This document addresses the remote systems and design integration aspects of the development of the Solid Waste Processing Center (SWPC), a facility to remotely open, sort, size reduce, and repackage mixed low-level waste (MLLW) and transuranic (TRU)/TRU mixed waste that is either contact-handled (CH) waste in large containers or remote-handled (RH) waste in various-sized packages. The vast and varying waste stream that is anticipated to enter this facility makes this an extremely complex challenge. In addition to the issues associated with handling RH-TRU waste, the SWPC will encounter containers sized anywhere from 1 gallon cans to 20ft x 13ft x 11ft boxes. The waste containers can be as heavy as 83,000 pounds, and the radiation levels can be as high as 20,000 R/hr at the container surface. Another aspect that makes this project complex is the remote environment, where tasks are inherently more difficult. Seemingly easy everyday tasks can be quite problematic or impossible to achieve remotely. Operator vision is limited to two dimensions (no depth of field), audio feedback is limited to what microphones and noise canceling technology can provide, and the sense of physically feeling motions or forces is absent without extensive sensor technology. It is critical that the project not underestimate the challenges of developing this facility. Key aspects in effectively succeeding at this effort and controlling costs include: Clearly defining scope and requirements with the involvement of users and stakeholders. Understanding the need for process design and tool flexibility to counteract the extensive uncertainties that will be encountered. Completing thorough design integration efforts up front. Paying significant attention to tool development, testing and validation for all process tasks. Commercial off-the-shelf tools are not designed for remote deployment and operation and will require adaptation. Being cognizant of the human-machine interface complexities associated with the deployment of numerous remote systems in one space. Utilizing discrete event simulation to focus on the logical structure of the facility and the movement of material through it. Understanding maintenance requirements. Evaluating the risk and consequences of equipment failures. Establishing and maintaining a cold mock up for testing, operator training, and operational task planning prior to and during operation of plant. Establishing a relationship with Labor for the development of the SWPC's own specialist operators to perform all remote tasks and maintenance.

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SummaryThe High Level Vaults (HLV) consists of three underground concrete vaults containing seven tanks. The tanks were used to support a variety of radiochemical processes conducted in the High Level Radiochemistry Facility (HLRF) hot cells. The HLRF is located adjacent to the east wall of the 325 Building, which also is known as the Radiochemical Processing Facility (RPL).Initial radiological and chemical conditions and video documentation of the interior of the HLV were obtained by disassembling the HLV high efficiency particulate air (HEPA) filter housings and inserting remote monitoring equipment through the openings. The radiological dose rates obtained near the filter housing inlets ranged from less than the minimum detectable amount (MDA) to 150 mRem/hr. The results indicated that the HLV access cover block could be safely removed.The weather barrier covering the HLV cover blocks was removed and discarded. To extend the working surface, a two-foot strip of concrete was installed around the perimeter of the HLV. Reinforced plastic sheeting was secured over the cover blocks to prevent rainwater incursion into the HLV.A work structure (containment) was erected over the HLV so the vault could be accessed while maintaining a radiologically controlled environment over the work area. The containment was installed so that both the key cover block and the inlet HEPA filter were enclosed. Positioning the containment in this manner was instrumental in maintaining proper air flow when removing and replacing the vault cover blocks. The vaults were exhausted via the RPL Radioactive Exhaust Ventilation System, and the existing system design and configuration was adequate to exhaust the containment and the vault being accessed.A portable gantry hoist erected inside the containment was used to remove the HLV key access cover block. A remotely operated vehicle (ROV), hand-held reach tools, and associated sampling equipment were inserted into each HLV via an open access cover block. The ROV was equipped with a robotic arm that was used to transport and maneuver radiological survey and characterization sampling equipment through the interior of the HLV. Hand-held extension tools manipulated through the HLV access openings were also used to obtain radiological dose rates and characterization samples.Characterization samples consisted of several removable contamination smears from the surfaces of the HLV walls and tanks, liquid obtained from the HLV sump trenches, and samples of debris (soil) from the HLV floor. Samples were submitted to the analytical laboratory and analyzed for total alpha (TA), total beta (TB), alpha energy analysis (AEA), gamma energy analysis (GEA), and beryllium by inductively coupled plasma (ICP) spectrophotometry. The analytical results indicated that the radiological characteristics were consistent within each HLV, and no beryllium was detected in the characterization samples.The dose data obtained during characterization activities indicate the maximum dose rates on the tanks are approximately 160 m...