Purpose of this document Innovative Technology Summary Reports are designed to provide potential users with the information they need to quickly determine if a technology would apply to a particular environmental management problem. They are also designed for readers who may recommend that a technology be considered by prospective users. Each report describes a technology, system, or process that has been developed and tested with funding from DOE'S Office of Science and Technology (OST). A

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... rt presents the full range of problems that a technology, system, or process will address and its advantages to the DOE cleanup in terms of system performance, cost, and cleanup effectiveness. Most reports include comparisons to baseline technologies as well as other competing technologies. Information about commercial availability and technology readiness for implementation is also included. Innovative Technology Summary Reports are intended to provide summary information. References for more detailed information are provided in an appendix. The self-contained pipe cutting shear was developed by Lukas Hydraulic GmbH & Co. KG to cut pipes up to 6.4 cm (2.5 in.) in diameter. This tool is a portable, hand-held hydraulic shear that is powered by a built-in rechargeable battery or a portable auxiliary rechargeable battery. Adding to its portability, it contains no hydraulic fluid lines or electrical cords, making it useful in congested areas or in areas with no power. Both curved and straight blades can be attached, making it adaptable to a variety of conditions. This tool i s easy to set up, operates quietly, and cuts through pipes quickly. It is especially useful on contaminated pipes, as it crimps the ends while cutting and produces no residual cuttings. This shear is a valuable alternative to baseline technologies such as portable band saws, electric hacksaws, and other hydraulic shears. Costs using the innovative shear for cutting 2.5 cm (I-in-) Pipe, for example, are comparable to costs using a conventional shear, approximately 80% of portable bandsaw costs and half of electric hacksaw costs. Technology Summary The Lukas unit is a hand-held, battery-operated hydraulic shear designed to cut piping and conduit measuring u,p to 6.4cm (2.5 in.) in diameter. The unit has a built-in rechargeable battery and can also to operate for over an hour without recharge. Additionally, it has no hydraulic fluid lines or electrical cords, which makes it extremely portable and adaptable to congested areas. It uses only non-toxic, non-hazardous, mineral-based hydraulic fluid. It weighs about 23 kg (50 Ib) and can be used on both horizontally or vertically oriented piping. This tool is suitable for indoor or outdoor use. accommodate a portable auxiliary battery, allowing it -- Problem Addressed The U.S. Department of Energy (DOE) is in the process of decontaminating and decommissioning (D&D) many of its nuclear facilities throughout the county. Facilities have to be dismantled and demolition waste must be sized into manageatile pieces for handling and disposal. Typically, the facilities undergoing D&D are contaminated, either chemically, radiologically, or both. In its D&D work, the DOE was in need of a tool capable of cutting steel and stainless steel pipe up to 6.4cm in diameter. The tool had to be easy and economical to operate, capable of operating in ambient temperatures from 3 to 4OoC, and easy to decontaminate using conventional equipment. Use of the tool also had to be safe for workers. The Lukas self-contained pipe cutting shear satisfies these needs and is an attractive alternative to traditional technologies used for similar cutting operations such as band saws, hacksaws, and other hydraulic shears. Features and Configuration Hand-held hydraulic shear, Lukas model LKE 70 (see figure) Approximate weight 23 kg (50 ib) Overall dimensions 85 cm x 26 cm x 17 cm high (33.5 in. x 10.2 in.-x 6.8 in. high) Shorffalls/Operator Concerns Despite several attempts, the Lukas self-contained pipe cutting shear was incapable of cutting through the 7.6-cm pipe. Also, although the shear is furnished with a sling, the unit is awkward for cutting pipes that are above waist level. Skills/Training Training of D&D workers is minimal if the trainees have basic operational knowledge of hand-held cutting tools. Training during the demonstration was completed in a matter of minutes. I Demonstration Summary This report covers the March 1997 demonstration, when the Lukas self-contained pipe cutting shear was demonstrated at the Hanford Site under controlled conditions at the C Reactor front face work area. Demonstratian Site ~Descriptlon At its former weapons production sites, the DOE is conducting an evaluation of innovative technologies that might prove valuable for facility D&D. As part of the Hanford Site Large-Scale Technology Demonstration (LSTD) at the C Reactor Interim Safe Storage (ISS) Project, at least 20 technologies will be tested and assessed against baseline technologies currently in use. DOE'S Office of Science & Technology/Deactivation and Decommissioning Focus Area, in collaboration with the Environmental Restoration Program, is undertaking a major effort of demonstrating improved and innovative technologies at its sites nationwide. If successfully demonstrated at the Hanford Site, these innovative technologies could be implemented at other DOE sites and similar government or commercial facilities. Appllcablllty This tool represents an innovative technology that can be used at DOE sites, and other similar public and commercial facilities in which pipes must be segmented to facilitate removal or disposal. The unit is ideally suited for cutting steel or stainless steel pipe or conduit up to 6.4 cm (2.5 in.) in diameter. Since this technology crimps the pipe ends and generates no waste cuttings, it is particularly valuable for work on pipes that potentially contain contamination or may be covered with a hazardous coating, such as lead-based paint. Because it is battery operated, the tool is useful in D&D operations where there is no convenient source of power. Key Demonstration' Results The Lukas shear was demonstrated to be capable of easily cutting through 2.54-and 5.08-cm (1and 2in.) steel pipes. Because of its portability, this technology was easier to use than the baselines in congested areas. Also, the tool proved effective in contaminated areas because it reduces the chance of creating airborne contamination as it produces no residual cuttings. Additionally, by crimping the ends of pipes as it cuts, it reduces the possibility of spreading contamination that-may be contained inside the pipelines. After a significant number of cuts, blades showed little sign of wear. Unlike the baseline hydraulic shears, cut edges were smooth and clean. Key demonstration results are summarized below. The innovative shear was demonstrated to be capable of cutting 2.54-and 5.08-cm (1-and 2-in.) steel pipes with wall thicknesses from 3 to 9 mm (1/8 to 3/8 in.), with ease. The tool can complete 88 such cuts without recharging the batteries. Full recharge takes 2 hours.