SRS Liquid Waste Program

Transcription

1 SRS Liquid Waste Program Mark Schmitz, Acting President & Project Manager Savannah River Remediation LLC Challenges in US DOE HLW Tank Management Doing More with What We Have! 1

2 SRR Waste Tank Cleanup Actinide Removal Process Modular Caustic Side Solvent Extraction Unit Saltstone Low-Level Waste Extracted High-Level Waste Extracted DWPF Waste Solidified Salt Waste Solidified SDUs 122M curies (48%) 33.4M gallons (93%) Glass Waste Storage Building 131M curies (52%) 2.6Mgallons (7%) Waste Tanks Sludge Radioactivity: 253 million curies Volume: 36.0 million gallons 43 Tanks Tank Closures Continue 5 tank closures completed during the past 6 years; 7 total at SRS 1 in progress; Began 1/19/16 Future Federal Repository 2

3 High-Hazard Operational Highlights 67 Interim canister storage positions modified & 9 new shield plugs successfully tested 4,000 th canister poured 12/31/15 60 % reduction in decontaminated salt solution disposal costs % radionuclide removal with Next Generation Solvent 2.6 million gallons of tank space gain (36 million gallon inventory) in FY15 78 % construction complete on 30-million gallon capacity Saltstone Disposal Unit ARP/MCU = Actinide Removal Process and Modular Caustic Side Solvent Extraction Unit 3

4 Doing More With What We Have A lot accomplished to lengthen the life and increase reliability of SRS Liquid Waste facilities more to do 600 SRS Liquid Waste Funding Profile FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 Funding PBR Funding includes ARRA, Base Scope, and SDU6/7 Line Items 4

5 SRR Lean Business System 5

6 Lean is NOT Cost Reduction Lean IS Better Use of Existing Resources Second year of Lean implementation ~$31 million in annual savings identified in FY15 (soft and hard $) >63 events with over 20% of workforce participation in FY15 Focuses on three areas Reduce Human Factors Error-Likely Situations Increase Production Throughput and Availability Improve Facility Condition Reliability 6

7 Error Proofing Complex Processes Increasing trend of transcription, data entry and procedure performance errors Analyzed possible root causes and determined that over time, excessive controls were introduced into procedures contributing to error-likely scenarios Two DWPF processes reviewed focused on Sequencing and flow of procedure Requirements Appropriate detail and clarity of steps Elimination of unnecessary steps and sign offs Benefits to date very positive: Employees engaged had favorable feedback Disciplined operations rigor while maintaining technical accuracy Ensured requirements were well understand and fully vetted Significant reduction in error likely situations 32 % reduction of pages 45 % reduction of steps 48 % reduction of sign-offs 7

8 Tank Closure Schedule Comparison % 40 Grouting Tank Closure schedule reduction Months Closure Documentation Sample Analysis 10 Sampling Sampling Preparation 0 Tank 18/ Tank Tank Tank Tank Tank 15 Future 8

9 Lean Results at SRS Liquid HLW Waste Program >$1.1B Cumulative Life-Cycle Cost Efficiencies Identified Salt batch qualification cycle time 66% reduction which equates to 8.5 months which equates to $1.0B in life-cycle savings SWPF Tie-In Schedule $55M life-cycle savings through 4 month reduction Error Proofing Complex Processes 32% reduction in pages 45% reduction in steps 48% reduction in sign-offs 25% reduction in planning cycle-time at SRR 50% reduction in design drawings and cycle time for engineering documents for tank closure 30% reduction in resources needed to operate Effluent Treatment Plant which equates to $ ½M per year 70 Events 11 Value Streams 25 percent workforce participation > 30 instances of regulator, stakeholder and customer involvement in events 48% schedule improvement and 25% improvement in cost efficiencies for tank closure 9