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

This article discusses safety management aspects of the Tokamak Fusion Test Reactor D&D, including daily and weekly safety meetings, zero tolerance for injuries, and proper tooling and equipment usage.

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

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  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 ANS D&D TRACKING ID: 79559

  2. 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 ANS D&D TRACKING ID: 79559

  3. Tokamak Fusion Test Reactor D&DSafety • Pre-lift meeting ANS D&D TRACKING ID: 79559

  4. 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) ANS D&D TRACKING ID: 79559

  5. 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 ANS D&D TRACKING ID: 79559

  6. Tokamak Fusion Test Reactor D&D Tooling • Broderson ANS D&D TRACKING ID: 79559

  7. Tokamak Fusion Test Reactor D&D Tooling • Brokk ANS D&D TRACKING ID: 79559

  8. Tokamak Fusion Test Reactor D&D Tooling Holmotro • Champion ANS D&D TRACKING ID: 79559

  9. Tokamak Fusion Test Reactor D&D Tooling • Wachs clamshell ANS D&D TRACKING ID: 79559

  10. Tokamak Fusion Test Reactor D&D Tooling • Wachs Guillotine ANS D&D TRACKING ID: 79559

  11. Tokamak Fusion Test Reactor D&D Tooling • Nibbler • Wide mouth portaband saw ANS D&D TRACKING ID: 79559

  12. Tokamak Fusion Test Reactor D&D Tooling • Water jet cutter ANS D&D TRACKING ID: 79559

  13. Tokamak Fusion Test Reactor D&D Platform Removals Platform • Platforms removed piece by piece rather than large awkward chunks. ANS D&D TRACKING ID: 79559

  14. Tokamak Fusion Test Reactor D&D Diagnostic Removals • Diagnostic removals complicated but well coordinated • Electrical first • Then line breaks • Then mechanical removals ANS D&D TRACKING ID: 79559

  15. Tokamak Fusion Test Reactor D&D Diagnostic Removals • Electrical trays first ANS D&D TRACKING ID: 79559

  16. Tokamak Fusion Test Reactor D&D Diagnostic Removals • Electrical first ANS D&D TRACKING ID: 79559

  17. Tokamak Fusion Test Reactor D&D Diagnostic Removals • Bay D XCS • Bay E XIS ANS D&D TRACKING ID: 79559

  18. Tokamak Fusion Test Reactor D&D Diagnostic Removals • Port cover line breaks ANS D&D TRACKING ID: 79559

  19. 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. ANS D&D TRACKING ID: 79559

  20. Tokamak Fusion Test Reactor D&D Diagnostic Removals • XIS Lead removals • Trained one crew to handle lead and package it for reuse or recycling. ANS D&D TRACKING ID: 79559

  21. 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. ANS D&D TRACKING ID: 79559

  22. Tokamak Fusion Test Reactor D&D Umbrella Lift • 10 point installation lift with hub vs. 5 point disassembly lift ANS D&D TRACKING ID: 79559

  23. Tokamak Fusion Test Reactor D&D Umbrella Lift • Installation lift vs. disassembly lift ANS D&D TRACKING ID: 79559

  24. 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. ANS D&D TRACKING ID: 79559

  25. Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals Pump Duct Pump Duct ANS D&D TRACKING ID: 79559

  26. Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals Pump Duct Pump Duct ANS D&D TRACKING ID: 79559

  27. Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals • Foam filled to control contamination • Separating duct for packaging after foam filled. ANS D&D TRACKING ID: 79559

  28. Tokamak Fusion Test Reactor D&D Vacuum Pump Duct Removals • Separated duct after foam filled • Water is a byproduct of foam Catch Basin ANS D&D TRACKING ID: 79559

  29. 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 ANS D&D TRACKING ID: 79559

  30. Tokamak Fusion Test Reactor D&D Shear Compression Panel Cover ANS D&D TRACKING ID: 79559

  31. Tokamak Fusion Test Reactor D&D Shear Compression Panel (SCP) SCP Cover removed Studs connecting SCP to coil cases ANS D&D TRACKING ID: 79559

  32. 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 ANS D&D TRACKING ID: 79559

  33. Tokamak Fusion Test Reactor D&D TF Coil Cutting - Marvel Saw ANS D&D TRACKING ID: 79559

  34. 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 ANS D&D TRACKING ID: 79559

  35. 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 ANS D&D TRACKING ID: 79559

  36. 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 ANS D&D TRACKING ID: 79559

  37. Tokamak Fusion Test Reactor D&D Basement Piping • Vacuum piping cut with WACHS cutter. • Line break with HP monitoring with Scintrex. WACHS Scintrex ANS D&D TRACKING ID: 79559

  38. 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. ANS D&D TRACKING ID: 79559

  39. Tokamak Fusion Test Reactor D&D Diamond Wire Cutting Support • Mask clean, decon, and disinfect. • Did not expect significant amount of time needed. ANS D&D TRACKING ID: 79559

  40. 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. ANS D&D TRACKING ID: 79559

  41. Tokamak Fusion Test Reactor D&D Lessons Learned • Sector lifted toward box. • Bumped Box Lid Box Lid ANS D&D TRACKING ID: 79559

  42. Tokamak Fusion Test Reactor D&D Lessons Learned • Lid fell – storage area / potential energy • Conduit represents box lid length Conduit (Box Lid) ANS D&D TRACKING ID: 79559

  43. 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. ANS D&D TRACKING ID: 79559

  44. 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!! ANS D&D TRACKING ID: 79559

  45. 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 ANS D&D TRACKING ID: 79559

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