Experimental Breeder Reactor II RCRA Treatment Cost Estimate

Transcription

1 INL/EXT Rev. Experimental Breeder Reactor II RCRA Treatment Cost Estimate S. R. Sherman C. J. Knight V. R. Sandifer February 006 The INL is a U.S. Department of Energy National Laboratory operated by Battelle Energy Alliance

2 INL/EXT Rev. Experimental Breeder Reactor II RCRA Treatment Cost Estimate S. R. Sherman C. J. Knight V. R. Sandifer February 006 Idaho National Laboratory Idaho Falls, Idaho 8345 Prepared for the U.S. Department of Energy Office of Nuclear Energy Under DOE Idaho Operations Office Contract DE-AC07-05ID457

3 ABSTRACT The purposes of this document are to identify those activities necessary to achieve Resource Conservation and Recovery Act (RCRA) clean closure of the Experimental Breeder Reactor II (EBR-II) facility located at the Materials and Fuels Complex (MFC), Idaho National Laboratory, in southeastern Idaho, and to present a best Rough Order of Magnitude (ROM) estimate of the costs to do so. Achievement of clean closed status is governed by the RCRA operation permit issued to the INL by the Idaho Department of Environmental Quality (IDEQ). This document is comprehensive in that treatment costs associated with all RCRA waste materials removed from the EBR-II complex during the RCRA-closure process are included in the cost estimate. Twenty three primary tasks were identified. For each task, costs were divided into three different categories effort, materials & supplies (M&S), and contingency. Also, the tasks were divided into three separate phases planning, execution, and treatment/disposal. In addition, a core level of staffing is described that provides the necessary support for all project tasks over the lifespan of the project. INL cost guidelines were used directly or indirectly to calculate effort, M&S, and contingency costs that are fully burdened with all applicable overhead costs and taxes. All costs are presented in FY 006 dollars. The projected total cost of achieving RCRA clean closure of the EBR-II facility is approximately $0.8M without contingency and $5.6M with contingency. Two preliminary schedules (with yearly costs) of tasks are provided. One schedule, spanning eight years, was developed assuming a maximum of two planning activities, two execution activities, and one treatment/disposal activity could take place at one time. The other schedule, spanning years, was developed assuming that a maximum of two activities could take place at any one time, and that activities could not be duplicated (i.e., not two simultaneous planning or execution activities). The first schedule attempts to shorten the treatment time as much as is practical given the throughput limitations of the current SCMS facility. It is anticipated that treatment time could be further shortened by constructing additional SCMS treatment systems and that this could be accomplished for a relatively small amount of funding. The second schedule attempts to spread out costs over more time in order to reduce the actual funding needed in any given year while still maintaining project continuity and momentum. This schedule may be adjusted to perform partial closures of specified systems, if DOE decides to utilize portions of the EBR-II Facility for new missions. There are two tasks identified which may not need to be performed if the Sodium Processing Facility at the MFC is re-started and in-situ sodium clean-up processes prove to be very effective. These tasks are the treatment of the Secondary Sodium Recirculation System and the Primary Tank Nozzle treatment. Without these tasks, the overall project cost is reduced by $3.4M, including contingency, for a smaller total project cost of $.M. As further planning and engineering are performed for the treatment tasks, cost information will be updated and refined. It is possible during the execution of the treatment tasks that some costs will increase and others will decrease. To address this expected variation, cost estimates will be revised as new information develops. iii

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5 CONTENTS ABSTRACT...iii ACRONYMS... ix PURPOSE... xi. RCRA PERMIT.... Regulatory Driver.... Clean Closure Definition....3 Achieving Clean Closure....4 Disposal or Decontamination of Equipment, Structures and Soils....5 RCRA Permit Implementation/Modifications/Reports/Documentation....6 INL Site Treatment Backlog Plan.... BACKGROUND CURRENT FACILITY ACTIVITIES Surveillance Corrective and Preventative Maintenance Administrative Support Staff Source of Personnel Responsible for Performing These Activities INDIVIDUAL TASK AND SYSTEM DESCRIPTIONS Primary Sodium Tank Primary Tank Cover Gas System NaK Transmitters Secondary Sodium Purification, Gas Recirculation and HMLD Systems Secondary Sodium Systems and Primary Sodium Transfer Line Intermediate Heat Exchanger and Reactor Building Piping Rotating Plugs, Seals and Superstructure Components Primary Tank Heaters... 9 v

6 4.9 Primary Tank Nozzles Fuel Handling Systems Primary Tank Cover Gas Sampling Supply System (PTCGSSS) Shutdown Coolers Reactor Building Storage Pit and Manipulators Cover Gas Cleanup System (CGCS) Alcohol Recovery Station (SCMS) Primary Purification and Sampling Support Systems Radioactive Sodium Chemistry Loop (RSCL) Reactor Building Storage Holes (Pentagon) Argon Purge System Argon Cooling System Hydrocarbon Analyzers Failed Fuel Transfer and Gas Collection System Fuel Element Rupture Detection (FERD) Secondary Sodium Recirculation System Cost Estimation assumptions Task Stages Effort Costs Core Staffing Requirements Core Project Staff Descriptions Commonly Used Materials and Supplies (M&S) General Assumptions PROJECT SUMMARY COSTS System Treatment Costs SYSTEM TREATMENT SEQUENCING Eight-Year Schedule vi

7 7. Twelve-Year Schedule REFERENCES APPENDIX A: INDIVIDUAL TASK COST INFORMATION APPENDIX B: CALCULATION OF EIGHT-YEAR SCHEDULE APPENDIX C: CALCULATION OF TWELVE-YEAR SCHEDULE FIGURES Figure. EBR-II Facility during operation (cooling towers now removed)... 3 Figure. EBR-II primary tank (top down view) showing reactor cover Figure 3. SBB and yard lines Figure 4. The IHX during EBR-II construction... 6 Figure 5. Insertion of rotating plugs Figure 6. Bottom of primary tank cover showing nozzle penetrations.... Figure 7. Primary Purification Cell entrance Figure 8. EBR-II RCRA Treatment Project organizational chart... 4 Figure 9. Standard Schedule Assuming up to 5 Simultaneous Activities Figure 0. Extended Schedule Assuming up to 3 Simultaneous Activities... 5 TABLES Table. Assumed Personnel Effort Rates in 006 Dollars, Fully Burdened Table. Core Staffing, Utilization Rates, and Monthly Effort Costs... 4 Table 3. Material and Services Costs Table 4. Summary of Task-Specific Costs Table 5. Yearly Costs of Eight-Year Schedule Table 6. Yearly Costs of Twelve-Year Schedule... 5 vii

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9 ACRONYMS ACS ANL CGCS CTP DOE EBR-II ETA FERD FFTF FFTS FTP FUM HEPA HMLD IBC IDEQ IHX IWTS INL MFC M&S NaK PCP PR/VSI PTCGSSS Argon Cooling System Argonne National Laboratory Cover Gas Cleanup System Controlled Temperature Profile U.S. Department of Energy Experimental Breeder Reactor II Engineering Task Analysis Fuel Element Rupture Detection System Fast Flux Test Facility Failed Fuel Transfer System Fuel Transfer Port Fuel Unloading Machine High Efficiency Particulate Air Hydrogen Meter Leak Detection System Inter-building Cask Idaho Department of Environmental Quality Intermediate Heat Exchanger INL Integrated Waste Tracking System Idaho National Laboratory Materials and Fuels Complex Materials and Supplies Sodium-Potassium Alloy EBR-II Plant Closure Project Preliminary Review/Visual Inspection Primary Tank Cover Gas Sampling Supply System ix

10 RCRA ROM RSCL SBB SCMS SPF SSDT TSD TSDF Resource Conservation and Recovery Act Rough Order of Magnitude Radioactive Sodium Chemistry Loop Sodium Boiler Building Sodium Component Maintenance Shop Sodium Processing Facility Secondary Sodium Drain Tank Treatment, Storage and Disposal Treatment, Storage and Disposal Facilities x

11 PURPOSE The purpose of this document is to identify those activities required to achieve Resource Conservation and Recovery Act (RCRA) clean closure for the Experimental Breeder Reactor II (EBR-II) facility and to treat and dispose of all waste generated. Upon completion of these activities, EBR-II will have met standards prescribed in the closure plan found in the RCRA operating permit (Ref. ). This permit was issued to INL/DOE by the Idaho Department of Environmental Quality (IDEQ) and contains a description of the systems in EBR-II requiring clean closure and a proposed process for achieving this certified status. This report includes a brief description of each EBR-II system requiring clean closure, a description of those various activities, and estimates for the duration and cost for each activity. This document also proposes sequencing of treatment for these EBR-II systems, and two alternative schedules for performing the described planning, treatment, and disposal activities. This schedule may be adjusted to perform partial closures of specified systems, if DOE decides to utilize portions of the EBR-II Facility for new missions. The cost estimates found in this report can be used as a basis for compiling funding requests for Department of Energy action or for scheduling activities based upon actual annual funding. This report also includes the baseline assumptions made during the development of these cost estimates. The Idaho National Laboratory currently operates the EBR-II facility in compliance with its RCRA permit. As previously agreed upon by DOE-Nuclear Energy, ongoing surveillance and maintenance activities are funded under the annual INL Infrastucture budget. These activities associated with accomplishing RCRA clean closure and final disposal of the waste resulting from the treatment and storage operations will require additional funding. Decontamination and decommissioning (D&D) planning efforts are not within the scope of this document, as the time frame for completing the D&D will be subsequent to RCRA closure and will be set by DOE. This document contains some information previously reported in the following documents: Experimental Breeder Reactor II Complex Transition Plan (Ref. ), EBR-II System Lay-up Plans Volumes I, II, and III (Ref. 3), Passivation of Residual Sodium in EBR-II Systems (Ref. 4), and Technical Information on the Carbonation of the EBR-II Reactor: Summary Report Part (Ref. 5), In-situ Method for Treating Residual Sodium (Ref. 6). xi

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13 . RCRA PERMIT. Regulatory Driver EBR-II buildings 766, 767 and 795 at the Materials and Fuels Complex (MFC) are operated under a RCRA permit issued to Argonne National Laboratory and DOE by the IDEQ on December 0, 00 and transferred to the Idaho National Laboratory on February, 005. This permit allows the continued storage of sodium metal located within the facility and the subsequent treatment of that sodium. It also contains a Closure Plan which outlines at a preliminary level the activities necessary to meet RCRA clean closure standards and the anticipated areas/systems of the facility requiring clean closure. It is recognized that the systems and activities described in this Closure Plan may change once the detailed engineering analyses are completed during the planning stages of each task. This will require some changes to the Permit which must be approved by the IDEQ. The initial permit was issued for ten years with the option to renew the permit for another ten years if adequate progress has been made towards clean closure during the initial time period of the permit. Therefore, it is anticipated that a total of twenty years will be available through the permitting process to complete clean closure. Currently the EBR-II facility is in full compliance with all conditions of the RCRA permit.. Clean Closure Definition Section 64. of the federal regulations for RCRA defines the closure performance standards which must be met to clean close a permitted facility. Specifically, it states that the owner or operator must close the facility in a manner that: Minimizes the need for further maintenance Controls, minimizes or eliminates, to the extent necessary to protect human health and the environment, post-closure escape of hazardous waste, hazardous constituents, leachate, contaminated run-off, or hazardous waste decomposition products to the ground or surface waters or to the atmosphere Complies with the closure requirements found in the permit for identified hazardous constituents..3 Achieving Clean Closure The activities covered in this document under each system heading are based upon the requirements found in the RCRA Permit Closure Plan and have the goal of satisfying the standards in Section., above. These clean closure standards are generally met by performing system flushes for sodium systems, followed by sampling or visual inspection to verify specified criteria have been met (i.e., all RCRA regulated materials and residues have been removed from the system). For the purpose of this cost estimate report, it is assumed that, where possible, an integrated approach is used to meet these requirements and is reflected in Section 8, System Treatment Sequencing, of this report. For example, utilizing flush water used in closing the secondary sodium system to subsequently flush the primary sodium tank minimizes the amount of wastewater generated, which must also be treated. An independent registered professional engineer (IPE) and Laboratory management will certify that the process has been performed in accordance with these established closure specifications identified in the EBR-II RCRA Permit Closure Plan at the conclusion of the clean closure process.

14 It is anticipated that for some systems or components, clean closure may not be achievable due to the inability to sample or inspect adequately to prove standards have been met. In these cases, an alternative process known as risk-based closure is available. This process requires making a case to IDEQ and obtaining their approval that any RCRA regulated waste materials that may remain in place do not present an excessive hazard to the public or the environment. This process involves risk and probability analyses..4 Disposal or Decontamination of Equipment, Structures and Soils Any hazardous debris generated during removal, decontamination and closure activities as described in the following sections will be characterized, stored and treated in the INL TSD Facilities (Treatment, Storage and Disposal) at the Materials and Fuels Complex (which include the Sodium Component Maintenance Shop), managed through the INL Site Treatment Plan (including milestones), and disposed in accordance with all applicable regulations..5 RCRA Permit Implementation/Modifications/Reports/Documentation During this process, it is mandatory that all requirements stated in the RCRA permit are implemented (e.g., daily inspections, maintaining trained personnel, keeping detailed operating records for all closure activities). In addition, it is anticipated that over the course of this closure period, the RCRA operating permit will require modifications which must be approved by the IDEQ. This is especially true for the Closure Plan found in the permit. At the time it was written, specified activities were included which were expected to be performed in the closure process. These activities may be significantly different once the engineering analyses of treatment activities are completed. If so, a permit modification, as outlined in the RCRA regulations, may be required. Modifications to the permit may also be necessitated by regulatory changes, incorporation of new tasks into the operating permit, development of partial closure plans, and development of several preliminary review/visual inspection (PR/VSI) reports. Additionally, a yearly activity report on the storage, removal and treatment activities that lead up to final closure of EBR- II must be submitted to IDEQ. This activity report outlines planned and removal and treatment activities for the upcoming fiscal year that are funded by DOE and reports on activities completed in the previous fiscal year. Finally, as each EBR-II system is treated, documentation must be generated to support the claim that the system has been clean closed. This documentation is collected, reviewed by an IPE, and submitted to IDEQ in a final closure report supporting the contention that the entire EBR-II facility has met RCRA clean closure standards. The acknowledgement by IDEQ that the Laboratory/DOE has met the standards stated in its approved closure plan constitutes certification that the facility is clean closed..6 INL Site Treatment Backlog Plan RCRA regulations generally require that all regulated wastes (including items containing sodium metal) be treated within one year of generation. IDEQ and DOE have a Site Treatment Plan (STP) which is used to track these items. Anything which cannot be treated within the required time frame is placed on the STP backlog and a treatment schedule is negotiated between IDEQ and DOE. Forty years of operating EBR-II resulted in the generation of a volume of approximately 5 m 3 of sodium-wetted components removed from its system and placed in RCRA permitted storage under this backlog. This report describes some systems (such as the Argon Purge System and the Fuel Element Detection System) that are included in the RCRA Permit Closure Plan that have already been removed from EBR-II and placed in RCRA storage and the STP backlog. Each year, the INL and the IDEQ agree to the amount of this backlog that must be successfully treated within the upcoming year. These activities are currently funded under the INL Infrastucture Budget and are not included in this document.

15 . BACKGROUND EBR-II was a 6.5 MW thermal sodium cooled research reactor that was designed and operated by Argonne National Laboratory West and is located at the present-day MFC at the INL (Figure ). Upon completion of construction in 964, the facility was operated until the final reactor shutdown in 994. In its operational lifetime, it was a test facility for fuels development, hardware development, materials irradiation, and system and control theory testing. Figure. EBR-II Facility during operation (cooling towers now removed). In October 994, the Department of Energy terminated the Integral Fast Reactor (IFR) Program, which included EBR-II. At that time, Argonne National Laboratory was directed to place EBR-II in a radiological and industrially safe condition. This task was defined and implemented by the EBR-II Plant Closure Project (PCP) and was completed in March 00. In the first phase of the PCP, fuel removal from the EBR-II reactor was commenced in October 994 and completed in December 996. The second phase of the PCP included draining the bulk sodium from the primary and secondary sodium systems and converting this sodium in the Sodium Processing Facility (located on-site) into a waste form suitable for disposal. Once most of the bulk sodium had been drained from the primary and secondary systems, a carbonation process (Ref. 5-7) was initiated to stabilize the residual amounts of sodium in these systems by creating a layer of sodium bicarbonate over the sodium. This step of the PCP was completed in early 00. The final phase of the PCP involved writing system lay-up plans (Ref. 4) for each EBR-II system. These lay-up plans identify the steps taken to achieve a radiologically and industrially safe condition and document the current status and state of each system. The PCP activities did not remove all of the residual sodium from the facility, and residual sodium remains that still must be treated. Future treatment activities are governed under a RCRA treatment and storage operating permit that was issued by the IDEQ to Argonne National Laboratory West (now part of the INL) and DOE in December 00. This permit allows the continued storage of sodium metal and sodium metal contaminated components and provides the authority and responsibility for completing treatment of the sodium (and contaminated components) by described deactivation methods. The initial permit has a 0-year time frame with the opportunity to renew it at the discretion of the IDEQ if sufficient progress is being made towards the end goal of RCRA clean closure. This report identifies the systems with residual sodium or sodium-wetted components and a brief description of the original system function. Due to the presence of bulk quantities of sodium in some 3

16 systems or due to problems of in-situ accessibility, not all systems will be treatable using the carbonation technology described in Ref Systems and components falling into this category will be treated inplace or removed and treated elsewhere with other techniques such as steam-and-nitrogen, water washing, or alcohol washing. Most components in this category will be treated at the Sodium Component Maintenance Shop (SCMS) located at the MFC using established wet-vapor nitrogen or sodium burning techniques. The sodium-contaminated materials will be tracked with the INL Integrated Waste Tracking System (IWTS). SCMS was originally built and operated as a support maintenance facility to clean sodium contaminated components from EBR-II to allow re-use or disposal. Since the shutdown of EBR-II in 994, SCMS has been utilized to treat EBR-II components scheduled for disposal and as a facility to perform waste treatment operations for other DOE-owned facilities. It is included in the INL s RCRA permit for treatment and storage of components contaminated with sodium or other regulated constituents. 4

17 3. CURRENT FACILITY ACTIVITIES One of the tasks of the EBR-II Plant Closure Project was to place the systems in the EBR-II facility in a lay-up condition to minimize maintenance and surveillance of the components. However there are many systems and components that still require regular surveillance and preventative maintenance to maintain them in an operable or safe condition. For designated systems or components, this is necessary to meet RCRA regulatory requirements until clean closure standards are met. Other systems or components are required for continued use by the INL site (so called hotel loads ), such as the MFC sitewide electrical distribution system, instrument air system or various steam and cooling water systems. The following is a brief summary of the resources that are required to perform this preventative maintenance and surveillance each year. The costs will continue to be incurred and funded under the INL Nuclear Operations budget until the RCRA treatment activities contained in this document are funded and implemented. 3. Surveillance Surveillance tours are conducted in the facility to maintain key components in an operable condition as required by the RCRA permit or because these systems and components are necessary for continued use by the MFC site. These inspections are defined in the RCRA permit and are recorded on approved checksheets that are kept on file in the EBR-II facility. The remaining tours are dictated by DOE Conduct of Operations requirements, best management practices and sound engineering principles. They include the log taking tours made to ensure equipment is functioning properly. 3. Corrective and Preventative Maintenance Some examples of systems/components which require corrective and preventative maintenance are Equipment and instrumentation required by the RCRA operating permit (e.g., carbon dioxide system, cover gas blanket monitoring, Primary Tank pressure instruments, cathodic protection for the Reactor building) EBR-II facility hotel loads including general lighting, electrical equipment, and ventilation and heating equipment, radiation and contamination monitoring, fire detection and protection systems, reactor building crane, etc. MFC-wide utilities (e.g., electrical distribution, site cooling water, pure water systems, site evacuation alarms, instrument air) Systems/components that contain materials controlled by environmental, safety and health rules (such materials would include asbestos lagging, the acid and caustic tanks used in the demineralized water system, instruments containing mercury, compressed gas, etc.) EBR-II facility infrastructure (e.g., painted surfaces, roofing integrity, plumbing and sewage, maintenance of office areas). 3.3 Administrative Support Staff Administrative support staff is required to perform the following tasks: Work control (lockout/tag-out, work request control, system configuration activities) 5

18 Updating of the system lay-up files as needed Initiating facility documentation changes as needed to reflect modifications or remediations (operating instructions, mechanical drawings and diagrams, electrical drawings). 3.4 Source of Personnel Responsible for Performing These Activities Nuclear Operations personnel are used to perform all activities. 6

19 4. INDIVIDUAL TASK AND SYSTEM DESCRIPTIONS Twenty four EBR-II systems and/or components are described in this section. Cost estimates and durations of planning, treatment, and disposal activities will be generated in later sections. The systems and components described are as follows.. Primary sodium tank. Primary tank cover gas system 3. NaK transmitters 4. Secondary sodium purification, gas recirculation, and HMLD systems 5. Secondary sodium system and primary sodium transfer line 6. Intermediate heat exchanger and reactor building piping 7. Rotating plugs, seals, and superstructure components 8. Primary tank heaters 9. Primary tank nozzles 0. Fuel handling systems. Primary tank cover gas sampling supply system. Shutdown coolers 3. Reactor building storage pit and manipulators 4. Cover gas cleanup system 5. Alcohol recovery station (SCMS) 6. Primary purification and sampling support system 7. Radioactive sodium chemistry loop 8. Reactor building storage holes 9. Argon purge system 0. Argon cooling system. Hydrocarbon analyzers. Failed fuel transfer and gas collection system 3. Fuel element rupture detection system 4. Secondary sodium recirculation system Under each system, the following subsection headings will be used: Affected Systems and Components, System Description, System Status, Proposed Treatment/Disposal, Assumptions, Dependencies, and End State Configuration. The Affected Systems and Components sub-section provides a brief statement of which EBR-II system, sub-system, or components is included with the listed EBR-II system. The System Description sub-section provides a brief explanation of the system, sub-system, or components listed in the Affected Systems and Components sub-section. The System Status sub-section describes the current state of the system in terms of its current inventory of RCRA materials, physical state, or other relevant information for treatment. The Proposed Treatment/Disposal sub-section describes the method(s) that might be used to treat the affected systems and components and how the wastes generated during treatment might be disposed. The Assumptions sub-section describes the specific assumptions used to generate a treatment cost estimate and to determine the end-state of the affected system and components after treatment. The Dependencies sub-section describes how the treatment of the affected system and components are linked or affected by other treatment/disposal activities. This information is most important when determining treatment schedules. The End State Configuration sub-section describes the final state of the system after completion of the EBR-II clean closure project. Such information is relevant to future D&D or facility re-use activities. 4. Primary Sodium Tank Affected Systems and Components 7

20 Primary sodium tank and the components located within it. This includes the primary sodium system and reactor vessel components. System Description EBR-II was a pool-type sodium-cooled nuclear reactor. During operation, the primary tank (Figure ) contained approximately 87,000 gallons of liquid sodium metal which was maintained at 700 F. The reactor vessel and primary coolant system are contained in the primary sodium tank and were operated while submerged in the liquid sodium coolant. An inert argon gas blanket was maintained at a differential pressure of of water to mitigate sodium/oxygen interactions. The reactor vessel, which encloses the reactor, is located at the bottom center of the primary tank. The main primary coolant pumps and Intermediate Heat Exchanger (IHX) are suspended from the tank cover and were submerged in the sodium pool during operation. The sodium coolant removed the heat produced by the reactor and transferred it to a secondary sodium system in the IHX. Two centrifugal primary pumps were used to maintain sodium circulation through the reactor and IHX. Other components contained within the primary tank include the fuel storage basket, the auxiliary coolant pump, immersion heaters, shutdown cooler bayonets, and associated sodium piping. Figure. EBR-II primary tank (top down view) showing reactor cover. System Status Bulk primary sodium has been drained from the tank and treated in the Sodium Processing Facility. Approximately 300 gallons of liquid sodium remained in the primary tank after draining. This sodium is referred to as residual sodium. In early 00, moist carbon dioxide was introduced into the tank to react the residual sodium and produce a surface layer of sodium bicarbonate on the residual sodium. Carbonation of the residual sodium was stopped in March 00, and then resumed in May 004 in order to react further the residual sodium. As of December 005, approximately 00 gallons of residual sodium in the primary tank were reacted to form sodium bicarbonate (Ref. 7). The residual sodium has been reacted to the extent that substantially all of the residual sodium that remained on the bottom, sides, and reactor cover at the end of bulk sodium draining has been reacted. The remaining 00 gallons of residual sodium reside in harder-to-reach places and may require more aggressive treatments (e.g., water washing) 8

21 to deactivate. The treatment of the residual sodium within the primary tank with humidified carbon dioxide was terminated in December 005, and now the primary tank is maintained under a static blanket of carbon dioxide. Proposed Treatment/Disposal The next treatment steps for the residual sodium in the primary tank may include an intermediate treatment step using steam, and will include a final treatment step of a water wash. The intermediate treatment step may or may not be necessary, and an analysis will be performed to determine whether such a step would be safe and cost-effective in reducing further the residual sodium amounts, or whether the primary tank could be water washed safely without first treating it aggressively with steam. Water washing may require a combination of heating or spraying to ensure adequate water coverage to all of the internal primary tank surfaces and recesses. Equipment will need to be installed to allow for water re-circulation within the primary tank. It is also anticipated that some chemical treatment system will be needed for the wash water in order to neutralize its ph. Current RCRA regulations require that treatment residues be removed from the system, so the wash water may need to be removed and treated outside of the primary tank. The primary purpose of any water treatment system will be to reduce the volume of the waste generated (e.g. boiling, evaporation) and to recover any solids generated or precipitated by the water treatment process for disposal in approved waste sites. Likely equipment to be used for the waste water handling and treatment are evaporators, forced-circulation crystallizers, filtration units (e.g., cake filters) and solid dryers. Purified waste water would be discharged after filtration, and the purified solid material would be disposed as solid waste. Emphasis will be placed on simplicity, lower capital cost, and robustness when choosing the right equipment for the job. Any residual liquid remaining in the primary tank after removal of the treatment water will be evaporated by heating the primary tank. The immersion heaters, Low Pressure Plenum Throttle Valves, Primary Sodium Transfer System, and Shutdown Cooler bayonets will be removed and treated outside of the reactor building in the Sodium Component Maintenance Shop (SCMS). Assumptions The primary tank immersion heaters, shutdown cooler bayonets, low pressure plenum throttle valves, and primary transfer system will be removed from the primary tank and treated in SCMS. The costs and methods for treating the rotating plugs and the primary tank nozzles will be evaluated separately. The final treatment step for the primary tank will be water washing. For the purposes of estimating treatment costs, it will be assumed that steam treatment of the primary tank will be performed. An engineering task will need to be completed that determines the engineering, installation, and evaporation of a wash water treatment system that is capable of treating up to 500 gallons/day. Dependencies If steam treatment is pursued, it must be completed before the primary tank is washed with water. 9

22 End State Some of the initial water used for washing the primary tank will come from water used to wash the secondary sodium system and the IHX. Planning and safety analysis for the water wash may be performed in parallel with any previously planned treatment activities. The primary tank will be RCRA clean and will be capable of partial RCRA closure. Some asbestos and lead will remain in place. The primary tank will be vented to the atmosphere through a HEPA filter. High radiation levels will remain in the primary tank after treatment. There may be residual fission products and fuel particles remaining in the primary tank after treatment. 4. Primary Tank Cover Gas System Affected Systems and Components Primary tank cover gas system. System Description The bulk sodium coolant in the primary tank was covered with an inert gas blanket during reactor operation to prevent sodium contact with air. The cover gas system drew gas from this inert blanket through nozzle penetrations in the primary tank cover. The gas stream was then circulated through the system and returned to the primary tank or vented to the suspect exhaust system. During reactor operation, the primary tank cover gas contained argon, nitrogen sodium vapor, sodium aerosols, and trace levels of other gaseous impurities. The sodium impurities in the cover gas were removed from the gas stream prior to its analysis in on-line monitoring instruments and other system components. The sodium impurities removal was accomplished through the use of two sodium vapor traps operating in series. The primary tank cover gas system maintained the gas blanket at a slightly positive pressure (approximately of water pressure). System Status The system is being maintained in active status. The cover gas has been changed from argon to carbon dioxide. Proposed Treatment/Disposal Once the RCRA treatment of the EBR-II primary tank has been completed, the cover gas system may be shut down and treated. In order to determine the extent of sodium contamination in the system, a visual inspection will be made of the system, beginning from the primary tank nozzles and working forwards through the system. This will require removal of some system piping to allow for these inspections. If sodium or treatment residual materials are found, the sections containing the material will be removed and sent to SCMS for 0

23 treatment. At SCMS, piping will be reduced in size in a containment tent and residual sodium will be treated in the containment tent, or the piping sections will be treated using the water wash system at SCMS. Components such as tanks may be treated in-situ with humidified nitrogen or steam. Once sodium treatment has been completed, the cleaned components can be discarded as radioactive waste. Treatment residuals in the water wash system will be neutralized and solidified for disposal as RCRA waste. Assumptions The radiation/contamination levels on removed components and piping will be low enough to allow treatment at SCMS. The floating head tank oil contains no PCBs. Additional funding will be required to complete asbestos removal. Dependencies The asbestos removal can be accomplished at any time. The cover gas system must remain in service until the EBR-II primary tank can be considered RCRA clean. End State Configuration The system is removed. 4.3 NaK Transmitters Affected Systems and Components All pressure transmitters and associated capillaries filled with NaK. System Description Transmitters using sodium-potassium eutectic, NaK, were used throughout the facility for pressure indication. These transmitters are found in various sizes. The transmitters consist of a diaphragm and a capillary tube, which were used to transmit a pressure signal to a sensor. System Status All NaK transmitters have been electrically de-energized and remain in place. Some transmitters extend inside and outside of the primary tank and secondary sodium system. It is estimated that there are approximately 4 g of NaK in each transmitter. There are 43 transmitters identified. Therefore, there is approximately kg of NaK that will require treatment from all of NaK transmitters. Proposed Treatment/Disposal The NaK transmitters located on the outside of the primary tank will be extracted and placed into drums and stored for processing at SCMS. The NaK transmitters located inside the primary tank are currently inaccessible and may not be retrieved until the primary tank is dismantled. Treatment consists of draining the NaK from the transmitter in an inert atmosphere inside a radioactive containment tent. Recovered

24 NaK will be placed into containers which can be placed in the SCMS water wash vessel for treatment. An apparatus may need to be designed to assist in the removal of NaK from these transmitters to increase the safety of the treatment process. Assumptions For the NaK transmitters located inside the primary tank, it is assumed that cutting the capillary line between the transmitter and the sensor would cause the sensor to drop further into the primary tank without pinching closed the capillary. This may allow for the reaction of the NaK in these sensors with primary tank wash water. Dependencies NaK transmitters in the primary tank will be separated from the capillary tubes and sensors prior to performing the primary tank water wash. End State Configuration All NaK transmitters are removed. All holes where the transmitters were located are plugged. 4.4 Secondary Sodium Purification, Gas Recirculation and HMLD Systems Affected Systems and Components Secondary sodium purification system, secondary gas recirculation system, Hydrogen Meter Leak Detection (HMLD) system, secondary sodium drain tank cover gas system. System Description The secondary sodium purification system was designed to remove impurities from the secondary sodium. Major components of this system include an electromagnetic (EM) pump, an economizer, monitoring/sampling equipment, and a cold trap. The secondary gas recirculation system consists of filters and a pump to supply gas to monitoring equipment for the secondary cover gas system. This includes the carbon dioxide and argon systems used to maintain an inert gas blanket on the secondary sodium drain tank (SSDT), IHX, and sodium loop piping. The HMLD system provided a means of detecting the onset of a water-to-sodium leak. The HMLD system consisted of 3 MHLD instruments located on the secondary sodium evaporators, super heaters, and on sodium piping. System Status A partial closure (Ref. 8) was completed on the secondary sodium purification system in 00. The HMLD instruments have been de-energized and remain in place. The gas recirculation system has been placed in a lay-up condition and remains in place. The HMLD system contains approximately 7 liters of sodium. The argon sampling system contains sodium frost and other residuals in the sodium vapor trap, filters, and some of the connecting tubing. Proposed Treatment/Disposal

25 The secondary sodium purification system components have been removed from the Sodium Boiler Building (SBB) and are in RCRA permitted storage. These items will be dismantled and treated in SCMS. The NaK cooling jacket on the secondary cold trap will be drained and treated in SCMS. The HMLD system will be removed from the SBB and placed in RCRA permitted storage until treated at SCMS. Treatment of the HMLD components will consist of draining sodium deposits and treating the remaining hardware in the SCMS water wash vessel. The majority of the secondary sodium drain tank cover gas systems will not require significant work, and will be treated with their associated sodium systems. The remaining sections of the system will be removed and treated at SCMS. Assumptions The radiation levels in the secondary cold trap will allow for its treatment at SCMS. Dependencies None. End State Configuration All equipment in the secondary purification system and the HMLD system are removed and treated. The portions of the secondary sodium drain tank cover gas system and secondary gas recirculation system that have not been removed are RCRA closed. 4.5 Secondary Sodium Systems and Primary Sodium Transfer Line Affected Systems and Components Secondary sodium system including the evaporators, superheaters and east wing piping. Primary sodium transfer line. System Description The EBR-II secondary sodium system provided a non-radioactive medium for transmitting heat from the primary sodium coolant to the steam system. The major portion of the system was a closed circulating loop. Sodium was routed through the intermediate heat exchanger (IHX), located in the primary tank, where it absorbed thermal energy from the primary sodium. The secondary sodium was then pumped through an EM pump to the steam evaporators and superheaters located in the SBB (Figure 3). To facilitate maintenance and allow for rapid draining of the secondary sodium system, a secondary sodium drain tank (SSDT) was provided in the west wing of the SBB. Drain lines and valves were provided from the sodium loop to allow draining of the entire secondary sodium volume into the SSDT. A surge tank was installed to provide a constant head of sodium, and to make up for expansion and contraction of the secondary sodium due to temperature changes. A recirculation and purification loop was connected to the SSDT. This loop re-circulated secondary sodium through a cold trap to remove contaminants and to provide motive force for refilling the secondary loop prior to start-up. An argon gas system was provided to maintain an inert atmosphere above the sodium in the surge tank and the SSDT, and provided an inert blanket to the rest of the secondary sodium system at times when the sodium inventory had been 3

26 discharged to the SSDT. A monitoring system was provided for the argon system to allow for identification of problems such as air leaks. The system was equipped with pressure protection devices. The primary sodium transfer line connects the SSDT to the SPF. This line was used to transfer bulk sodium from the tank to the SPF for processing. Figure 3. SBB and yard lines. System Status All bulk sodium has been drained from the system and processed at the SPF. The system still contains approximately 50 gallons of residual sodium. The system also contains powdered and solid sodium bicarbonate and sodium carbonate that has resulted from the reaction of approximately 50 gallons of residual sodium with humidified carbon dioxide (Ref. 4). The system is maintained under a dry carbon dioxide cover gas at ambient temperature. The primary sodium transfer line is in a stand-by condition. The timing of the removal and treatment of this line is conditional upon receiving bulk sodium for processing from the Fast Flux Test Facility FFTF D&D work. If it is decided that the bulk sodium being stored at the FFTF facility will be treated at the INL s SPF, then the line can remain in place until that job is completed. Otherwise, the line will need to be removed and treated on a more immediate time scale. The activities and costs associated with treating this transfer line are not included in this estimate. Proposed Treatment/Disposal Two different treatment processes will be used for the secondary sodium system. Systems will either be treated in place or disassembled and removed for treatment in SCMS. Initially, it will be necessary to remove large or free-volume restricted pockets of sodium. Such deposits can be found in the bottom of the evaporators, superheaters, and in some piping sections. The sodium deposits may be removed by physically cutting the deposit away from the larger unit or drilling holes and melting out the sodium. The technique chosen for removing bulk sodium deposits will be decided on a case-by-case basis and will depend upon safety and how the mechanical removal of the deposit would affect the treatment of remaining components. Treatment of sodium in-situ will require the use of steam-and-nitrogen, humidified nitrogen, or water washing. As a final step, all components will be water washed or water flushed to ensure complete 4

27 sodium deactivation. Water flushing may require repeated fillings and fluid recirculation. Wash water collected from this system will be saved and used, if possible, to water wash the primary sodium system. It is anticipated that some chemical treatment system will be needed for the wash water in order to neutralize its ph. Current RCRA regulations require that treatment residues be removed from the system, and the water wash would be capable of performing this task. The primary purpose of any water treatment system will be to reduce the volume of the waste generated (e.g. boiling, evaporation) and to recover any solids generated or precipitated by the water treatment process for disposal in approved waste sites. Any residual liquid remaining in the secondary sodium system after removal of the treatment water will be evaporated by blowing dry and/or warmed air or nitrogen through the system until dryness. All asbestos lagging removed will be sent off-site for disposal. All NaK transmitters will be removed and treated at SCMS. Assumptions There are no unknown volumes of residual sodium in the system (all bulk locations known). An intermediate treatment process (i.e., steam-nitrogen) may be required before the system components are water-washed. The secondary system has some tritium contamination. The sodium pressure relief system does not contain any sodium. The flush water will not be sufficiently corrosive over the treatment time period to cause pipe failure in the chrome-molybdenum steel. Dependencies The water flush step will be performed before the primary tank is water washed. The HMLD is removed prior to further treatment of the secondary sodium system. End State Configuration The components remaining in the facility after treatment are RCRA clean. The system is vented to atmosphere with no HEPA filter. A significant amount of asbestos lagging has been removed from system piping. 4.6 Intermediate Heat Exchanger and Reactor Building Piping Affected Systems and Components IHX and reactor building piping. System Description 5

28 The IHX (Figure 4) is the heat exchanger that transported the thermal energy from the primary sodium system to the secondary sodium system. It was submerged in the primary tank sodium pool during reactor operation. It is a shell-and-tube heat exchanger design, with the secondary sodium flowing through the tubes in the heat exchanger. Heat exchange between the primary sodium and the IHX was performed by direct thermal contact of the primary sodium with the shell of the heat exchanger. System Status The IHX has been isolated from the secondary sodium loop by cutting and capping the main sodium lines outside of the EBR-II reactor building. Most of the secondary sodium has been drained from the IHX and reactor building piping. It is estimated that approximately 40 gallons of residual sodium remain at the bottom of the IHX with smaller trace amounts still remaining in the reactor building piping. The sodium in the IHX is coated with a thin layer of sodium bicarbonate, having been treated with humidified carbon dioxide for approximately week. Proposed Treatment/Disposal Two options are available for treating the IHX: ) removal of the IHX and treatment in SCMS, or ) treatment in place (the method discussed in the initial RCRA permit). Although an engineering evaluation will be required to determine the best method of treatment, this cost estimate assumes that the preferred option is to remove the IHX and treat it in SCMS. Removal of the IHX, while more laborintensive, may be safer and offer more assurance of completing the treatment task. Also, removal of the IHX allows for greater access to locations in the primary tank, which may be of some value to those who may have to decontaminate and decommission (D&D) the reactor at some point in the future. Removal equipment is available but will require refurbishment. There also exists a maintenance procedure for performing the removal operation. Treatment of the IHX at SCMS will involve draining any large pockets of sodium left in the IHX, dismantlement of the IHX, and treatment of components in the SCMS water wash vessel. Figure 4. The IHX during EBR-II construction. 6

29 If the engineering evaluation determines that deactivation in-place is the best method, there is a procedure, NRP-EBR-004 (Ref. 9), to deactivate the IHX. Steam-and-nitrogen and water wash could be used to deactivate the residual sodium and remove reaction products. Wash water could be recycled to wash the primary tank. Any NaK transmitters will be removed and treated in SCMS. Assumptions The IHX can be removed from the primary tank and treated in SCMS. The will be no residual sodium remaining on the outside of the IHX when it is withdrawn from the primary tank. The radiation exposure for pulling the IHX does not present a significant hazard to workers, or can be managed to acceptable limits. Dependencies If performed, an in-place water wash is performed prior to water washing the primary tank. If the IHX is removed, the IHX is removed prior to performing the water wash of the primary tank. End State Configuration The IHX is removed from the primary tank, or it is RCRA clean. The inlet and outlet piping are removed. If the IHX is removed, a cover plate is installed in place of the IHX. 4.7 Rotating Plugs, Seals and Superstructure Components Affected Systems and Components Large and small rotating plugs, control rod drive mechanisms, the INSAT, the BFTF, the reactor cover locks and drives, and safety rod drives. System Description The rotating plugs (Fig. 5) sit atop the primary tank and provide access to the nuclear reactor fuel assembly grid while maintaining a seal against air intrusion. The seal is provided by a combination of mechanical design and a trough of tin bismuth eutectic (M.P. 8 F) in which the large and small plugs could rotate when the eutectic material was heated and melted. The troughs contain approximately 4,000 lbs of tin-bismuth eutectic. Tin-bismuth eutectic is not currently regulated under RCRA, but the eutectic may contain RCRA-regulated components and will need to be tested before deciding a treatment/disposal pathway. Atop the rotating plugs sits a superstructure containing the cover drive and locks, control rod drive mechanisms, safety rod drive mechanisms, the INSAT and the BFTF. The cover drive and locks are mechanisms that were used to raise and lower the reactor cover and to lock it in place during operating. 7

30 The control rod and safety rod mechanisms were used to raise and lower the control and safety rods in the reactor core. The INSAT was used to detect temperatures at various locations within the reactor core. The BFTF was a system used to detect traces of breached fuel by-products. These items penetrate the primary tank within the rotating plugs. System Status The reactor cover is in a raised position and has been de-energized and mechanically blocked to keep it from moving. The control rod drive mechanisms have been de-energized and welded to keep them from moving. The control rods have been disconnected and removed. The safety rod drive mechanisms has been fully lowered and de-energized. The safety rods have been removed. The BFTF and INSAT systems have been de-energized and have been welded into position. Proposed Treatment/Disposal It is assumed that the entire rotating plug assembly must be removed from the primary tank to access the seal troughs for testing and possibly removal. To do this, the superstructure assemblies and components will be removed. It is anticipated that the superstructure components will not require treatment and could be disposed directly to an acceptable waste site as scrap material, and an evaluation will be made to determine this prior to disposal. Unless the reactor cover can be lowered without the help of the cover drive and lock mechanisms in the superstructure, the cover drive and locks will need to remain in place until the primary tank has been water washed. Other components in the superstructure can be removed at any time. After the primary tank is water washed, the reactor cover will be lowered into place, and the remaining superstructure components will be removed to allow for removal of the rotating plugs. Figure 5. Insertion of rotating plugs. The rotating plugs will then be lifted and the troughs inspected for sodium contamination. If there is sodium contamination in the troughs, the troughs will be cut into sections and physically removed from 8

31 the system. An inspection can also be made of the underside of the rotating plugs to look for residual sodium pockets. Although it is anticipated that there will be no residual sodium on the bottom of the rotating plugs after the primary tank has been fully treated and water washed, a visual inspection of the bottom of the rotating plugs will provide verification of this belief, or it will trigger further planning and treatment activities as needed to achieve RCRA closure. If no residual sodium is found on the bottom side of the rotating plugs, then no further treatment will be necessary for the approximately 58 primary tank nozzles that penetrate the rotating plugs. Assumptions The seal troughs can be cut away without difficulty for removal. The seal troughs can be cut into sections small enough to fit within storage containers. Heat will be applied to the plug components and possible the primary tank to facilitate plug removal. The radiation levels emitted from the reactor vessel will be low enough with the reactor cover down to allow for safe removal of the rotating plugs and the seal troughs. All components which extend through the small plug (gripper, holddown, control rod drives, etc.) will be cut off at the plug and allowed to drop into the primary tank. Dependencies The primary tank cover must be lowered before removing the rotating plugs. The primary tank cover cannot be lowered until the primary tank has been water washed. The superstructure components with the exception of the cover drive and locks can be removed at any time. The rotating plugs should be removed and inspected prior to inspecting and treating other EBR-II nozzles unless otherwise directed by specific procedures. End State Configuration The superstructure and components are removed. The rotating plug is back in place with or without the seal troughs. Lead used for shielding remains in place. 4.8 Primary Tank Heaters Affected Systems and Components All six primary tank heaters and thimbles. System Description 9

32 The primary sodium tank heating system provided auxiliary heating of the primary bulk sodium to maintain a bulk sodium temperature above 350 F when the reactor was not operating. The system consists of six electrical heaters. The electrical heaters were inserted into the primary sodium inside thimbles. Each thimble is approximately 30 feet long and 8 inches in diameter. The thimble itself is partially filled with sodium to facilitate heat transfer between the heater and the thimble. The space above the sodium metal within the thimble is filled with carbon dioxide. System Status All six thimbles are currently in place and are de-energized. Proposed Treatment/Disposal The thimbles will be removed from the reactor, placed into specially constructed wooden boxes for transport to SCMS, and transported to SCMS for cleaning and disposal. Assumptions Removal of the thimbles will require heating of the primary tank to weaken any sodium seal between the thimble and the thimble portal. The radiation levels of the thimbles will allow for contact work. Dependencies Thimble removal should be accomplished after the primary tank has been water washed. Thimble removal is best timed to match with the preparations for removing the rotating plugs (heating the primary tank). End State Configuration The thimbles will have been removed from the primary tank and disposed. The holes created by the thimble removal are plugged. 4.9 Primary Tank Nozzles Affected Systems and Components All nozzle penetrations that are not grouped in with other sub-systems already discussed. System Description Penetrations through the primary sodium tank cover are made through nozzles (Fig. 6). There are up to approximately 58 nozzles which may require further treatment upon completion of the primary tank water wash step. These nozzles vary significantly in size, shape, configuration, and the potential for sodium contamination within the nozzle. 0

33 Figure 6. Bottom of primary tank cover showing nozzle penetrations. System Status All nozzles remain in place and are undergoing residual sodium treatment along with the rest of the components in the primary tank. Proposed Treatment/Disposal As the rotating plugs, IHX, shutdown cooler bayonets, and the low pressure throttle valve flow meters are pulled for treatment, an inspection will be made of the penetration area for each of the nozzles containing these devices. Based on the sum of these inspections, a determination will be made as to the effectiveness of the previous sodium treatment efforts for the nozzles, and whether the remaining nozzles not previously inspected should be inspected and cleaned. If a nozzle must be inspected, the component in the nozzle will be lifted by the reactor building crane and the surfaces exposed to sodium aerosol will be inspected. If sodium is found, the nozzle component will be transferred to SCMS for treatment, and the hole plugged. If disposal of the component is a problem, the component can be re-inserted into its assigned nozzle after it has been cleaned. Pulling of components from nozzles may require the primary tank be heated to facilitate easier component removal. Assumptions For cost purposes, it is assumed that all components must be removed and treated at SCMS. Radiation levels are low enough to allow for removal and treatment. All nozzles contain only sodium aerosol and not bulk sodium which can be easily removed by direct water washing or a wet vapor nitrogen treatment process at SCMS. Dependencies Nozzle removal cannot be performed until the primary tank has been water washed. This activity is best timed to be performed last, after every other necessary task has been performed and an inspection database has already been assembled.

34 End State Configuration All nozzle penetrations are sodium-free. Nozzles may contain original equipment or be covered with metal plates. 4.0 Fuel Handling Systems Affected Systems and Components The fuel unloading machine (FUM), main core gripper, holddown mechanism, transfer arm, storage basket, interbuilding casks (IBCs), and fuel transfer port. System Description The EBR-II reactor was re-fueled by using fuel handling equipment located inside and outside of the primary tank. The components inside the primary tank include the main core gripper, the holddown mechanism, the transfer arm, and the fuel transfer port (FTP). The components outside the primary tank include the drive mechanisms for the gripper, holddown, transfer arm and storage basket, the FUM, two IBCs, and an unshielded auxiliary coffin. The internal portion of the FUM is radioactively contaminated and contains sodium and sodium-air reaction products. The FUM-gripper sense rod contains depleted uranium. The FTP contains sodium-contaminated piping and a lead-filled rotating valve. The FUM main cask contains approximately 4,000 lbs of lead, all fully contained inside of carbon steel shells. The vapor trap installed on the FUM contains approximately 8,000 lbs of lead which is also fully contained inside of carbon steel shells. The FUM shielding shells are expected to be radiologically contaminated but are not expected to be contaminated with sodium. There is a gripper installed on the FUM, and the gripper is known to contain depleted uranium slugs which are fully contained inside stainless steel shells. System Status The main core gripper and the holddown mechanism remain in the primary tank and are welded in place to prevent their removal and to negate the risk of falling. The drive motor for the gripper has been removed. The transfer arm has been released from its support and lowered to the bottom of the primary tank to minimize stored energy. The storage basket has been lowered and secured in place, and the drive motor has been removed. The sodium-contaminated FTP components and shielding have been removed from the primary tank and put into RCRA-permitted storage. The FTP penetration into the primary tank has been sealed with a cover plate. The FUM remains in place on the EBR-II main operating floor. Both IBCs have had their tanks of mercury removed. One IBC and the auxiliary coffin are in the EBR-II reactor building. The other IBC is located in the Fuel Conditioning Facility adjacent to the EBR-II reactor building. The FUM remains in its operational configuration with the exception that the argon cooling system components were removed. The FUM inlet and outlet pipes, the hex guide tube, the gripper, the gripper chains and chain drive components, the rotating valve, the vapor trap, and the molecular sieve contain sodium contamination. A blanket of carbon dioxide remains inside the FUM to protect against air intrusion. Proposed Treatment/Disposal The main core gripper and holddown mechanism will be separated from the rotating plug and allowed to drop into the primary tank. The storage basket and transfer arm will remain suspended from the primary tank cover. These components will be treated concurrently with the primary tank. The FTP components, FTP shielding, auxiliary coffin, and IBCs will require sodium and lead removal and will be transferred to

35 SCMS for treatment with wet vapor nitrogen to remove sodium metal contamination. All treated components will be disposed as low level radioactive waste. The FUM will be disassembled in place and the sodium-wetted components will be transported to SCMS for final treatment along with all other fuel handling components removed from the system. The depleted uranium slugs located in the FUM gripper and all lead shielding will be transported out of the reactor building for disposal as mixed waste. Assumptions The fuel handling components removed from EBR-II will not contain bulk sodium. Dependencies The rotating plugs will be treated prior to this system. End State Configuration All components exterior to the primary tank have been removed and treated. Components located within the primary tank are RCRA clean. 4. Primary Tank Cover Gas Sampling Supply System (PTCGSSS) Affected Systems and Components Primary tank cover gas sampling supply system. System Description The Primary Tank Cover Gas Sampling Supply System (PTCGSSS) was provided to supply primary tank cover gas to various monitoring systems. This system analyzed the cover gas for radioactive and chemical impurities. This system utilized two vapor traps and two aerosol filters in parallel to remove residual sodium aerosol from the primary tank cover gas. System Status The PTCGSSS and primary chromatographs have been de-energized. Both vapor traps have been removed and the annunciators associated with this system have been de-activated. Proposed Treatment/Disposal The PTCGSSS will be dismantled and placed in drums for water washing at SCMS. Assumptions There is no bulk sodium within the system. Asbestos removal can be accomplished at any time. Dependencies None. 3

36 End State Configuration The system is removed. 4. Shutdown Coolers Affected Systems and Components Shutdown cooler bayonet heat exchangers, liquid-to-air heat exchanger and chimney. System Description Two shutdown cooling loops were installed on the primary tank. These shutdown cooling loops were used to remove reactor decay heat during reactor shutdown. Each loop consisted of a bayonet-type heat exchanger immersed in the primary sodium tank sodium and a box assembly containing a finned-tube, liquid-to-air heat exchanger and chimney, located outside of the reactor building. The shutdown coolers used NaK as a heat exchanger fluid. The shutdown coolers operated by natural convection and no pumps were used to transport the NaK. System Status The NaK in the shutdown cooling loops was drained in 999, and the residual NaK in the coolers was fully deactivated in 00. The shutdown coolers are now partially RCRA-closed (Ref 0). The heat exchanger bayonets that extend into the primary tank still contain approximately 5 gallons of NaK in each bayonet. In each bayonet, approximately gallons of NaK is free flowing, while 3 gallons are sealed inside the bayonet. The two bayonets have been physically isolated from the shutdown coolers, and the piping, as it exits the primary tank cover, has been cut, capped and welded. Asbestos is located on top of the bayonets. Proposed Treatment/Disposal Asbestos lagging on the bayonet nozzles will be removed. Then the bayonets will be removed from the primary tank and placed into a wash tube. The wash tubes will be stored in a permitted facility until the bayonets can be treated in SCMS. In SCMS, the bulk NaK in the bayonets will be removed and treated in the water wash vessel. Treatment of this NaK will be done in conjunction wtih NaK removed from other EBR-II sources. Residual NaK in the bayonets will be treated with water in the wash tubes. Assumptions Radiation levels will be low enough to allow the anticipated treatment paths. The bayonet coolers can be removed with the primary tank at ambient temperature. The portion of the shutdown coolers that have been partially closed will require no further action. Dependencies None. End State Configuration Asbestos materials remains in the shutdown cooler heat exchangers and external piping. 4

37 The bayonet coolers are removed and the nozzles covered with metal plates. 4.3 Reactor Building Storage Pit and Manipulators Affected Systems and Components Reactor building storage pit, its contents, and associated manipulators. System Description The reactor building storage pit is a metal lined concrete pit that is approximately 8 x 8 x 37. It is located on the main operating floor of the Reactor Building. The pit has two lead glass windows and two master slave manipulators which provide remote handling capability. An inventory of the pit taken on 0 April 997 showed the following items: Heater thimble with heaters control rod pulling pipes 5 thimble nozzles New and used primary tank heaters O- thimble (empty) With the shutdown of EBR-II, the storage pit now provides storage for highly radioactive components with some components containing solid sodium residues. It can be expected that the items inventoried in 997 plus additional items can be found in the pit. Components in the pit that were originally wetted with sodium can be easily identified because they are contained within Klorastic or double polyethylene bags. System Status There are several sodium and radioactively contaminated components in the pit. The bottom of the pit is also known to be radioactively contaminated and contains some miscellaneous debris. Proposed Treatment/Disposal When a component is suspected of sodium contamination, it will be removed from the storage pit and placed into a wash tube. Other components will be sectioned directly and placed into drums for disposal. Some of the components are assumed to be highly contaminated and will require special handling. Once the components are removed, the debris at the bottom of the pit will be removed and the walls and floors of the pit will be cleaned. The manipulators are known to contain sodium residue and will be dismantled and treated at SCMS. A determination will need to be made regarding the proper disposition of the lead glass windows. Assumptions Some materials may have high radiation levels that will require extensive shielding. Dependencies Once the planning tasks have been completed, this work can be carried out at any time. End State Configuration 5

38 All components located in the storage pit have been characterized, stored, treated, managed, and/or disposed in accordance with all applicable regulations. The storage pit is empty and decontaminated. The lead glass windows are removed. The disposition of the windows will have to be determined by the project. 4.4 Cover Gas Cleanup System (CGCS) Affected Systems and Components Cover gas cleanup system components located in the Reactor Building 767, cover gas cleanup system components located in the CGCS Building 795. Main Loop System Description The main loop portion of the CGCS consists of a piping arrangement which drew radioactive argon from the primary tank cover gas through a nozzle, passed it through components designed to remove sodium vapor, particulates, and radioactive isotopes, and returned cleaned argon to the cover gas blanket in the primary tank through another nozzle. After the EBR-II reactor was shut down, the system provided a g as purge to the large rotating plug annulus to reduce sodium aerosol accumulation. The system contained a gas pre-heater, a sodium removal condenser (controlled temperature profile (CTP) condenser) and aerosol filters located within a large lead-shielded structure inside the reactor building. There is one NaK pressure transmitter located in the CGCS instrument cabinet. CGCS Ancillary System Description The CGCS Ancillary System sampled the primary tank cover gas and then concentrated and analyzed the gas for xenon-tag isotopes. Major components of this system include two sample compressors, three primary tag traps, three secondary tag traps, two cryogenic pumps, a sample vile, and a sample cylinder. Main Loop System Status The main loop system contains sodium. Although aerosol filters were installed to remove sodium from the cover gas prior to cryogenic distillation, there is a potential for sodium residue to exist in components within the CGCS Building 795, as evidenced by observations from workers when the system was in operation. The CGCS main loop piping has been physically separated from Building 795. A by-pass line has been installed that connects the primary tank cover gas space to the system in order to allow for the exchange of humidified carbon dioxide and other sodium treatment gases. In Building 795, valves have been aligned and blocked to allow the existing pressure relief systems to provide passive pressure protection for the main-loop piping, primary tag beds, and cold box. An inspection cover has been installed on the CGCS valve pit to allow for daily surveillance. The filter elements in the final gas filters have been removed. The freon in the CGCS compressor refrigeration units has been removed. Argon and instrument air supplies have been isolated and the nitrogen supply to the system has been removed. Oxygen monitoring has been secured. The system heaters, instrumentation, compressors, and other equipment have been electrically deactivated and the annunciators associated with this system have been deactivated. The mass spectrometer computer has been removed. CGCS Ancillary System Status 6

39 The mass spectrometer has been removed and relocated to the MFC Analytical Laboratory. The tag trap system has been isolated from the CGCS and vented to the suspect exhaust system. All miscellaneous lead bricks and lead-shot bags have been removed. The 5 -thick lead shield surrounding the sample vial and the 6 -thick lead shield surrounding the secondary tag beds have been identified with Hazardous Material Warning labels. The oxygen analyzers have been isolated. The measuring cell has been removed from each oxygen analyzer and the lead, silver, and potassium electrolyte in each cell has been removed and disposed. The humidifier and humidifier reservoir have been drained. Proposed Treatment/Disposal The CGCS main loop piping has been initially treated with humidified carbon dioxide to carbonate at least some portion of the residual sodium within it (Ref. 8). The CTP condenser, pre-heater, aerosol filters, NaK transmitter, piping, valves, and re-heater will be cut out and treated at SCMS. The CTP condenser will likely require a two-step treatment process at SCMS consisting of exposure to wet-vapor nitrogen and a water or alcohol wash. Lead shielding will be removed when it becomes unnecessary. If the lead shielding isn t needed for any other purpose in the laboratory, it will be sent off-site for treatment and disposal as hazardous or mixed waste. Asbestos lagging will be removed and disposed as needed. The aerosol filters will be removed and treated at SCMS. A section of piping in the CGCS building will be removed upstream and downstream of the compressors and samples will be taken to verify the presence or absence of sodium. If the piping is free of sodium, no additional work is required. If sodium is found, the entire system will be removed and cleaned at SCMS. Charcoal in the charcoal absorber beds will be removed and disposed. Assumptions Radiation levels will be low enough to allow handling without shielding. There is at least one drum of piping and equipment that will need to be treated at SCMS. Dependencies None. End State Configuration Asbestos may remain in the CGCS Building. Power is still supplied to the CGCS Building for heating, lighting, and air-conditioning. All components of the system in Building 767 are removed. No lead or asbestos associated with this system are in Building Alcohol Recovery Station (SCMS) Affected Systems and Components Alcohol recovery station in SCMS (part of the current alcohol wash station). System Description 7

40 There are two methods in SCMS for treating sodium contaminated components. The first is to use moisture to react with the sodium, as in the Water Wash System. The second is to use alcohol. The alcohol recovery system in SCMS is a component of the alcohol wash system. The sodium-alcohol reaction is less vigorous than the sodium-water reaction, and so delicate parts can be washed without the accompanying rapid production of thermal energy. Alcohol washing of sodium contaminated components would be required if there are components in EBR-II that will be reused or that have significant value for the design of new reactor components (e.g., material interrogation of EBR-II reactor components exposed to 40 years of a fast neutron flux). As the alcohol is used to rinse sodium-contaminated components, it becomes increasingly contaminated with reaction products, namely sodium ethoxide. Once the alcohol reaches pre-defined concentration limits of reaction by-products, it must be regenerated (purified) and the reaction by-products removed. The existing system for performing this task is a thin-film evaporator. The thin-film evaporator has proved to be unreliable, and the alcohol recovery system now sits in a stand-by condition, awaiting a decision about whether to dismantle the system and dispose of the alcohol, refurbish the existing system and recycle the alcohol, or replace it with another system that might be more reliable and recycle the alcohol. The current equipment is located in the Sodium Component Maintenance Shop (SCMS), located at the Materials and Fuels Complex (MFC). Assumptions It is assumed that the alcohol wash station will be needed in the future, and that the alcohol recovery system will be replaced with a more reliable system. The replacement station will be used to purify the existing alcohol. The replacement station can be used for other RCRA-treatment tasks, as needed. Dependencies While the replacement of the existing system could be performed at any time, it would be best to do the replacement as soon as possible because the contaminated alcohol must be declared a waste product subject to disposal if no action is taken in the near term. End State Configuration A new, more reliable alcohol recovery station is installed in SCMS or the existing system is refurbished. The current inventory of contaminated alcohol has been purified and the waste products separated and disposed. 4.6 Primary Purification and Sampling Support Systems Affected Systems and Components Primary purification system, primary sodium sampling system. 8

41 System Description The primary sodium purification system circulated sodium from the primary sodium tank through a cold trap in order to remove sodium oxide and sodium hydride. The system also included a nuclide trap to remove radioactive cesium from the sodium. The sodium flowed from the primary tank through a nozzle and entered the purification surge tank. The sodium exited the surge tank and flowed to the primary purification cell (PPC, Figure 7) where it passed through the system inlet valve, a DC-EM pump, an economizer, and then the cold trap. The pump, cold trap, and economizer are located in the PPC at the basement level of the reactor building. The surge tank is in the depressed area of the reactor building. The cold trap was cooled by a NaK jacket. The NaK cooling loop was connected to a NaK-silicone oil heat exchanger. The NaK loop was connected to a dump tank in the sub-basement, which was used to rapidly drain the NaK from the loop in the event of a leak. Figure 7. Primary Purification Cell entrance. System Status Electrical heaters for the system have been de-energized and the system piping has been isolated, cut and capped from the primary tank. The cold trap and nuclide traps have been removed and are located in storage. All NaK (approximately gallons) has been drained from the system and placed in storage. Approximately 0 tons of lead bricks are still in place for use as shielding. Some pipe insulation contains asbestos. The system piping containing sodium is radioactively contaminated and contains fission products. There is lead shielding encased in concrete surrounding the surge tank. The surge tank contains a depleted uranium plug for shielding. Proposed Treatment/Disposal 9

42 All components of the primary sodium sampling system will be removed and treated at SCMS. Lead shielding materials that are no longer useful will be sent off-site for disposal. The depleted uranium plug will be removed and disposed as low-level waste. Asbestos lagging will be removed as needed and disposed as low-level waste. All piping, valves, flow meters, and pumps containing sodium will be cut out and treated at SCMS. The NaK transmitters (7) will be removed and treated at SCMS. The economizer will be cut out, capped and moved to SCMS for eventual treatment. The solid sodium within the components will be heated and drained. Sodium collected in this manner will be washed in 5-lb increments in the SCMS water wash vessel. The nuclide and cold traps will remain in storage until the Remote Treatment Facility or other such facility is built and operational, where these traps will be treated. The NaK removed from the system will be treated in SCMS along with the NaK removed from the shutdown coolers. Assumptions The lead bricks can be recycled. A sodium melt station will be constructed at SCMS. Dependencies None End State Configuration All sodium piping is removed from the purification and sampling cells. Some asbestos lagging may remain. The purification cell door is shut and locked. All filter components, lead shield, and all components of the primary sodium sampling system are removed. 4.7 Radioactive Sodium Chemistry Loop (RSCL) Affected Systems and Components The five RSCL cells and all related piping and components. System Description The RSCL system was designed and constructed to provide a facility for testing material samples and a location for on-line devices used for monitoring impurity levels in sodium in a radioactive environment. It is located in the basement of the reactor building adjacent to the primary purification system area. The RSCL is connected to the inlet and outlet lines of the primary purification system and utilized the surge tank and siphon break in common with that system. Stub lines are provided to connect the five RSCL cells to the supply and return headers. The five cells are designated A, B, C, D, and E. Cell A contains the plugging temperature indicator and the vacuum distillation sampler. Cell B contains the oxygenhydrogen-tritium module. Cell C contains the specimen equilibration module. Cell D contains the analytical cold trap. Cell E was never used. The shielding of the RSCL is arranged to provide access to 30

43 any individual cell while the main loop was in operation. The RSCL is isolated from the primary sodium tank. System Status The system has been isolated. All electrical circuits have been de-energized. The system is full of frozen primary sodium. The cells may also contain asbestos. Proposed Treatment/Disposal The piping, electrical heating wiring, and instruments for this system will be removed and placed into drums. The drums will be stored until processed at SCMS. Asbestos lagging will be removed as needed and disposed. Lead shielding that is no longer needed will be disposed. The three NaK pressure transmitters in this system will be removed and sent to SCMS for treatment and disposal. All radioactive components that do not contain RCRA-regulated materials will be disposed as low-level radioactive waste. In order to perform this job properly, a walkway may need to be constructed above the RSCL cells. The RSCL cell doors will be removed and disposed since they contain lead. Removal of the doors will also have the added benefit of de-classifying the RSCL cells as confined spaces. Assumptions Everything can be removed from the RSCL cells. Radiation levels are low enough to allow access to all RSCL components. Dependencies If the RSCL system is removed before the Primary Purification System is treated, a walkway must be constructed above the cells to allow access to the Primary Purification System. End State Configuration All system piping and instrumentation are removed. All lead shielding is removed and disposed. All RSCL cell shield doors are removed and disposed. 4.8 Reactor Building Storage Holes (Pentagon) Affected Systems and Components The reactor building storage holes and all contents located within the pentagon area. System Description Sixteen storage holes are located in a shielded area of the reactor building operating floor near the Storage Pit. Each hole consists of a diameter by 38 long pipe that expands to a 4 diameter at the top 3 of each hole. The area on the operating floor around the storage holes is provided with a lead shielding structure having five irregular sides; hence the designation pentagon. The shield wall contains two lead glass windows, a jib-mounted remote manipulator and various access ports. There is a 50-ton large 3

44 diameter shear in the pentagon that was used for cutting components into disposable lengths. A movable hood with a HEPA filtered exhaust system is provided for contamination control inside of the pentagon. An inventory of components in the holes was taken on 0 April 997. The components found in the holes include the INSAT, INCOT, and BFTF experimental hardware, several control rod drives, and several experimental subassembly test equipment. No special nuclear materials are stored in the holes. System Status The storage holes have been covered to eliminate debris from falling into them. The holes are currently occupied by various reactor components, some of which may have been sodium wetted when they were placed into the holes. Proposed Treatment/Disposal There are approximately 5 components that must be removed. Many of these components may contain sodium or be coated with sodium residues. To determine which components will require treatment, the contents of each hole must be lifted and inspected. Sodium-contaminated components will be placed into wash tubes for treatment in SCMS. Some of the components can be reduced in size with the 00-ton shear if necessary to facilitate treatment and/or disposal. Once all of the holes have been emptied, a remote camera will be used to verify that all debris has been removed, and the holes will be cleaned to remove residual sodium and suspect materials. A grappling device will need to be designed and fabricated that will be capable of retrieving loose components. Assumptions Some material may have high radiation levels that will require extensive shielding. Dependencies Once the planning activity is completed, the execution and clean-up activities can be performed at any time. End State Configuration All the components that were stored in the holes are removed, treated, and disposed. The storage holes are empty and decontaminated in regard to RCRA regulations. 4.9 Argon Purge System Affected Systems and Components Argon purge system. System Description The argon purge system was used to reduce cover gas radioactivity and reduce concentrations of contaminants such as methane, helium, and nitrogen. This system used two vapor traps and two aerosol filters in parallel to remove residual sodium aerosol from the cover gas. System Status 3

45 The argon purge system s sodium-wetted components have been removed and are in storage awaiting treatment and disposal at SCMS. No further action is required on this system to achieve RCRA closure. Proposed Treatment/Disposal All sodium-contaminated components currently in storage will be treated at SCMS under the INL Site Treatment Plan Backlog. The cost for this treatment effort is not included in this cost estimate. Assumptions No further work on this system is needed within the facility. Dependencies None. End State Configuration System has been removed. 4.0 Argon Cooling System Affected Systems and Components Argon cooling system (ACS). System Description The argon cooling system circulated cover gas through fueled and non-fueled subassemblies for heating (during transfers into the primary tank) or cooling (during transfers out of the primary tank). The ACS used two vapor traps and two molecular sieves to remove radioactive sodium aerosol from the argon gas before this gas was re-circulated through the ACS. These components were located in the depressed area of the reactor building behind lead shielding. System Status The ACS has been dismantled with all sodium-wetted components (i.e., molecular sieves and vapor traps) removed and placed into storage for treatment at SCMS. The lead shielding has been removed. The nozzle to the primary tank has been isolated. The fuel transfer port has been removed and a blank flange installed to seal the hole. No further action is required for this system to achieve RCRA closure. Proposed Treatment/Disposal All components currently in storage will be treated at SCMS under the INL Site Treatment Plan Backlog. The cost of this treatment effort is not included in this cost estimate. Assumptions None. Dependencies 33

46 None. End State Configuration All system components are removed. The electrical control panel remains in place but is de-energized. 4. Hydrocarbon Analyzers Affected Systems and Components Hydrocarbon analyzers. These analyzers are covered in the RCRApermit (Ref. ) as part ofthe Cover Gas Ancillary Systems. System Description The hydrocarbon analyzers were part of the Argon Cover Gas system and were used to sample the cover gas to detect hydrocarbons in the cover gas. Hydrocarbons would be found in the cover gas if oil leaked into the primary tank. System Status The hydrocarbon analyzers have been removed and are in storage awaiting treatment at SCMS. Proposed Treatment/Disposal All components currently in storage will be treated at SCMS under the INL Site Treatment Plan Backlog. The cost of treating the hydrocarbon analyzer components is not included in this cost estimate. Assumptions There is residual sodium in these components. Dependencies None. End State Configuration All systems are removed. 4. Failed Fuel Transfer and Gas Collection System Affected Systems and Components Failed fuel transfer system components. System Description The failed fuel transfer system (FFTS) was designed for transferring failed fuel elements from the primary tank into a special cask. The gas collection system was designed to collect gas samples from 34

47 breached fuel subassemblies in the storage basket. The FFTS has never been used and the gas collection system has not been used for more than 5 years. System Status The FFTS and gas collection system sodium-wetted components have been removed and are in storage awaiting treatment at SCMS. The lead shielding for the failed fuel transfer port has been removed. No further action is required for this system to achieve RCRA closure. Proposed Treatment/Disposal All components currently in storage will be treated at SCMS under the INL Site Treatment Plan Backlog. The cost for this treatment effort is not included in this cost estimate. Assumptions There is only aerosol sodium in the wetted components. Specialty waste containers will be required. Dependencies None. End State Configuration All systems removed. 4.3 Fuel Element Rupture Detection (FERD) Affected Systems and Components Fuel element rupture detection system. System Description The FERD system was designed to detect and to measure an increase in delayed-neutron emitting fission products in the sodium coolant during reactor operation. Such information is needed to detect and determine the magnitude of fuel cladding breaches. Primary sodium entered t he FERD system inlet line near the discharge of the IHX, passed through a flow meter, neutron detectors, a DC EM pump, and then returned back to the primary tank. The DC EM pump, system surge tanks (), flow meter, and neutron detectors were located behind lead shielding in the reactor building depressed area. System Status The FERD system components that were wetted with sodium have been removed from the reactor building depressed area and placed into storage. No FERD components remain in the EBR-II facility that will require further treatment. Proposed Treatment/Disposal 35

48 All components currently in storage will be treated at SCMS under the INL Site Treatment Plan Backlog. The cost for this effort is not included in this cost estimate. Assumptions No further actions are needed in the EBR-II facility for this system. Dependencies None. End State Configuration All system piping and shielding are removed from the EBR-II facility. 4.4 Secondary Sodium Recirculation System Affected Systems and Components Secondary sodium drain tank and secondary sodium recirculation system ( Recirc System ). System Description This system was used to circulate secondary sodium contained in the Secondary Sodium Drain Tank (SSDT) to prevent stratification, to fill the secondary sodium system following maintenance, and to supply sodium to the secondary sodium system as needed. This system consists of the 7,000-gallon SSDT, two recirculation pumps and associated piping. System Status The system is in a standby condition at ambient temperature pending its future use to support the Sodium Processing Facility (SPF). SPF is under consideration for use to treat approximately 300,000 gallons of sodium metal stored on the Hanford site. A trade study written in 00 (Ref. 0) indicates that transporting the sodium from the Fast Flux Test Facility (FFTF) to the INL, processing it at SPF, and sending the by-product back to Hanford may be more cost-effective than building an SPF facility at the Hanford site. The Recirc System contains sodium, and sodium residuals, from the bottom of the SSDT outlet valves through the transfer line and to the SPF. There is sodium in the tank outlet lines and a residual heel exists in the SSDT of approximately 5 gallons. The system contains 4 NaK transmitters. Proposed Treatment/Disposal When it is decided that the Recirc System is no longer needed to support SPF, this system must be treated along with the other EBR-II sodium-contaminated systems. All system piping and the NaK transmitters will be removed and transferred to SCMS for treatment The SSDT will be treated by draining any remaining sodium from the tank, exposing it to wet vapor nitrogen or steam and nitrogen, and then flushing it with water. Assumptions The secondary sodium has some tritium contamination. 36

49 Dependencies Treatment of the system should not be pursued until a decision is made on whether it will still be needed to support SPF. End State Configuration The SSDT remains in place. System piping and pumps are removed. 37

50 38

51 5. Task Stages 5. COST ESTIMATION ASSUMPTIONS It is assumed that any given RCRA-treatment task can be separated into three stages: planning, execution, and treatment/disposal. The planning stage involves the development of engineering task analyses (ETAs), procedures, procurement of equipment, and so forth. The execution stage involves the performance of a given task in the EBR-II facility such as the removal of equipment. The treatment/disposal stage usually involves treatment of waste and equipment at SCMS and/or the disposal of all waste materials generated during the execution and treatment stages. The stages are considered as separate activities, and each task is divided into planning, execution, and treatment/disposal stages. For scheduling purposes, it is not necessary that each stage immediately follow a preceding stage unless it makes sense to do so in regard to safety, environmental, or storage issues. It is necessary, however, that planning precede execution, and that execution precede treatment and disposal. 5. Effort Costs The cost estimates for labor are calculated using 006 INL average hourly rates and overhead/fringe rates. The costs presented are fully burdened and contain fringe and overhead costs. Table shows the personnel effort rates assumed for this cost estimate. 39

52 Table. Assumed Personnel Effort Rates in 006 Dollars, Fully Burdened Rates ($/hour) Administrative Project management Scheduler 7.35 Facility management Secretary Engineering Chemical Electrical Environmental Mechanical Safety Maintenance Electrical Instrument and Calibration 63.7 Mechanical Operations Facility manager 9. Technicians 9. Waste specialist Staff specialist 9. Support Health physics 75.5 Industrial hygiene Plant services Drafter Materials handling Analytical laboratory 9.49 Technical writing/procedures Core Staffing Requirements It was assumed in the development of the cost estimates that a core, baseline staffing of the EBR-II facility is needed to perform the designated tasks and to maintain project continuity. This staffing is in addition to the staffing identified to perform any specific task. While the task-specific staffing will change with each task, the core staffing will be maintained for all planning, execution, and treatment activities. The level of effort exerted by the core staffing is assumed to be proportional to the demands of the project. The core staffing composition and effort levels shown in Table 3 were calculated assuming a full project load of two simultaneous planning tasks, two execution tasks, and one treatment/disposal task. If the project load is less than this for any particular month, then the effort costs for the core staff are reduced in a proportional manner. For example, if in a given month there are only three tasks taking place, then the core staffing costs is assumed to be three-fifths of the total given in the table. 40

53 Table. Core Staffing, Utilization Rates, and Monthly Effort Costs Job Title Utilization Rate Average Monthly Cost Project Management Project manager 0.50 $,500 Scheduler 0.0 $,00 Facility Operations Facility manager 0.5 $4,000 Secretary.00 $6,800 Staff specialist 0.50 $7,900 Facility area supervisor 0.50 $7,900 Storage facility supervisor 0.5 $4,000 EBR-II technician 0.75 $,900 Support Personnel Safety engineer 0.5 $4,00 Industrial hygienist 0.0 $,600 Procedure specialist 0.0 $,00 Materials handling 0.0 $,00 Analytical laboratory 0.0 $,00 Drafting 0.0 $,000 Total 4.60 $67,500 Figure 8 shows an organizational chart for the project. The chart shows the reporting relationships for project personnel. Constant staffing and task-specific personnel are shown in the figure. 4

54 Figure 8. EBR-II RCRA Treatment Project organizational chart Core Project Staff Descriptions Project Management Project Manager The project manager is responsible for the overall management of the project. He or she coordinates the efforts of engineering, construction, and operations personnel to ensure all project goals are met and are done so within budget and scheduling constraints. The project manager is also responsible for planning, scheduling, and determining the allocations of funding for project tasks. The project manager works sideby-side with the Nuclear Operations Facility Manager to perform planning and coordinate work and budgeting activities. Project Support Secretary: The secretary maintains the project files and supporting documents, prepares correspondence with DOE and IDEQ personnel, assists in assembling regulatory paperwork, and provides administrative support as needed to project personnel. The secretary is expected to be the librarian of the project documents and to safeguard them against dispersion or destruction during the project. Scheduler: The scheduler provides support to the project manager by generating and maintaining current resource-loaded schedules of project activities. Analytical Laboratory: The Analytical Laboratory personnel perform chemical analyses as needed to properly characterize hazardous materials found in EBR-II systems within the RCRA regulatory 4

55 framework. They are also expected to analyze post-treatment samples to verify compliance with RCRAclosure criteria. Engineering ChE, EE, ME, Drafting: Chemical engineers, electrical engineers, mechanical engineers, and drafting personnel are employed as needed to perform project planning, help assemble treatment procedures, perform technical and safety reviews, assist in task scheduling, and other tasks. Nuclear Operations TSDF Manager The Treatment, Storage and Disposal Facilities (TSDF) Manager is the nuclear facility manager responsible for managing all administrative, operational and regulatory activities associated with the operation of INL treatment, storage and disposal facilities, which includes EBR-II and SCMS. This member of the project team works side-by-side with the project manager to perform planning and coordinate work and budgeting activities. Support Services Plant services, Nuclear Maintenance, health physics, industrial hygiene, safety engineering: Support services are provided by various MFC organizations to ensure that the work being carried out is done safely and within all applicable safety and work procedure rules and guidelines. This category includes general plant services (crafts), Nuclear Maintenance (Mechanical and I&C technicians), health physics support, industrial hygiene support, and safety engineering. EBR-II Facility Area Supervisor (FAS) The EBR-II FAS is responsible to the TSDF Manager for the daily work control requirements for treatment activities, preventative maintenance, calibrations, RCRA surveillance and other activities in the EBR-II facility. The FAS implements and facilitates activities prescribed in engineering tasks and operating procedures. He or she is responsible for writing System Treatment Plans, which incorporate instructions from engineering evaluations, and documents final system status following treatment operations. The EBR-II FAS is also responsible for reviewing transfers of RCRA-regulated materials into and out of the EBR-II facility for compliance with Waste Acceptance criteria. EBR-II Technicians: EBR-II technicians monitor the RCRA required data on equipment and systems within the facility and perform lockout/tagout and configuration control of EBR-II systems in support of treatment activities. They will also perform certain treatment activities at the discretion of the EBR-II area manager. TSDF Staff Specialist The TSDF staff specialist interacts with the other site groups (e.g., engineering, procedures, etc.) on behalf of the TSDF Manager to ensure facility representation with these groups in regard to planning and treatment activities and for performing surveillance of facility activities in SPF, SCMS, and storage facilities. The specialist must also identify trends and problems by monitoring facility records and log sheets. SCMS FAS 43

56 The SCMS FAS is responsible to the TSDF Manager for supervising the treatment activities that are carried out within SCMS. He or she is responsible for work controls and procedures, scheduling, management of SCMS technicians, and in ensuring that all waste generated in the facility conforms has a path forward for disposal. SCMS Technicians: The SCMS technicians perform all treatment activities that take place within the facility including the packaging of waste containers, operating the water wash vessel, performing sodium melt-and-drain operations, operation of the Alcohol Wash Station and the Solidification Station, and other tasks needed to carry out the treatment operations. TSDF Staff Environmental Engineer: The environmental engineer provides guidance on how to conform to the current RCRA regulations in regard to waste handling, treatment and disposal. They are also expected to provide information on the costs of disposing of specific items. Waste Specialist: The waste specialist oversees the handling, packaging, and disposal of specific items within the context of existing RCRA and other environment regulations, waste acceptance criteria, and other rules. Process Specialist: Process specialists provide information and guidance on carrying out specific treatment operations either within the EBR-II facility or at SCMS. They are expected to participate in the development of work procedures, safety reviews, and in monitoring the progress of operations carried out using their process specialty. Storage Facilities FAS The storage facility FAS is responsible to the TSDF Manager for the storage of RCRA regulated waste from EBR-II, preventative maintenance, RCRA surveillance, and other activities associated with RCRApermitted storage facilities (i.e., Sodium Storage Building, Outside Radioactive Storage Area, Radioactive Scrap and Waste Facility). 5.4 Commonly Used Materials and Supplies (M&S) The following costs were assumed when calculating materials and supplies costs for the various execution and treatment/disposal tasks. 44

57 Table 3. Material and Services Costs Cost ($) Units Analytical Laboratory Sodium samples Test Lead samples Test Caustic samples Test Compressed Gas Carbon dioxide 0.35 lb Carbon dioxide tank rental 75.0 month Nitrogen 0.37 HCF Nitrogen tank rental 0.00 month Drums and Waste Containers Drum 6.0 Each BR 90 Waste Bins Each Waste Box Each Treatment Materials Anti-contamination clothing 00.0 Set Aquaset 70.0 Bag Ferrous Sulfate 7.0 lb Envirocare of Utah, LLC Macro-encapsulation (Class A or below) 6.8 Cubic Foot Shipping,000.0 Truck Load Disposal Costs Radioactive Pb 30.0 Cubic Foot Asbestos.0 Cubic Foot Drum (solid low level waste) 00.0 Each Waste Box 3,000.0 Each 5.5 General Assumptions Some materials already removed from the EBR-II facility or that will be removed from the facility during EBR-II RCRA clean-up will have radiation levels too high to allow treatment without extensive shielding or remote handling in a hot cell environment. Such items may be better treated in the Remote Treatment Project (RTP), currently under design at MFC. Until that facility is constructed and becomes operational, it will be assumed that high-radiation items will be stored in the Radioactive Scrap and Waste Facility (RSWF) at MFC and not treated as part of the general RCRA clean-up process. Excluding those high radiation items, it is assumed that all systems or components not treated in-situ at the facility will be treated at the SCMS. The following rates and capacities pertain to treatment of sodium and NaK at SCMS: Both sets of high efficiency particulate air (HEPA) filter banks must be changed out after processing 00 gallons of sodium or NaK Sodium can be processed at 5 lbs/batch (approximately gallons each) 45

58 NaK can be processed at 7 gallons/hour Scrubber water capacity is 70 gallons at 5 wt% sodium or potassium hydroxide Scrubber water must be neutralized, drained, and solidified for disposal at the solidification station It takes approximately 3 weeks to set up, perform, and clean up after a NaK campaign The solidification station can treat approximately 5 drums per week The solidification station requires 3 SCMS technicians, a supervisor, a Health Physics Technician, and a part-time waste specialist A bench-scale test is needed every time a batch is solidified at the solidification station A sodium melt station will be constructed for this work, and it will be operated at the SCMS It is assumed that the current alcohol recovery system will be dismantled and a new alcohol recovery system will be assembled, one that offers greater reliability and better economics than the current system. The costs and timelines for performing this replacement are calculated as a separate item from the rest. Even if it is decided that no alcohol recovery system will be needed in the future, the current stock of sodium-contaminated alcohol will still need to be treated and/or disposed at some real cost. This item will be included as a stand-in for either contingency. For disposal of the waste materials, it is assumed that all industrial and radiological waste streams have an assumed path forward, and that the waste will be sent to a disposal facility owned by the federal government. These assumptions have been made for the purposes of generating the cost estimates in this report and should not be used in place of a specific cost analysis for any one portion of the task list that would emerge from the detailed engineering planning that will necessarily precede the execution of any of the clean-up and treatment tasks outlined in this report. 46

59 6. System Treatment Costs 6. PROJECT SUMMARY COSTS The estimated cost associated with RCRA-treatment of each EBR-II system is given in Table 4. System costs are the costs associated with the performance of individual RCRA-treatment tasks for each EBR-II system. The costs are divided into effort, materials and supplies (M&S), and contingency costs. The numbers in the table are given in FY06 dollars. Table 4. Summary of Task-Specific Costs Description Effort M&S Contingency Total Primary Tank Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters,08 5 7,5 Rotating Plugs, ,99 NaK Transmitters Primary Tank Cover Gas System, ,699 PTCGSSS Cover Gas Clean-up System Main Loop ,3 Building Alcohol Recovery Facility Primary Purification System, ,356 RSCL ,0 Shutdown Coolers Storage Pit Storage Holes ,037 Secondary Na System, ,880 Intermediate Heat Exchanger ,035 Secondary Na Purification System Fuel Handling System Nozzles Argon Purge System Argon Cooling System Hydrocarbon Analyzers Failed Fuel Transfer System FERD Secondary Na Recirculation System,0 0 4,57 Totals 5,398,685 4,77,360 The breakdown of costs for each system is given in Appendix A. In addition to the task-specific costs, there are costs associated with the core staffing required to maintain the project. In Section 6.3 this core staffing was described. At a full task load (two planning tasks, two execution tasks, and one treatment/disposal task) in a given month, the core effort costs were calculated to 47

60 be $67,500/month. With the duration and sequencing of the project yet to be determined, it is difficult to assign directly a total core staffing cost. An estimate can be made, however, by assuming that the cost of the core staffing is directly proportional to the task workload in any given month. With this assumption, the cost of core staffing is only 0% of the total for one task, 40% for two simultaneous tasks, and so on up to the maximum workload of five simultaneous tasks in a given month. This assumption allows for the calculation of a core staffing unit cost, which is equal to $67,500/5, or $3,500/month/task. A further analysis of the information given in Appendix A shows that there are 80 months of planning, 6 months of execution tasks, and 79 months of treatment/disposal tasks in real time, for a total of 75 task-months. Multiplying the number of task-months times the core staffing unit cost (75 task-months times $3,500/month/task) gives a total core staffing cost for the duration of the project at $3,7K, without contingency. If a 3% contingency factor is used, the total core staffing costs increases to $4,95K. Therefore the overall project costs are summarized as follows: This cost is in FY06 constant dollars. Task-Specific Effort $5,398,000 Core Staffing Effort $3,7,000 M&S $,685, Sub-Total $0,795,000 Contingency $4,760, Total $5,555,000 The total project cost will change as the work is projected into future years and the costs are most likely to escalate over the lifetime of the project due to inflation. There are two tasks identified which may not need to be performed if the Sodium Processing Facility at the MFC is re-started and in-situ sodium clean-up processes prove to be very effective. These tasks are the treatment of the Secondary Sodium Recirculation System and the Primary Tank Nozzle treatment. Without these tasks, the overall project cost is reduced by $3.4M, including contingency, for a smaller total project cost of $.M. As further planning and engineering are performed for the treatment tasks, cost information will be updated and refined. It is possible during the execution of the treatment tasks that some costs will increase and others will decrease. To address this expected variation, cost estimates will be revised as new information develops. 48

61 7. SYSTEM TREATMENT SEQUENCING Two proposed schedules of activities are presented in this section. The first schedule organizes events under the assumption that up to two planning activities, two execution activities, and one treatment/disposal activity can take place at any given moment. The second schedule shows a slower rate of progress in any given year by assuming that only one planning activity, one execution activity, and one treatment/disposal activity can take place at any given moment. In constant FY06 dollars, the cost of each schedule is the same, but if costs are allowed to escalate with the yearly rate of inflation, the cost of the longer schedule will be greater because of the schedule s longer time span. For each schedule, the list of activities has been divided into linked activities, and independent activities. Linked activities must be performed in the sequence prescribed in the schedule, while independent activities can be performed in any order, independent of other tasks. These schedules are intended to support more detailed planning in the future, and should not be the sole source of information for calculating detailed cost or scheduling information for any individual task. These schedules do provide a reasonable time frame for the performance of the EBR-II RCRA clean-up project, and show that the project can be completed in 8- years. This time frame is compatible with the expectations of the current RCRA permit, which calls for RCRA-clean closure of the EBR-II facility by 0 (initial 0-year permit plus renewal). In addition, it is anticipated that treatment time could be further shortened by constructing additional SCMS treatment systems and that this could be accomplished for a relatively small amount of funding. Schedules may be adjusted to perform partial closures of specified systems, if DOE decides to utilize portions of the EBR-II Facility for new missions. 7. Eight-Year Schedule An 8-year schedule is shown in Figure 9. In this schedule, planning activities are shown either as a blue bar or as a sequence of 0 s, execution activities are shown as a red bar or as a sequence of s, and treatment/disposal activities are shown as a sequence of s. Approximate yearly costs for this schedule are shown in Table 5. The costs in the table are given in constant FY06 dollars (left column), and in escalated dollars (right column) with the assumption of a 3% yearly escalation factor. Table 5. Yearly Costs of Eight-Year Schedule Year Core Effort Task-Months Non-escalated Cost ($K) Escalated Cost ($K) 38,64, ,999 4, ,436 5, ,346 4, ,793 4, ,073 3,56 7,378,645 8,367,68 Totals 75 5,556 7,956 49

62 Linked Activities Year Month Primary Tank Primary Na Steam Treatment 0 0 Primary Na Water Wash Treatment of Wash Water Primary Tank Cover Gas System NaK Transmitters 0 Secondary Sodium System 0000 IHX 000 Rotating Plugs Fuel Handling System 00 Primary Tank Heaters 0000 Primary Tank Nozzles 0000 Planning Activity Execution Activity Treatment/Disposal Independent Activities Year Month PTCGSSS 0 Shutdown Coolers 00 Reactor Building Storage Pits 0000 CGCS Main Loop CGCS Building Alcohol Recovery Facility Primary Purification System RSCL 0000 Reactor Building Storage Holes 0000 Secondary Sodium Purification System, HMLD 0 Secondary Sodium Recirculation System 00 Planning Activity Execution Activity Treatment/Disposal Figure 9. Standard Schedule Assuming up to 5 Simultaneous Activities 50

63 With the 8-year schedule, planning and execution activities occur within the first six years, and the last two years of the schedule is limited to treatment/disposal activities. According to the schedule, all RCRA-regulated materials can be treated and/or removed from the EBR-II facility within six years, with the remaining two years dedicated to treating and disposing the remaining waste materials at SCMS. With the facility clean of RCRA-regulated materials after six years, RCRA-closure of the facility can be sought by the seventh year of the project. 7. Twelve-Year Schedule A -year schedule is shown in Figure 0. In this schedule, planning activities are shown either as a blue bar or as a sequence of 0 s, execution activities are shown as a red bar or as a sequence of s, and treatment/disposal activities are shown as a sequence of s. Approximate yearly costs for this schedule are shown in Table 6. The costs in the table are given in constant FY06 dollars (left column), and in escalated dollars (right column) with the assumption of a 3% yearly escalation factor. Table 6. Yearly Costs of Twelve-Year Schedule Year Core Effort Task-Months Non-escalated Cost ($K) Escalated Cost ($K),3,3 7,39, ,930, ,34, ,670 3, ,84, ,536 3,08 8,370,94 9 9,6, ,685 3,504 4,705 3,635,443,983 Totals 75 5,556 30,4 With the -year schedule, only one planning activity, one execution activity, and one treatment/disposal activity can be performed at any one time. This limitation forces the schedule to spread out over a longer frame. This also has the effect of spreading out project costs over a longer period of time, so that the cost of the project in any one year are less than for more accelerated schedules. The disadvantage of a longer schedule is the effect of inflation on the overall project cost, so that the total project cost will be higher at the end of the project ($30,4K) that would be incurred with the eight-year schedule ($7,956K). With this schedule, the EBR-II facility could be RCRA-closed by the th year, a time period that is compatible with the existing facility RCRA permit (assuming a 0-year extension). 5

64 Year Month Linked Activities Primary Tank Primary Na Steam Treatment 0 0 Primary Na Water Wash Treatment of Wash Water Primary Tank Cover Gas System NaK Transmitters 0 Secondary Sodium System 0000 IHX 000 Rotating Plugs Fuel Handling System 00 Primary Tank Heaters 0000 Primary Tank Nozzles Planning Activity Execution Activity Treatment/Disposal Year Month Independent Activities PTCGSSS 0 Shutdown Coolers 0 0 Reactor Building Storage Pits 0000 CGCS Main Loop CGCS Building Alcohol Recovery Facility Primary Purification System RSCL 0000 Reactor Building Storage Holes 0000 Secondary Sodium Purification System, HMLD 0 Secondary Sodium Recirculation System 0 0 Planning Activity Execution Activity Treatment/Disposal Figure 0. Extended Schedule Assuming up to 3 Simultaneous Activities 5

65 8. REFERENCES. EBR-II RCRA Permit, INEEL HWMA/RCRA Final Partial Permit EPA No. ID , Doc. No. W000-0-ES Revision.. Experimental Breeder Reactor II Complex Termination Plan, F AP-00, February 4, EBR-II/SPF System Layup Plans, Volumes I, II, and III (on-site at MFC). 4. ANL-NT-03, Passivation of Residual Sodium in EBR-II Systems, S.R.Sherman, C.J. Knight, July INL/EXT Rev. 0, Technical Information on the Carbonation of the EBR-II Reactor, Summary Report Part : Laboratory Experiments and Application to EBR-II Secondary Sodium System, S.R. Sherman, April U.S. Patent 6,99,06 B, In-Situ Method for Treating Residual Sodium, July 9, 005, S.R. Sherman, S.P. Henslee. 7. Interoffice Memorandum, Cessation of Humidified Carbon Dioxide Treatment of EBR-II Primary Tank, October 5, 005, From S.R. Sherman to R.L. Batten and V.R. Sandifer. 8. ANL-W HWMA/RCRA Interim Status Closure Plan for the Primary Tank Shutdown Coolers and the Primary Purification Sodium Potassium Alloy (NaK) Coolant Loop (Building 767), March 00, Doc. No. W ES NRP-EBR-004, Sodium Deactivation of Primary Tank, ANL Facilities Division EBR-II Non-Routine Procedure, April 5, Hanford Site Sodium Disposition Trade-off Study, April 00, Argonne National Laboratory, Fluor Hanford Company. 53

66 APPENDIX A: INDIVIDUAL TASK COST INFORMATION 54

67 This appendix contains cost information on the individual clean-up tasks associated that must be performed in order to RCRA clean-close the EBR-II facility. The data is presented in a series of tables. Each table provides information on one task. The tables are divided into planning, execution, and treatment/disposal stages. For each stage, a stage duration (in months) is provided. This shows the estimated amount of time needed to complete the stage. Underneath the duration, information concerning the number of people involved (#), the utilization of those people in man-months (MM), and the total effort costs of those people are provided. Cost information on extra supplies, equipment, or disposal costs are provided also for each stage. The totals provided on each page show the total cost of performing the planning, execution, and treatment/disposal stages for the given task. Within this appendix, the tasks are arranged and referenced in the following order. The order of arrangement is historical and does not reflect any suggested sequence of tasks.. Primary Na Intermediate Treatment with Steam (Carbon Dioxide Atmosphere). Primary Na Water Wash 3. Evaporation and Treatment of Primary Tank Wash Water 4. Primary Tank Heaters 5. Rotating Plugs and Seals/Cover-Drive and Locks 6. NaK Transmitters 7. Primary Tank Cover Gas System 8. PTCGSSS 9. Cover Gas Clean-up System Main Loop 0. Cover Gas Clean-up System Building. Alcohol Recovery Facility Replacement and Treatment of Alcohol Inventory. Primary Purification System 3. RSCL 4. Shutdown Coolers 5. Storage Pit 6. Storage Holes 7. Secondary Sodium System 8. Intermediate Heat Exchanger 9. Secondary Sodium Purification System 0. Fuel Handling System. Nozzles. Secondary Sodium Recirculation System The costs in the tables do not include contingency. 55

68 . Primary Sodium Intermediate Treatment with Steam (Carbon Dioxide Atmosphere) Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 3 0 Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6, ,974, ,34,099 0,967, ,96 5,80 5,80 6,36 5, ,49 3,043 5,68,099 9,833,775,445,6 Effort Sub-Totals 35,7 89,049 Supplies/Equipment Steam generator and support equipment 30,000 Supplies Sub-Totals 30,000 Totals 35,7 9,049 56

69 . Primary Tank Water Wash Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6, ,896 47,64 66,59 6,385,099,099 0,967, ,788 5,80 5,80 6,36 5, ,39 3,043 5,68,099 9,833,775,445,6 Effort Sub-Totals 8,036 63,6 Supplies/Equipment Water level measurement and pumping system 50,000 Supplies Sub-Totals 50,000 Totals 8,036 3,6 57

70 3. Evaporation and Treatment of Primary Tank Wash Water Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 6 9 Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 6 5,896 3,58 6,36 66,59 6,385 9, ,844,099,099 0,967 0, ,80 3,47 3,69 6,5,775,445 Effort Sub-Totals 84,54,993 0,643 Evaporation equipment Waste disposal materials Disposal costs 50,000 0,000 5,000 Supplies Sub-Totals 50,000 5,000 Totals 84,54 37,993 35,643 58

71 4. Primary Tank Heaters Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6, ,97 88,788 47,64,099 0,967, ,576 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 4 63, ,347, , ,434 48, ,60 Effort Sub-Totals 00,579 44,53 5,95 Custom packaging material 40,000 Disposal costs,000 Supplies Sub-Totals 40,000,000 Totals 00, ,53 53,95 59

72 5. Rotating Plugs and Seals/Cover Drive and Locks Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing Supplies/Equipment Waste boxes, custom tools and rigging Maintenance and upgrades to lifting equipment Disposal costs 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 6 4,49 33,8 6, ,70 399, ,39 9 7,390, ,49 89,77 48, ,30 Effort Sub-Totals 74,674 77,30 34,984 50,000 00,000,000 Supplies Sub-Totals 50,000,000 Totals 74, ,30 336,984 60

73 6. NaK Transmitters Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 0.5,79,099 6,36, ,059 5, ,80 47,49 4,059 3,043 3,043 Effort Sub-Totals,890 7,08 80,34 Disposal costs,000 Supplies Sub-Totals,000 Totals,890 7,08 8,34 6

74 7. Primary Tank Cover Gas System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,955 55, , , ,80 33,8 97,47 94,858 78,60, , ,90 05, ,78 Effort Sub-Totals 4,448 59,35 666,34 Tools and Boroscope Waste Containers Disposal costs Floating head tank oil treatment 75,000 5,500,600 0,000 Supplies Sub-Totals 75,000 8,00 Totals 4, ,45 694,44 6

75 8. Primary Tank Cover Gas Sampling Supply System (PTCGSSS) Effort Rates Planning Execution Treatment/Disposal ($/month) # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099,099 0,967, ,394 5,80 5,80 6,36 5,80 3,69 3,043 5,68,099 9,833,775,445, ,69 94,858 6,087 6,087 Effort Sub-Totals,099 0,00 5,565 Waste containers Disposal costs 0,000 3,000 Supplies Sub-Totals 3,000 Totals,099 0,00 65,565 63

76 9. Cover Gas Clean-up System, Main Loop Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 4 4 Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,38 88,788 3, ,867 44,394 3,47 94,858 6,087,97 5, ,39 89,77 64, ,73 Effort Sub-Totals 5,588 63,876 4,970 Supplies/Equipment Drums, containers, boroscope, tools 30,000 Disposal costs 8,000 Supplies Sub-Totals 30,000 8,000 Totals 5,588 93,876 49,970 64

77 0. Cover Gas Clean-up System, Building Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 3 3 Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 3 33,96,934,97 6,36 6, ,043 5, ,49 4,88 48,708 Effort Sub-Totals 49,53 78,959 77,555 Disposal costs,000 Supplies Sub-Totals,000 Totals 49,53 78,959 78,555 65

78 . Alcohol Recovery Facility Replacement and Treatment of Alcohol Inventory Effort Rates Planning Execution Treatment/Disposal ($/month) # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,948 8,8, ,974 5,549,099,934 44, ,49 4,88 48, ,,7 Effort Sub-Totals 53,83 3,75 88,778 New evaporation equipment 50,000 Waste boxes (3) Drums (0) and disposal 9,000,000 Supplies Sub-Totals 50,000 0,000 Totals 53,83 63,75 98, , ,30 66

79 . Primary Purification System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 8 47,64 3,47 88, , ,867 44, , , Effort Sub-Totals 76,543 88,6 803,43 Supplies/Equipment Tools, wash systems, waste drums, etc. 40,000 Waste boxes (3) Asbestos and lead waste boxes 30,000 0,000 Supplies Sub-Totals 40,000 50,000 Totals 76,543 8,6 853,43 67

80 3. Radioactive Sodium Chemistry Loop (RSCL) Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing Supplies/Equipment Tools, wash systems, waste drums, etc. Waste boxes (5) Disposal costs 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 3,47, ,88 3,60 33,8 89, ,60 66, ,39 89,77 6,36 4 5,73 Effort Sub-Totals 6, ,35 3,365 0,000 Supplies Sub-Totals 0,000,500 Totals 6,787 69,35 34,865,500 0,000 68

81 4. Shutdown Coolers Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 6 Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing Supplies/Equipment Tools, wash systems, waste drums, etc. Waste boxes (5) Disposal costs 5,948 3,58 6,36,099 6, ,36 6,648,099 0,967, ,394 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,8.5 39,54 6,087, ,858 89,77 6,36 4 5,73 Effort Sub-Totals 4,00,04 35,985 0,000 Supplies Sub-Totals 0,000,500 Totals 4,00 4,04 374,485,500 0,000 69

82 5. Storage Pit Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 6,36,099 0,967, ,985 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,8 5 6,36 5,80 65,7, ,49 4,88 48, ,30 Effort Sub-Totals 9,7 35,58 77,555 Supplies/Equipment Tools, wash systems, waste drums, etc. 30,000 Disposal costs 50,000 Supplies Sub-Totals 50,000 Totals 9,7 65,58 37,555 70

83 6. Storage Holes Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385, ,354,099 0,967,099 33,8 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, , ,354 47,49 78,60, ,49 4,88 48, ,30 Effort Sub-Totals 9,7 38,678 77,555 Supplies/Equipment Tools, wash systems, waste drums, etc. 30,000 Disposal costs 50,000 Supplies Sub-Totals 30,000 50,000 Totals 9,7 348,678 37,555 7

84 7. Treatment of Secondary Sodium System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 4 3 Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,896 64,945 88, , ,934 66,59 84,575 97,47 94,858 5,73 44, ,49 4,88 48,708 39,30 Effort Sub-Totals 05,69 78,534 77,555 Nitrogen Waste boxes (0) Other treatment equipment 30,000 5,000 50,000 50,000 Supplies Sub-Totals 85,000 50,000 Totals 05,69 83,534 37,555 7

85 8. Intermediate Heat Exchanger Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing Supplies/Equipment General waste packaging materials Materials for shipment of IHX to SCMS Special tools, rigging, etc. Disposal costs 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,708 33, ,967 99,887 6,36 79,049 39,30, ,49 4,88 48, ,30 Effort Sub-Totals 8,004 97,465 77,555 40,000 0,000 30,000 90,000 Supplies Sub-Totals 60,000 0,000 Totals 8,004 37, ,555 73

86 9. Secondary Sodium Purification System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 4 Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 6,36, ,867 44,394 5,80 5,80 6,36 5,80 3,69 3,043 5,68,099 9,833,775,445,6 6,087, ,39 89,77 64, ,73 Effort Sub-Totals 7,335 57, ,074 Waste packaging materials Disposal costs Supplies Sub-Totals 9,500 Totals 7,335 57, ,574 6,500 3,000 74

87 0. Fuel Handling System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 4 Engineering Maintenance Operations Support Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385 3,47,97,099 0,967, ,394 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445, ,8 3, ,39 89,77 54,945 6, ,73 Effort Sub-Totals 54,669 0,8 370,074 Supplies/Equipment Mercury, lead, contaminated waste disposal Waste packaging materials 00,000,000 Supplies Sub-Totals,000 Totals 54,669 0,8 59,074 75

88 . Nozzles Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6, ,36 44, ,47,099 0,967, ,774 5,80 5,80 6,36 5,80 9 4,88 3,043 5,68,099 9,833,775,445,6 6 97, ,60 Effort Sub-Totals 60, ,478 75,677 Supplies Sub-Totals Totals 60, ,478 75,677 76

89 . Secondary Sodium Recirculation System Effort Rates ($/month) Planning Execution Treatment/Disposal # MM Cost,$ # MM Cost, $ # MM Cost, $ Duration 3 Engineering Maintenance Operations Support Supplies/Equipment Chemical Electrical Environmental Mechanical Safety Electrical Instrument and Calibration Mechanical FAS Technicians Waste Specialist TSD Staff Specialist Health Physics Industrial Hygiene Plant Services Drafting Materials Handling Analytical Laboratory Technical Writing 5,948 3,58 6,36,099 6,385,099 0,967,099 5,80 5,80 6,36 5,80 3,043 5,68,099 9,833,775,445,6 3,58 6,36, , ,80 66,365 8,8 89,77 56,50 66, ,49 4,88 6, ,30 Effort Sub-Totals 50,97 93,59 45,083 Waste boxes and drums Nitrogen Tools and equipment Disposal costs 5,000 0,000 30,000 55,000 Supplies Sub-Totals 55,000 55,000 77

90 APPENDIX B: CALCULATION OF EIGHT-YEAR SCHEDULE 78

91 Eight-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment 9,775 Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters 5,990 85,00 90,530,000 Primary Tank Cover Gas System PTCGSSS,430 Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building 3 56,500 94,800 Alcohol Recovery Facility 4 59, ,00 3,533 60,000 Primary Purification System RSCL Shutdown Coolers 46,330 Storage Pit 4, ,000 30,000 Storage Holes 4,470 64,500 30,000 Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 0 63, , ,063,000 Core Staffing Costs 305,00 8,85 45,765 Totals 38 task-months $,64,308 79

92 Eight-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment 9, ,700 30,000 Primary Na Water Wash 6 05,660 Treatment of Wash Water 6 09,050 3,99 50,000 Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System 5 08,9 PTCGSSS,400 74,580 3,000 Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility 6,67 Primary Purification System RSCL Shutdown Coolers 63,300 4,000 Storage Pit 6 48,000 50,000 Storage Holes 4 39, ,000 Secondary Sodium System 4 3,780 94,667 85,000 Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 775, ,66,60, ,000 Core Staffing Costs 335,60 8,85 83,060 Totals 49 task-months $3,998,64 80

93 Eight-Year Schedule: Year 3 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash 4 69,500 50,000 Treatment of Wash Water 37,067 Primary Tank Heaters Rotating Plugs & Seals 8 30,750 NaK Transmitters Primary Tank Cover Gas System, , ,57 75,000 PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building 3 47,500,000 Alcohol Recovery Facility Primary Purification System 5 00,00 RSCL 4 7,90 Shutdown Coolers Storage Pit Storage Holes 3 44,000 50,000 Secondary Sodium System,04,333 Intermediate Heat Exchanger 3 9,660 73,00 60,000 Secondary Na Purification System 30,50 Fuel Handling System Nozzles Secondary Na Recirc System 57,630 Sub-Totals 4 784,408 3,30,0,399,657 36,000 Core Staffing Costs 366,0 350,865 67,805 Totals 58 task-months $5,435,975 8

94 Eight-Year Schedule: Year 4 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water 5 85,333 48,00 5,000 Primary Tank Heaters 4 4,30 Rotating Plugs & Seals 8,0,667 50,000 NaK Transmitters Primary Tank Cover Gas System 6,063 8,000 PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System 4 5,000 40,000 RSCL 3 36,400 0,000 Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System 3 376,400 50,000 Intermediate Heat Exchanger 4 9, ,400 0,000 Secondary Na Purification System Fuel Handling System 6,50 Nozzles Secondary Na Recirc System Sub-Totals 6 76,80 4,03,480 9,38,063 43,000 Core Staffing Costs 9, ,0 37,95 Totals 39 task-months $4,345,768 8

95 Eight-Year Schedule: Year 5 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters 8 506,000 93,373 5,000 Rotating Plugs & Seals 7, ,80,000 NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL 3 36,400 Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 88,400 Fuel Handling System 3, ,830,000 Nozzles 4 68,930 58,667 Secondary Na Recirc System 5 466,583 55,000 Sub-Totals 4 68,930,840,883 9,009,03 340,000 Core Staffing Costs 6,00 335,60 37,95 Totals 35 task-months $3,79,75 83

96 Eight-Year Schedule: Year 6 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters 4 386,747 Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop 4 44,080 3,800 30,000 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 3 36,500 30,00 Fuel Handling System Nozzles 8 469, ,587 Secondary Na Recirc System 7 653,7 Sub-Totals 4 44,080 7,445, ,834 60,000 Core Staffing Costs 6,00 59,335 67,805 Totals 3 task-months $3,073,44 84

97 Eight-Year Schedule: Year 7 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop 4 508,000 8,000 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System 5 456,945 50,000 RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 05,500 Fuel Handling System Nozzles 66,93 Secondary Na Recirc System Sub-Totals,36,738 58,000 Core Staffing Costs 83,060 Totals task-months $,377,798 85

98 Eight-Year Schedule: Year 8 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System 5 456,945 RSCL 4 365,590,000 Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System 3 84,000 55,000 Sub-Totals,06,535 77,000 Core Staffing Costs 83,060 Totals 35 task-months $,366,595 86

99 APPENDIX C: CALCULATION OF TWELVE-YEAR SCHEDULE 87

100 Twelve-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building 3 56,500 94,800 Alcohol Recovery Facility 4 59, ,00 3,533 60,000 Primary Purification System RSCL Shutdown Coolers Storage Pit 4,470 73,800 30,000 Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 37, ,800 3,533 90,000 Core Staffing Costs 67,805,040 30,50 Totals task-months $,,548 88

101 Twelve-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment 39,550 Primary Na Water Wash 3 0,830 Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters 5,990 85,00 90,530,000 Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building 3 47,500,000 Alcohol Recovery Facility 6,67 Primary Purification System RSCL Shutdown Coolers Storage Pit 4 95,00 47,333 50,000 Storage Holes 4, ,500 30,000 Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 0 89, , ,630 8,000 Core Staffing Costs 5,550 67,805 9,530 Totals 7 task-months $,39,55 89

102 Twelve-Year Schedule: Year 3 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment 3 4,700 30,000 Primary Na Water Wash 3 0,830 Treatment of Wash Water 6 09,050 3,00 50,000 Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System 3 64,975 PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit 94,667 Storage Holes 3 44,000 50,000 Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 376, , ,667 30,000 Core Staffing Costs 83,060 9,530 76,75 Totals 3 task-months $,930,87 90

103 Twelve-Year Schedule: Year 4 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals 77,688 NaK Transmitters Primary Tank Cover Gas System 3 64, , ,094 03,000 PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger 4 3, ,000 85,000 Secondary Na Purification System 3 9,660 Fuel Handling System Nozzles Secondary Na Recirc System Sub-Totals 468, , ,094 87,000 Core Staffing Costs 83,060 37,95 45,765 Totals 4 task-months $,340,57 9

104 Twelve-Year Schedule: Year 5 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water 3 0,5 50,000 Primary Tank Heaters Rotating Plugs & Seals 6 33,063 NaK Transmitters Primary Tank Cover Gas System 4 43,6 PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System 9 85, ,400 50,000 Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System 6,50 Nozzles Secondary Na Recirc System Sub-Totals 8 95,3,054, ,56 00,000 Core Staffing Costs,040 83,060 06,785 Totals 7 task-months $,669,749 9

105 Twelve-Year Schedule: Year 6 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash 67,375 Treatment of Wash Water 6,400 48,00 5,000 Primary Tank Heaters 4 4,30 Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger 5 365,00 60,000 Secondary Na Purification System Fuel Handling System Nozzles 7,33 Secondary Na Recirc System Sub-Totals 5 3, ,875 48,00 75,000 Core Staffing Costs 76,75 83,060 5,55 Totals 8 task-months $,84,08 93

106 Twelve-Year Schedule: Year 7 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals 9,50,500 50,000 NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop 4 44,080 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL 4 7,90 Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger 3 397,400 0,000 Secondary Na Purification System Fuel Handling System Nozzles 3 5,698 Secondary Na Recirc System Sub-Totals 366,968 9,50, ,400 70,000 Core Staffing Costs 67,805 37,95 45,765 Totals 3 task-months $,535,733 94

107 Twelve-Year Schedule: Year 8 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters 8 506,000 93,373 5,000 Rotating Plugs & Seals 3 368,80,000 NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System 3, ,830,000 Nozzles 7,333 Secondary Na Recirc System Sub-Totals 755,333 9,009,03 85,000 Core Staffing Costs 83,060 37,95 Totals task-months $,369,70 95

108 Twelve-Year Schedule: Year 9 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters 4 386,747 Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS,430,400 Cover Gas Clean-up: Main Loop 6,400 30,000 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System 5 00,00 RSCL Shutdown Coolers 46,330 63,300 0,000 Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System Fuel Handling System Nozzles Secondary Na Recirc System 7 40, ,733 Sub-Totals 8 58, , ,480 50,000 Core Staffing Costs,040 83,060 37,95 Totals 9 task-months $,6,4 96

109 Twelve-Year Schedule: Year 0 Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS 74,580 3,000 Cover Gas Clean-up: Main Loop 6,400 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System 4 5, ,67 90,000 RSCL 6 7,800 0,000 Shutdown Coolers 6 48,000,000 Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 30,50 94,00 Fuel Handling System Nozzles 33,47 Secondary Na Recirc System 57,630 Sub-Totals 3 88,40,30, ,894 45,000 Core Staffing Costs 45,765 83,060 83,060 Totals 7 task-months $,685,39 97

110 Twelve-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL 7 639,73 Shutdown Coolers 4 365,590,000 Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 94,00 05,500 30,000 Fuel Handling System Nozzles Secondary Na Recirc System,06,483 55,000 Sub-Totals,0,683,0,83 07,000 Core Staffing Costs 83,060 83,060 Totals 4 task-months $,704,66 98

111 Twelve-Year Schedule: Year Task Planning Execution Treatment and Disposal Equipment/ Other M $ M $ M $ $ Primary Na Steam Treatment Primary Na Water Wash Treatment of Wash Water Primary Tank Heaters Rotating Plugs & Seals NaK Transmitters Primary Tank Cover Gas System PTCGSSS Cover Gas Clean-up: Main Loop 4 508,000 8,000 Cover Gas Clean-up: Building Alcohol Recovery Facility Primary Purification System RSCL Shutdown Coolers Storage Pit Storage Holes Secondary Sodium System Intermediate Heat Exchanger Secondary Na Purification System 3 36,500 Fuel Handling System Nozzles Secondary Na Recirc System 93, ,000 55,000 Sub-Totals 93,37 0,08,500 63,000 Core Staffing Costs 5,55 5,550 Totals task-months $,43,6 99