ML20082A106

Process Control Program

ML20082A106
Person / Time
Site:	Wolf Creek
Issue date:	11/14/1983
From:	Koester G KANSAS GAS & ELECTRIC CO.
To:	Harold Denton Office of Nuclear Reactor Regulation
References
KMLNRC-83-145, PROC-831114, NUDOCS 8311180047
Download: ML20082A106 (28)

Text

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SYSTEM COMPONENT DESCRIPTION g.

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1.0 SCOPE 1.1 PURPOSE

[A he purpose of the process control program is to provide reasonable assurance that the final solidified products produced i

by the installed cement solidification system at the Nb1f Creek Generating Station (WCGS) meet or exceed all federal, state and local requirements pertaining to the solidification, transportation and disposal of low-level radioactive waste.

1.2 APPLICABILITY te process control program is applicable to all solidification evolutions involvirg the installed cement solidification system at WCGS.

2.0 REFERENCES

AND DEFINITIONS

2.1 REFERENCES

2.1.1 NUREG-0800

Standard Review Plan Section 11.2 Liquid Waste Management Systems

2.1.2 NUREG-0800

Standard Review Plan Section 11.4 Solid Waste Management Systems 2.1.3 Branch Technical Position 11-3, " Design Guidance for Solid Radioactive Waste Management Systems Installed in Light Water Cooled Nuclear Power Reactor Plants" 2.1.4 10CFR29, " Standards for Protection against Radiation" 2.1.5 10CFR60 2.1.6 100FR71, " Packaging of Radioactive Material for Transport and Transportation of Radioactive Materials under Certain Conditions"

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2.1.7 NUREG-0472, Revision 3, " Standard Radiological Effluent Technical Specifications for Pressurized Water Reactors" 2.1.8 Technical Position of Warte Form, March 3,1983 2.1.9 Stock Equipnent Company, Technical Manual for the Wolf Creek Generating Station's Installed Cement Solidification System 2.2 DEFINITIONS 2.2.1 FSW - Free standing water is required which is not'

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chemically or mechanically combined with the solidification binder.

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2.2.2 Structural Stability - The ability of the solidified product to withstand the pressure normally exerted on radioactive waste, disposed of by shallow-land burial.

2.2.3 Verification Sample - A small sample normally 200m of the waste stream to be solidified which is used to check that proper c ment, waste, chemical additives are being utilized in the full-scale solidification to produce acceptable solidified prcducts.

3.0 DETAILED SYSTEM DESCRIPTION 3.1 SOLIDIFICATION SYSTEM DESCRIPTION The installed cement solidification system is designed to solidify the three primary waste streams generated at NCGS: boric acid concentrates, sodium sulfate concentrates and spent bead resins.

The system consists. of three major subsystems:

3.1.1 Cement storage and filling systes which include the bulk storage silo, day tank and required support equipment, 3.1.2 Drum conveying system which includes the necessary equipment to locate the drums at the cement filling station and to safely move the cement loaded drums to the radwaste, and 3.1.3 Decanting station which includes the necessary controls and monitoring devices required to deliver properly decanted resin slurries to the radwaste filling station.

3.2 PROCESS PARAMETERS 3.2.1 PROCESS DESCRIPTION Prior to solidifying radioactive waste in a full-size container, a process control verification test will be performed (se Section 3.5.2). The purpose of the verification test will be to determine the proper quantities of cement, lime and calcium chloride re. quired to be placed in each 55-gallon drum. The verification test will also indicate the required amount of pH additive required to be added to the waste pretreatment tank to insure the proper pH is obtained.

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Once a satisfactory verification test has been performed, the radwaste operator will begin the solidification evolution. The required quantities of lime and calcium chloride will te placed in the 55-gallon drum prior to ~

placing the container on the drum conveying system. '

Once the lime and calcium chloride have been placed in the container, the container will be placed on the drum conveying system and moved to the cement fill station, where the required quantity of Portland Type 1 cement will 1-3 v

t be placed in the detrn. A mixing weight will be placed in

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the drtan following con =ete additicn. The drum conveying system will then move the cement-filled drum to the loaded' drtan storage area.

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.c-Se installed overhead crane systent will transfer the oment-filled drum to the radwaste fill station where the wet radioactive waste will be metered into the drum. We drum will then be placcd in the drt:m tumbler ard tumbled for.the required time.

3.2.1.1 Binder We solidification binder used in the installed solidification systen is Portland Type 1 hydraulic cement.

3.2.1.2 Line A predetermined quantity of lime is added to each container. The lime serves two purposes:

a.

Increase the pH of the waste to 10.5,'and b.

React with the boric acid to form insoluble

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boron salts. Wis prevents the boron from retarding the hydration of the cment.

3.2.1.3 Calcium Chloride Calcium chloride is added to the solidification binder to accelerate the hydration of the canent.

3.2.1.4 Lithium Hydroxide Lithium hydroxide is added to the influent waste stream as required to insure product pH will be at least 10.5.

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3.2.2 WASTE BOUNDARY CONDITIONS In order for radioactive waste solidified with Portland cement to meet the stability requiraaents, certain boun3ary conditions must be achieved.

3.2.2.1 pH te waste stream pH affects the ability of the cement to hydrate. The solidification process at WCGS incorporates the addition of lime in the solidification binder and lithium hydroxide as a waste pretreatment.

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-3.2.2.2 Boric Acid i,

Boric acid'affects the ability of=the cement to

- properly solidify the waste stream by providing an l acidic environment. The boron present in the waste stream also affects the hydration process of the binder. ' he solidification process at NCGS inccrporates the use of lime -(Ca(OH)2) to _ react

.with boron to form insoluble salts.

'3.2.2.3 ' Sodium Sulfate ~

he presence of sodium sulfate in the waste stream can cause a flash set of the solidification binder producing excessive heat from the hydration of the cement binder.

3.2.2.4 Bead Resin

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- When solidifying depleted-bead resin, care nist be taken to insure the active sites have been L

pretreated'with lime. This will prevent the active sites frrm_ removing divalent or trivalent

-ions f p the cement / waste slurry.

3.2.2.5 Oil Wastestreamscentbiningoil'volumesgreaterthan l

that which can be soM dified by the installed cement system'will be solidified by using an acceptable vendor process control program or otherwise disposed of.

3.3 DETAILED SYSTEM DE:SCRIPTION 3.3.1 CEMENT SIORAGE: SYSffb' DESCRIPCION 3

The STOCK solid radwaste system for NCGS begins with a _

cement filling system for onsite storage of large quantities of cement as well as the control eqdipnent and instrumentation to accurately transfer measured quantities of cement to standard 55-tJallon drums. Although the entire cement filling process.is carried out in safe areas of the plant, the equipment has been precision. engineered for dust-free operation so that no cement dust will enter the plant atmosphere or cause. deposits on the outside surface of the drums which might subsequently become contaminated.

The entire cement filling system is operated frrn its own control console located adjacent to the cement filling station and the conveyor system. Controls, monitoring devices and alarm indicators have been centralized in this location for ease of operation and to keep the operator informed of system status and operation.

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Incoming cement is transferred into the storage silo utilizing the fluidizing equipment and blowers mounted on the cement delivery truck. Gement is again fluidized and transferred in small increments on operator comand to the inside cement filling station day tank as needed. Mounted above the day tank is a dust collection system interconnected to the day tank, the drum feeder assambly fill nozzle and to the storage silo to maintain vacuum conditions and dast containment at all times.

Standard 55-gallon drums frcm a clean storage area enter the cement filling station on a STOCK roller conveyor and are individually positioned beneath the cement fill nozzle. A predetermined anount of cement is placed into each drum by the action of a screw feeder located at the day tank discharge hopper. The weight of cement per drum is determinr51 in accordance with the process sample verification which is performed on each batch of radioactive waste to be processed (see Section 3.5.2).

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' Dece a drum has been filled with cement and sealed, it is conveyed to the drum staging area for pickup by the bridge crane. The crane may transfer the drum either to a drum

. storage area or to the drum processing enclosure where the decanting and druming equipment remotely apply measured quantities or,specified proportions of radioactive slurries i

and concentrates.

An air compressor system is included in the cement filling system and is housed in an environmentally-controlled room located at the base of the storage silo to provide process air free of oil and water contaminants. STOCK-supplied transfer piping supplies air to the pneumatic conveyor, the h

fluidizing jets in both the silo discharge zone and in the

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day tank discharge hopper, the automatic filter cleaning equipnent in the dust collection system, the bell-type shut-off valve in the cement fill nozzle orifice and to the air-cil cylinder operting the drum scale platform.

The cement filling system performs a number of related s'

functions:

inspection of drums and caps for damage and proper thread line, long-term storage of large quantities of cement under controlled conditions, application of the specified quantity of cement and the mixing weight to the drum, recording of drum tare weight and filled weight and drum sealing.

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The coment filling system has been provided with the

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following systes and emponents.

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3.3.1.1 Cement Storage Silo-We cement storage silo is*of cylindrical construction with a dishal head and conical discharge section, fabricated from 1/4" AS'IM A-283-C steel. Double-welded construction throughout assures dust-tight integrity and vacuum maintenance. Storage capacity is 1,530 cubic feet of cement.

We silo is filled from self-unloading delivery trucks through a 4" diameter fill line. The fill line includes a clean-out port at its highest elevation and is connected to a discharge box centered-on the top of the silo. We discharge box allows the canent to fall evenly inside the tank during filling.

Also located at the top of the silo is an inspection manhole and a 5" diameter vent line which is conne-ted to the dust collection system located on the cement filling station day tank.

Access to the top of the silo is provided by a hand ladder with safety cage arx3 a maintenance platform with perimeter railing--all designed and constructed to OSHA standards.

Cement is discharged from the bottom of the silo to a pneumatic conveyiry systs. The pneumatic conveying system is mounted to the inlet chute.

The pneumatic conveyiry system connects to the cement silo via a dust-tight inlet chute and a manually-operated shut-off valve. The sides of the discharge cone of the cile directly above the shut-off valve are sloped at a 500 angle frm horizontal. Ten automatically _ controlled air fluidizing nozzles are installed in the perimeter of the discharge cone to prevent packing of the cment powder.

3.3.1.2 Silo Pressure Relief Valve A mechanical pressure relief valve is mounted at the top of the silo to prevent possible pressurization of the silo.

It is set to open at 10" of water and, through a limit switch, energizes a red alarm.

3. 3.1. 3 Silo Hich-Level Controls The cement storage silo is e,ipped with a sonic high-level sensor located at the normally filled 1-7

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level of the silo. When activated by abnormally high cement levels, the control energizes two red lights located at the cement filling station electrical console and located on the exterior

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wall of the silo.

The high-level control also activates an audible alarm located at the top of the silo.

During normal filling of the silo, placing the ON/0FF switch to the ON position will energize two green lights located on the exterior side wall of

-the silo and in the rear of the cement filling station console. Placing the ON/0FF switch into ON position also energizes the dust collector.

3.3.1.4 Silo cement Level Indicator A mechanical level indicator is provided for monitoring the amount of cement remaining in the silo.

A 4-figure digital readout located in the air canpressor room displays in tenths of feet the level of cement remaining in the silo.

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3.3.1.5 Silo Fluidizing System TYansfer of cement from the storage silo to the air conveyor equipment is facilitated by an air fluidizing system. The air fluidizing system consists of an air filter with automatic drain, an accumulator tank for air storage, a pulsator motor with cycle timer and ten fluidizing nozzles.

The nozzles are deployed at various levels art;.J the perimeter of the silo discharge cone.

All nozzles are connected by a common manifold to a pulsator solenoid valve located next to the silo discharge cone downstream of the accumulator tank.

The cement conveying system controls are interlocked to the fluidizing system, permitting a pulsator motor and cycle timer to open for several brief intervals before tha start of each conveying cycle. Short bursts c:

pressure air through the fluidizing nozzles at ar. the canent in the discharge cone area of the silo facilitating its passage to the cement chute for controlled application to the fluidizing vessel.

3.3.1.6 Air Compressor Systen An air canpressor system is installed in a separate room attached to the base of the cement storage silo to cupply process air to the canent 1-8 y._._

filling'systen. We pneumatic equiptent is an iMependent aM self-contained systm including all necessary components to provide the required '

delivery of air for the cement filling system frce of any oil or water contamination. te air system

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is equipped with two air compressors, coalescing filtars, air dryers and pressure regulators.

3.3.2 CMENT FILLING SYSTEM We cement filling system incitdes all the equipment necessary to transfer cement from the storage silo into the drum. Se four principal items of equipment are: an air conveyor unit to transfer cenent to the day tank, the day tank, a screw teeder assembly which precisely meters the applicaton of cement into each drum and a dust collector assembly designed to remove the cement dust generated at each point in the process, 3.3.2.1 Air Conveyor System An air conveyor system is utilized to transfer canent frm the cenent storage silo to the cement day tank. The system has an operating capacity of transferring 153 lbs/1.5 n.inutes. Cmpressed air at 80-100 psi (30 SCFM) is required to operate the systen.

Cement in the silo discharge cone is fluidized by the continuous application of high-pressure air.

Wis allows the cenent to drop into the fluidizing i

vessel of the air conveyor system without packing. Once the fluidizing vessel is filled with cement, unregulated air at 80-100 psi is introduced into the vessel. The unregulated air aerates the canent and causes the pressure in the vessel to increase. hhen pressure in the

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fluidizing vessel reaches 15 psi, the unregulated air is stopped. Regulated air then forces the aerated cement from the fluidizing vessel into the transfer line. We transfer line is connected to the day tank. The regulated air forces the canent in the transfer line into the day tank.

The conveying cycle is emplete when the transfer line is empty.

3.3.2.1.1 Air Conveyor Booster Jet The air conveyor discharge pipin) into the day tank contains a pneumatic boostar jet to impart additional accelerating force and mixing action to the cement flow. Air application to the booster jet is regulated at the 1-9 1r

pneumatic control panel by an air service valvo.

3.3.2.1.2 Conveying Fault Timor

'The conveyirry fault timer is included to automatically stop the conveying process if a batch of cament is not completely evacuated fran the fluidizing vessel to the day tank within a specified interval.

3.3.2.2 C ment Filling Station Day Tank he day tank of the cement filling station is located inside the radwaste building aM is designed to hold sufficient cement for one day's operation. The tank has a net storage capacity of 50 cubic feet. We air conveyor system is capable of filling the day tank in 1.25 hours2.893519e-4 days <br />0.00694 hours <br />4.133598e-5 weeks <br />9.5125e-6 months <br />.

We day tank is rectangular in shape with all four sides tapered sharply into an integral discharge hopper. W e entire assembly is fabricated from 1/4" AS m A-283-C steel utilizing double-welded construction for strength and dust-tight integrity. The tank itself and equipnent mounted thereon is accessible by a welded steel service ladder and a bar-grating maintenance platform surrounded by OSIIA specified double handrailing.

Fluidized cement fran the air conveyor enters the day tank through a discharge box thich distributes the conent evenly inside the tank.

he day tank is equipped with a mechanical pressure-relief valve. The pressure-relief valve is set to open at 10 inches of water to prevent the possible over pressurization of the day tank.

A sonic high-level sensor located at the normally filled level of the day tank provides iMication of day tank level. We day tank has sufficient capacity to complete the transfer of a batch of cement should the high-level set point be reached during transfer. The day tank is equipped with an interlock to prevent the transfer of cement to the day tank once the day tank high-level alarm has been reached.

We transferring of cenent from the day tank to the drtrn screw feeder assembly is facilitated by four fluidizing nozzles located in the wall of the discharge hoppar. The nozzles are connected by a 1-10 y

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1 cannon manifold to a solenoid valve and the compressed air supply.

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3.3.2.3 Screw Feider Assembly We screw Seeder assembly is used to transfer cement fran the day tank discharge hopper to the fill nozzle. W e fill nozzle is placed inside the 55-gallon detrn. The screw feeder consists of a tapered, rolled, steel screw driven at 25.7 rpm.

This provides a cement delivery rate of 110 cubic feet per hour.

We screw feeder discharges to a vertical exit hopper. The drum fill nozzle is attached to the base of the exit hopper. We walls of the exit hopper are installed at a steep angle to prevent the accumulation of cement in the exit hopper.

3.3.2.4 Dust Collection Systen A Torit filter cartridge-type dust collector is installed with the cement filling systen to provide vacutra conditions within the systen and to eliminate area contamination from airborne canent dust. We dust collection equipment is mounted to the top of the day tank for direct dust collection from the day tank but, is also interconnected throughout the cement fillirg systen. The dust collection system takes a suction on the cement filling system at the following points:

a Cement silo, b.

Silo fluidizing vessel, and c.

Exit hopper.

Air is drawn in by the system vent fan through nine filter cartridges housed within the dust collector. Dust is captured on the exterior surface of the elements while filtered air passes out through the filters to the exhaust discharge port and into the radwaste building ventilating systen. The capacity of the ventilation system at the dust collector is 1,200 SCFM @ 6" H 0.

2 The filter elements are alternately cleaned in groups of three. Each group of filters is equipped with a solenoid valve and wilI adnit high-pressure air to the center of the filter elanents. At ten-seconi intervals a pulse of low-voltrue, high-pressure air is directed into the center of the selected elements. The dislodged 1-11 t

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9 dust falls into the day tank where it is utilized for drtrn filling.

te dust collector is electrically interlocked to

'j operate automatically whenever any of the following operations are i* itiated:

n a.

Drum Filling - by moving console selector switch SSS7 to either the AtTr0MATIC or MANUAL drum fill position.

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Storage Silo Filling - by moving selector switen SS28 at the silo to the ON position.

c.

Cement Conveyina to the Day Tank - by depressim the AIR START pusnbutton at the l

electrical console.

3.3.3 DRUM CONVEYING SYSTEM 2e drtrn conveying system consists of the roller conveyor used to transport drtrns through the cement fillirg station area and the integral lift asse:nbly and scale platform which raise the drtrns to the cenent fill nozzle for filling.

3.3.3.1 Roller Conveyor te roller conveyor is divided into four distinct sections. The first section is a flat drtru staging area seven feet in length for drtrn inspection, numbering and cap removal. The secon3 section is the scale platform and drtrn lift area which hydraulically elevates one drtrn at a time, for filling and weighing. We third section is a lory, flat receiviry area for inserting the mixing might and replacing the cap. We fourth section is a floating storage area approximately 22 feet in length for conveying filled dettns to the i

traveling bridge crane pickup point. The length of the storage area is designed to hold enough prefilled drtIns for one day's normal needs.

All individual rollers in the conveyor are provided with dust-proof sealed hearirgs. Five brake rollers are spaced thror

,ur the storage area of the conveyor.

3.3.3.2 Scale Platform A scale platform is installed for weighing individual drums.

It is located beneath the elevating section of the roller conveyor.

It consists of three 500-pourd capacity load cells.

l The outputs of the three cells are added by the 1-12

load cell suming junction in the electrical console aM the total is displayed on one of two,

LED-type, three-figure digital readouts on the electrical console. The readout labeled DRLM TARE displays the weight of the empty drtzn when the scale plat' form is in its 16wered position. This tare weight is retained in a menory circuit of the electronic weighiry systen. The readout labeled DRLM NET displays the continuously changing not weight of cement as it is beirn injected into a drum.

When the desired net weight of cement is reached arrl the feal screw is deactivated, the operator will depress the CLEAR TARE pushbutton on the electrical console. This allows the tare weight to be added to the net weight of cement. tis is the net weight of the drum.

3.3.3.3 Mixina Weichts We mixing weight is an 19-inch length of #10 reinforcing bar bent at its t1-1/4" diameter)0 : inclined angle.

midpoint to a 120 W e devico weighs 6.45 lbs. and is inserted into each drum at the cement filling station after the cement has been applied to the drum. The mixing weight imparts mixing action to the contents in the drumning operation.

3.4 SYSTEM CONTROL 3.4.1 SYSTEM CONTROL PANEL me syste.n control console is a free-standing, desk-type' enclosure for single unit control of the overhead traveling i

bridge crane, the decanting station, the cement druming station ard the operations section for radwaste feel system control of tanks, pumps and valves.

All control and indication devices requira3 for remote operation of the STOCK travelirg bridge crane, decanting /

drumnity stations, and the spent resin / evaporator bottoms tanks and associated system valves and ptrnps are located on the vertical front face and operator's writing table of the console. te control console consists of three modularized sections, each approximately 24" wide, which couprise the operational controls of the radwaste system.

The drum processing control section contains a graphics display panel of the system and all manual switches and visual indicators for operatirn the decanting /druaming stations. An annunciator panel, process salection panel, status display and control panel and operations panel 1-13

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comprise the control sector for this section of the control console.

Incated in the bridge crane control section are the TV monitors with their control-units conveniently grouped for

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operator surveillande while operating the crane. Spring loaded, toggle-type control handles are provided t.o operate the crane, in addition to a crane control panel with indicators and controls for grab elevation, crane operation / status, lighting, grab operation / status and crarm,TV circuit selection.

'Ihe control section contains an annunciator panel, meter panel, tank /p mp status display and control panel and valve operations panel for spent resins and evaporator bottoms waste control.

Ptanovable front panels and hinged doors on the lower front and entire rear of the console provide for easy access to equipment for maintenance and replacement. A graphics display panel provides a visual process flow schmatic for the decanting and drumming stations.

3.4.1.1. Process Selection Panel i

'Ihe process selection panel is positioned below the graphics display. The process selection panel contains the following control and instrmentation:

a.

Evaporator Bottoms Waste Operations Select, b.

Decant Tank Gallons 530 gallons full

range, c.

Machinery Air psig 150 psig full range (PI2),

d.

Flush Water psig 100 psig full range

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Evaporator Bottoms Primary Feed Temp Op _ g_

240VF.

full range, and f.

Evaporp. tor Bottoms Secondary Feed Temp OF-full range.

3.4.1.2 Status Display and Control Panel The status display and control panel is below the process selection panel and contains digital readout displays which serve as both status displays and controls. 'Ihe following readouts are functionally grouped on the status display and control panel:

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a.

Evatorator Bottoms / Chemical Waste Metering Pump GallisEs - IMicates the total numoer of gallons of waste material metered into a drun.

The readout is displayed in half-gallon increments to correspond to the delivery rate

.s of th6 meterirg pump. -

b.

1st Count /2nd Count - A pair of thumbwheel switches are provided with which to select the amount of waste, in gallons, to be metered into the drun. The switches can be usal in three different combinations:

IST COUNT only, 2ND COUNT only, or 1ST COUNT and 2ND COUNT combination for double filling. Each switch is set to the nearest half gallon increnent.

Also, both the decant metering punp and evaporator bottans/chanical waste metering pump can be set to fill a drun simultaneously or in any 1st and 2nd count combinations, such as setting the 1st fill from the decant tank ard the 2rd fill from the evaporator bottans metering pump.

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Drumina Station On/Off - A separate two-position selector switch is used as an ON/0FF switch to energize the relay logic for the drumning station controls.

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Drum or Tank Radiation Level / Roentgens Per Hour - The 1,000R radiation monitor consists of a scintillator detector and its associated electronics and display package. The system is designed as a dual-channel systen with an operating range of 1,000R to 10 mr.

A three-position selector switch, with DRUM RADIATION /OFF/ TANK RADIATION clockwise indicators is provided to display the radiation signal from either the decant tank or the drunning station scale, via the radiation level display.

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Drum Gross Weight /Lbs. - A readout provides the weight of a processed drum via an electronic weighing system.

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Zero Scale - A black zero scale pushbutton is provided to reset the drun gross weight display to zero before or after weighing a drun.

3.4.1.3 Operations Panel

'Ibe eparations panel is positioned imnediately below the status display and control panel ard mounted on the desk top of the control console.

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a.

Evaoorator Bottoms / Chemical Waste Metering Pumo Gallons - Indicates the total number of gallons of waste material metered into a drun. The readout is displayed in half-gallon increnents to correspond to the delivery rate

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.e of themeterirrj punp. -

b.

1st Count /2nd Count - A pair of thumbwheel switches are provided with which to select the amount of waste, in gallons, to be metered into the drum. The switches can be used in three different combinations: IST COUNT only, 2ND COUNT only, or IST COUNT and 2ND COUNT combination for. double filling. Each switch is set to the nearest half gallon increent.

Also, both the decant metering pump and evaporator bottoms /chanical waste metering pump can be set to fill a drun simultaneously or in any 1st and 2nd count combinations, such as setting the 1st fill from the decant tank aM the 2M fill fran the evaporator bottans metering pump.

c.

Druming Station On/Off - A separate two-position selector switch is used as an ON/0FF-switch to energize the relay logic for the drumuing station controls.

-d.

Drum or Tank Radiation Level / Roentgens Per Hour - The 1,000R radiation monitor cc:.iists of a scintillator detector and its associated electronics and display package. The system is designed as a dual-channel systen with an operating range of 1,000R to 10 mr.

A three.

position selector switch, with DRUM RADIATION /OFF/ TANK RADIATION clockwise indicators is provided to display the

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radiation signal from either the decant tank or the drtnining station scale, via the radiation level display.

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Drum Gross Weight /Lbs. - A readcut provides I

the weight of a processed drum via an electronic weighing system.

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Zero Scale - A black zero scale pushbutton is provided to reset the drun gross weight I

display to zero before or after weighing a l'

drum.

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3.4.1.3 Operations Panel l

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The oparations panel is positioned imediately below the status display and control panel aM mounted on the desk top of the control console.

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The operations panel contains pushbuttons or pushbutton/iMicator light combinations for additional operator-controlled functions.

The operations panel contains the followiny

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controls add instrumentati6n:

3.4.1.3.1 Flush Drun Fill Line Energizas valve operators to open the proper valves to allow flush water through the decant metering pump,

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drant to drum fill line aM the slurry filling nozzle to clean the line.

3.4.1.3.2 Flush Evaporator Bottms/ Chemical Waste Feed Line Energizes valve operators to open the proper valves to allow flush water through the evaporator bottoms metering pnp and into the select evaporator bottoms waste feed line. 'Ibe chemical waste feed line is flushed independent of the evaporator bottoms metering p'n9-3.4.1.3.3 Enclosure Washdown Energizes valve operators and a rotating spray drive motor to allow flush water through a revolving manifold to clean the inside of the dr'um processing enclosure.

3.4.1.3.4 Drum Washdown Energizes valve operators to open proper valves to allow flush water through a manifold within the dr u processing enclosure to wash down the exterior surfaces of a drun. The washdown can be energized when the drun is either tumbling or at rest.

3.4.1.3.5 Auto on Energizes the automatic mode of the drun processing cycle. Assuming all conditions are satisfied, the drun will proceed through a complete cycle automatically.

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3.4.1.3.6 Hatch Open Energizes a solencid valve which causes a pnetInatic. actuator to raise the drum

. processing enclpsure hatch cover to the fully open position.

3.4.1.3.7 Manual Advance Permits step-by-step advancanent through the drixn processing cycle rather than automatic advancement.

3.4.1.3.8 Hatch Closed Energizas a solenoid valve which causes the same actuator to lower the drtra processing enclosure hatch cover to the fully closed position. The light indicates that the hatch is fully closed.

3.4.1.3.9 Skip Operation Depressing the red SKIP OPERATICN pushbutton will cause tne drumning sequence programmer to cycle through the steps in the automatic cycle without the equipment actually performig the operation. The lights on the right side of the graphic display panel will flash on as the progra.uner cycles through each step in the automatic sequence, lettig the.

operator know which steps are being by-passed. The programner will continue to cycle until the buttons are released. Drtrn processing may be continued from any point in the sequence as log as the permissives are j

satisfied.

3.4.1.3.10 Energency Stop De-energizas the drtmning cycle circuit imnediately. This button is indeceMent of the decanting operation.

i 3.4.1.4 Graphics Display I

A graphics display panel, located below the annunciator panel on the left vertical section of j..

the control console, represents the decanting and drumnig stations, with associated interconnecting piping, valves, pumps and equipnent. 'Ihe symbols 1-17

__ r.

t

on the left represent the decanting station, with the decant tank, mixer, decant arm and decant pump. Red lights indicate mixer running, arm movertent up or down, decant punp running, and high-or low-level tank status. We circle under e

i the tank represents the decant metering pmp with a piston in the center and four valves which can be opened in various combinations of opened or closed depending upon the mode of operation and direction of flow through the pung. The puup port valves light (red) when open, turn off when closed. The pung piston will light (amber) when intake is complete and turn off upon discharge.

The pump valve ard piston lights visually iMicate that the pump is in operation and show which valves and lines are in use. The shut-off valves, for _ flush / spray lines and for tank feed loops, have red (open) and green (closed) iMicating lights, which are operated from valve actuator limit switches, to give positiva indication of valve position. We metering pump and process valving along with the piping flow indications (amber), verify to the operator which process lines are in use for a particular station operation.

The symbols at the center of the mimic represent the drumning station, showing the drumning enclosure and evaporator bottoms metering ptrup, along with associated piping and valves.

In addition to the valve, pump and flow indicators, there are two rotational arrows in the center of the drum symbol which light (red), after each revolution of the DRLM TUMBLE cycle, giving positive indication that the drun is being tumbled.

~~

On the right side of the mimic is a vertical row of iMicator lights that identifies each sequence of the druming operation cycle. We drtraning cycle is initiated a M completed at the Load Position sequence. During the druuming operation, the operator knows the status ard position of the drum by referencing the glowing (amber) indicator light, which identifies the drumning cycle sequence occurring. We indicator lights provide greater flexibility in operation by allowing the operator to change from the automatic mode to MANUAL ADVANCE at any stage in the requence or to skip sequences, for example, advancing the step programner to the CLNiP 2M step fran the CAP / TUMBLE EOSITION for a contaminated drun washdown, and returning the operation to the automatic mode to complete the drtraning cycle.

The drumning cycle sequence irdicator lights also 1-18 t

serve as a troubleshooting aid by indicating which sequence the drumning cycle was in when a fault trip occura, thus allowing the operator to manually reset the sequence progranmer at the desired st.ep for restarting the drumming operation.'

3.4.1.5 < Annunciator Panel Annunciator windows above the graphics display panel provide the following fault or status indication to the radwaste operator:

a.

demineralizer water pressure, b.

machinery air pressure, c.

cacant tank high-level, d.

select feed loop valve,

e. _ motor overload tripped, f.

drum process cycle complete, g.

no cap in drum, h.

no fill selection (gallons of fill),

i. drum overfill,

j. drum process fault, and k.

evaporator bottoms feed line tanperature high.

3.4.2 CEMENT FILLING STATION CONTROLS I

The electrical control console contains all controls for operating the cement filling station. 'Ihe controls and instrumentation are located at various points in the console and are listed below by area.

3.4.2.1 Console Control Panel The operations and control panel is mounted on the desk top of the control console. The operations and control panel contains the following system indications.

3.4.2.1.1 Control on/Off The two-position selector switch energizes the canplete canent filling station and all control circuitry.

I 1-19 1r

r 3.4.2.1.2 Main Tank High [evel A red indicator light informs the

(.)

operator of high cement level in the

~

, main storage silo.

Input is provided a

by the silo high-level sensor.

3.4.2.1.3 Day Tank High Ievel A red indicator light informs the operator of high cement level in the day tank.

Input is provided by the day tank high-level sensor.

In a high-level condition, cement conveying to the day tank will cease as soon as the current cycle is completed.

3.4.2.1.4 Ehergency Stop A red pushbutton' imediately de-energizes the cement filling station control circuitry including any operations in progress.

3.4.2.1.5 Air Compressot A red pushbutton energizes the control and power circuits to the air compressor system, including the desiccant dryers and electric drain trap. 'Ihe pushbutton will light the red AIR CCt4 PRESSOR iMicator light on the control panel.

3.4.2.1.6 Vent Fan A red pushbutton energizes the control-..

ard power circuits to the dust collector system ventillation fan.

Operation of the dust collector system is automatic whenever dru:n filling operations are initiated or when cenent is being loaded into the storage silo or transferred to the day tank.

However, this pushbutton is provided to enable the operator to activate the dust collection system independently as needed. The pushbutton will light the red VENT FAN indicator light on the control panel.

3.4.2.1.7 Feed Screw Running A red irdicator light informs the operator that the day tank feed screw 1-20 y

-,._ r L

m conveyor is operating.

Input is provided by the DRUM FILL PER4IT pushbutton located on the right side wall of the console.

,.i 3.4.2.1.8 ' Air Conveyor on70ff The two-position selector switch energizas the complete air conveyor process and circuitry.

3.4.2.1.9 Air Start A black pushbutton starts the air

-conveyor transferring cement. The process will continue until the day

_ tank high-level is reached or SS73 is turned off.

3.4.2.1.10 Scale Zero A black pushbutton enables the operator to recalibrate the platform scale after each drttu filling operation.

3.4.2.1.11 Clear Tare A black pushbutton releases the drun's tare weight fran storage in the electronic memory circuit and adds it to the net weight of the cenent in the drun. We total weight is then displayed as DRUM TARE weight.

3.4.2.1.12 Fluidize Day Tank A black pushbutton opens a solenoid valve permittirg air injection into the day tank discharge hopper. @is I

pronotes canent flow to the feed screw and will continue as long as PB100 is depressal.

3.4.2.1.13 Conveying A red indicator light informs the operator that a batch of cement has been fluidized in the air conveyor and is en route to the day tank.

Input is provided by the fluidizer vessel pressure switch.

i l

1-21 e--

~.

kA

-J 3.4.2.1.14 Auto / Manual Fill Drun A spring-return toggle switch enables the operator to selectively fill druns 3

with canent by setting the desiral weight on the thumbwheel switch or by visually monitoring the weight as it appears on the DRUM NET readout.

3.4.2.1.15 Drun Raise /Iower A spring-return toggle switch is provided to raise and lower the drun on the scale platform. 'Ibe switch lever must be held in the appropriate position for the control to be energized. Automatic circuitry prevents overtravel in either direction.

3.4.2.1.16 Drun Tare An LED-type digital readout displays the enpty weight of a drum moved into position on the scale platform.

3.4.2.1.17 Drun Net An LED-type digital readout displays the net weight of cenent in the drun as it is being filled. When filling is canplete and the CLEAR TARE pushbutton is depressed, this weight is blanked arrl the combined weight of the cenent and the drun weights are displayed at the DRIN TARE display.

j

[

3.4.2.1.18 Set Net Weight i

A thumbwheel switch is provided to i

permit the operator to program into the l

electronic weighing systen the required l

amount of cement to be added to the Crun.

In the manual drun filling mode, this switch is not utilized.

3.4.2.1.19 Drun Fill Permit j

A pushbutton located alone near the top of the right side of the electrical i

console enables the operator to l

initiate the dra filling operation, as long as the scale platform has been l

completely raised.

l i

l-22 f

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s 3.,4. 3 DDCANTING STATION CONTROLS We decanting station is functionally controlled by the operator fran the control console decanting and drumning section by means of selector switches and pushbuttons, with iMicators aM indicator lights su;iplanenting the controls. Controls and monitoring devices have been proiided to allow for ease of operation aM to inform the operator of station status and operation.

The decanting station has been providad with tha STOCK solid radwaste system to accurately decant slurries prior te drtrn filling. This station is a compact assembly of components attached to both sides of a 12" thick steel shield wall. Mounted on the maintenance side of the shield wall are all motors, pneumatic valves, actuators and as many of the gear reducers as is practical. On the process side of the wall are the decanting tank and the pumping ems of the metering and decanting puups.

4 Incoming waste slurries are transferred from the liquid radwaste systen storage tanks to the decanting tank through the piping manifold. During this filling operation, the decant tank mixer is automatically operated to ensure that the slurry is a uniform mixture. Upon completion of the filling operation, an automatic flush operetion is initiated to flush the fill line to the decant tank and the feed line back to the liquid system storage tank. After this flush operation has been completed, the slurry is allowed to settle for a predetermined period of time. This settling time allows for the separation of colids and water to a uniform level bed-of-solids.

Once this settling period has elapsed, the water level and water-solid interface level are accurately measured with sensors mounted on the decanting arm and STOCK designed solid state equipnent. These readings are displayed on the.

control console and inform the operator as to whether excess water is to be removed or if water is to be added to the decant tank. Wis is done in accordance with the process control program in order to achieve the correct solid / water ratio consistent with the pretested solidification formula for the waste stream.

Excess water is removed with decanting equipnent and returned to the liquid radwaste systen storage tanks by means of a specially designed decanting pump. Wis minimizes the amoun". of water requiring disposal.

After the decant tank has been prepared with the correct solid / water ratio, the mixer is then autanatically started and operated for a predetermined period of time to ensure that the slurry is again uniform. While the slurry is being mixed, the op3rator is then able to record the radiation level of the slurry to be processed with the radiation detector provided with the decanting station.

1-23 t

The STOCK metering pump is used to transfer the prepared decant tank slurry to the drumirn station for drum processing. The pump and its associated controls allow the operator to program accurate punp quantitites to be 9

processed in each drun. Once programed, the pumping operation becanes part of the autattatic processing cycle at the drunming station. We metering ptrup is also used for transferring decant tank contents back to the waste stream storage tank.

3./.4 DRUtti1NG STATION CONTROLS All controls for operation of the dru=ing station are located imediately adjacent to the decanting station controls. A single selector switch on the front face of the control console energizes the druming station control circuits. Cmplete monitoring of operation of the drunming station can be accomplished by watchiry the graphics display panel while the drumming station is in use. %e operator has the option of druming either decanted wastes or concentrator wastes as well as any combination of the two.

We drumming station is a compact assembly of components to drun radioactive slurries ard solutions in 55-gallon druns with cenent solidification binder. For safety in operation and for maintenance, the equipnent is attached to both sides of a-12-inch thick. steel shield wall. On the safe side of the wall are mounted all motors, pneunatic valves, actuators and as many of the gear reducers as is practical. On the hot side of the wall are the puuping ends of the metering pump and the drun processing enclosure. The 12-inch thick steel shield wall provides the equivalent of 39 inches of concrete shielding, allowing personnel to be present on the safe side of the wall during operation for maintenance or for other purposes.

The druming station is remotely operated fran the console which is provided with the control station. Controis and monitoring devices have been providcd to allow autanatic or manual operation and to inform the operator of strtion status and operation.

The druming station allows druns to be filled with either evaporator concentrates or resin slurries.

Prior to druning operations process control verification tests are performed in accordance with the requiranents of the process control program. Once a satisfactory verification sample has been performed, the required quantity of waste is programed into the waste meter punp controls. We meterity punp will autanatically transfer the required quantity of waste to the disposal container.

Disposable containers which have been prefilled with concrete at the cement filling station are transferred to 1-24 l

v

the drum positioning platform inside the drum processing enclosure. Onca the drum is inside the drum processing enclosure, the station operator shuts the drum processing enclosure hatch isolating the drum processing enclosure from the station's environment.

4 With the metering oumos and the aooropriate feed controls setuo for the correct ouantity of waste (S), drum processing can then be initiated. The movement of the drum through the drumming station cycle is automatic, once the drun has been loaded into the drum processing enclosure and the hatch has been closed. The drum is uncapped, filled, recapped, clamoed, tumbled and unclamoed. This operational secuence may be repeated in the automatic cycle to permit

.the drum to be filled twice.

Upon completion of the automatic process cycle, the drum is returned to the load / unload position within the drum processing enclosure.

The operator then initiates remote opening of the hatch and lowers the crane's drum grab into the enclosure. The drum grab is equioDed with a downward viewing camera, which allows the oDerator to inspect the drum. Smear surveys of the drums are performed prior to removing the drum from the drum processing enclosure.

Should the drum be contaminated tc levels greater than the allowable limits as specified in A9CFR173, the drum is washed down with a water saray and decontaminated prior to removal.

After the coerator has verified that the tou head of the drum is free from contamination, he then raises it out of the drum Drocessing enclosure and positions it uoan the scale platform. Once the drum has been released, the drum's weight and radiation level are then measured and

[

recorded. Displays for these functions are provided at the l

control console and provide valuable information as to the decay pit and location at which-the drum shoeld be stored.

• ~

l i

3.5 SOLIDIFICATION SAMPLE VERIFICATION 3.5.1 RECIRCULATION OF WASTE STREAMS 3.5.1.1 Prior to sampling radioactive waste hold up tanks for process control samole verification, each tank shall be recirculated until the tank volume has been turned over a minimum of three times.

3.5.1.2 No waste should be added to a radwaste tank after samoling has been performed. Waste for.other than solidification should also not be removed from the tank after sampling.

l I

Should waste be added to the batch orior to comolet-ing the solidification of the batch, solidification activities will be secured.

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V 3.5.1.3 The radioactive waste tank shall remain in the recirculation mode during sampling and solidification operations.

3.5.1.4 Should recirculation of the tank be secured at any time orlor to solidification, the tank must be placed in the recirculation mode until the tank volume has been turned over a minimum of three times.

3.5.2 VERIFICATION SAMPLE REQUIREMENTS 3.5.2.1 Solidification samole ver'fication will be performed on each batch of each tyoe radioactive waste until standard cement-to-waste ratfor. have been developed and proven to produce acceptable products on a minimum of ten consecutive batches.

3.5.2.2 Once the standard ratios have been oroven to produce acceptable solidified products for ten consecutive batches of each type radioactive waste, solidification sample verification recuirements will be decreased to at least once every tenth batch of each tYoe of radioactive waste.

3.5.2.3 Should any solidification verification samole prove to produce unsatisfactory solidified products, solidification verification sampling recuirements will be increased to every batch of each type radioactive waste until the criteria of Steo 3.5.2.1 are met.

3.5.3 WASTE IDENTIFICATION 3.5.3.1 Each verification sample shall be analyzed for the following minimum characteristics:

3.5.3.1.1 011 3.5.3.1.2 pH 3.5.3.1.3 Temperature

'"~

3.5.3.1.4 Percent by weight salts 3.5.3.1.5 Isotopic analysis 3.5.4 SOLIDIFICATION SAMPLE ACCEPTANCE CRITERIA 3.5.4.1 Visual insoection of the end oroduct af'ter ~

solidification must indicate a dry, free standing, nonolithic structure.

3.5.4.2 The end product must resist 9enetration when orobed with a scatula or comoarable firm object.

1-26

_ r

KANSAS GAS AND ELECTRIC COMPANY THE ELECTAC COMPANY OLENN L MOESTER v<s persicaset - souctaam November 14, 1983 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C.

20555 KMLNRC 83-145 Re:

Docket No. STN 50-482 Ref: 1) Letter KMLNRC 83 -230 dated 8/5/82 from GLKoester, KG&E, to HRDenton, NRC

2) Letter KMLNRC 83-012 dated 1/26/83 from GLKoester, KG&E, to HRDenton, NRC

3) Letter KMLNRC 83-022 dated 3/4/83 from GLKoester, KG&E, to HRDenton, NRC

4) Letter SLNRC 83-0036 dated 7/8/83 from NAPetrick, SNUPPS, to HRDenton, NRC Subj: Process Control Program (PCP)

Dear Mr. Denton:

The Referenced letters transmitted the Wolf Creek Technical Specifications to the NRC for review. In accordance with the request by Mr. Joseph Holonich, NRC Project Manager for the Wolf Creek Application, transmitted herewith are five copies of the Wolf Creek Generating Station Process Control Program (PCP). The PCP is being submitted in accordance with Technical Specification 6.13.1 for NRC review and approval.

Yours very truly, (Jiu GLK:bb Attach cc: JHolonich (2)

WSchum/ASmith I, l 201 N. Market - Wichita, Kansah - Man Address: PO. Box 208 I Nchita, Kansas 67201 - Telephone: Area Code (316) 261-6451 f

1:

e 1

OATH OF AFFIRMATION STATE OF KANSAS

)

) SS:

COUNTY OF SEDGWICK )

I, Glenn L. Koester, of lawful age, being duly sworn upon oath, 'do depose, state and affim that I am Vice President - Nuclear of Kansaa Gas and Electric Company, Wichita, Kansas, that I hrsve signed the foregoing letter of transmittal, kn3w the contents thereof, and that all statements contained therein are true.

KANSAS GAS AND ELECTRIC COMPANY l

Ily, f4u()

_ Q Glenn L.

Koester o

vice President - Nuclear E.D.',Prothro, Assistant Secretary c

+

STATE OF KANSAS

)

) SS:

COUNTY OF SEDGWICK )

BE IT REMEMBENED that on this 14th day of November, 1983

, before me, Evelyn L. Pry, a Notary, personally appeared Glenn L. Koester, Vice President - Nuclear of Kansas Gas and Electric Corapany, Wichita, Kansas, who is personally known to me and who executed the foregoing instrument, and he duly acknowledged the execution of the satte for and on behalf of and as the act and deed of said cort. oration.

I have hereunto set my hand and affixed my seal the

.. M.gn <IN, WITNESS WIIEREOF,**:"date/'and year above written.

."4*s&"

5. *., /b v&p) - -

• goTA

/

i 3

./

gg*G A d w d.

'a

,e,.!

(velyn/L. Fry,fgtary 5,_..,. -

My Commission expires on August 15, 1984, t

--