silo 3 - U.S. Department of Energy

OBS
Process Control Plan for the Silo 3 Project
Document No. 40430-PL-0003, Rev. 1
Jacobs Project Number 35H19605
September 5, 2003
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0 5.3 CONTAINER MANAGEMENT AND SAMPLING SYSTEM CONTROL PHILOSOPHY
The Container Management and Packaging System is a vendor-supplied package. After
final design, the vendor will provide a final detailed control system configuration and a
detailed sequence of operation.
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The system is a continuously manned operation. The operators perform several manual
steps to prepare the bags for filling. These steps include placing the Packaging Frame onto
the Package Loading Stand, placing the container in the frame, positioning the loading
spout, and coupling the container to the spout. The operator then activates the aeration
blower, pre-inflating the container to conform to the frame.
Operator interface is based primarily on local operation with input via local push buttons
and hand switches. A primary hand control station is provided at the Package Loading
Stand, and other control stations are provided as required for operation for the
downstream conveyors. These control stations are suitably configured for manipulation by
the operators, who are in standing positions alongside the conveyors.
Control of the actual filling of the bags is a combination of manual, semi-automatic, and
fully automated operations. Coupling the bag to the filling port, inflating the inner liner, and
confirming an adequate closure are semi-automatic operations. Dispensing the material
into the bag and operating the vibrating densification device are automated to reduce the
possibility of overfilling. The operator initiates a filling sequence after having positioned the
bag and having confirmed proper seal to the spout. The material discharge valve opens,
and material begins to fill the container'', The vent valve opens to allow the deaeration
blower to remove air from the bag as it is being filled. The densification'vibrator is
activated when a fill weight of approximately 20 percent of anticipated final weight has
been reached. Operators are required to visually monitor the filling level and be prepared
to halt the filling process .as required; bullet cameras are provided in both fill heads to
facilitate this. If overfilling occurs, a manually operated vacuum line is provided to allow
operators to remove material from the bag and transfer it to the PRS.
After the container is filled, the operator raises the loading spout, adjusts the inner-liner
seal, and heat-seals the liner using the RF sealerle. The inner liner is then detached from
the loading spout, and the gross weight of the entire assembly is measured and recorded.
Using local hand controls, the operator moves the Packaging Frame from the Package
Loading Stand to the Packaging Staging Conveyor, where swipe sampling is performed.
The frame is then transferred to the Airlock Conveyor, and finally to the Off-Loading
Conveyor. Position switches and interlocks on the conveyors and doors ensure that:
'' Mixed additive solution is sprayed into the Discharge Chute Assemblies during the entire filling
cycle. Once the container is full, the chute assembly's nozzles are flushed with process water,
which also enters the container. See Section 8.0 for further .details on the Additive System.
''The RF sealer provides a double seat at the top of the inner liner, with in-between perforation that
enables the operator to tear. away the inner liner rather than cut it.
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