Safety Management Aspects of the Tokamak Fusion Test Reactor D&D
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Transcript of 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
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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
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Tokamak Fusion Test Reactor D&DSafety
• Pre-lift meeting
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Tokamak Fusion Test Reactor D&DSafety
• 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)
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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
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Tokamak Fusion Test Reactor D&D Tooling
• Broderson
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Tokamak Fusion Test Reactor D&D Tooling
• Brokk
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Tokamak Fusion Test Reactor D&D Tooling
• Champion
Holmotro
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Tokamak Fusion Test Reactor D&D Tooling
• Wachs clamshell
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Tokamak Fusion Test Reactor D&D Tooling
• Wachs Guillotine
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Tokamak Fusion Test Reactor D&D Tooling
• Nibbler
• Wide mouth portaband saw
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Tokamak Fusion Test Reactor D&D Tooling
• Water jet cutter
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Tokamak Fusion Test Reactor D&D Platform Removals
• Platforms removed piece by piece rather than large awkward chunks.
Platform
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• Diagnostic removals complicated but well coordinated
– Electrical first
– Then line breaks
– Then mechanical removals
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• Electrical trays first
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• Electrical first
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• Bay D XCS
• Bay E XIS
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• Port cover line breaks
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• 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.
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Tokamak Fusion Test Reactor D&D Diagnostic Removals
• XIS Lead removals
• Trained one crew to handle lead and package it for reuse or recycling.
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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.
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Tokamak Fusion Test Reactor D&D Umbrella Lift
• 10 point installation lift with hub vs. 5 point disassembly lift
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Tokamak Fusion Test Reactor D&D Umbrella Lift
• Installation lift vs. disassembly lift
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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.
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Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals
Pump Duct
Pump Duct
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Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals
Pump Duct
Pump Duct
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Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals
• Foam filled to control contamination
• Separating duct for packaging after foam filled.
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Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals
• Separated duct after foam filled
• Water is a byproduct of foam
Catch Basin
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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
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Tokamak Fusion Test Reactor D&D Shear Compression Panel Cover
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Tokamak Fusion Test Reactor D&D Shear Compression Panel (SCP)
SCP Cover
removed
Studs connecting SCP to coil cases
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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
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Tokamak Fusion Test Reactor D&D TF Coil Cutting - Marvel Saw
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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
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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
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Tokamak Fusion Test Reactor D&D Basement Piping
• Vacuum piping Under Bay C pump duct
• Line break• Took the extra
time to build scaffolding
Piping
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Tokamak Fusion Test Reactor D&D Basement Piping
• Vacuum piping cut with WACHS cutter.
• Line break with HP monitoring with Scintrex.
WACHS
Scintrex
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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.
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Tokamak Fusion Test Reactor D&D Diamond Wire Cutting Support
• Mask clean, decon, and disinfect.
• Did not expect significant amount of time needed.
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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.
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Tokamak Fusion Test Reactor D&D Lessons Learned
• Sector lifted toward box.
• Bumped Box Lid
Box Lid
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Tokamak Fusion Test Reactor D&D Lessons Learned
• Lid fell – storage area / potential energy• Conduit represents box lid length
Conduit (Box Lid)
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Tokamak Fusion Test Reactor D&D Lessons Learned
• 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.
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Tokamak Fusion Test Reactor D&D Lessons Learned
• 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!!
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• 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