EXCITATION OF STRUCTURAL RESONANCE DUE TO A BEARING FAILURE

Vibration due to a bearing failure in a pump created significant vibrations in a fifteen foot by fifteen foot by eight feet tall mounting platform due to excitation of resonant frequencies. In this particular application, an 18,000 pound pump was mounted to a structural steel platform. When bearing damage commenced, the platform vibrated with sufficient magnitude that conversations could not be heard within forty feet of the pump. Vibration analysis determined that the frequency of the bearing was coincident to one of the natural frequencies of the pump, which was, in turn, coincident to one of the natural frequencies of the mounting platform. This coincidence of frequencies defines resonance. Resonance creates excessive vibrations when the natural frequency of a structure is coincident to an excitation frequency. In this well documented case, the excitation frequency was related to ball bearing failures. The pump is a forty foot long vertical pump used to mix nuclear waste in 1,300,000 gallon tanks. A 300 horsepower drive motor is mounted to a structural steel platform on top of the tank. The pump hangs down into the tank from above to mix the waste and is inaccessible after installation. Initial awareness of the problem was due to increased noise from the pump. Initial vibration analysis indicated that the vibration levels of the bearing were within the expected range for this type of bearing, and the resonant condition was not obvious. Further analysis consisted of disassembly of the motor to inspect the bearings and extensive vibration monitoring. Vibration data for the bearings was obtained from the manufacturer and compared to measured vibration plots for the pump and mounting platform. Vibration data measured along the length of the pump was available from full scale testing, and vibrations were also measured at the installed pump. One of the axial frequencies of the pump, the platform frequency in the vertical direction, and the ball spin frequency for the bearing were multiples of each other. This resonant condition was detected before other damage occurred, and further damage due to the resonant condition was prevented through vibration analysis

BLENDING STUDY FOR SRR SALT DISPOSITION INTEGRATION: TANK 50H SCALE-MODELING AND COMPUTER-MODELING FOR BLENDING PUMP DESIGN, PHASE 2

The Salt Disposition Integration (SDI) portfolio of projects provides the infrastructure within existing Liquid Waste facilities to support the startup and long term operation of the Salt Waste Processing Facility (SWPF). Within SDI, the Blend and Feed Project will equip existing waste tanks in the Tank Farms to serve as Blend Tanks where 300,000-800,000 gallons of salt solution will be blended in 1.3 million gallon tanks and qualified for use as feedstock for SWPF. Blending requires the miscible salt solutions from potentially multiple source tanks per batch to be well mixed without disturbing settled sludge solids that may be present in a Blend Tank. Disturbing solids may be problematic both from a feed quality perspective as well as from a process safety perspective where hydrogen release from the sludge is a potential flammability concern. To develop the necessary technical basis for the design and operation of blending equipment, Savannah River National Laboratory (SRNL) completed scaled blending and transfer pump tests and computational fluid dynamics (CFD) modeling. A 94 inch diameter pilot-scale blending tank, including tank internals such as the blending pump, transfer pump, removable cooling coils, and center column, were used in this research. The test tank represents a 1/10.85 scaled version of an 85 foot diameter, Type IIIA, nuclear waste tank that may be typical of Blend Tanks used in SDI. Specifically, Tank 50 was selected as the tank to be modeled per the SRR, Project Engineering Manager. SRNL blending tests investigated various fixed position, non-rotating, dual nozzle pump designs, including a blending pump model provided by the blend pump vendor, Curtiss Wright (CW). Primary research goals were to assess blending times and to evaluate incipient sludge disturbance for waste tanks. Incipient sludge disturbance was defined by SRR and SRNL as minor blending of settled sludge from the tank bottom into suspension due to blending pump operation, where the sludge level was shown to remain constant. To experimentally model the sludge layer, a very thin, pourable, sludge simulant was conservatively used for all testing. To experimentally model the liquid, supernate layer above the sludge in waste tanks, two salt solution simulants were used, which provided a bounding range of supernate properties. One solution was water (H{sub 2}O + NaOH), and the other was an inhibited, more viscous salt solution. The research performed and data obtained significantly advances the understanding of fluid mechanics, mixing theory and CFD modeling for nuclear waste tanks by benchmarking CFD results to actual experimental data. This research significantly bridges the gap between previous CFD models and actual field experiences in real waste tanks. A finding of the 2009, DOE, Slurry Retrieval, Pipeline Transport and Plugging, and Mixing Workshop was that CFD models were inadequate to assess blending processes in nuclear waste tanks. One recommendation from that Workshop was that a validation, or bench marking program be performed for CFD modeling versus experiment. This research provided experimental data to validate and correct CFD models as they apply to mixing and blending in nuclear waste tanks. Extensive SDI research was a significant step toward bench marking and applying CFD modeling. This research showed that CFD models not only agreed with experiment, but demonstrated that the large variance in actual experimental data accounts for misunderstood discrepancies between CFD models and experiments. Having documented this finding, SRNL was able to provide correction factors to be used with CFD models to statistically bound full scale CFD results. Through the use of pilot scale tests performed for both types of pumps and available engineering literature, SRNL demonstrated how to effectively apply CFD results to salt batch mixing in full scale waste tanks. In other words, CFD models were in error prior to development of experimental correction factors determined during this research, which provided a technique to use CFD models for salt batch mixing and transfer pump operations. This major scientific advance in mixing technology resulted in multi-million dollar cost savings to SRR. New techniques were developed for both experiment and analysis to complete this research. Supporting this success, research findings are summarized in the Conclusions section of this report, and technical recommendations for design and operation are included in this section of the report

TANK 21 AND TANK 24 BLEND AND FEED STUDY: BLENDING TIMES, SETTLING TIMES, AND TRANSFERS

The Salt Disposition Integration (SDI) portfolio of projects provides the infrastructure within existing Liquid Waste facilities to support the startup and long term operation of the Salt Waste Processing Facility (SWPF). Within SDI, the Blend and Feed Project will equip existing waste tanks in the Tank Farms to serve as Blend Tanks where salt solutions of up to 1.2 million gallons will be blended in 1.3 million gallon tanks and qualified for use as feedstock for SWPF. In particular, Tanks 21 and 24 are planned to be used for blending and transferring to the SDI feed tank. These tanks were evaluated here to determine blending times, to determine a range of settling times for disturbed sludge, and to determine that the SWPF Waste Acceptance Criteria that less than 1200 mg/liter of solids will be entrained in salt solutions during transfers from the Tank 21 and Tank 24 will be met. Overall conclusions for Tank 21 and Tank 24 operations include: (1) Experimental correction factors were applied to CFD (computational fluid dynamics) models to establish blending times between approximately two and five hours. As shown in Phase 2 research, blending times may be as much as ten times greater, or more, if lighter fluids are added to heavier fluids (i.e., water added to salt solution). As the densities of two salt solutions converge this effect may be minimized, but additional confirmatory research was not performed. (2) At the current sludge levels and the presently planned operating heights of the transfer pumps, solids entrainment will be less than 1200 mg/liter, assuming a conservative, slow settling sludge simulant. (3) Based on theoretical calculations, particles in the density range of 2.5 to 5.0 g/mL must be greater than 2-4 {micro}m in diameter to ensure they settle adequately in 30-60 days to meet the SWPF feed criterion (<1200 mg/l). (4) Experimental tests with sludge batch 6 simulant and field turbidity data from a recent Tank 21 mixing evolution suggest the solid particles have higher density and/or larger size than indicated by previous analysis of SRS sludge and sludge simulants. (5) Tank 21 waste characterization, laboratory settling tests, and additional field turbidity measurements during mixing evolutions are recommended to better understand potential risk for extended (> 60 days) settling times in Tank 21

EFFECTS OF OXYGEN AND AIR MIXING ON VOID FRACTIONS IN A LARGE SCALE SYSTEM

Oxygen and air mixing with spargers was performed in a 30 foot tall by 30 inch diameter column, to investigate mass transfer as air sparged up through the column and removed saturated oxygen from solution. The mixing techniques required to support this research are the focus of this paper. The fluids tested included water, water with an antifoam agent (AFA), and a high, solids content, Bingham plastic, nuclear waste simulant with AFA, referred to as AZ01 simulant, which is non-radioactive. Mixing of fluids in the column was performed using a recirculation system and an air sparger. The re-circulation system consisted of the column, a re-circulating pump, and associated piping. The air sparger was fabricated from a two inch diameter pipe concentrically installed in the column and open near the bottom of the column. The column contents were slowly re-circulated while fluids were mixed with the air sparger. Samples were rheologically tested to ensure effective mixing, as required. Once the fluids were adequately mixed, oxygen was homogeneously added through the re-circulation loop using a sintered metal oxygen sparger followed by a static mixer. Then the air sparger was re-actuated to remove oxygen from solution as air bubbled up through solution. To monitor mixing effectiveness several variables were monitored, which included flow rates, oxygen concentration, differential pressures along the column height, fluid levels, and void fractions, which are defined as the percent of dissolved gas divided by the total volume of gas and liquid. Research showed that mixing was uniform for water and water with AFA, but mixing for the AZ101 fluid was far more complex. Although mixing of AZ101 was uniform throughout most of the column, gas entrapment and settling of solids significantly affected test results. The detailed test results presented here provide some insight into the complexities of mixing and void fractions for different fluids and how the mixing process itself affects void fractions in Bingham plastic fluids, which have a measurable yield stress

NITRATE CONVERSION OF HB-LINE REILLEXTM HPQ RESIN

Reillex{trademark} HPQ ion exchange resin is used by HB Line to remove plutonium from aqueous streams. Reillex{trademark} HPQ resin currently available from Vertellus Specialties LLC is a chloride ionic form, which can cause stress corrosion cracking in stainless steels. Therefore, HB Line Engineering requested that Savannah River National Laboratory (SRNL) convert resin from chloride form to nitrate form in the Engineering Development Laboratory (EDL). To perform this task, SRNL treated two batches of resin in 2012. The first batch of resin from Reilly Industries Batch 80302MA was initially treated at SRNL in 2001 to remove chloride. This batch of resin, nominally 30 liters, has been stored wet in carboys since that time until being retreated in 2012. The second batch of resin from Batch 23408 consisted of 50 kg of new resin purchased from Vertellus Specialties in 2012. Both batches were treated in a column designed to convert resin using downflow of 1.0 M sodium nitrate solution through the resin bed followed by rinsing with deionized water. Both batches were analyzed for chloride concentration, before and after treatment, using Neutron Activation Analysis (NAA). The resin specification [Werling, 2003] states the total chlorine and chloride concentration shall be less than 250 ppm. The resin condition for measuring this concentration is not specified; however, in service the resin would always be fully wet. Measurements in SRNL showed that changing from oven dry resin to fully wet resin, with liquid in the particle interstices but no supernatant, increases the total weight by a factor of at least three. Therefore, concentration of chlorine or chloride expressed as parts per million (ppm) decreases by a factor of three. Therefore, SRNL recommends measuring chlorine concentration on an oven dry basis, then dividing by three to estimate chloride concentration in the fully wet condition. Chloride concentration in the first batch (No.80302MA) was nearly the same before the current treatment (759 ppm dry) and after treatment (745 ppm dry or {approx}248 ppm wet). Treatment of the second batch of resin (No.23408) was very successful. Chloride concentration decreased from 120,000 ppm dry to an average of 44 ppm dry or {approx}15ppm wet, which easily passes the 250 ppm wet criterion. Per guidance from HB Line Engineering, SRNL blended Batch 80302 resin with Batch P9059 resin which had been treated previously by ResinTech to remove chloride. The chloride concentrations for the two drums of Batch P9059 were 248 ppm dry ({approx}83 ppm wet) {+-}22.8% and 583 ppm dry ({approx}194 ppm wet) {+-} 11.8%. The blended resin was packaged in five gallon buckets

Analysis of Turbulent Mixing Jets in Large Scale Tank

Flow evolution models were developed to evaluate the performance of the new advanced design mixer pump for sludge mixing and removal operations with high-velocity liquid jets in one of the large-scale Savannah River Site waste tanks, Tank 18. This paper describes the computational model, the flow measurements used to provide validation data in the region far from the jet nozzle, the extension of the computational results to real tank conditions through the use of existing sludge suspension data, and finally, the sludge removal results from actual Tank 18 operations. A computational fluid dynamics approach was used to simulate the sludge removal operations. The models employed a three-dimensional representation of the tank with a two-equation turbulence model. Both the computational approach and the models were validated with onsite test data reported here and literature data. The model was then extended to actual conditions in Tank 18 through a velocity criterion to predict the ability of the new pump design to suspend settled sludge. A qualitative comparison with sludge removal operations in Tank 18 showed a reasonably good comparison with final results subject to significant uncertainties in actual sludge properties

ELAWD GROUT HOPPER MOCK-UP TESTING

A 10-inch READCO mixer is used for mixing the premix (45 (wt%) fly ash, 45 wt% slag, and 10 wt% portland cement) with salt solution in the Saltstone Production Facility (SPF). The Saltstone grout free falls into the grout hopper which feeds the suction line leading to the Watson SPX 100 duplex hose pump. The Watson SPX 100 pumps the grout through approximately 1500 feet of piping prior to being discharged into the Saltstone Disposal Facility (SDF) vaults. The existing grout hopper has been identified by the Saltstone Enhanced Low Activity Waste Disposal (ELAWD) project for re-design. The current nominal working volume of this hopper is 12 gallons and does not permit handling an inadvertent addition of excess dry feeds. Saltstone Engineering has proposed a new hopper tank that will have a nominal working volume of 300 gallons and is agitated with a mechanical agitator. The larger volume hopper is designed to handle variability in the output of the READCO mixer and process upsets without entering set back during processing. The objectives of this task involve scaling the proposed hopper design and testing the scaled hopper for the following processing issues: (1) The effect of agitation on radar measurement. Formation of a vortex may affect the ability to accurately measure the tank level. The agitator was run at varying speeds and with varying grout viscosities to determine what parameters cause vortex formation and whether measurement accuracy is affected. (2) A dry feeds over addition. Engineering Calculating X-ESR-Z-00017 1 showed that an additional 300 pounds of dry premix added to a 300 gallon working volume would lower the water to premix ratio (W/P) from the nominal 0.60 to 0.53 based on a Salt Waste Processing Facility (SWPF) salt simulant. A grout with a W/P of 0.53 represents the upper bound of grout rheology that could be processed at the facility. A scaled amount of dry feeds will be added into the hopper to verify that this is a recoverable situation. (3) The necessity of baffles in the hopper. The preference of the facility is not to have baffles in the hopper; however, if the initial testing indicates inadequate agitation or difficulties with the radar measurement, baffles will be tested

SAVANNAH RIVER SITE TANK 18 AND TANK 19 WALL SAMPLER PERFORMANCE

A sampling tool was required to evaluate residual activity ({mu}Curies per square foot) on the inner wall surfaces of underground nuclear waste storage tanks. The tool was required to collect a small sample from the 3/8 inch thick tank walls. This paper documents the design, testing, and deployment of the remotely operated sampling device. The sampler provides material from a known surface area to estimate the overall surface contamination in the tank prior to closure. The sampler consisted of a sampler and mast assembly mast assembly, control system, and the sampler, or end effector, which is defined as the operating component of a robotic arm. The mast assembly consisted of a vertical 30 feet long, 3 inch by 3 inch, vertical steel mast and a cantilevered arm hinged at the bottom of the mast and lowered by cable to align the attached sampler to the wall. The sampler and mast assembly were raised and lowered through an opening in the tank tops, called a riser. The sampler is constructed of a mounting plate, a drill, springs to provide a drive force to the drill, a removable sampler head to collect the sample, a vacuum pump to draw the sample from the drill to a filter, and controls to operate the system. Once the sampler was positioned near the wall, electromagnets attached it to the wall, and the control system was operated to turn on the drill and vacuum to remove and collect a sample from the wall. Samples were collected on filters in removable sampler heads, which were readily transported for further laboratory testing

EFFECTS OF ALTERNATE ANTIFOAM AGENTS, NOBLE METALS, MIXING SYSTEMS AND MASS TRANSFER ON GAS HOLDUP AND RELEASE FROM NONNEWTONIAN SLURRIES

Gas holdup tests performed in a small-scale mechanically-agitated mixing system at the Savannah River National Laboratory (SRNL) were reported in 2006. The tests were for a simulant of waste from the Hanford Tank 241-AZ-101 and featured additions of DOW Corning Q2-3183A Antifoam agent. Results indicated that this antifoam agent (AFA) increased gas holdup in the waste simulant by about a factor of four and, counter intuitively, that the holdup increased as the simulant shear strength decreased (apparent viscosity decreased). These results raised questions about how the AFA might affect gas holdup in Hanford Waste Treatment and Immobilization Plant (WTP) vessels mixed by air sparging and pulse-jet mixers (PJMs). And whether the WTP air supply system being designed would have the capacity to handle a demand for increased airflow to operate the sparger-PJM mixing systems should the AFA increase retention of the radiochemically generated flammable gases in the waste by making the gas bubbles smaller and less mobile, or decrease the size of sparger bubbles making them mix less effectively for a given airflow rate. A new testing program was developed to assess the potential effects of adding the DOW Corning Q2-3183A AFA to WTP waste streams by first confirming the results of the work reported in 2006 by Stewart et al. and then determining if the AFA in fact causes such increased gas holdup in a prototypic sparger-PJM mixing system, or if the increased holdup is just a feature of the small-scale agitation system. Other elements of the new program include evaluating effects other variables could have on gas holdup in systems with AFA additions such as catalysis from trace noble metals in the waste, determining mass transfer coefficients for the AZ-101 waste simulant, and determining whether other AFA compositions such as Dow Corning 1520-US could also increase gas holdup in Hanford waste. This new testing program was split into two investigations, prototypic sparger-PJM tests and modeling being conducted at the Pacific Northwest National Laboratory (PNNL), and small-scale agitation tests and evaluations of effects waste and AFA ingredients have on gas retention and mass transfer being conducted at SRNL. Only work conducted at SRNL is reported here. Key results are: (1) The unexpected gas holdup behavior reported in 2006 for a small-scale agitation system is confirmed. The gas holdup data from small-scale and bench-scale impeller-type mixing systems reported herein show very different trends than the behavior exhibited by the prototypic sparger-PJM mixing system tested in the PNNL APEL facility. Results obtained from testing this 1/4-scale prototypic mixing system will be reported by PNNL. The reason for this difference in holdup behavior between the two different mixing systems is not known at this time. Consequently, data from the small mechanical agitation systems should not be extrapolated to prototypic plant conditions. (2) Bench-scale and small-scale tests conducted with Dow Corning 1520-US AFA show it to be a viable replacement to Dow Corning Q2-3183A AFA. This alternative AFA will, however, require significantly higher dosage (concentration) to perform the same antifoam function. (3) Addition of noble metals to the AZ-101 waste simulant does not produce a catalytic gas retention effect with the AFA. The Gas holdup is similar whether or not noble metals are present in the AZ-101 simulant. (4) Mass transfer tests were performed in a large (0.76 m diameter) bubble column filled to 1.3, 3.4, and 7.4 m elevations with water and the AZ-101 waste simulant. Mass transfer coefficients for air bubbles emanating from a prototypic 0.051 m diameter sparger were obtained from the transient decay of dissolved oxygen concentration in the initially saturated fluids. Adding AFA to water reduces the mass transfer coefficient slightly. AFA addition reduces the mass transfer coefficient for AZ-101 simulant more than it does for water because the shear strength of the simulant allows for larger bubble sizes, and larger bubbles have smaller surface area for mass transfer than small bubbles for the same void volume

CFD [computational fluid dynamics] And Safety Factors. Computer modeling of complex processes needs old-fashioned experiments to stay in touch with reality.

Computational fluid dynamics (CFD) is recognized as a powerful engineering tool. That is, CFD has advanced over the years to the point where it can now give us deep insight into the analysis of very complex processes. There is a danger, though, that an engineer can place too much confidence in a simulation. If a user is not careful, it is easy to believe that if you plug in the numbers, the answer comes out, and you are done. This assumption can lead to significant errors. As we discovered in the course of a study on behalf of the Department of Energy's Savannah River Site in South Carolina, CFD models fail to capture some of the large variations inherent in complex processes. These variations, or scatter, in experimental data emerge from physical tests and are inadequately captured or expressed by calculated mean values for a process. This anomaly between experiment and theory can lead to serious errors in engineering analysis and design unless a correction factor, or safety factor, is experimentally validated. For this study, blending times for the mixing of salt solutions in large storage tanks were the process of concern under investigation. This study focused on the blending processes needed to mix salt solutions to ensure homogeneity within waste tanks, where homogeneity is required to control radioactivity levels during subsequent processing. Two of the requirements for this task were to determine the minimum number of submerged, centrifugal pumps required to blend the salt mixtures in a full-scale tank in half a day or less, and to recommend reasonable blending times to achieve nearly homogeneous salt mixtures. A full-scale, low-flow pump with a total discharge flow rate of 500 to 800 gpm was recommended with two opposing 2.27-inch diameter nozzles. To make this recommendation, both experimental and CFD modeling were performed. Lab researchers found that, although CFD provided good estimates of an average blending time, experimental blending times varied significantly from the average