DSHW-1997-002923 - 0901a068801584d4

imB DEFENSE AND UVUNCH VEHMB DIVISION
P.O. BOX 689
BRIGHAM CITY, UT 84302-0689
801-863-35n
May 21, 1997
W300:FY97:052
Dennis R. Downs, Director
Division of Solid and Hazardous Waste
288 North 1460 West
P. O. Box 144880
Salt Lake City, Utah 84114 -4880
Attention: JefF Vandel
THtOKOL
AEROSPACE & INDUSTRIAl TECHNOlOGIf S
RECEIVED
MAY 2 7 1997
Division of Solid & Hazardous Waste
Utah Department of Environmental Quality
Dear Mr. Downs,
Subject: RD&D Tank Certification and Washout Mishap
Pursuant to our RD&D pennit, paragraph IV.G.3,1
those tanks listed in IV.B. This tank certification should
project. I have enclosed a copy ofthe initial inspect on
repairs have been properly completed.
am submitting an independent tank certification for
take us through the completion ofthe RD&D
as well as the re-inspection certifying that the
Mr. Curtis of my staff spoke with Mr. Vandel on
during the last washout operation, and to let him
in the hydrolysis tank in excess ofour permitted
ofa safety investigation into the cause ofthese pops
revealed inconclusive results. We will now begin
within the 7 days allowed in the RD&D pennit.
Mjay 13 to inform him of some pops we had heard
that we may need to store the removed propellant
limil. The need for this additional time is the result
We have now completed the investigation which
hydrolysis operation and expect to be completed
know
time
the
lfyou have any questions regarding our RD&D opei ation, please contact Gene Curtis at [phone].
"I certify under penalty of law that this doc jment and all attachments were prepared under my
direction or supervision in accordance with a system design to assure that qualified personnel
properly gather and evaluate the informaticn submitted. Based on my inquiry ofthe person or
persons who manage the system, or those persons directly responsible for gathering the
information, the infonnation submitted is, o the best ofmy knowledge and belief, true, accurate,
and complete. I am aware that there are sijjnificant penalties for submitting false information,
including the possibility of fines and impriiionment of knowing violations."
J.MJ. Thompson, Director
Safety, Environmental and Support
cc: G. L. Mower, K. G. Curtis
EL0)RADO ENGINEERING Jff
DESIGNERS /CONSULTANTS
CERTIFICATE OF INSPECTIONS
I, Kenneth T. Smith, P.E. have ins
Hydrothermal Oxidation (HTO) tank system;
facility located at the Thiokol Corporation
made as results of an inspection on April 17,
plant
The inspection found the Hydrolysis
Oxidation Reactor to be in compliance with
regulations, namely: 40 CFR 264.192, paragjraph
paragraph (e). The secondary containment
be satisfactory.
;pjected the recent repairs on the Hydrolysis and
for the Solid Rocket Motor Disposal (SRMD)
west of Brigham City, Utah. The repairs were
1&97 (see attached pages)
and Hydrothermal Oxidation tank systems and
R|esource Conservation and Recovery Act (RCRA)
(b) and subparagraphs (1) through (6), and
sVstems repairs were inspected and were found to
The metal tank which the April 17* inspection found unanchored does not have to be
anchored since it does not contain or handle hazardous waste.
The Hydrolysis and HTO systems are
end of which time another inspection is requiied
tliis I certify under penalty of law that
under my direction or supervision in accordaiice
personnel properly gather and evaluate the
person or persons who manage the system,
the information, the information submitted
accurate, and complete. I am aware that
information, including the possibility of fine
DATE: /^-/fV^A/^-TZ
/
suitable for another 12 months operation: at the
per the RD&D pennit.
document and all attachments were prepared
with a system designed to assure that qualified
information submitted. Based on my inquiry of the
those persons directly responsible for gathering
to the best of my knowledge and belief, true,
are significant penalties for submitting false
ind imprisonment for knowing violations.
or
ii,
tliere
^{^^^i^yije^^^^i..,.i^sz^
KENNETH T. SMITH, P.E.
Utah License No. 146517
El Dorado Engineering, Inc.
2964 West 4700 South, Suite 109
Salt Lake City, Utah 84118
"<^^ or ^>
2964 WEST 4700 SOUTH, SUITE 109 • SALT LAKE CITY, UTAH 84118 • [phone] • (FAX [phone]
EL DORADO E
DESI6NER1 IS/C
GINEERING
/CONSULTANTS
OFINSPBCnOMS CERHFICAra
I, Kenneth T. Smith, P.E. have inspected tfie Hydrolysis and Hydrothermal Oxidation
CHTO) tank systems for the SoUd RoclsBt Motor Disposal (SRMD) facility located at the Thiokol
Coipoiation plant west cf Brigbam Qty, Utah. My duties were to perform and provide an
annual inspection and certification in accordance with the requiieoioits of paragraph IV.G.3. of
module IV-4, May 31.1994 RD&D permit por tbe facility.
The inspection found the Hydrolysis and Hydrothennal Oxidation tank systems and
Oxidation Reactor to be in compliance witfa Resource Conservation and Recovery Act (RCRA)
x^ulations, namely: 40 CFR 264.192, panigraph (b) and subparagraphs (1) through (6), and
paragr^h (e) except as noted below. The secondary containment systems were inspected for
cnK:ks> evidence of corrosive attack, adequu^ of sealants at construction or expansion joints,
and evidence of frost heaving, and were foimd to be satisfactory except as noted below.
The foUowing minor de^ciencies Mtere found and should be corrected before the tank
systems and Oxidation Reactor are retumed lo service. See attadied Inspection Rqport dated
Apnl 18, 1997 for details. j
1. Seal hairline cracks in the Transport/Hydrolysis Tank (THC) secondaiy
containment system.
2. Secure tank and ancillary equipment on THC pad.
3. Seal hairline cracks in the I [TO secondary containment system curbs and vault.
Once the above noted minor deficiencies are conected, the Hydrolysis and HTO systems
axe suitable for another 12 months operaiion; at the end of which time another inspection is
required per the RD&D permit.
I certify under penalty, of law diat tus document and all attachments were prepared under
my direction or supervision in accordance with a system designed lo assure that qualified
personnel properly gather and evahiate thit infonnation submitted. Based on my inquiry of the
person or persons who manage the system^ or those persons directly responsible for gathedng
the information, the information submitted is^ to the best of my knowledge and belief, true,
accurate, and complete, I am ware that there are significant penalties for submitting ^dse
ine and imprisonment for knowing violations. information, including the possibili^ of
DATE: /If lr J :il.l^^J
.• _ ^ i^,*- .*ji(
KENNETH T. SMmi, P.E.
Utah License No. 146517
El Dorado Engineering, Inc.
2964 West 4700 Soudi, Suite 109
Salt Lake City, Utah 84118
9«eAU/i>AT d70fl ftoiJTM itiirrr ioa • «AITI ktcv rirv UTAM naim • iRnii <iMi.«7nR • IFAX mnn ««iufl«Qa
w f I u ; *+e/ ox. I u . *j w^j^v- o^wuc^uf-to r
EL DORADO ENGINEERING
DESIGNERli/CONSULTANTS
im:.
April 18, 1997
Inspection Rqx>rt - SRMD Hydrolysis and Hjydothermal Oxidadoti (HTO) Tank Systems
Tbe tank systeins are located at the iliiokDl Coipoiatian plant west of Brigham City,
Utah, and xequiie assessment and certification by a qoalified, independent professional engineer,
at least every 12 months. (Reference para^^h IV,G.3. of RD&D permit. May 31, 1994.)
Assessment was performed on April 17, 1997 by Kenneth T. Smith (Utah FE License No.
146517) enployed by El Dorado Engineering, Inc. OBDE), SaU Lake City, Utah.
Hydrolysis System
Tbe 'Hansport/Hydrolysis Container diHC), Figure 1, is the only hazardous waste vessel
in the system (identified as "Hydrolysis Tank* in paragraph IV.B.2., of May 12. 1994 RD&D
permit). The empty THC intonal and exemal surfiaces were visually inspected. Internal
inspection of the empty vessel was peiforroed with the aid of a flashlight through the 12 1/2"
inside diameter nozde in tbe center of the mjain lid. No evidence of lei^dng or corrosive attack
were found.
The ancillary equiimient was inspected and no corrosive attack OT evidence of leaking was
found. A metal tank (about 4*0 x 6'-6'' tall) on the northwest comer of the pad should be
anchor bolted to the concrete pad. A small condaiser tank and the one inch diameter PVC line
entoing the top of the tank requite more siecure mounting (see Figure 2). Recommend that
tanks and line be anchored/secured.
The THC secondary containment system (reinforced ccmcrete, curbed pad and below
grade vault) were inspected, see Figure 2.
found. Joint silicone rubber seals were in
No evidoice of conosive attack of the concrete was
latis&ctory conditirai.
The below grade vault had been well cleaned, and was entered and visually inspected.
The vault floor sur&ce showed no cracking and tbe floor-to-wall joins appeared to be in
satisfactory condition. Hairline cracks w^ present in portions of tiie vault walls; attached
Figures 4 dirough 7 show approximate crack locations. The hairline cracks at the vault corners
were barely visible. The other hairline cracks were slightly more open, the largest crack was
in the west wall (see Figure 6) and measured at slightly more tfaan the diickness of one sheet of
paper* or about .005 inches near its upper isnd. The top edges of the vault walls were visually
inspected to see if the cracks passed through the walls. No through oacking was found.
Recommend that suitable sealants/caulks bi( applied to all cracks.
Fage 1 of 10
^Faper thickness was later measured at 0.003 inches.
2964 WEST 4700 SOLITH SurTF 109 • ftAi T I AKJF r.rrv liTAu «Mii(i • fiinii aacflvaa • <EAV /MAH a*n.«<icia
tt—^1 \ inu) u^t. ^^ y ( IU : 4d/Bl. luidy/Nu. a&tsu^Du Ma p
No evidence of frost heaving was fimuid.
Conclude that the Hydrolysis System, once the areas discussed above are addressed, is
suitable for use until the next annual inspectipn, 12 months hence
Hydrothennal Oxidation (HTO) System
The HTO system is located inside a temporary building. Figure 3 shows the plan view
of tbe concrete secondary containment pad and vault, and equipment layout inside the building.
The three tanks, identified in the May IZ, 1995 RD&D permit, paragraph IV.B. as:
Hydrolyzed Fropellam Storage I^k, Mix
TM200, TK400, and TK800 respectively, 4ere inspected
inspected, per RD&D permit requirem»n.
Hie three tanks (TK200. 400 & 800) were visually inspected externally. No evidence
of corrosive attack, cracking, or lealdng were found. T^uiks were anchored per design.
The Oxidation Reactor was visually inspected extemally (no access to internals). No
conosive attack, cracking, or lealdng was found. Reactor anti-sway brace (at northeast end of
reactors skid) was installed. Reactor was anchored to floor per design.
Tank, and Effluent Storage Tank; numb&ed as
The Oxidation Reactor was also
The HTO ancillary equipment was
leaking was found. Equipment was adequately
condition ranged ftom damp
conosive attack were found
injected and no corrosive attack or evidoice of
supported.
The HTO secondary cmtainment system consists of a reinforced concrete pad, curbed
on thr% sides, sloped to drain into a bdow grade vault which runs the fiill laigth of the
southwest side of ths pad.
The vault bad been weJl denned, and was entered and visually inspected. Floor
to about 1/8 inch of clear water o) it. No cracks or
in fhe vault floor. The floor-to-wall jamts appeared
to be in satisfactory conditicn. Hairline oacks were present in the ade walls at
two ofthe four comers and several otha places; see Figure 3 for crack locations.
The cracks typically startedat tbe tqp of the vault walls and progressed downward
about three quarters of the wall heights. Visual inspections of the tops of the
vault walls, and of their outer surfaces (where visible) showed that most of the
cracks extended tfiiough the walls (at least at their upper ends). Comer cracks
were very fine (narrow in widdi). Wall cracks were somewhat wider, the widest
czack was in the northeast iwall and was about 0.01 inches wide near its upper
end. Tlte vault walls showed no evidence of corrosive attack. Recommend that
suitable sealant/caulk be applied to all cracks.
Page 2 of 10
ynuiu't.^^ Ml lU:44/'Bi. 1 U : ay/NU. a&ouiiOU C4a at' &
• The pad to curb intersections wepinapected fee full length of fte northeast curb
and for about 3 feet of die other two curbs (ancillary equipment q>Iash guards
prevent iniq«ctUm of tbe remaining curb to pad intersections). Intersections
tqipeared to be satisfactory.
• The curbs were inspected Ibr oJacking and two (Z) hairline caacks wexe found
located approximately as shown in P^ure 3. Recommend that these be canlked.
• Tlie ccmcrete pad showed no aackmg or conosive attack.
• J^ egcpeuuion joints appeaned to be in satisfiactaiy condititm.
No evidence of frost heaving was found.
Conchide that the HTO System, once arias discussed above are addressed, is suitable for
use until the next annual inspection, 12 mcmdii hence.
Page 3 of 10
V invjj u«. t^n a ( i:4o/si. lu: oa/jnu. jooucrou f4j r
'.IMMm OOWC'OM^
fMiS07V-l$l4l2V
EbMP moucn OMSOM or wuquv ca
nCEBNW.
.SU"»'l.T UHT
WAICR fWkaiOOwN u<
NDf MCUMUC
™nr^i_.i-."iizi!^4£^
->i'T,^
I
yaiii5sss»op»gp»yaa»xpiS^Ki
\i ^. (—..^.j..4..; JU»^.^4L. -S
Kr ^-^ .1'. • \ ;l!
THCRMM. WEIL WTH
KNSOR. tB IVCeS)
n uttXr 11061 nna Vf Snw tmxit Of. im tmti, )u mm Mt* /»ies. ooiT nw^ mvccnoN -.
ruL 1 1/r tHRuocD UNCU. rmMnr. u Mff ftn noouoi HDU: MvucMm 'M/DKan (Ma flusiNC ca' IA OL
umt oun W aja (Xir.D MflP:
XA u.> Hi 00.11/r PK.
SEC yifyi
•i>ves ©-
i^T CKCHAMCIIII
XaberarSiTirrfKjrrrn .1 • A
FIGURE 1: ELEVATION VKW OF THC
•1. ' '
\ I n\^f u*+. ^^ ' 1 u ; *• u/- o J.. lU.OW^j,^. OoVU^..,U l*+o ir
^e^.Tly\$9€CVioy^
—^'•=—-' ^ n- -1 ft -fcauiaMWi
r
/TKSCJA
^<tf
At
A^6
»* 85- -
M L-?J4*—^/•'-4*'
Vatat4 fe4-^"\>«f.p
?5'
5 P
<13I
sW
-•-•-^^
-g35r <H3/ A37
PviJ^tclre Z\ V\TO ;P\«»vv\/»-L<jj
0
SICEt I
FIGURE 4: HYORaVSIS SYSTEM VAULT
EAST WALL
VISUAL IMffCCnCN OM </17/a7
I. ram jtwt MAIQC (NO jomr
Tmuoi tm.).
I CRAOC lOCAmW DMOISOnS
: nil MV<
Ci u a c ^
(J c
0
"*!•*< <»«. . V A *iv I \j .. ai lu; '40^,3 1. l<j;o»^„i^. o;^uu<;uu f *+o r
(DC nc. nif^ mn
FIGURE 5: HYDROLYSIS SYSTEM VAULT
SOUTH WALL
VISUAL INSPECTION 0< */l7/97
p^o^e e ^>t \
^
SCC Norc t.
-^'""^-ffiRtmHiECCSS—
(ltPJC«.|
«I"
^
FIGURE 6: HYDROLYSIS SYSTEM VAULT
WEST WALL
VCUU WSPECnON on 4/l?/g7
nuKnifwdi
— — t
STEEL L-
\inu, u<t. H'i ^, iu:^w/oi. i u : o»^ «u. oauuci^u r •'to r ic
CK OM. nUi SWT'
^
6-4* /^
^
-z^
SEE MOTE 1.
7^^
7-6"
FIGURE 7: HYDROLYSIS SYSTEM VAULT
NORTH WALL
VISUAL IHSPECTIQN ON 4/17/97
o e
^
o o
o o
o e
•z^
^
^