Replacement of Melter 2 at the Defense Waste Processing Facility (DWPF) - 18608

The original DWPF melter was replaced in 2002 with an identical unit, and radioactive operation of Melter 2 commenced in 2003. After nearly 14 years of service, a lower electrode failure of Melter 2 occurred in February 2017 which required its removal and replacement with Melter 3. The scope of the replacement outage involves several significant evolutions: - Shutdown of Melter 2 and placement into a safe state; - Remote external and internal inspection of Melter 2 to chronicle its condition prior to removal; - Disassembly and removal of Melter 2 from the process cell; - Placement of Melter 2 into a storage box and transport to a storage vault; - Preparation and initial testing of Melter 3 prior to transport to the DWPF; - Transport to the DWPF and installation of Melter 3 in the process cell; - Final startup testing and initiation of radioactive operation. Upon determination that repair of Melter 2 was not feasible, DWPF created an outage team to integrate schedules and resources needed to execute melter replacement as well as including maintenance scope for facility work that can only be performed when the melter is de-energized. The execution of this scope required integration with other mission critical outage activities already in progress, and planned to start, including initial facility tie-in scope for the new Salt Waste Processing Facility (SWPF). This unplanned addition of the melter replacement scope to the existing outage scope resulted in the longest facility outage period since the initiation of radioactive operations at the DWPF in 1996. Successful completion of this scope across all Liquid Waste facilities would require balance - for schedules, resources, priority, funding, etc. To overcome the significant challenges created by this additional scope, a WAR Room was established to ensure adequate integration and coordination of critical resources, and daily progress. The execution of this scope has required the integration of nearly two dozen work groups across multiple facilities at Savannah River Site (SRS), in addition to support from nearly a dozen vendors. The melter replacement outage was executed with a high degree of disciplined operation to ensure the facility was ready to resume glass pouring operation in time to support restart of the Liquid Waste program at the Savannah River Site (SRS). This paper will provide a brief overview of Melter 2 operational history. The execution of the removal and replacement operations will be described with a specific focus on lessons learned and opportunities where the outage execution diverged from the original Melter 1 replacement outage. It is expected to be of interest to vitrification facilities, as well as facilities, which require remote maintenance and replacement of large process equipment. (author)