ML20008F618
| ML20008F618 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 03/19/1981 |
| From: | Mooney J CHEM-NUCLEAR SYSTEMS, INC. |
| To: | |
| Shared Package | |
| ML20008F609 | List: |
| References | |
| SD-OP-004, SD-OP-4, NUDOCS 8104210388 | |
| Download: ML20008F618 (38) | |
Text
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tEvis:O=s REY. L DESCRIPTION DATE APPROVED
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l THIS DOCUMENT HAS BEEN PREPARED IN ACCORDANCE WITH CNSI CN-AD-003, REV.
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'g#3 PARACRAPH 3.7, " PROCEDURE FOR. DOCUMENT PREPARATION". THIS PROCEDURE IS ISSUED g
FOR USE AT FLORIDA POWER CORPORATION AND SHALT., BE VALID UNTIL APRIL 9, 1981.
d IT HAS BEEN SUBMITTED TO THE CNSI SAFETY REVIEW BOARD IN ACCORDANCE WITH g
l CN-AD-001.
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l REVIEWED BY QUALITY ASSURANCE 8,
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NOTE: THIS INFORMATION IS CONSIDERED PROPRIETARY AND IS NOT TO BE RELEASED e
WITHOUT WRITTEN PERMISSION OF CHEM-NUCLEAR SYSTEMS, INC.
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REVISION STATUS SHEET 1
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10 11 12 13 14 15 16 17 m
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N SHEET 18 19 20 21 22 23 24 25 26 27 28 g
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PREPARED DATE l
CHEM - NUCLEAR SYSTEMS, INC.
CO CHECKED TITLE i
TEMPORARY OPERATINC PROCEDURE FOR
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b ENGWE E R CNSI MOBILE CEMENT SOLIDIFICATION UNIT m_
NO. 1-(MSU-C-1) l
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APPROVE D CONTR ACT NO.
DOCUMENT NO.
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TAELE OF CONTENTS _
P, age
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1.0 S, COPE 3
3 1.1 Purpose 1.2 Applicability
2.0 REFERENCES
SYSTEM DESCRIPTION AND REQUIREMENTS _
4 3.0
4 System Description
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3.1 Equipment Description Precautions and Limitations 9
3.2 10 3.3 Interf ace Requirements 3.4 Acceptance Criteria 3.5 OPERATING PROCEDURE _
10 4.0 16 System Assembly System Preoperational Testing 17 4.1 22 4.2 4.3 Liner Set-Up 25 System Operation 26 4.4 4.5 System Shutdown j
System Disassembly 4.6 i
i RECORDS AND REPORTS _
28 5.0
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Process Memo contamination and Radiation Surveys 28 5.1 Radioactive Shipment Record (RSR) 5.2 5.3 l
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- SCOPE 1.1 Purpose
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This document contains detailed operating procedures to be used during the operation of the. CNSI Mobile Cement Solidification Unit Number One.
It provides instructions for proper startup, norisal operation and shutdown as well as precautions necessary in the unit's safe operation.
The Process Control Program is in-corporated as reference 2.13.
1.2 Applicability The instructions contained in this document apply only to the CNSI Cement Solidification Unit Number One on PWR and resin vastes.
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2.0 REFERENCES
2.1 QA-AD-001, Quality Assurance Program 2.2 CN-AD-019, CNSI ALARA Policy 2.3 EN-AD-001, Drawing Control Program 2.4 EN-AD-002, Design Control Program 2.5 NRC Regulatory Guide 1.143, Design Guides for Radioactive Waste Management Systecs, Structures, and Components Installed in
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Light-Water Cooled Nuclear Power Plants
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2.6 NRC Regulatory Guide 8.8, Information Relevant to Ensuring that Occupational Radiation Exposures at Nuclear Power Station will be As Low As Reasonably Achievable 2.7 NRC Regulatory Guide 8.10, Operating Philosophy for Maintaining c
Occupation Radiation Exposures As Low As Reasonable Achievable 2.8 10 CFR 20, Standards for Protection Against Radiation l
l 2.9 10 CFR 50, Appendix B, Quality Assurance Criteria for Nuclear l
Power Plants and Fuel Reprocessing Plants 2
2.10 10 CFR 71 Appendit E, Quality Assurance Criteria for Shipping Packages for 8.sdiation Material A
o 2.11 CHEli-NUCLEAR SYSTEMS, INC.
- DRAWINCS, 700 Series; 701-100; y
c 701-101 2.12 CHEM-NUCLEAR SYSTEMS, INC. CASK HANDLINC PPSCEDURES 5
2.13 Process Control Progran for CNSI Cement Solidification Units.
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3.0
- SYSTEM DESCRIPTION AND REQUIREMENTS I.
3.1 System Description.
The CNSI Mobile Cement Solidification System uses cement to harden radioactive weste into a solid, liquid-free matrix.
The following steps are involved:
3.1.1 The radioactive waste is transferred from the utility to a disposable liner. The liner contains an installed mixing blade and say contain a disposable filter for dewatering of slurries.
3.1.2 The operator conditions the vaste to ensure proper curing.
This conditioning may include dewatering of slurries and addition of chemicals to adjust pH.
3.1.3 Cement is adde [ to the liner af ter the vaste has been conditioned.
The cement is added Wile continuously mixing the waste.
l 3.1.4 Agitation continues antil the predetermined quantity of cement has been added.
The liner is then allowed to f
cure until the vaste - cement mixture solidifies.
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l 3.2 Eculoment Description All of the solidification equipment is contained and transported in the mobile cement solidification trailer and the bulk cement storage trailer.
Some of the process equipment is mounted on
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portable skids located outside the trailer during operation.
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l 3.2.1 Waste Trs.nsfer System 3.2.1.1 The purpose of this system is to transfer radioactive vaste from the facility radwaste system to the disposable liner for solidifi-cation and ultimate off-site shipment.
E 3.2.1.2 Major components of the vaste transfer system include:
twa 2-inch teflon lined, braided stainless steel hoses, a 2 inch air-operated l
ball valve (WS-1), manually operated ball R
valves for sampling and flushing (WS-2, E
WS-3),
and the fillhead isolation valve 5
o (WS-4).
3.2.1.3 Alarms and indicator circuits in the control l
panel interlock with control power for the waste isolation valve (WS-1).
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3.2.2 Devetering Svstem 3.2.2.1 The purpose of the dewatering system is to remove excess water from resin slurries in
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the disposable liner and to sample weste in the liner.af ter chemical addition.
3.2.2.2 2he major components of the dewatering system include two 1-1/2 inch teflon-lined, braided stainless steel hoses and an air-operated positive displacement pump.
3.2.3 Liner Ventilation System 3.2.3.1 The purpose of the liner ventilation system is to maintain a slight negative pressure in the*1tner" to insure no release of vapor or particulate matter during processing.
3.2.3.2 Major components of the liner ventilation system include an electrically operated ventilation blower, a dust filter / moisture separator, and hoses from the fillhead vent connection to the utility's off-gas system.
This system must be in operation prior to waste transfer and must remain in operation throughout the solidification process.
3.2.4 Cement Transfer System (4-3.2.4.1 The purpose of the cement transfer system is
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to transfer the required amount of cement from the bulk storage trailer to the liner.
3.2.4.2 The major components of the cement transfer system are the Vac-Konveyor, a bulk cement porta-filter, blower, an aeration blower, a load cell, and necessary hoses and controls.
E 3.2.4.3 The aeration blower fluidizes the cement in the bulk cement trailer where it is vacuumed into the Vac-Konveyor. When the Vac-Konveyor is full, it then pressurizes and transfers the cement into the liner.
The porta-filter cleans the exhaust air from the Vac-Konveyor.
5 The load cell provides total cement weight e
added to the liner.
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3.2.5 Hydraulic System 3.2.5.1 The purpos'5 of the hydraulic system is to f
supply motive power to operate the liner mixer blade at the correct speed.
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3.2.5.2 The major components of the hydraulic system include:
the hydraulic power plant (mounted in the mobile unit trailer), the hydraulic mixer motor mounted on the fillhead, a flow meter providing direct mixer speed indication and necessary high pressure hoses and fittings.
3.2.6 Fillhead and Fillhead Skirt Assenbly 3.2.6.1 The purpose of the fillhead assembly is to channel the flow of waste, chemical condi-tioner, and cement into the liner.
It also provides an off gas ventilation path from the liner, and supports the hydraulic mixer motor and electronic controls.
t 3.2.6.2 The major fillhead components are:
3.2.6.2.1 Waste pipe connection and iso-lation valve.(WS-4) 3.2.6.2.2 Devater pipe connection and
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isolation valve (DW-1)
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3.2.6.2.3 Ventilation pipe connection 3.2.6.2.4 waste conditioning piping and l
isolation valve (WS-4) o 3.2.6.2.5 Electronic controls for T7 g
camera; level probes for weste, y
cement and high levels; float s wit ch for high-high liner level; high liner pressure s witch; liner temperature R
monitoring connections; fillhead proximity switch; skirt g
proximity switch N
3.2.6.2.6 The fillhead skirt mounts be-O tween the fillhead and liner to prever splashing the fillhead underside during cperation and C
provide access to connections 7
under the fillhead g
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3.2.7 Waste conditioning System 3.2.7.1 The purpose of the waste conditioning system is to transfer the exact amount of con-I ditioning chemical insuring the correct solidification reaction.
3.2.7.2 The major components of the waste condi-tioning system include a positive displace-ment pump and transfer hose connecting the pump vith the fillhead.
3.2.8 Control system 3.2.8.1 The purpose of the control system is to pro-vide,.,isjications of system conditions-alarm conditions, and interlocks for various equip-ment and control system components.
3.2.8.2 Electrical controls and indications include:
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control power on indication, main power on indication, clock, radiation monitor, high-l high level alarm, fillhead pressure alarm, l
fillhead position alarm, high level indi-cation, cement level indication, vaste level indication, spare level indications, TV camera and display, TV camera light control, l
waste isolation valve control and indication, mixer speed indication, low mixer speed
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alarm, hydraulic oil temperature alarm, liner and fillhead temperature
- alarms, cement transfer controls, cement batch indication, and hydraulic motor controls.
i 3.2.8.3 The pneumatic controls and indications iu-clude:
main air isolation s witch and o
pressure indication, dewat ering pump air I
s witch regulator and pressure indication, E"
fillhead cooling air flow indicator, camera air flow indicator, air dryer purge control, dewatering pump suction and discharge gauges, j
porta-filter differential pressure
- gauge, 5
l waste isolation valve s wit ch, regulator and s
l pressure indication, vent filter differential C
pressure gauge, caustic pump air s wit ch,
regulator and pressure indication, and 3
caustic pump counter.
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.T 3.2.9 Radiation Monitoring System 3.2.9.1 The purpose' of the radiation monitoring sys-tem is to provide a secondary means of moni-(
toring actual radwaste flow to the liner and a means of identifying then flush require-ments have been completed on the radwaste line.
3.2.9.2 System components include a G-M detector mounted on the vaste isolation valve, one on fillhead and one in the MSU trailer, and a visual display and alarm on the main control panel.
3.3 Precautions and Limitations 3.3.1 Radiological Precautions 3.3.1.1 The CNSI operator shall acquire a Radiation Work Permit (or equivalent) from the faci-lity's Health Physics Department and shall comply with the applicable radiation pro-tection precautions of the facility providing the weste.
l 3.3.1.2 The CNSI operator shall, follow the radio-logical precautions outlined in the utility's radiological control procedures to minimize
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the spread of cor.camination and to limit per-sonal exposure to ionizing radiation.
3.3.1.3 The CNSI operator shall wear the dosimetry equipment and protective clothing provided by the utility's Health Physics Department during all operations of the a:obile unit.
c 3.3.1.4 A radiation and contamination survey shall be performed on the unit and all other CNSI equipment on the day of operation, after maintenance on potentially contaminated com-ponents of the mobile unit, and at additional E
times as determined by good radiological pre-S l
cautions and procedures.
The CNSI operator C
shall record (and retain) the results of these surveys in the daily operating log.
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c 3.3.2 Ceneral Precautions 3.3.2.1 Any modifications to equipment or operating e
procedures shall be performed in accordance with the approved CNSI procedures listed in h
Section 2.0 above.
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.. r 3.3.2.2 If at any time difficulties are encountered with any part of this procedure, the operator shall cease operations and notify the Mana-
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ger, Solidification Services or the Project
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Engineer, Solidification.
1 3.3.2.3 The sampling frequency and verification r
requirements of Reference 2.13 shall be followed at all times.
CAUTION:
SODIUM HYDROXIDE IS EXTREMELY CAUSTIC AND THE l
OPERATOR SHALL PREVENT CONTACT WITH SKIN, i
CLOTHING AND EYES.
IF SODIUM HYDROXIDE CON-l TACTS SKIN, WASH THOROUCHLY WITH VINECAR AND j
WATER. IF IT COMES IN CONTACT WITH THE EYES I
OR'CPEN WOUNDS, FLUSH WITH LARGE AMOUNTS OF WATER FOR 15 MINUTES AND CONTACT MEDICAL PER-SONNEL AS SOON AS POSSIBLE.
3.4 Interface Requirements 3.4.1 The CNSI mobile solidification unit requires the follm ng support services from the utility:
d 3.4.1.1 Electrical Power:
480 VAC/3 phase /60 Hz at 120 AMPS supplied with one cable.
3.4.1.2 Service air: 75 SCFM at 80 psig min._, clean,
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dry air.
(This service can be supplied with one hose or two.)
3.4.1.3 Service water: 25 GPM at 80 PSI.
3.4.1.4 waste:
Two-inch 150 PSI ANSI flange connection.
o 3.4.1.5 Vent: 4 inch vent blower discharge to plant j
off gas system at about 150 SCFM, a:
l 3.4.1.6 Telephone service for com=unications bet ween the utility radwaste operator and the CNSI g
operator as well as for long distance and g
local business calls.
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3.4.1.7 The utility must be prepared to accept pro-o cess chemicals and cement shipments prior to y
the arrival of the unit on-site.
3.4.1.8 The utility shall issue, according to its e
radiation protection procedures, a Radiation o
Work Permit (RW) to the CNSI operator before L
3 operations begin.
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.Y 3.4.1.9 The utility shall provids the CNSI operator with any clothing or equipment for necessary radiation protection.
3.4.1.10 A controlled area must be established around the processing area.
3.2.1.11 Utility personnel shall designate an area to be used for test solidifications.
3.2.1.12 The utility will provide crane services, torque wrenches, and other material necessary for loading the disposable liners and pre-paring the solidified waste for shipment.
3.2.1.13 The utility may be required to provide a
forklift capable of 4000 lb. at 6 ft. moment arm to unload the removable skids and place f
them in position for full-scale solidif *. cation.
3.2.1.14 The utility will provide a sodium hydroxide storage area (55 gallon drums) which is maintained at 600-850F.
3.5 Acceptance Criteria 3.5.1 Radioactive waste solidified in a fu'11-scale liner shall be considered acceptable if the following conditions f(
are met:
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3.5.1.1 Visual inspection of the end-product, normally 48-96 hours after process com-pletion, shows a uniform product with no free-standing water.
o 3.5.1.2 The end product, after satisfactory visual inspection, resists penetration with a broom-E*
handle size woden paddle.
NOTE:
CEMENT DOES NOT FULLY " CURE" FOR 30 DAYS BY ASME STANDARD.
THE FINAL PRODUCT WILL HAVE STRONGER PROPERTIES AFTER 30 DAYS BUT IS S
ACCEPTABLE POR SHIPMENT AFTER THE ABOVE CRITERIA IS MET.
S 4.0 OPERATING PROCEDURE 4.1 System Assembly NOTE: THE INSTRUCTIONS CONTAINED IN THIS SECTION APPLY ONLY TO h
INITIAL MOBILE UNIT ASSEMBLY FOLLOWING ARRIVAL AT THE UTILITY.
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r 4.1.1 Pre-operational checks are specified in Section 4.2 and shall be conducted after the unit is assembled.
CAUTION: PORTIONS OF THE MOBILE UNIT MAY BE CONTAMI-NATED FROM PREVIOUS SOLIDIFICATION OPERATIONS.
THE CNSI OPERATOR SHALL FOLLOW PROPER RADIO-LOGICAL PRECAUTIONS TO PREVENT THE SPREAD OF CONTAMINATION WHILE PERFORMING ALL STEPS PRE-CEDED BY THE NOTATION: (RADWASTE) 4.1.2 Obtain a Radiation Work Permit from the utility's Radiation Health Physics Department.
4.1.3 Survey the installation area for radiation and contami-nation. Assist the Radiation Health Physics Department in determining"~th " location of any radiation barriers, decontanination requirements, etc.
4.1.4 Position the mobile cement solidification unit trailer and the bulk cement storage trailer.
NOTE: ALTHOUCH THE VAC-KONVEYOR SYSTEM HAS BEEN DE-SIGNED AND TESTED TO HANDLE CEMENT TRANSFERS UP TO 100 FEET, POSITIONING THE CEENT TRAILER AS CLOSE AS POSSIBLE TO THE LINER FILLING POSITION REDUCES THE POSSIBILITY OF CEENT LINE PLUG-UPS.
4.1.5 Set all power disconnects in the "off" position.
Con-
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nect the electrical power supply.
Energize the main g
trailer disconnect.
4.1.6 Unload the trailer and position for use the following equipment:
4.1.6.1 (RADWASTE) Fillhead and Skirt - The fillhead/
skirt sust be positioned within reach of the mobile unit crane unless prior arrangements
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have been made with the utility for a sep-l arate crane to handle routine fillhead/ skirt moves. The fillhead and skirt must be secure to a 55 gallon drum.
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4.1.6.2 Vac-Konveyor c,
c 4.1.6.3 (RADWASTE) Process Piping Skid 3
4.1.6.4 (RADWASTE) Vent Filter / Moisture Separator 4.1.6.5 Porta-Filter e
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.r 4.1.6.5 Porta Filter 4.1.6.6 Conditionidg Pump 4.1.6.7 Work Platform 4.1.6.8 Load Cell 4.1.7 Using operational Form A-1, connect the entire mobile solidification unit.
When mating flanged gaskets, the operator shall use new viton gaskets or flexicalic gaskets, as appropriate.
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FORM A-1 HOSE / CABLE CONNECTION
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NOTE: WHEN CONNECTING ELECTRICAL CONTROL WIRING USE CAUTION TO AVOID DAMAGINO PINS.
PRIOR TO CONNECTING HOSES AND CABLES, MOBILE EQUIPMENT SHOULD BE POSITIONED IN THE OPERATIONAL POSITION AND CABLE / HOSE RUNS LAYED OUT TO EACH COMPONENT. ALL HOSES AND CABLES INSIDE THE RAIN'ASTE BUILDING SHALL BE SLEEVED WITH POLY SLEEVING.
1.
MOBILE UNIT (TRAILER) CONNECTION BOX Electrical Mobile Unit Connections Rose / Cable Connections Label
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Fillhead Video To Monitor Fillhead Video Vac-Konveyor Control Vac-Konveyor Control Vac-Konveyor Batch Reset Vac-Konveyor Batch Reset Fillhead Temperature Fillhead Temperature Process Skid Control Process Skid Control Fillhead Control Fillhead Control Fillhead Instrumentation Fillhead Instrumentation Waste Line Radiation Monitor Waste Line Radiation Monitor Mobile Unit Connections Hose / Cable Connections Label l
I Vac-Konveyor Vessel Pressure l
Vac Vessel Pressure
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Fillhead Cooling Fillhead Cooling To Dryer To Dryer g
l Valve Air Valve Air l
Purge Air Purge Air Dewater Pump Dewater Pump From Dryer From Dryer Vac-Konveyor Supply Supply Pressure Vac-Konveyor O
Caustic Pump Counter Caustic Soda Counter Caustic Pump Caustic Soda Pump E
Mobile Unit Connections Hose / Cable Connections Label Main Air Main Air Camera Air Camera Air 21 Waste Vent Diff. High Waste Vent Diff. High Waste Vent Dif f. Low Waste Vent. Diff. Low
?t l
Purge Air Out Purge Air Out o
l Camera Flush Pilot Camera Flush E*
l Portavac Differential High Portavac Differential High l
Portavac Differential Low Portavac Dif ferential Low Plug in 3 prong connector from pump skid under mobile unit connection 8
7 box.
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PROCESS PIPING SKID Electrical:
Process Skid Control Process Skid Control Waste Line Rad Monitor Waste Line Rad Monitor Pneumatic:
Dewater Pump Dewater Pump s
To Dryer To Dryer From Dryer From Dryer Purge Air Purge Air Tee between lubricator and Main Air filter (main air)
Valve Air Valve Air Main Air From Utility Main Air From Utility Servict Water From Utility Service Water Camera Flush Pilot Camera Flush Pilot Camera 4,ir Camera Air To Fillhead To Fillhead Plant Air To Vac-Konveyor Plant Air To Vac-Konveyor Dry Air To Vac-Konveyor Dry Air To Vac-Konveyor 3.
VAC-KONVEYOR Pneumatic:
Vessel Pressure Vessel Pressure Supply Pressure Supply Pressure Dry Air Supply Dry Air Supply Electrical:
Vac-Konveyor Control Vac-Ko,nveyor (6 Pin)
Control Vac-Konveyor Batch Reset To Vac-Konveyor (3 Pin) f-Batch Reset f
4 WASTE VENT BLO'4R Pneumatie:
Waste Vent Filter Suction Waste Vent Filter Suction Waste Vent Filter Discharge Waste Vent Filter Discharge Electrical:
3 Prong Male Plug Poner From Forward MSU g
Trailer (3 Prong Female) m 5.
FILLEEAD E
Pneumatic:
Camera Air And Flush Camera Air And Flush Cooling Air Fillhead Cooling Air
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Electrical:
Camera Camera J-102 (16 Fin)
J-102 To Fillhead 3
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P-103 (6 Fin)
P-103 J-101 (14 Pin)
J-101 To, Fillhead Control e
C Connect proximity switch between fillhead and fillhead skirt.
6.
OPERATIONAL HOSES 6.1 (RADVASTE) Connect a 2-inch steel braided ' waste hose from WS-1
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outlet to WS-4 using the new Flexicalie. gsskets.
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DOCUMENT 14 SD-OP-004 J
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r 6.2 (RADWASTE) Connect a 2-inch steel braided weste hose from US-1 l
inlet to the utility radvaste systes using new Flexicalic l
6.3 (RADWASTE) Connect a 2 1/2 inch hose from fillhead to suction of l
vent blower (filter inlet) using cam-lok fittings.
I' 6.4 (RADWASTE) Connect a 2 1/2 inch vent hose from vent blower dis-I charge to plant off gas system.
6.5 (RADWASTE) Connect a 2 1/2 inch vent hose from vent filter to vent blower inlet.
NOTE:
(RADWASTE) Where two filters are used in series, con-nect discharge / suction hose between the two.
6.6 Connect the 2 inch aim s~e from cement blower discharge to Vac-Konveyor.
6.7 Install cement discharge fittings under each tank of bulk cement trailer.
6.8 Connect the 3 inch cement hose from cement truck to the Vac-Konveyor suction.
6.9 Connect the 1 inch hose from cement blower discharge to cement trailer.
6.10 Connect the 2 inch cement hose from Vac-Konveyor discharge to the
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fillhead.
6.11 Connect the 1 inch, three foot line from cement trailer tee to bottom cement suction.
6.12 Connect the 4 inch vent hose from Vac-Konveyor to porta filter suction. Although not required, a 4 inch vent discharge hose may be used on porta filter discharge to route the exhaust away from solidification or plant areas.
E 6.13 (RADWASTE) Connect the 1 1/2 inch stainless steel wound teflon hose from DW-7 to the plant return dewater line using new Flexicalic gaskets.
N 6.14 Connect hydraulic supply and return lines to mixer motor from M
hydraulic unit connections under the MSU.
o 6.15 Connect the 3/4 inch sodium hydroxide line to sodium hyd toxide j
fitting on fillhead.
7.
Hoses, flanges and valves in the dewater and waste lines shall be pressure tested to 150 PSI after inital assembly.
The pressure test 8
shall be accomplished by applying demin water to all lines for 30 7
minutes. No leakage allowed.
Results of the hydro shall be documented 5i in the daily operations log.
This completes the assembly and equipment set-up.
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'r-4.2 System Preoperational Testine 4.2.1 The following general-re'quirements shall be observed:
4.2.1.1 A radiation survey is required daily before
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preoperational testing.
4.2.1.2 Preoperational testing is required daily before san.ple testing or batch solidifi-j cation.
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4.2.2 Complete the preoperational ch eck-list, Form A-2.
Any unsatisfactory condition shall be resolved before proceeding.
4.2.3 Hydraulic Unit Preparations:
4.2.3.1 Check hydraulic oil sump level.
Refill if less than half full.
4.2.3.2 Check hydraulic oil temperature.
Ensure oil temperature is greater than 700F.
4.2.3.3 Inspect unit for evidence of leakage.
4.2.4 Energize main control panel.
The following startup indications should be visible:
Panel Desienations Startuo Indication Control Power On (White)
Main Power On (White)
Fillhead Positioned Positioned (Green)
Waste Valve Shut (Green)
Digital Clock Energized (Set To Correct Time)
C Hydraulic Motor Off (Green)
Porta Vac Off (Green)
Cement Blower Off (Green)
E Waste Vent Blower Off (Green)
Aeration Blower Off (Green)
R" I
l Temp. indication selected to fillhead.
NOTE:
CONTROL POWER FOR CONTROL PANEL IS DISTRIBUTED THROUGH M
THE FILLHEAD CONNECTORS.
ENSURE THESE CONNECTIONS ARE o
MADE.
c DO NOT PROCEED WITH THIS PROCEDURE UNTIL ALL ITEMS IN THE PREOPERATIONAL CHECKLIST (FORM A-2) ARE COMPLETED Oc SATISFACTORILY.
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oocuutNT 16 SD-OP-004 J
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T 4.3 Liner Set @ (The liner set-up and fillhead installation will be done outside the yellow room) 4.3.1
& nitor cask and liner movements and operations con-ducted by the utility.
k CAUTION:
LINER MAY BE PRESSURIZED.
OPEN WITH CAUTION.
4.3.2 Open and inspect liner for foreign material and damage.
Record the liner condition in the daily operational log.
4.3.3 Test the proximity switch prior to tightening assembly to liner, see Form A-3.
Attach the fillhead hold-down chain locking devices.
~~ n._
4.3.4 Install the following: Level Probes, Temperature Probe, Dewatering leg (if required) and cement nozzle.
Tie probes and connections with lanyard so they can be handled from skirt door.
The level probes are set at the height specified by reference 2.13.
4.3.5 Install the disposable skirt liner on the fillhead i
skirt. Ensure skirt door is not obstructed.
4.3.6 Connect cement hose and devater leg and cocplete Form A-3.
4.3.7 Position the fillhead and skirt assembly over the liner. Lower the assembly slowly with skirt door open.
I Feed lanyard holding probes / connections through skirt door prior to landing assembly.
Connect the level leads and thermocouple leads.
NOTE:
It may be necessary to rotate the assembly a slight amount to allow mixer blade shaf t to j
engage with mixer motor shaft.
E Do not skirt clamp holddown bolts em lie.ars sich are to be used for resins or other high level waste.
4.3.8 Clamp the fillhead assembly to the liner.
4.3.9 Conduct startup valve lineup on fillhead, Form A-4 4.3.10 Check proper connection of all hoses to the fillhead.
3
-c 4.3.11 Ensure service water and air are supplied to process skid and start fillhead camera air and test the TV camera. Test the water spray to camera lense.
e
.2 4.3.12 Test the hydraulic system at minimum speed.
Check for
[
3 proper hydraulic speed control and mixer operation.
Secure the mixer.
4.3.13 Inspect the hydraulic and pneumatic hoses for leakage
- 0 4
and damage.
5, poCUMENT REV.
WEET 17 SD-OP-004 J
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FORM A-2 PREOPERATION CHECKLIST Date Operator Location 1.
Portland I cement inventory tons (8 con min.)
2.
Sodium hydroxide inventory gallons (75 gal. min.)
Verify sodium hydroxide is less than 6 months old and has been stored at temperatures betwen 600 and 800F.
Initial 3.
Survey meters and installed radiation monitor calibrated and checked.
SAT UNSAT I
s 4
Hose inspection completed.
SAT UNSAT 5.
Contrclied area established.
SAT UNSAT l
.6.
Proper liner (s) on hand and inspected, ntstber SAT UNSAT' i
t O
7.
Connect air line to pump and sodium hydroxide discharge hose to fillhead.
Test NaOH pump from control console.
Init ial 8.
Install sodium hydroxide pump in barrel.
g S
Initial C,
e 9.
Ensure filter water is clean and the water level is between 5 and 10 o
l inches by stick measurement.
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Initial 1
e 10.
Pre-load the liner to be used with the CNSI supplied additive.
O t
Initial 3
N.
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' 7-FORM A-3 ALARM AND INTERLOCK TESTING k-Date Operator
_ Location A satisfactory test of alarms and interlocks shall be conducted prior to each solidification. Consecutive order of tests is not mandatory.
1.
Fillhead asse=bly position switch.
CAUTION:
FILLMEAD SHOULD BE IN A SAFE POSITION AND HYDRAULIC MOTORSPEED CC:iTROL SET AT MINIMUM PRIOR TO TESTING.
1.1 Attempt to open 'a*S-1 EtFrirlhead not in position. WS-1 should not open.
SAT 1.2 Attecpt to start the cement blower. Cement blower should not start.
SAT 1.3 Attemp to start the hydraulic motor. Motor should not start.
SAT 1.4 Atte=pt to start the aeration blower. Blower should not start.
SAT l
f 2.
Position fillhead assembly on the linet and ensure proximity switch activates. Open WS-1.
Ensure Vac-Konveyor is in the discharge only C
i i
mode and start the cement blower.
SAT l
l 2.1 Move the fillhead out of position.
SAT SAT I
2.2 Ensure WS-1 shuts.
2.3 Ensure cement blower shuts off.
SAT h
o 3.
HI-HI Level Switch (RADWASTE) c 3.1 With fillhead assembly installed, open WS-1, start the cement blower.
S SAT T
!E 3.2 Lift the HI-HI-level switch manually.
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3.3 Ensure WS-1 shuts.
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3.4 Ensure cement blower shuts off v SAT
-S 3.5 HI-HI level alarm sounds ca control console.
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4.
High Level Alarm. (RADWASTE)
Ensure the fillhead is installed. Open WS-1,, start the cement blower.
Short the high level alarm leads in the fillhead.
4.1 Ensure WS-1 shuts.
SAT 4.2 Ensure cement blower stops.
SAT 4.3 Ensure high level alarm sounds SAT 5.
Waste level alarm. (RAIf4ASTE)
Open WS-1 and short the waste level alarm lesds in the fillhead. Ensure WS-1 shuts.
SAT o
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. *I FORM A-4 VALVE LINEUP SHEET i
VALVE STARTUP SHUTDOWN NO.
DESCRIPTION POSITION POSITION WS-1 Waste Isolation Valve Shut (Green) Shut (Green)
WS-4 Waste Isolation (Fillhead)
Open Shut WS-5 Waste Flush Shut Shut WS-3 Sample / Flush (Waste)
Shut Shut WS-2 Sample / Flush (Waste)
Shut Shut DW-1 Dewater Isolation (Fillhead)
Open Shut DW-2 Dewater Pump Isolation (Suction)
Open Shut DW-7 Dewater Pump Isolation (Discharge)
Shut (Note 1) Shut i
DW-8 Dewater Pump Discharge Flush Shut (Note 1) Shut DW-3 Dewater Flush Shut Shut DW-6 Dewater Sample Shut Shut DW-4 Devater Suction Gage Isolation Open Shut
[
DW-5 Dewater Discharge Gage Isolation Open Sliut C-2 Bulk Cement Butterfly Valve Open Shut e
C-3 Air to Cement Trailer Open Shut C-4 Air to Cement Trailer Open Shut CPS-1 Waste Conditioner Valve Open Shut NOTE 1:
DW Valve 7 will be open on startup when processing slurries / resins
{
and dewater system is utilized.
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SMEET 21 l
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g 4.4 System Oeeration 4.4.1 Verify the following conditions.
4.4.1.1 The utility has indicated that the vaste is ready to be transferred.
4.4.1.2 Hydraulic motor speed is adjusted to the slowest speed before starting.
4.4.1.3 Preoperational checklist has been completed satisfactorily.
4.4.1.4 Alcrm and interlock testing has been com-pleted satisfactorily.
l 4.4.2 Co=plete the startup portion of the valve lineup, For=
A-4 4.4.3 On the main control panel:
4.4.3.1 Energize the radiation monitor.
I 4.4.3.2 Start the off gas ventilation blower. Ensure filter is adjusted to between six and twenty inches of water.
l 4.4.3.3 Start the temperature recorder.
]
4.4.3.4 If the vaste to be added is resin, start the mixer and leave running at 40 rpm.
4.4.3.5 Open the vaste isolation valve, WS-1.
4.4.4 Contact the utility waste operator and notify him that e
the system is ready to receive waste.
l 4.4.5 When was te flow commences, observe the flow on the TV l
monitor. Observe radiation monitor to verify flow.
l NOTE: WHEN THE REQUIRED AMOUNT OF WASTE' HAS BEEN RE-5 CIEVED THE WASTE LEVEL ALARM WILL ACTIVATE AND R
US-1 WILL SHUT.
THE CPERATOR SHOULD ATTEMPT 'ID C
i VERIFY THE ACTUAL VOLUME OF WASTE TRANSFERRED BY l
MORE THAN ONE SOURCE OF INFORMATION I.E; TV CAMEF4 LEVEL INDICATIONS, UTILITY WASTE OPERA-5 TOR'S KNOWLEDGE OF WASTE TRANSFERRID OR ESTIMATED WASTE PUMPING RATES.
C 4.4.6 When the desired volume of waste has been transferred, O.
ensure that the utility secures waste flow.
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...F NOTE: IF THE WASTE ADDED WAS RESIN SLURRY, PROCEED WITH 4.4.7.
IF THE WASTE ADDED WAS CONCENTRATED
~
LIQUIDS, PROCEED WITH STEP 4.4.10.
TKE CNSI OPERATOR MUST DEWATER RESIN SLURRIES TO ENSURE PROPER WASTE TO CEMENT RATIO.
THE AMOUNT OF WATER TRJ3STERRED WITH THE SLURRY MAY VARY AND OPERATING EXPERIENCE WILL DICTATE THE NUMBER OF TIMES THE SLURRY WILL NEED DEWATERING.
4.4.7 Notify the utility that dewatering is ready to begin.
4.4.8 When the utility is ready to receive resin dewater, l
start the dewater pump. Run the devater pump until the waste level alarm clears and observe the water level l
with the TWcamera: Secure the devater pump i. hen slurry appests to have approximately 2 inches of water on top i
of the resin heads 4.4.9 Repeat 4.4.4 (after opening WS-1) through 4.4.8 until resin slurry is at the waste level alarm point with approximstely 2 inches of water on top of the resin I
beads.
NOTE: IF TEE WASTE RECEIVED WAS HOT CONCENTRATES, SODIUM HYDRO-XIDE MAY BE ADDED AND THE WASTE ALLOWED TO COOL PRIOR TO ADDING CEMENT. THIS WILL RESULT IN ELIMINATION OF ANY HOT VAPORS IN THE OFF-GAS SYSTEM AND REDUCE OVERALL CURING
/
TEMPERATURE.
PROCEED WITH 4.4.10 IF WASTE IS TO BE COOLED.
PROCEED WITH 4.4.20 IF SOLIDIFICATION IS TO FOLLOW IMMEDIATELY OR IF WASTE IS NOT HOT CONCENTRATES.
4.4.10 Calculate the required amount of sodium hydroxide to be added ut_ilizing the calculations of the Process Control Program.
O 4.4.11 Start the mixer and adjust the speed to approximately 40
[g rpm.
4.4.12 Start the sodium hydroxide addition pump on the MC Panel ar.d add 757. of the required amount and secure the pump.
~
4.4.13 Secure the: mixer for 15 minutes after the sodium hydro-zide addition is complete.
M e
4.4.14 Secure the off gas ventilation blower and connect fill-g a
head ventilation line to the plant's off gas system, 4.4.15 Allow the waste to cool.
8 CAUTION: NEVER ALLOW TREATED WASTE TO COOL LESS THAN 1040 F OR 7
PRICIPATATES WILL FORM ALONC LINER WALLS AND BOTTOM.
g 4.4.16 Reconnect the ventilation blower system and start the blower.
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.5 SD-OP-004 23 j
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. r-4.4.17 Start the mixer and adjust speed to 40 rpm and mix for 5 minutes.
4.4.18 Open DW-6 and WS-2.
Start the devater pump slowly and run for 5 minutes.
Open WS-3 and draw 100 m1 sample from WS-5.
Shut WS-3.
4.4.19 Heasure pH and verify correlation of pH with sodium hydroxide added.
Repeat Step 4.4.12 after adding l
required amount of sodium hydroxide to adjust pH between 10 and 11.5.
4.4.20 If vaste was not cooled, conduct Steps; 4.4.10, 4.4.11, I
4.4.12, 4.4.18, and 4.4.19.
4.4.21 Flush Procedure 1
.,,m..
4.4.21.1 Open WS-2, DW-6, DW-8 and crack open SW-1.
Secure flush and devater pump after 30 seconds.
4.4.21.2 Shut WS-2.
Open WS-3 and crack open WS-5.
Shut WS-5.
Shut WS-3.
4.4.21.3 Shut DW-6 and DW-8.
Open DW-3.
Shut DW-3.
Shut SW-1.
4.4.21.4 Notify plant for vaste line flush. Open WS-1 and flush for 30 seconds. Repeat as necessry
(-
not to exceed 50 gallons. Check flow with TV camera and WS-l' radiation monitor.
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4.4.22 Operate the mixer at 40 rpm for.15 mi,utes after sodium hydroxide addition. Monitor temperature rise during the reaction period.
1.
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CAUTION: IF TME TEMPERATURE IN THE LINER IS ABOVE 1800F, THE l
WASTE SHOULD BE ALLOWED TO COOL TO LESS TRAN 1600F i
BEFORE ADDIriG CEMENT TO PREVENT COILING IN THE LINER l
DURING THE CEMENT IIME.
4.4.23 Set the cement batch counter on the Vac-Konveyor to the number of batches calculated on the process control p
program, sample verification.
h 4.4.23.1 Energize the porta-vac.
3 4.4.23.2 Energize the cement blower and loadeell.
4.4.23.3-Shif t the manual cycling control level on the Vac-Konveyor to automatic cycling. Acti-E vate dyna-dor to 50 SCFH and cleanout valve 7
to 90 PSI.
$i j
f 4.4.23.4 Ensure mixer RPM is set at 40 RPM.
Increase
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speed to 100 RPM when approximately 67% of g
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the cement has been added.
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4.4.24 When the required amount of cement has been added, the cement level alarm should alarm.
The operator should total weights of the batches as a back-up for cement addition.
The Vac-Konveyor will stop trassferring cement. Af ter three minutes the operator shall:
4.4.24.1 Secure th'e cement blower end eight inch bulk trailer isolation valve.
4.4.24.2 Secure the porta vac.
4.4.24.3 Slow the mixer motor to minimum and secure the hydraulic unit.
l l
NOTE: THE PROCESS IS NOW COMPLETE. THE " CURE" TIME TO f
A WATER-FREE, HARD MONOLITH SHOULD BE 48 TO 96 HOURS.,3taQCEED DIRECTLY TO SECTION 4.5.
4.5 System Shutdown 4.5.1 Perform the shutdown portion of the Valve Line-Up Sheet of (Form A-4) and document completion in the operator's daily log.
I NOTE: THE UTILITY MU3T HOVE LINER CUT OF THE YELLOW ROOM.
4.5.2 Secure the off gas ventilation blower.
4.5.3 (FJ.D*4ASTE) Open the skirt door and disconnect the cement and dewater line. Disconnect the electrical leads.
4.5.4 (FJUT4ASTE) Release the skirt from the cask and lif: the fillhead and skirt off the barrel-top opening of the liner several inches.
4.5.5 (RADWASTE) Remove disposable skirt protector ar.3 place e
into liner.
Install the protective bag around skirt E
bottom.
cc 4.5.6 (RADWASTE) Place fillhead/ skirt assembly on the 55 gallon drum.
4.5.7 (RAIT4ASTE) Install the ventilation lid on the disposable 2
i liner. Disconnect waste vent blower discharge hose and C
connect off gas hose to liner top.
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NOTE: MOVE LINER BACK TO YELLOW ROOM.
S 4.5.8 Initiate and complete the administrative requirements of Section 5.0 of this procedure for shipment of radio-eo active waste.
i N
4.5.9 Proceed as indicated below:
- 4. 5. 9.1 If another solidification operation will
(
E take place icimediately (same day), return to g'
Section 4.3 above.
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..f 4.5.9.2 If another, solidification will be conducted but not on the same day, proceed as follows:
(
~4.5.9.2.1 Secure the CCTV monitor and the remote radiation monitor.
4.5.9.2.2 Secure service air on the PC Panel.
Check all pneumatic s witches in the "of f" position and all air valves shut.
4.5.9.2.3 Turn off the MC Panel.
4.5.9.2.4 Secure electrical power by placing all breakers in the "off" positions.
4.5.9.2.5 To resume unit operation, the operator should return to Sec-l tion 4.2 above.
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4.6 System Disassembly CAUTION: PORTIONS OF THE MOBILE SOLIDIFICATION UNIT ARE POTENT-IALLY CONTAMINATED FROM OPERATION.
THE CNSI OPERATOR SHALL FOLLOW PROPER RADIOLOGICAL PRECAUTIONS k"dILE PER-FORMING ALL STEPS OF THIS SECTION PRECEDED BY THE NOTATION. (RADWASTE).
4.6.1 During disassembly of the Mobile Solidification Unit, the CNSI operator shall ensure the following:
4.6.1.1 That all hoses and cables are coiled as they I
are removed and set aside for loading into i
the trailer.
o D
4.6.1.2 That blank flanges and end protectors are installed.
AFTER BLANK FLANGES ARE IN-STALLED ON WASTE LINES, OFF-CAS VENTILATION LINES AND DEWATER LINE FLANGES, EACH FLANGE SHALL BE BAGGED WITH YELLOW POLY AND TREATED E
AS CONTAMINATED.
S O
4.6.1.3 That a visual inspection is performed as each cable and hose is handled and that defects 3
and discrepancies are noted in the Operator's S
Daily Log.
When unit dis as s embly has been completed, report all noted, discrepancies to the Manager, Solidification Services so that e
re placemer;t parts may be obtained.
3 i
4.6.2 Position the fillhead in a convenient location for hose removal.
4.6.3 Air flush the conditioner transfer lines as follows:
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4.6.3.1 Remove the conditioner pick up tube from the conditioner storage container and place it in a containeF filled with water.
(,
4.6.3.2 Disconnect the conditioner transfer hose fro =
the fillhead and place the free end in an empty conditioner storage container.
4.6,3.3 On the MO Panel, start the conditioner trans-fer pun:p and run until a minimum of 15 gallons of water has been pumped through the conditioner hose.
4.6.3.4 With the conditioner pickup hose in a clean area, continue to pump for 5 minutes then secure the conditioner transfer pump.
4.6.3.5 Clean any spilled conditioner off the fillhead.
4.6.4 De-energize the MC Panel, secure the utility-furnished service air, service water, and electric power to the trailer.
NOTE: STEPS 4.6.5 THROUGH 4.6.9 MAY BE PERFORMED IN ANY ORDER.
- 4. 6. 5 -
Disconnect the electric cables, the hydraulic hoses, and the air supply lines from the fillhead.
4.6.6 Disconnect the following hoses:
4.6.6.1 (RADWASTE) Waste transfer hose from Valve WS-2.
Install the blank flanges.
4.6.6.2 (RADWASTE) Of f gas ventilation hose.
e 4.6.7 On the CNSI trailer, disconnect the following:
h 4.6.7.1 All electrical control cables 4.6.7.2 All pneumatic supply hoses 5
e7 4.6.7.3 All CCTV Monitor & Control Cables 4.6.8 On the process piping skid, disconnect the following:
3 e
4.6.8.1 Service water hose 4.6.8.2 All electrical cables e
S 4.6.8.3 (RADWASTE)
Hose bet ween waste isolation d*
valve (WS-1) and plant vaste connection.
Install blank flanges.
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4.6.8.4 (RADVASTE) Waste transfer hose to fillhead.
Install blank flantes.
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4.6.8.5 Air supply to wste isolation valve (WS-1).
4.6.8.6 Pneumatic control hoses.
k 4.6.9 Disconnect the hydraulic hoses from the hydraulic skid.
4.6.10 Load the skids into the mobile unit trailer as follows:
4.6.10.1 Load the plant connection stand using the installed crane.
4.6.10.2 (PADWASTE) Load the skirt and fillhead into its container and place it into the trailer.
4.6.10.3 Load the Vac-Konveyor into the trailer.
m.
4.6.11 Disconnect the electrical power supply from the trailer.
(
4.6.12 Document coepletion of the disassembly in the operator's i
daily log.
t 5.0 RECORDS AND REPORTS 5.1 Process Memo The process memo shall follow shipment and appropriate copies mailed to the Manager, Solidification Services and the Billing
(
Department.
i 5.2 Contamination and Radiation Survevs 5.2.1 A copy of the survey shall accompany the shipment. This survey may be performed by the utility or its designated l
shipper.
i l
5.3 Radioactive Shipment Report (RSR) f oc 5.3.1 The RSR shall be filled out by the utility in accordance with the instructions contained on the reverse side of the form.
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