Journey to Commissioning
At the Hanford Vit Plant, commissioning is fully underway for the Direct-Feed Low-Activity Waste (DFLAW) process. Vitrification, the plant’s core process, converts nuclear waste into a stable glass form for safe disposal. Commissioning verifies that the plant’s functionality, operator training and proficiency, and safety protocols are acceptable and ready for full operations.
It’s the final step before full operation, targeted to begin in 2025. Follow the commissioning journey (details below) to see how the Vit Plant will achieve safe and effective waste treatment and significantly reduce environmental risks.
Commissioning Overview
Commissioning 101
What is it?
Commissioning consists of a series of tests ensuring all systems work together safely and efficiently before processing low-level radioactive waste.
Safeguarding Waste Treatment: The WTP Commissioning Process
To ensure safe and efficient operation, the Hanford Waste Treatment and Immobilization Plant (WTP) undergoes a rigorous commissioning process. This involves meticulous testing, starting with non-radioactive materials, to progressively verify that all systems meet design and safety requirements.
The process progresses from individual components to integrated facility demonstrations, culminating in DFLAW hot commissioning, which incorporates low-level radioactive waste. Readiness assessments at key points confirm the plant’s preparedness for each step.
Following Department of Energy (DOE) standards and industry best practices, WTP commissioning ensures reliable and safe vitrification of tank waste.
Why is it important?
- Confirms a smooth and safe transition to full operation
- Ensures the plant meets its operational goals from the start
- Optimization of site procedures
- Lays the foundation for successful long-term plant operations
What are we doing now?
Preparing for cold commissioning is a crucial step before moving on to the treatment of low-level radioactive materials.
Crews completed Safety Instrumented Function (SIF) tests throughout the Low-Activity Waste Facility to test and verify various systems responded correctly to off-normal events. SIFs are secondary safety systems built to prevent situations that could potentially harm the plant, workers, or the environment. In total, the LAW Facility contains 37 unique SIFs. The testing activities demonstrate that these systems’ hardware and software work together and function correctly – a critical step for cold commissioning preparation.
Cold Commissioning Management Assessment (CCMA)
What is it?
The CCMA is an independent review led by the contractor and observed by the Department of Energy (DOE) and other stakeholders. The intent of the CCMA is to provide a formal verification of WTP’s readiness for Cold Commissioning with simulated waste materials. During the Pre-Cold Commissioning Phase, simulants do not produce nitric oxide (NOx) in the melter off gas, so ammonia is not needed for treatment. However, during Cold Commissioning, simulants do produce NOx, requiring ammonia for treatment. Because NOx and ammonia are significant hazards, an independent review (CCMA) of the plant, personnel, and documentation is conducted to ensure safety before Cold Commissioning testing begins. The DOE must formally approve the start of the Cold Commissioning Testing Phase based on the CCMA results.
Why is it important?
- Ensures WTP’s cold commissioning programs meet industry safety standards including the safe and compliant operation with the system producing NOx
- Identifies any areas for improvement before processing radioactive tank waste (People, Plant and Paper)
- Provides a foundation for successful hot commissioning, when radioactive waste is processed
In preparation for cold commissioning, the plant’s emergency response team coordinates drills with the Hanford Fire Department to ensure fully integrated knowledge and understanding of response procedures and plans.
The Commissioning Journey
Pre-Cold Commissioning focuses on preparing and testing systems to ensure they are correctly installed and ready for further commissioning. Key activities include:
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- System Walkdowns and Inspections: Verify proper installation and design compliance.
- Completion of Punch List Items: Address any potential remaining construction deficiencies.
- System Configuration Verification: Ensure systems are set up as per design.
- Pre-Operational Testing: Test individual components in a non-radioactive environment.
- Documentation Review and Approval: Confirm readiness through thorough documentation checks
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Cold Commissioning involves testing with non-radioactive materials to ensure system functionality and performance. Key activities include:
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- Integrated System Testing: Verify interconnected systems work together as designed.
- Functional Performance Testing: Assess system performance under simulated conditions.
- Control and Monitoring Systems Verification: Test control systems and monitoring equipment.
- Documentation and Reporting: Record test results and prepare performance reports.
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Hot Commissioning involves processing actual tank waste from the Hanford Tank Farms to confirm operational readiness. Key activities include:
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- Introduction of Tank Waste from the Hanford Tank Farms: Start with small quantities, gradually increasing to full levels.
- Performance Validation: Validate all systems’ performance and compliance with safety standards.
- Operational Adjustments: Optimize system performance and address issues.
- Compliance Verification: Confirm adherence to regulations and safety standards.
- Final Documentation and Approval: Prepare comprehensive reports and obtain regulatory approvals for full-scale operations.
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The Low-Activity Waste Facility houses two 300-ton nuclear waste melters—the largest in the nuclear industry—which will heat Hanford’s low-activity tank waste and glass-forming materials to 2,100 degrees Fahrenheit.
Containers filled with molten test glass are moved remotely by operators through the LAW Facility to the export bay before being transported offsite.
Commissioning Steps
There are multiple steps that must be completed during commissioning. During each commissioning step, we verify that our people, plant, programs, policies and procedures are ready for operations. We ensure our team members are fully trained and proficient in their area of responsibility and accountability. To verify the plant is ready for operation, our equipment and systems must be tested and verified to be fully functional as designed. The programs, policies and procedures must be in place, verified and shown to be effective as we demonstrate our readiness for cold and then hot commissioning.
Remaining Steps in the Commissioning Journey
Bringing WTP’s DFLAW systems online involves a sequenced commissioning process. This means individual systems within the plant, like mechanical handling, are brought online and tested individually, then together to ensure they function safely and efficiently before full-scale waste treatment begins. This systematic approach ensures the entire plant operates as designed to convert low-activity waste into stable glass. Learn more about the remaining steps before full-scale, sustained operations.
* Click on the icons below to learn more about the steps involved in cold and hot commissioning
Cold Commissioning
Hot Commissioning
Cold Commissioning
Cold Commissioning Definition
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Cold Commissioning Definition
Cold commissioning is a series of tests designed to evaluate WTP’s readiness to operate. The Cold Commissioning Management Assessment (CCMA) plays a vital role in this by ensuring WTP’s preparedness for safe and efficient commissioning and waste treatment operations. Here’s what it assesses:
- Maturity of Operational Practices: The CCMA evaluates how well-established the WTP’s procedures are for managing operations, particularly in the areas of safety, quality, and efficiency.
- Identifying Improvement Opportunities: The assessment goes beyond just identifying potential problems; it also helps pinpoint areas where the WTP can further enhance its operational management practices.
- Preparation for Full Operations: This assessment specifically focuses on operational readiness for cold commissioning (using simulated waste materials) and future full operations, excluding the radiological aspects.
- DOE Requirement: The CCMA is a mandatory step required by the Department of Energy (DOE) to ensure the contractor’s readiness for sending Direct-Feed Low-Activity Waste (to the LAW facility) and Effluent Management Facility (EMF) operations before cold commissioning can proceed.
In simpler terms, the Cold Commissioning is plant testing using waste feed simulants (non-radioactive, but still chemically hazardous). Hot Commissioning is plant testing using actual tank waste from the Hanford Tank Farms (radioactive and chemically hazardous waste).
Begin Cold Commissioning Management Assessment
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The CCMA ensures WTP is ready for safe and efficient waste treatment. It evaluates the WTP’s operational practices, identifies areas for improvement, and assesses readiness. Essentially, it’s a critical review that helps WTP optimize operations for successful commissioning.
Formal CCMA Readiness Review
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The Cold Commissioning Management Assessment (CCMA) is a critical assessment by an external team to evaluate the WTP’s readiness for cold commissioning with simulated waste materials. It provides DOE with confidence before authorizing cold commissioning testing.
DOE Approval To Proceed
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DOE Approval to Proceed is based on the results of the CCMA. This validates the contractor’s safe and compliant operation readiness and grants authorization for WTP to proceed with cold commissioning testing.
Cold Commissioning Testing
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Cold Commissioning Testing rigorously tests melter performance using a more hazardous simulant (“Cold Commissioning Simulant”) compared to the “Tuning Feed”. Testing occurs over several months. It ensures the melter processes can handle the higher hazard materials it will encounter during hot commissioning with radioactive waste. The Environmental Performance Demonstration Test (EPDT) is also conducted during the Cold Commissioning Testing. EPDT involves rigorous testing to verify the facility meets all environmental regulations and standards.
Finish Cold Commissioning
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Cold Commissioning testing is now complete and signifies the ability to proceed with the next step in the commissioning readiness process known as Hot Commissioning.
Hot Commissioning
Hot Commissioning Definition
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Hot Commissioning Definition
Following Cold Commissioning, Hot Commissioning is the phase in the startup of the facility where radioactive tank waste is introduced into the system for the first time. This phase is critical for testing and validating the equipment, processes, and operational procedures, and ensuring that the plant operates safely and effectively before transitioning to full-scale, continuous operations.
Begin Hot Commissioning
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Hot Commissioning uses low-level radioactive tank waste. Readiness assessments at key points confirms the plant’s preparedness for each step in that process. It follows a set of mandated DOE readiness activities before approval to use radioactive tank waste for testing.
Implementation Verification Review
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The Implementation Verification Review (IVR) is an external assessment verifying the complete and proper implementation of the documented safety analysis before hot commissioning can begin.
Management Self-Assessment
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The Management Self-Assessment (MSA) is an external review simulating the Contractor Operational Readiness Review (CORR) to identify any areas for improvement before CORR. It indicates readiness for the CORR and assesses the project’s operational effectiveness.
Contractor Operational Readiness Review
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The Contractor Operational Readiness Review (CORR) is an external review by the Contractor, similar to the CCMA, but focused on readiness for Hot Commissioning Testing (HCT) with radioactive waste. It is conducted by independent reviewers to assess compliance with DOE requirements.
DOE Operational Readiness Review
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The DOE Operational Readiness Review (DORR) is the final external review conducted by DOE itself to ensure the WTP meets all regulatory requirements for handling radioactive waste. It follows DOE Order 425.1 to validate safe and compliant operation readiness.
DOE Approval To Proceed
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DOE Approval to Proceed is issued through a formal review based on DOE Order 425.1. This validates the contractor’s safe and compliant operation and grants authorization for WTP to proceed with hot commissioning testing.
Hot Commissioning Testing
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Hot Commissioning is a critical phase where actual radioactive waste from the Hanford tank farms is used to test the entire system’s ability to safely vitrify (immobilize) the waste in glass. It involves testing for both chemical and radiological hazards.
Commissioning Finish and Turnover
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The commissioning finish and handover is based on DOE’s formal review and approval for full operation based on successful completion of all readiness reviews and testing. It ensures facility operation aligns with the approved safety plan and confirms the contractor’s readiness to begin operations.
Finish Hot Commissioning
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Upon successful completion of the above steps, formal authorization from the DOE and all stakeholders is granted, signifying their confidence in the facility’s readiness for safe and effective waste treatment.
Cold Commissioning Management Assessment FAQs
What is a Cold Commissioning Management Assessment (CCMA)?
A two-week on-site review conducted by an external independent team to verify that people, plant, and paper are ready to safely start cold commissioning testing. The CCMA enables the start of Cold Commissioning Testing once authorized by DOE based on the CCMA results.
What does a CCMA review?
It examines personnel qualifications, documentation, safety compliance, and team communication effectiveness.
Who conducts the CCMA?
An independent team of experts in commissioning, operations, safety, and quality assurance.
When is the CCMA conducted?
The CCMA is completed before the actual cold commissioning testing activities begin. It acts as a pre-flight check before starting Cold Commissioning.
Are there any standard CCMA guidelines?
Yes, the CCMA Preparation Plan and CCMA Implementation Plan. The purpose of the CCMA Preparation Plan is to provide risk reduction by ensuring that people, plant, and paper are ready for the external CCMA team’s review. The CCMA Implementation Plan contains the details of the execution of the CCMA.
Cold Commissioning FAQs
What is Cold Commissioning?
Cold commissioning is a crucial stage in the Hanford Waste Treatment and Immobilization Plant (WTP) project lifecycle. It’s essentially a series of final tests performed to verify the functionality, operability, and safety of the plant’s systems without using radioactive materials.
Why is Cold Commissioning important?
Cold commissioning is vital for WTP’s success. By testing systems with a non-radioactive simulant, it exposes and fixes problems early, verifies equipment works together seamlessly, and trains staff in a safe environment. This lays the groundwork for safe and efficient radioactive waste treatment.
What is the difference between Cold and Hot Commissioning?
Cold commissioning uses a non-radioactive simulant to test the WTP’s systems for functionality and safety. It’s like a practice run to iron out any wrinkles before introducing radioactive waste. Hot commissioning, on the other hand, brings radioactive tank waste into the plant for vitrification.
What is the role of Operations and Maintenance (O&M) during Cold Commissioning?
Operations and Maintenance (O&M) are critical throughout the entire WTP project lifecycle. During these phases, O&M works hand-in-hand to ensure safe and effective operation while meeting stringent regulatory requirements. This involves verifying that systems perform and are maintained as designed through initial calibrations and functionality testing.
O&M also plays a vital role in ensuring the effectiveness of procedures for personnel safety, safe operation of the radioactive waste treatment equipment, and maintaining proper documentation for regulatory compliance.
What is the duration of Cold Commissioning?
The exact duration of WTP’s cold commissioning is variable. Depending on system complexity, testing scope, and technical challenges, it can take several months to complete.
Who is involved in Cold Commissioning?
Engineers, technicians, operations, and maintenance personnel all collaborate to test and verify each facility aspect. Everyone on the project, including Safety & Health staff, Environmental personnel, Project Managers and Administrative staff all play a key role in Cold Commissioning.
When does a facility transition from Cold to Hot Commissioning?
After all systems pass the cold commissioning tests, the hot commissioning process begins. Hot commissioning can’t start until after several DOE-required evaluation and assessment steps. Hot commissioning ensures safe operation with radioactive tank waste prior to full-scale, sustained operations.