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Introduction

Savannah River Mission Completion, LLC (SRMC) is currently contracted to operate the Liquid Waste (LW) system at the Savannah River Site (SRS) under prime contract 89303322DEM000068 with the U.S Department of Energy. The LW system consists of several facilities to safely receive, store, treat, and permanently dispose of radioactive waste. The Defense Waste Processing Facility (DWPF) Melter is used to process high-level nuclear waste at SRS by melting a mixture of nuclear waste and borosilicate glass and pouring it into canisters for storage. Periodically, due to component degradation and failure, the DWPF Melter Frame and Vessel Assembly must be replaced in its entirety. Some components are fully integrated into the Frame and Vessel upon assembly. If any one of those components fail, the Melter Frame and Vessel must be replaced. DWPF Melters 1 and 2 have been replaced. Melter-3 is currently in service. Melter-4 has been fabricated and assembled awaiting replacement of Melter-3. Melter-5 is needed as a back-up for future replacement of Melter-4.

The DWPF Melter assembly (~22’ L ~11’ W ~10’ H, weighing approximately 65 tons assembled) consists of a water jacketed 304-L (UNS S30403) stainless steel vessel and top head supported by a structural 304-L Stainless Steel frame. This assembly will be located and operated within a remote shielded facility. The assembly is installed/removed/maintained using only a remotely operated bridge crane. Because of this remote deployment and the need to fit-up with support equipment, there are strict tolerances associated with the Melter Frame and Vessel.

The Vessel and Top Head are lined with layers of refractory materials that insulate the Melter and contain the molten glass during operation. These refractory materials are installed in the Vessel following completion of Vessel and Frame fabrication and testing.

Significant design details and historical fabrication information are provided in Section 3 below.

1. Purpose

PRIMARY SCOPE – Melter Frame and Vessel Assembly Fabrication

The purpose of this inquiry is to solicit supplier market interest in providing the DWPF Melter-5 Frame and Vessel Assembly. SRMC will use the information obtained in your response to this Expression of Interest (EOI) to determine market interest and the feasibility of said process. This EOI is for INFORMATIONAL PURPOSES ONLY.

OPTIONAL SCOPE – Melter Refractory Material Installation

In addition to the primary scope, above, this inquiry is to solicit supplier market interest in also providing the DWPF Melter Refractory Material installation as a supplemental activity following Frame and Vessel fabrication. The intent of making this scope optional is to ensure that qualified Frame and Vessel fabricators are not excluded simply because they do not want to perform or are incapable of performing the refractory installation. SRMC will use the information obtained in your response to this Expression of Interest (EOI) to determine market interest and the feasibility of said process. This EOI is for INFORMATIONAL PURPOSES ONLY.

The current SRMC schedule projects issue of a formal RFQ for this procurement in late CY23.

2. Technical and Programmatic Requirements

The DWPF Melter-5 procurement will be Build-To-Print with SRMC providing all design drawings and specifications to the supplier.

Technical and Programmatic requirements for DWPF Melter Frame and Vessel are described in Specification M-SPP-S-00122, Rev. 0. Please note that the Melter specification requires the supplier Quality Assurance program to comply with NQA-1 based on Safety related aspects of the Vessel and Frame. However, SRMC will revise the Quality Assurance program requirements to allow Supplier to have an implemented Quality Assurance program based on Nationally recognized consensus standards. Also note that the vessel is to be fabricated by an ASME Section VIII qualified shop but not Code stamped.

Technical and Programmatic requirements for DWPF Refractory Material Installation are described in the Statement of Work M-SOW-S-00025, Rev. 0 (Installation of Melter Refractory and Insulation Materials). Certain specifications and Statement of Work may be available upon request.

3. Design Details and Historical Fabrication Information

Melter Frame & Vessel

The 304-L (UNS S30403) Melter frame (~22’ L ~11’ W ~10’ H) is fabricated from heavy walled structural tubing and built-up structural sections. Its assembly involves much welding. Future remote deployment of the Frame as well as remote attachment of services and utilities requires precise positioning of the Melter Vessel, other components and utility attachment points (nozzles). Prior experience has shown that to achieve and maintain Frame tolerances, dimensional stability was achieved by allowing extended stress relaxation time or by stress relieving heat treatment. Also, substantial machining allowance was provided on critical surfaces where necessary to accommodate movement during welding and/or stress relief.

The Melter Vessel consists of a 8’4-1/2” OD by 1-1/2” Wall by approximately 7’ H 304-L shell welded to a forged support ring and a dished bottom head. An angled riser section is welded to a reinforcing pad on the shell. All exterior surfaces of the vessel have ribs welded on along with 3/8” cover plates to form water cooling channels. As described above, the extensive welding can introduce significant stress which has been relieved via heat treating. As with the frame, stress relieving heat treatment and significant temporary bracing has been used to prevent and/or address material movement. Following heat treatment, interior surfaces are machined to achieve cylindricity and Bottom Head curvature. Mating surfaces are machined for proper fit-up with the Melter Frame and Top Head. Others, such as nozzles are also precisely machined.

The Melter Top Head is an 1-1/8” thick ASME flanged and dished head that similarly receives welded cooling channels. It includes 10 vertical nozzles. The Top Head also requires precise tolerance machining of ID, flange and nozzles.

Melter Refractory Installation

Melters 1 and 2 had Refractory Materials Installation and Melter dry-out performed by a refractory subcontractor at the supplier’s shop. Melter-3 had Refractory Materials Installation and Melter dry-out performed by a refractory subcontractor at Savannah River Site. Because Savannah River Site does not currently have a suitable location available on-site for refractory installation, Melter-4 had Refractory Materials Installation and Melter dry-out performed by a refractory subcontractor at a nearby off-site location after receipt from the Frame/Vessel supplier.

Please note that M-SOW-S-00025, Rev. 0 refers to a rotating trammel assembly that has been used in the past to verify positioning of the assorted refractory blocks. The Melter design has been changed for Melter-5 to eliminate the bottom nozzle that was previously used to mount the trammel. It is expected that another method of precisely measuring the position of refractory blocks, such as a laser tracker, will be incorporated for this installation.

The major refractory materials, including Monofrax K-3, Zirmul, Korundal and T30 are provided by SRMC. Minor materials are to be provided by the installer. M-SOW-S-00025 describes details. Certain specifications and Statement of Work may be available upon request.

Space will also be needed for the Melter Top Head flipping assembly (~18’ L ~12’ W ~9’ H). A suitable crane system will be required to lift and precisely place the refractory blocks.

It is not expected that all potential Frame and Vessel fabricators are capable of performing or desire to perform refractory material installation themselves. A sub-tier supplier may be used for this activity as has been done in the past.

Additional drawings and photographs may be available upon request.

4. Expression of Interest Submittal Requirements

Sources Sought/EOI Responses are due by close of business (COB) April 14, 2023.

SRMC requests that your EOI Response provide the following:

1. Technical Approach

• Describe your firm/team’s technical methods and approach.

2. Organization and Experience

• Demonstrate your firm/team’s organization and applicable past experience.

3. Quality Assurance Program

• Submit your firm/team’s quality program.

4. Service Capability (Resources, Equipment, Personnel, and Facilities)

• Describe your firm/team’s in-house capabilities with respect to the scope/magnitude of this task.


• Describe anticipated in-house versus sub-tier activities with respect to the scope/magnitude of this task.

5. Estimate/Schedule

• Provide a Rough Order of Magnitude (ROM) budget estimate and schedule based on the information provided herein.

5. Expression of Interest Logistics

All logistics and questions should be directed to Matt Spivey at (803) 845-0049 or email matthew.spivey@srs.gov.

6. Vendor Information

To register as a potential offeror, you will be required to fill out and complete the following forms from our external website:

http://www.savannahrivermissioncompletion.com/business

Go to: Puridiom Supplier Vendor Updates for the following forms:

• Supplier Information Form (OSR 46‐9, Rev 2011‐05‐25),


• W9 (Rev. January 2011),


• I‐312 Non-Resident Taxpayer Registration Affidavit Income Tax Withholding


• Electronic Funds Transfer Form (08/31/10 Rev.2)

7. Procurement Reference Documents

Procurement reference documents such as standard terms and conditions, standard representations and certifications, subcontractor safety program guidance, and other forms are located on the Savannah River Mission Completion Homepage at

http://www.savannahrivermissioncompletion.com/business

Attachments/Links