions, set-points, and ICS actions are defined in detail in the BPCS Software Requirements Specification documents: DUF6-C-SRS-002 and DUF6-X-SRS-002.

3.2.7 Specific Commitments

No specific commitments have been made regarding the PCW System.

3.3 ENGINEERING DISCIPLINARY REQUIREMENTS

3.3.1 Civil and Structural

3.3.1.1 Requirement: All PCW associated equipment and piping shall be seismically supported on a building structure or foundation. This system is classified as PC-1.

Basis: To provide safe operation, not to become a missile, and to prevent personnel injury.



3.3.2 Mechanical and Materials

3.3.2.1 Requirement: Pump Type. The system shall have two 100% capacity water pumps. The chilled water pumps shall be horizontal, centrifugal, and electric motor driven. See vendor document E06-00-0031 for additional information.

Basis: A 100% capacity standby pump is incorporated into the system design to provide redundancy and increase system availability. Electrically driven centrifugal pumps are typically used in this type of service.

3.3.2.2 Requirement: Pump Flow. The chilled water pump flow rate shall be determined from the sum of the maximum equipment heat rejection loads plus 25% excess capacity and from the overall system temperature difference.

Basis: The system must be sized in order to provide adequate flow to satisfy the heat rejection and temperature requirements of the process system equipment that it serves.

3.3.2.3 Requirement: Chiller Type. The system shall have two 100% capacity process chillers. The process chillers shall be the electric driven type. See vendor document E13-00-0001 for additional information.

Basis: A 100% capacity standby chiller is incorporated into the system design to provide redundancy and increase system availability. Electrically driven chillers are typically used in this type of service.

3.3.2.4 Requirement: System Fluid. The process chiller fluid shall consist of a mixture of 20% propylene glycol and 80% water by mass (minimum content of Glycol).

Basis: System fluid is selected to be non-toxic and to prevent freezing at low ambient temperatures.

3.3.2.5 Requirement: Chiller Flow Rate. The process chiller flow rate shall be determined from the sum of the maximum equipment heat rejection loads plus 25% excess capacity and from the overall system temperature difference.

Basis: The system must be sized to provide adequate flow in order to satisfy the heat rejection and temperature requirements of the process system equipment that it serves.

3.3.2.6 Requirement: Chiller Heat Load. The process chiller heat load shall be determined from the sum of the maximum heat loads from all of the equipment connected to this system plus 25% excess capacity.

Basis: The PCW System must be sized to satisfy the heat rejection requirements of the process system equipment that it serves.

3.3.2.7 Requirement: Chiller Exit Temperature. The temperature of water leaving the chiller shall be a maximum of 34ºF (1ºC); based on the highest allowable inlet temperature of any of the equipment cooled by this system.

Basis: The PCW System supply temperature must satisfy the requirements of the process system equipment that it serves. The POS and the de-ionized water scrubber heat exchangers require a chilled water supply temperature of 34ºF (1ºC).



3.3.2.8 Requirement: Chiller Material. Materials used for the process chillers shall be the manufacturer’s standard. See vendor document E13-00-0001 for additional information.

Basis: The materials used in the construction of the chillers shall be selected based on their suitability for the fluids being handled and the expected system design conditions.

3.3.2.9 Requirement: Chilled Water Compression Tank. There shall be one 100% capacity process chilled water compression tank with a total volume 24.5ft3.

Basis: The compression tank is sized to ensure that the system is protected from over-pressurization due to fluid thermal expansion under worst case conditions and to provide the required system pressure (see 3.3.2.10).

3.3.2.10 Requirement: Pressure. The PCW System shall be operated at a pressure above the maximum operating pressure of any of the process systems served.

Basis: The system shall maintain a slightly higher pressure to ensure that there will be no leakage from the process systems into the PCW System.

3.3.2.11 Requirement: Piping Design Pressure and Design Temperature. Design pressure for piping shall be at least the pump shutoff head plus system static head. Design temperature for piping shall be at least the maximum system operating temperature.

Basis: Design pressure and design temperature represent the maximum conditions that could occur in the system during normal operation or anticipated transient conditions. All equipment and piping in the system will be designed to operate safely at or below these design conditions. Designing to these conditions will minimize the possibility of system damage due to pressure and temperature conditions.

3.3.2.12 Requirement: Discharge and Suction Pipe Velocities. The maximum fluid velocity at pump discharge shall be 12 feet per second. The maximum fluid velocity in the suction piping shall be 3-7 feet per second.

Basis: Maximum fluid velocities are selected based on limiting one or more of the following to acceptable limits: piping system pressure drop, pipe erosion, fluid cavitation, and noise generation.

3.3.2.13 Requirement: Piping Material. Materials for piping shall be welded carbon steel.

Basis: Carbon steel piping is inexpensive and has adequate corrosion resistance for the fluid being used.

3.3.2.14 Requirement: Codes. All piping shall be in accordance with ASME B31.3.

Basis: This code is used to properly size and design the system piping. Following this code helps to ensure that an acceptable and safe design is produced.



3.3.3 Piping Stress Analysis & Support Requirements

3.3.3.1 Requirement: Piping shall be routed and supported in such a manner that the stresses due to the imposed loads are below the ASME B31.3 Code allowable limits and the forces and moments on connected equipment are below the manufacturers’ acceptable values.

Basis: Designing to these criteria reduces the possibility of pipe failure and damage to connected equipment due to overstressing of piping system components.

3.3.3.2 Requirement: Pipe supports shall be designed in accordance with the requirements of Section 321 of the ASME B31.3 code and the requirements of the AISC Manual of Steel Construction, Allowable Stress Design, Ninth Edition.

Basis: These requirements have been established to ensure that piping supports are properly designed. Correct design of the piping supports is necessary in order to prevent excessive piping; equipment and support stresses; leakage at piping and equipment joints; excessive piping sag or distortion; and other unwanted conditions in the system.

3.3.3.3 Requirement: Piping and pipe support code compliance shall be demonstrated by one of the following methods:

• Method A - Comprehensive analytical methods that include the use of piping analysis computer software to calculate stresses and support loads and demonstrate compliance with code requirements.

• Method B - Chart methods that include the derivation of pipe support spans and guidelines for locating restraints such that the stresses do not exceed the code allowable values.

Method A shall be used primarily for all piping with an operating temperature equal to or greater than 300ºF and/or subject to pressure transient loads. Method B shall be used for all other piping. It is expected that the majority of piping systems will be qualified by Method B.

Specific runs of pipe within the scope of Method B may be analyzed by Method A as an acceptable alternative when more accurate values of pipe responses, such as nozzle loads, pipe stresses, or support loads, are required.

Basis: These two methods are accepted industry practices for determining piping and pipe support code compliance. Compliance with the codes is necessary to ensure that the system is properly designed and to reduce the possibility of piping and/or support failure and/or equipment damage.

3.3.3.4 Requirement: The pipe support arrangement shall be based on the approach of maximizing the use of a limited number of pre-qualified Unistrut standard support types.

Basis: This requirement simplifies the design of the support system by reducing the number of non-standard supports used in the design.



3.3.3.5 Requirement: The use of snubbers shall be avoided whenever possible.

Basis: Snubbers have a high failure rate and have a tendency to leak. Therefore, piping systems without snubbers require less maintenance.

3.3.3.6 Requirement: The structural elements that constitute the entire pipe support assembly, including pipe attachments and supplementary steel, shall be verified for strength and code compliance for the load combinations and acceptance stress criteria specified by the governing codes.

Basis: The entire support assembly must be properly designed and analyzed in order to prevent failure of the structure and/or damage to the connected piping system and equipment.

3.3.3.7 Requirement: Pipe support loads shall also be checked to ensure that they are not excessive with respect to stress guidelines for local pipe stresses at the interface of piping and supports.

Basis: In order to prevent failure of the pipe at the support locations, the support loads must not cause the local stresses of the pipe to exceed the allowable stresses.

3.3.4 Piping Welding Requirements

3.3.4.1 Requirement: Permissible use of flanges for "all welded systems" shall be restricted to connections to equipment and/or to permit maintenance under special conditions.

Basis: Some pieces of system equipment may have to be procured with flanged connections. Flanges shall be kept to a minimum in order to eliminate the potential for leakage at connection points.

3.3.5 Pressure Vessel Analysis Requirements

3.3.5.1 Requirement: Pressure vessels’ structural integrity and operability shall be assured by strict implementation of ASME BPVC, Section VIII, Division 1 and Division 2 (alternative rules for vessel qualification).

Basis: These codes are used to properly design the pressure vessels within the system. Following these codes ensures that an acceptable and safe design is developed.

3.3.5.2 Requirement: The qualification based on the Division 1 shall also require use of the WRC Bulletin 107 and Bulletin 297 - “Local Stresses in Spherical and Cylindrical Shells due to External Loading” and “Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles - Supplement to WRC Bulletin 107”.

Basis: This requirement is used to properly design the pressure vessel nozzles and attachments within the system. This requirement ensures that an acceptable and safe design is developed.



3.3.5.3 Requirement: In case of need, due to complexity of geometry and/or loading, application of the Division 2 may be utilized (use of the Finite Element Method, qualifying the vessel discontinuity based on the stresses at the point). The vessel structural integrity shall be demonstrated by meeting all allowable stress limits for all load combinations provided by the ASME Code.

Basis: This requirement is used to properly design the pressure vessels within the system. This requirement ensures that an acceptable and safe design is developed.

3.3.5.4 Requirement: Where applicable, design rules of the AISC Manual of Steel Construction, Allowable Stress Design, Ninth Edition, shall be implemented for the various vessel-supporting components.

Basis: This code is used to properly design the steel supports for the pressure vessels. Following this code ensures that an acceptable and safe design is developed.

3.3.6 Chemical and Process

3.3.6.1 Requirement: Handling of inhibited propylene glycol will be done with the appropriate PPE.

Basis: Proper handling of chemicals is required to prevent personnel exposure.

3.3.6.2 Requirement: Handling of Refrigerant R-22 will be done with the appropriate Personal Protective Equipment (PPE).

Basis: Proper handling of chemicals is required to prevent personnel exposure.

3.3.7 Electrical Power

3.3.7.1 Requirement: 460 Volt AC Motors. Low voltage motor control equipment shall be housed in MCCs with NEMA Class I Type B wiring. In general, individual motor controllers shall be across-the-line type, combination starters with magnetic-only type molded case circuit breaker, air break magnetic contactor, and solid-state overload relay. The circuit breaker and starter combination shall have a minimum interrupting capacity at 480 V of 65,000 amperes rms. Circuit breaker handles shall have provisions for padlocking in the “OPEN” position.

Motor control circuits shall be rated at 24 Vdc derived from dual redundant power supplies. Control wiring to MCCs shall be terminated on terminals mounted in the starter compartment. Use of auxiliary contacts will be minimized since monitoring and interlocking to the motor starters shall be through a communications bus (e.g., Devicenet). A red "RUN" indicating light shall be provided on the door of each starter compartment.

Power shall be distributed to individual 480 V loads (other than motors) by means of thermal-magnetic circuit breakers located in motor control centers. Circuit breakers shall have a minimum interrupting capacity at 480 V of 65,000 amperes rms. Selected motors that have extended starting times shall be provided with solid-state reduced voltage starters, with a primary circuit breaker disconnect (soft start). No bypass or isolation contactors shall be provided.

Basis: Consensus industry standard practice.



3.3.7.2 Requirement: AC Motors. Under steady state running conditions, voltage at the motor terminals shall be maintained within 90 to 110 percent of motor rated voltage. Voltage at the terminals of running motors shall not dip below 70 percent of motor rated voltage when starting the largest motor on that bus system.

All AC motors shall be suitable for full-voltage starting. In general, they shall be designed to accelerate their connected loads with a minimum 80 percent voltage at the motor terminals. Other engineering approved reduced voltage motor starting methods shall be used if the degree of inrush current is excessive.

Motors for the loads requiring successive starts shall be rated for multiple start duty cycle.

Basis: NEMA MG 1, an industry consensus standard, provides operational requirements for motors.

3.3.7.3 Requirement: Fractional Horsepower Motor Controls. Starters for single phase, fractional horsepower, 115V motors shall be air break, manually operated, across-the-line type, providing thermal overload protection only. The starters shall be mounted near the motors they control. Several starters may be grouped on a single feeder protected by a 20Amp circuit breaker located in a 208Y/120 V power panel board.


3.3.7.4 Requirement: Motor Ratings. Motors from 200 hp to 300 hp shall be rated 460 V, 60 Hz, 3 phase, and shall be powered from 480 Vac switchgear.

Motors ½ hp to 150 hp shall be rated 460 V, 60 Hz, 3 phase, and generally shall be powered from 480 Vac motor control centers.

All AC motor operators for the motor operated valves shall be rated at 460 Vac, 60 Hz, 3 phase, and be powered from the motor control centers. Motors less than ½ hp shall be rated 120 V, 60 Hz, 1 phase.

Basis: Consensus industry standard equipment ratings.

3.3.7.5 Requirement: Motor Wiring Methods. Flexible conduit connections shall be utilized between conduit and motor terminal boxes to reduce the transmission of vibration.


3.3.7.6 Requirement: Motors. All motors shall be rated, built, tested, and applied in accordance with ANSI C50.41 and NEMA Standard MG 1. Low voltage motors shall be designed for Class B temperature rise and shall be provided with Class F or better insulation.

Basis: ANSI and NEMA consensus industry standards. Insulation is in accordance with standard engineering practice.



3.3.8 Instrumentation and Control

3.3.8.1 Requirement: Instrumentation and Control are detailed in DUF6-C-SRS-002 for Paducah and DUF6-X-SRS-002 for Portsmouth. Alarms and interlocks are also detailed in these documents.

Basis: To satisfy served equipment requirements.

3.3.9 Computer Hardware and Software

There are no specific hardware or software requirements for the PCW System.

3.3.10 Fire Protection

Not applicable to this SDD.

3.4 TESTING AND MAINTENANCE REQUIREMENTS

3.4.1 Testability

3.4.1.1 Requirement: Flow elements and pressure and temperature indicators shall be provided in the system piping.

Basis: In addition to monitoring system operation, permanently installed meters and indicators will be used for system performance testing when the system is initially started.

3.4.2 TSR-Required Surveillances

Not applicable to this SDD.

3.4.3 Non-TSR Inspections and Testing

Instruments are periodically tested and/or calibrated through a calibration program. The instrumentation subject to the program is tested and/or calibrated based on manufacturer recommendations, engineering, and operational experience.

3.4.4 Maintenance

Prescribed equipment in this system is subject to periodic maintenance through a preventative maintenance program. The equipment subject to the program is maintained and tested based on manufacturer recommendations, engineering, and operational experience.

3.4.4.1 Requirement: Replacement and/or servicing of the chiller may be required during the life of the facility:

• Cleaning of the condenser tubes

• Oil filter change

• Oil Change



• Refrigerant re-charge

Basis: Manufacturer’s recommendation as described in Trane’s Installation Operation and Maintenance manual

3.5 OTHER REQUIREMENTS

3.5.1 Security

There are no special security requirements for the PCW System. The PCW System is within the boundary of the DUF6 Conversion Facility. Security requirements applicable to the DUF6 Conversion Facility can be found in the Facility Design Descriptions (DUF6-UDS-FDD-PADU / DUF6-UDS-FDD-PORT).

There are no Special Nuclear Material (SNM) protection requirements for the PCW System.

3.5.2 Special Installation Requirements

There are no special installation requirements for the PCW system.

3.5.3 Reliability, Availability, and Preferred Failure Modes

A Reliability, Availability, and Maintainability (RAM) report has been prepared based on operating Dry Conversion Facilities in Richland, Washington and Lingen, Germany. The DUF6 Conversion Facilities are based on the same technology as these Dry Conversion Facilities, and lessons learned from installation, operation, and maintenance of these facilities has been incorporated into the design of the PCW System. The RAM analysis is documented in DUF6-G-M-STU-006.

3.5.4 Quality Assurance

The System was designed using the Project Quality Assurance Plan (DUF6-BWCS-PLN-003) that is based on ASME NQA-1-2000 to comply with DOE Order (O) 414.1 and 10 Code of Federal Regulations (CFR) 830, Subpart A, Quality Assurance.

3.5.5 Miscellaneous

There are no unique requirements developed that do not fit into the categories above.



4 SYSTEM DESCRIPTION

4.1 CONFIGURATION INFORMATION

Refer to P&IDs D-C-1300-PCW-0156-M for Paducah and D-X-1300-PCW-0156-M for Portsmouth sites for a detailed system diagram, including system boundaries and the specific pieces of equipment in the PCW System.

4.1.1 Description of System, Subsystems, and Major Components

The system diagram for the PCW System is shown on Piping and Instrumentation Diagram (P&ID) D-C-1300-PCW-0156-M for Paducah and D-X-1300-PCW-0156-M for Portsmouth. This P&ID shows all of the equipment and piping that are provided to meet the requirements associated with the PCW System.

The PCW System is composed of the following major equipment:

• Process Chillers (Tag numbers: C-0-PCW-CH-001-GSN & C-0-PCW-CH-002-GSN for Paducah and X-0-PCW-CH-001-GSN & X-0-PCW-CH-002-GSN for Portsmouth)

• Process Chilled Water Pump (Tag Numbers: C-0-PCW-PP-001-GSN & C-0-PCW-PP-002-GSN for Paducah and X-0-PCW-PP-001-GSN & X-0-PCW-PP-002-GSN for Portsmouth)

• Process Chilled Water Compression Tank (Tag Numbers C-0-PCW-VS-001 for Paducah and X-0-PCW-VS-001 for Portsmouth)

• Air separator (tag number X-0-PCW-SP-050-GSN for Portsmouth; C-0-PCW-SP-050-GSN for Paducah)

The chillers are two 100% capacity water cooled helical rotary chillers. They are designed, tested, and stamped in accordance with ASME pressure vessel code for refrigerant side working pressure of 300 psig and waterside working pressure of 215 psig. The chillers have an electrical load of 76.4 kW and a capacity of 48.3 tons per unit. The expansion tank has a maximum allowable working pressure of 150 psi with a capacity of 180 gallons. A relief valve, located at the outlet of the compression tank, protects the system from over pressure. The air separator has a maximum working pressure of 125 psi with a maximum flow of 90 gpm to remove entrained air.

4.1.2 Boundaries and Interfaces

The PCW System consists of all the piping, in-line equipment, valves, and specialty items shown on the system P&ID. The isolation, throttling, and instrument root valves and the instruments located in the heat exchanger supply and return piping are also a part of the PCW System. The process heat exchangers that the PCW System serves are not considered to be a part of this system. The boundaries between the PCW System and the process systems are at the manifold valves to the POS and HFR systems.



The process chillers and the controls and equipment supplied with them are a part of the PCW System. The condenser section of the process chillers interfaces with the CCW System. The boundary between these two systems occurs at the connection flanges between the chillers and the CCW System piping.

Instrument air is supplied to the compression tank through a hose connection. Only the hose connection, interconnecting piping, valves, and fittings that are hard piped to the PCW System are considered to be a part of this system.

Instrument air is also supplied to the air operated isolation valves at the inlet to each of the process chillers. The boundary between the PCW System and the IAS is at the inlet to the solenoid valve.

The PCW System interfaces with the following plant systems:

• HFS

• IAS

• ICS

• POS

• CCW

• Plant Electrical System (PES)

4.1.3 Physical Location and Layout

The process chillers, process chilled water pumps, compression tank and air separator are located in the HF Scrubber Room in the Conversion Building.

The system is arranged so that the process chilled water pumps discharge to the process chillers and then out to the system supply piping. The system return piping is connected to the discharge of each heat exchanger and is routed back to the pump suction piping. The compression tank is connected to the suction piping of the process chilled water pumps. The air separator is in the suction piping of the process chilled water pumps. All of the piping in the PCW System is in the Scrubber Room.

4.1.4 Principles of Operation

The PCW System provides chilled water to plant equipment from the process chillers. The PCW System uses a water mixture of propylene glycol and water as antifreeze, due to the low temperatures required.

The system functions to provide chilled water to the following plant equipment, in addition to any others, as required:

• HFR System (heat exchangers for the de-ionized water scrubbers)

• POS (KOH scrubber condensers)



The PCW System is designed to remove the maximum heat rejected from the systems identified above. The PCW System is provided with excess heat rejection capacity to allow for transient conditions where additional cooling may be required. The CCW System provides the heat sink for the process chillers. The process chilled water pumps will distribute cooling fluid throughout the system.

The PCW System is operated at a pressure above the maximum operating pressure of any of the process systems served in order to minimize the potential for leaks of process fluids into the PCW System.

The system design permits shutdown and maintenance of the individual items of equipment without interruption of the cooling function of the rest of the system.

4.1.4.1 Major Equipment

The PCW System includes the following major pieces of equipment:

• Process Chillers (Tag numbers: Paducah: C-0-PCW-CH-001-GSN and -002-GSN; Portsmouth: X-0-PCW-CH-001-GSN and -002-GSN)

• Process Chilled Water Pumps (Tag numbers: Paducah C-0-PCW-PP-001-GSN and –002-GSN; Portsmouth: X-0-PCW-PP-001-GSN and –002-GSN)

• Compression Tank (Tag number: Paducah C-0-PCW-VS-001-GSN; Portsmouth X-0-PCW-VS-001-GSN)

• Air Separator (tag number X-0-PCW-SP-050-GSN for Portsmouth; C-0-PCW-SP-050-GSN for Paducah)

4.1.5 System Reliability Features

Two 100% capacity process chilled water pumps are included in the system design. One pump will be in operation and the other pump will be in standby. The standby pump provides redundancy for the system if the operating pump fails. It also allows for maintenance on one of the pumps while the system is operating.

Two 100% capacity process chillers are included in the system design. One process chiller will be in operation and the other will be in standby. The standby process chiller provides redundancy for the system if the operating chiller fails. It also allows for maintenance on one of the process chillers while the system is operating.

4.1.6 System Control Features

Process chilled water is pumped to either chiller CH-001 or CH-002 for cooling. Each chiller is controlled by a local autonomous control system. In the event that a system experiences trouble or failure, a trouble signal is sent to the ICS. The exact cause of the problem will be indicated at the chiller control panel near the equipment. The PCW return temperature and common chiller outlet temperature are monitored by the ICS.

Local pressure and temperature indications are provided at the outlet of each chiller, to facilitate system balancing and to assess chiller performance.



The system employs a pressurized compression tank in the system return. The compression tank is equipped with local pressure and level indication to facilitate local manual system filling and pressurization.

An ICS-operated, pneumatically actuated, on-off valve is provided in the PCW supply line to each chiller to automate chiller switchover. During chiller switchover, both valves remain open for a predetermined period of time before isolation of the off-line chiller.

Process Chilled Water Pumps PP-001 and PP-002 are redundant pumps operating in a continuously circulating system. One pump is in operation at all times. The common discharge header pressure is monitored by the ICS. Local pressure indication is provided at the discharge of each pump. The PCW pumps can be operated from the ICS or from the appropriate MCC cubicle. Selection of Remote or Local operation is made at the MCC cubicle.

When Remote mode is selected at the MCC cubicle, operation of the pumps is from the ICS. Remote-Automatic or Remote-Manual operation is possible by selection from the Operator Workstation (OWS). Remote-Manual operation allows the Operator to start or stop the pumps from the OWSs.

In the Remote-Automatic mode of operation, the first pump started from an Operator Workstation becomes the duty pump. The other pump becomes the standby pump. The ICS allows a fixed time period for the primary pump to establish successful operation, defined as the receipt of feedback status and the establishment of a predetermined pump discharge header pressure. In the event that successful operation is not established within the prescribed time period, the ICS will automatically start the standby pump. If the failure is caused by loss of discharge header pressure and the duty pump is still running, it will continue to run until stopped by the Operator.

In the Local mode of operation, operation of the pumps will be from the MCC. When Local operation is selected, operation from the ICS is not possible. Local or Remote operating mode and motor feedback status will be available at the OWSs.

All motors are capable of being locked out at the MCC during service and maintenance operations.

For detailed information on automatic actions, interlocks, and alarms, refer to the Software Requirement Specification documents (DUF6-C-SRS-002 for Paducah and DUF6-X-SRS-002 for Portsmouth).

4.2 OPERATIONS

4.2.1 Initial Configuration (Pre-Startup)

Set initial valve and switch alignment. Verify that the CCW System is operating. Verify that the HFR System and POS System are ready to accept chilled water and ensure that the PCW System has been properly installed, wired, filled, and functionally tested.



4.2.2 System Startup

Verify that the CCW System is operating. Confirm that valves C/X-0-CCW-VA-0014 and C/X-0-CCW-VA-0024 are operating normally. Verify CCW water is flowing in and out of the process chillers. Once the HF recovery system and POS are ready to accept chilled water, the chillers should be started in accordance with the supplier’s operational manual. Start-up shall comply with the operational procedure, DUF6-C-OPS-0514 and DUF6-X-OPS-0514.

4.2.3 Normal Operations

System normal operations are defined in Paducah SOP, DUF6-C-OPS-0514 and Portsmouth SOP, DUF6-X-OPS-0514. During normal operation of the PCW System, one 100% capacity process chilled water pump and one 100% capacity process chiller will be in operation. Both the backup pump and the backup process chiller will be in standby mode.

The process chiller operates to maintain the set point temperature (34oF) of the fluid supplied to the system. The inlet valves on both process chillers are air-operated which allows these valves to be remotely actuated. The air-operated valve will remain closed for the chiller that is in standby mode.

Inlet and outlet valves for all heat exchangers serviced by the PCW System are manual valves. Placing equipment in and out of service requires the Operator(s) to manually position these valves. Under normal operation, the throttle valves in each branch are set during initial system balancing and then left in that position.

There are transmitters in the PCW System that will relay information back to the Central Control Room (CCR) through the ICS. This will allow the Operator(s) to monitor the status of the system remotely. The following signals will be monitored: (All tag numbers are prefixed with C-0-PCW for Paducah and X-0-PCW for Portsmouth).

• Process Chilled Water Pumps, PP-001 and -002, Status (YS0011 and YS0021)

• Process Chillers, CH-001 and -002, Status (YS0013/0023) and Trouble (XA0013 and XA0023)

• Process Chiller Inlet Valves (YS0012 and YS0022)

• Fluid Supply Pressure (PI0001)

• Fluid Supply Temperature (TI0002)

• Fluid Return Temperature (TI0003)

• Compression Tank pressure (PI0003)

• Fluid Supply Flow (FAL0001) - Portsmouth Only

4.2.4 Off-Normal Operations

Alarm response procedures have been developed to address Off-Normal Operations. See DUF6-C-OPS-0622 for Paducah and DUF6-X-OPS-0622 for Portsmouth.



4.2.5 System Shutdown

SOPs have been developed for Paducah (DUF6-C-OPS-0514) and Portsmouth (DUF6-X-OPS-0514) to ensure that the system can be shut down safely and successfully.

4.2.6 Safety Management Programs and Administrative Controls

The overall site safety management plans and programs are defined in the Safety Management Program Descriptions for the DUF6 Conversion Project, DUF6-U-SMP-005. The following programs and plans are applicable to the PCW System:

• Initial Testing, In-service Surveillance and Maintenance Programs

• Operational Safety Programs

• Procedures and Training Program

• Human Factors Process

• Quality Assurance Programs

• Emergency Preparedness Programs

• Management, Organization, and Institutional Safety Provisions

4.3 TESTING AND MAINTENANCE

4.3.1 Temporary Configurations

Temporary modification and configurations are non-routine and not predictable, the procedures and acceptance criteria for temporary configuration changes are unique. As such, they will be handled on an individual basis with sufficient detail described in the design change documentation.

4.3.2 TSR-Required Surveillances

No TSRs have been identified for the PCW System.

4.3.3 Non-TSR Inspections and Testing

Instruments are periodically tested and/or calibrated through a calibration program. The instrumentation subject to the program is tested and/or calibrated based on manufacturer recommendations, engineering, and operational experience.

4.3.4 Maintenance

Prescribed equipment in this system is subject to periodic maintenance through a preventative maintenance program. The equipment subject to the program is maintained and tested based on manufacturer recommendations, engineering, and operational experience.



4.3.4.1 Post-Maintenance Testing

Post-maintenance testing will be described in the applicable work control documents.

4.3.4.2 Post-Modification Testing

As modification is non-routine and not predictable, the procedures and acceptance criteria for modifications are unique. As such, they will be handled on an individual basis with sufficient detail described in the design change documentation.



ATTACHMENT A, SOURCE DOCUMENTS Page 1 of 1

DUF6-C-SRS-002 Paducah BPCS Software Requirements Specification

DUF6-X-SRS-002 Portsmouth BPCS Software Requirements Specification

DUF6-C-TSR-002 Technical Safety Requirements for the DUF6 Conversion Facility, Paducah, Kentucky

DUF6-X-TSR-002 Technical Safety Requirements for the DUF6 Conversion Facility, Piketon, Ohio

DUF6-UDS-SRD-PADU Paducah System Requirements Document

DUF6-UDS-SRD-PORT Portsmouth System Requirements Document

DUF6-C-DSA-001 Paducah Conversion Facility Documented Safety Analysis

DUF6-X-DSA-001 Portsmouth Conversion Facility Documented Safety Analysis

DUF6-C-G-NPH-001 Design Requirements for Natural Phenomena Hazards Mitigation, Paducah DUF6 Conversion Facility

DUF6-X-G-NPH-001 Design Requirements for Natural Phenomena Hazards Mitigation, Portsmouth DUF6 Conversion Facility

DUF6-PLN-007 Radiation Protection Program



ATTACHMENT B, SYSTEM DRAWINGS Page 1 of 1

Paducah D-C-0000-PCW-0063-M Process Flow Diagram Process Chilled Water System

D-C-1300-PCW-0156-M Piping and Instrumentation Diagram Process Chilled Water System

Portsmouth

D-X-0000-PCW-0063-M Process Flow Diagram Process Chilled Water System

D-X-1300-PCW-0156-M Piping and Instrumentation Diagram Process Chilled Water System



ATTACHMENT C, SYSTEM PROCEDURES Page 1 of 1

DUF6-X-OPS-0514 Operation of the Process Chilled Water System DUF6-X-OPS-0622 Process Chilled Water System (PCW) Alarm Response DUF6-C-OPS-0514 Operation of the Process Chilled Water System -DUF6-C-OPS-0622 Process Chilled Water System (PCW) Alarm Response



ATTACHMENT D, OTHER DESIGN OUTPUT DOCUMENTS Page 1 of 1

Specifications DUF6-G-SPC-156700 Process Chillers

DUF6-G-SPC-153651 Miscellaneous Horizontal Pumps

Calculations 02561-102-EM-450 Process Chilled Water System Pump and Pipe Sizing 02561-102-EM-451 Process Chilled Water System Head Tank Sizing 02561-102-EM-452 Process Chilled Water System Chiller Sizing

END OF DOCUMENT