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AFPC Norm Decontamination Facility Plant

(NDF) 1.1. IntroductionIntroduction

- The passage of produced water through pipe work and plants leads to the The passage of produced water through pipe work and plants leads to the

built up of Norm scale on the inner surfaces, which can present an built up of Norm scale on the inner surfaces, which can present an

external radiation Hazard during normal operation and an Internal and external radiation Hazard during normal operation and an Internal and

external hazard during maintenance work.external hazard during maintenance work.- AFPC have made a policy decision to manage the NORM wastes in AFPC have made a policy decision to manage the NORM wastes in accordance with best international practice.accordance with best international practice.- AFPC constructed a Norm Decontamination plant by the AEA AFPC constructed a Norm Decontamination plant by the AEA Technology. Technology.

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- The AFPC NDF plantThe AFPC NDF plant is used to remove NORM contaminated scales is used to remove NORM contaminated scales from Production equipments in order to be prepared for re-use or from Production equipments in order to be prepared for re-use or safe disposal.safe disposal.

- The plant is run continuously for 10 HRs per day and 365 days per year The plant is run continuously for 10 HRs per day and 365 days per year

(except the break down maintenance & De- sludging shutdowns)(except the break down maintenance & De- sludging shutdowns)

- Sump pumps to transfer process water from the jetting bays / lancing Sump pumps to transfer process water from the jetting bays / lancing

machine into settling tanks that designed to allow fine NORM machine into settling tanks that designed to allow fine NORM

particulate to fall out of suspension in the process water stream.particulate to fall out of suspension in the process water stream.

- The AFPC NDF plant achieves decontamination level down to 0.37 The AFPC NDF plant achieves decontamination level down to 0.37

Bq/Cm² for Alpha radiation and 3.7 Bq/Cm² for Beta radiation.Bq/Cm² for Alpha radiation and 3.7 Bq/Cm² for Beta radiation.

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2. NDF Main Parts:

1- A general area with:1- A general area with:

a) Operators Change room with showers: with barriers and a) Operators Change room with showers: with barriers and monitoring equipments monitoring equipments

b) Visitors Change room with showersb) Visitors Change room with showers

c) A hooded Gas Cutting area: breathing air supply is c) A hooded Gas Cutting area: breathing air supply is required for Operatorsrequired for Operators

d) An active Laundry: with ventilation and waste feed direct d) An active Laundry: with ventilation and waste feed direct to a disposal tankto a disposal tank

e) A water Jetting area for Decontaminatione) A water Jetting area for Decontamination

  

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2- A Pump House with High Pressure Pumps for Equipments Decontamination:

* Process water is extracted from settling tanks and

conveyed to the water filter units, where cartridges will

remove particulate down to 10 micron.

a) High pressure pump for tubular decontamination

b) Low pressure pumps for sump and water re-circulation

3-  Active air samplers to monitor airborne activity and ventilation system

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Extract Ventilation System

HEPA filters

4- A tubular Decontamination plant for tubes Decontamination:

- 1000 bar operational pressure

- It is hydraulically operated and controlled de- scaling

machine

water chiller: is to cool the process water temperature which has gained heat after passing through high pressure pumps and lances.

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5- A lay down area for equipments dismantling to be

decontaminated

6- A Lay down area for decontaminated equipments7- A temporary waste store building for main and secondary waste temporary storage. 8- Health Physics Laboratory

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Guard

House

AFPC NDF Plant Layout

Main Gate

Tubular lance 1K.bar Press

Tubular C.Room

Jetting Bays2.K. bar. pressure

Burning Bay

W.Shop

Offices Mess Room

Controlled AreaTube RacksContaminated Equipments

Visitors Change

Rooms

Lau

ndry

Contaminated Scale Drum Store

W.C

Primary Settling

Tanks

HPS Office

Dismantling Bay

Clean Area

Secondary Settling Tanks

Pump House

Hepa Filter Room

Store

Op.Cha.

Room

Air

Luck

Delay Tanks

H. VAC

S.Ch.R

W. Chiller A. Chiller

Sun

Shade

- Gat

e

Bar

r ie r

B

arr i

e r

NDF Layout

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The NDF External Layout

Air Luck

Drum Store

Clean Area

Main Gate Guard

Offices, Mess Room, W.C. Spares Stores

Controlled Area At The back

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Burning Bay

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High Pressure Jetting Bay

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Tube Plant Machine

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Jetting & Burning Curtain

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Waste Bags

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Filters Bank

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Controlled AreaContaminated Equipments

Wrapping

1. Received items are wrapped in plastic bags.2. Vehicle wheels must be checked by the plant

HPS Prior to leave the Plant. Apply Decontamination if required.

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H.P.S Office

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3. Decontamination of equipment

1. Receipt of equipment from Owners with all the required info 1. Receipt of equipment from Owners with all the required info included in job work Request form (Owner name, indicator and included in job work Request form (Owner name, indicator and telephone number, location, equipment explanation for reused telephone number, location, equipment explanation for reused OR scrap, numbers of equipments, Norm certificate checked by OR scrap, numbers of equipments, Norm certificate checked by the location RPS, job priority based on equipments reuse or the location RPS, job priority based on equipments reuse or HSE condition) HSE condition)

2. NDF Plant manager and HPS Recheck the work request 2. NDF Plant manager and HPS Recheck the work request information and compare.information and compare.

3. HPS Recheck the Norm contamination of the received 3. HPS Recheck the Norm contamination of the received equipmentsequipments

4. Off loading At NDF controlled area4. Off loading At NDF controlled area5. Check the vehicle body and wheels prior to leave the facility and 5. Check the vehicle body and wheels prior to leave the facility and

Decontaminate if requiredDecontaminate if required

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Clothing Minitor

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Air Sampler

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PPEs

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6. Write NDF Local number7. Organizing Job based on priority8. Start Decontamination based on equipments type until back ground 9. NDF contact the person who raised the WO when achieve the Decontamination.

10. Transport the Decontaminated equipments to the Central work shop for maintenance OR contact the Owner to take the equipments back as required.10. Issue Clearance Certificate OR Radiological Survey Report as required

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Norm Yards Decontamination Management ProcessFlow Chart

OPX/M, Focal Point - Equipments Decontamination Priorities - OPX/M to specify the inventory of the reused and scrap equipments:

Re-used equipmentsOPX/M

Inventorying the priorities of

equipments by type

- OPX/M to raise Immpower work request to NDF based on job necessity including all details (Norm reading, hot work if requested to be applied after decontamination, and effective by high pressure water jetting. Confirm the priority of urgent job-OPX/M to raise another W.R to OTS/2 for the equipments that need maintenance after decontamination.- OPX/M to raise transportation W.O to OTS/3 to transport equipments to NDF, from NDF to OTS/2 , and from OTS/2 to the main area location.

-ODS/N (NDF), to schedule the Normal job decontamination priority.- OPX/M to confirm the priority for the urgent requirements including all details.

NDF, to check all the details.Carry out the decontamination process, attach the required radiological reports.

-NDF, contact the Owner for the reused equipments (No maintenance requirements need), to take them back to the area with in maximum one week. - OTS/3 to insure equipments transportation from NDF to the main location within maximum one week.

RPS to inventory the equipments based on Norm contaminated level for each type

Scrap Equipments-OPX/M raise Immpower

work request to NDF including the Norm reading

- OPX/M raise WO to OTS/3 for equipments transportation to

and from NDF.

-NDF, schedule priorities and carry out Decontamination

-NDF, to contact OTS/3 (Telephone call or e-mail) to transport the achieved equipments to Omar scrap yard with all the radiological details report.-- OTS/3 achieve the transportation within maximum 2 weeks plan.

-PLS is responsible for dispatching the clearance Decontaminated scrap Equipments to SPC or to Hamaa factory under Omar RPS Norm re-survey official

reporting

RPS to attach the Norm inventory with readings

- NDF, to contact OTS/2 for the equipments that need maintenance with all official radiological report

and required PPEs recommendation if required.

-OTS/2 will arrange transportation from NDF to the work shop through OTS/3 within maximum one week.

- OTS/2 to contact the owner to remove equipments after repairing.

OPX/M to contact OTS/3 to insure transportation to remove all achieved equipments from OTS/2 W.Shop to the Owner area.

Notes: 1- To nominate the Omar scrap yard focal points that will be responsible for the decontaminated scrap materials from NDF as a central yard for all areas scrap accumulation. OPO action2- To specify Transportation responsibility (The materials Owner has to request transportation from PLS for all required steps.3- Equipments Owner has to response of removing achieved material from NDF, delay will cause facility space confusion. 4- Material s wrapping and packaging as per procedures to be applied under the RPS consultancy and authority. 5- Area RPS has to be informed to carry out double check of the received / decontaminated equipments from NDF prior to use them. 6- Area RPS is authorized for all Norm activities in his area and responsible to follow up all required procedures and registers details.7- Area RPS has to feed back to NDF with regard to the Norm reading of the decontaminated materials received from NDF, and to inform for any deviation of the attached clearance certificate.

Norm Yards Decontamination Management ProcessFlow Chart

OPX/M, Focal Point - Equipments Decontamination Priorities - OPX/M to specify the inventory of the reused and scrap equipments:

Re-used equipmentsOPX/M

Inventorying the priorities of

equipments by type

- OPX/M to raise Immpower work request to NDF based on job necessity including all details (Norm reading, hot work if requested to be applied after decontamination, and effective by high pressure water jetting. Confirm the priority of urgent job-OPX/M to raise another W.R to OTS/2 for the equipments that need maintenance after decontamination.- OPX/M to raise transportation W.O to OTS/3 to transport equipments to NDF, from NDF to OTS/2 , and from OTS/2 to the main area location.

-ODS/N (NDF), to schedule the Normal job decontamination priority.- OPX/M to confirm the priority for the urgent requirements including all details.

NDF, to check all the details.Carry out the decontamination process, attach the required radiological reports.

-NDF, contact the Owner for the reused equipments (No maintenance requirements need), to take them back to the area with in maximum one week. - OTS/3 to insure equipments transportation from NDF to the main location within maximum one week.

RPS to inventory the equipments based on Norm contaminated level for each type

Scrap Equipments-OPX/M raise Immpower

work request to NDF including the Norm reading

- OPX/M raise WO to OTS/3 for equipments transportation to

and from NDF.

-NDF, schedule priorities and carry out Decontamination

-NDF, to contact OTS/3 (Telephone call or e-mail) to transport the achieved equipments to Omar scrap yard with all the radiological details report.-- OTS/3 achieve the transportation within maximum 2 weeks plan.

-PLS is responsible for dispatching the clearance Decontaminated scrap Equipments to SPC or to Hamaa factory under Omar RPS Norm re-survey official

reporting

RPS to attach the Norm inventory with readings

- NDF, to contact OTS/2 for the equipments that need maintenance with all official radiological report

and required PPEs recommendation if required.

-OTS/2 will arrange transportation from NDF to the work shop through OTS/3 within maximum one week.

- OTS/2 to contact the owner to remove equipments after repairing.

OPX/M to contact OTS/3 to insure transportation to remove all achieved equipments from OTS/2 W.Shop to the Owner area.

Notes: 1- To nominate the Omar scrap yard focal points that will be responsible for the decontaminated scrap materials from NDF as a central yard for all areas scrap accumulation. OPO action2- To specify Transportation responsibility (The materials Owner has to request transportation from PLS for all required steps.3- Equipments Owner has to response of removing achieved material from NDF, delay will cause facility space confusion. 4- Material s wrapping and packaging as per procedures to be applied under the RPS consultancy and authority. 5- Area RPS has to be informed to carry out double check of the received / decontaminated equipments from NDF prior to use them. 6- Area RPS is authorized for all Norm activities in his area and responsible to follow up all required procedures and registers details.7- Area RPS has to feed back to NDF with regard to the Norm reading of the decontaminated materials received from NDF, and to inform for any deviation of the attached clearance certificate.

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Clean Equipments Area

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4. Important Issues Of AFPC NDF Plant:

1) Modern, closed recycled process water system, Air extracts 1) Modern, closed recycled process water system, Air extracts system (safer)system (safer)

2) Tight environmental controls2) Tight environmental controls

3) All NDF workers are Norm aware and radio logically 3) All NDF workers are Norm aware and radio logically classifiedclassified

4) All the plant workers carry out annual Radiological and 4) All the plant workers carry out annual Radiological and Medical examination at AESC Establishment. Medical examination at AESC Establishment.

5) Personal Film Badges are inspected each two months by 5) Personal Film Badges are inspected each two months by AESCAESC

6) All unsafe act/condition and incidents shall be reported6) All unsafe act/condition and incidents shall be reported

7) The plant building is air conditioned to give a maximum 7) The plant building is air conditioned to give a maximum working temperature of 25 C°working temperature of 25 C°

8) Work schedule is 12 hrs day shift, Actually 9 HRs work 8) Work schedule is 12 hrs day shift, Actually 9 HRs work (From 06:00 to 08:30, from 09:30 to 12:00, from 13:00 to (From 06:00 to 08:30, from 09:30 to 12:00, from 13:00 to 15:00 and from 16:00 to 18:00 HRs)15:00 and from 16:00 to 18:00 HRs)

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9) HPS Checks vehicle body and wheels prior to leave the plant. Apply Decontamination if required10) All employees wear the appropriate PPEs as required (Where Respiratory Protective Equipment (RPE) is provided for use in particular Circumstances)11) First Aid is provided at all times12) All employees shall be made aware of Permanent Instruction, which is to be followed in the event of an incident requiring First Aid or Ambulance.13) The Norm contaminated scale & Sludge are removed from the tanks, and containerized in plastic drums and stored in the waste drum store through a sequentially De-sludging shutdown of the plant.