Safety Management Aspects of the Tokamak Fusion Test Reactor D&D

June 5, 2003 ANS D&D TRACKING ID: 79559 1

Safety Management Aspects of the Tokamak Fusion Test Reactor D&D

Mike Viola (TFTR Construction Manager)2003 American Nuclear Society Annual Meeting

June 5, 2003


Tokamak Fusion Test Reactor D&DSafety

• Daily meeting at the start of the day – openly solicited hazards or recent events (often mini toolbox safety meeting)

• Weekly safety meeting

• Zero tolerance for even minor cuts and bruises

• 100% supervision – Construction Manager and lead technicians

• Pre/post job briefs



• Pre-lift meeting



• Inspect tools prior to use

• Fall protection – emphasized and regularly reviewed

• Construction Grade extension cords and cannot daisy chain

• Chicago air fitting not auto shutoff – air connection whips and flow restrictors (reputable suppliers)


Tokamak Fusion Test Reactor D&D Tooling

• Correct tool always ordered or made!• Bought specialized tools up front

– Broderson

– Brokk

– Champion vs. Holmotro

– Wachs clamshell

– Wachs guillotine

– Nibblers and wide-mouth Portaband Saws

– Water-jet cutter

– Aerial lifts and forklifts



• Broderson



• Brokk



• Champion

Holmotro



• Wachs clamshell



• Wachs Guillotine



• Nibbler

• Wide mouth portaband saw



• Water jet cutter


Tokamak Fusion Test Reactor D&D Platform Removals

• Platforms removed piece by piece rather than large awkward chunks.

Platform


Tokamak Fusion Test Reactor D&D Diagnostic Removals

• Diagnostic removals complicated but well coordinated

– Electrical first

– Then line breaks

– Then mechanical removals



• Electrical trays first



• Electrical first



• Bay D XCS

• Bay E XIS



• Port cover line breaks



• Diagnostic vent

• Ran throughout the room to service tritiated exhaust.

• Could have been confused with conduit or other piping; so it was marked with yellow paint.



• XIS Lead removals

• Trained one crew to handle lead and package it for reuse or recycling.


Tokamak Fusion Test Reactor D&D Umbrella Lift

• Lift of Umbrella Structure was the heaviest lift (92 tons) of the project.

• Umbrella lift simplified compared to original installation.

• Considered a “Critical Lift” – extensive forethought and planning resulted in a smooth event.



• 10 point installation lift with hub vs. 5 point disassembly lift



• Installation lift vs. disassembly lift


Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals

• Complicated extrication:

– Major line break.

– Unusual shape and center of gravity.

– Supports welded after bolts installed.

– Floor plates not consistent.



Pump Duct

Pump Duct



Pump Duct

Pump Duct



• Foam filled to control contamination

• Separating duct for packaging after foam filled.



• Separated duct after foam filled

• Water is a byproduct of foam

Catch Basin


Tokamak Fusion Test Reactor D&D Shear Compression Panel

• Special sockets for shear compression panel (SCP) and cover bolts

• Repetitive motion issues– Limited to 2 hours

continuous effort– 4 hours per day


Tokamak Fusion Test Reactor D&D Shear Compression Panel Cover


Tokamak Fusion Test Reactor D&D Shear Compression Panel (SCP)

SCP Cover

removed

Studs connecting SCP to coil cases


Tokamak Fusion Test Reactor D&D Poloidal Coil Removals

• Began to cut PF’s after the umbrella removed.

• Removed stack 9 lower in sections from around the machine.

WACHS guillotine


Tokamak Fusion Test Reactor D&D TF Coil Cutting - Marvel Saw


Tokamak Fusion Test Reactor D&D TF Coil Cutting - Marvel Saw

• One time the coil vibrated off of the saw. The coil had been wrapped with Nomex for shipping and was slippery enough to vibrate off of its supports.

• Strapped coil to wood stand and applied nonskid tape to the floor


Tokamak Fusion Test Reactor D&D Basement Piping

• Heating/ cooling pipes cut with WACHS cutter.

• Complicated rigging set up

• Used personnel scissor lifts for access.

Piping



• Vacuum piping Under Bay C pump duct

• Line break• Took the extra

time to build scaffolding

Piping



• Vacuum piping cut with WACHS cutter.

• Line break with HP monitoring with Scintrex.

WACHS

Scintrex


Tokamak Fusion Test Reactor D&D Diamond Wire Cutting Support

• Three enclosure setup.

• Complicated task with many levels of support.

• Went smoothly due to complete mockup of process.


Tokamak Fusion Test Reactor D&D Diamond Wire Cutting Support

• Mask clean, decon, and disinfect.

• Did not expect significant amount of time needed.


Tokamak Fusion Test Reactor D&D Special Problems

• Penetration jelly was extremely slippery– citrus cleaner, floor stripper, etc results in mixed waste issues.

• ZEP products smell and produce phosgene vapors in the same room as an arc.

• Lead – had lots of shielding – trained separate crew to handle and paint.

• Wall access difficult (Broderson, JLGs).• Block wall was hard to disassemble because blocks were

RTV’d together.• Cruder demolition rigging techniques vs. Precision fixtures

for assembly.


Tokamak Fusion Test Reactor D&D Lessons Learned

• Sector lifted toward box.

• Bumped Box Lid

Box Lid



• Lid fell – storage area / potential energy• Conduit represents box lid length

Conduit (Box Lid)



• Supervision at all times!

• Tooling – Quickly demonstrate that management supports all work to be done properly with the right tool. Developed various fixtures and tooling for specific tasks. Take the time and wait as needed.

• Contamination Control and Decon.

– Pro-active approach – an ounce of prevention...

– Active involvement of hp’s. – Lots of experience, good ideas.



• Safety first – really! Stopped work whenever any confusion or apparent trend developed.

• Daily kickoff meeting / Weekly Safety meeting

• Developed excellent teammanship and safe working environment. Used individual experience and talents wherever possible.

• Procedures/techniques – procedures used 100% BUT crews often developed new ideas which were fed back into procedure review and JHA analysis – never stop thinking!!


• Acknowledgement: This work was supported by U.S. DOE Contract AC02-76CH03073

• More information on the TFTR D&D Project, including all presentations at a Lessons Learned Workshop, can be found at HTTP://dd.pppl.gov

Documents

Safety Management Aspects of the Tokamak Fusion Test Reactor D&D