Summary of Lessons Learned James H Chrzanowski DD

Summary of Lessons Learned James H. Chrzanowski D&D Lessons Learned Workshop June 25 -26, 2002 PPPL June 25 -26, 2002 D&D Lessons Learned Workshop 1

Lessons Learned Ø Engineering and Planning Activities – Engineering – Work Control Center – Cost and schedule Ø Safety and Health Physics Ø Electrical Safety Ø Field Activities Ø Tritium Retention/line breaks and decontamination Ø Waste Management June 25 -26, 2002 D&D Lessons Learned Workshop 2

Engineering and Planning Ø Early design and planning are essential for a successful project Ø Accountability using Engineering Work Packages (EWP’s) has minimized problems in the field Ø Communication between groups is essential Ø Effective use of meetings can be beneficial Ø The Work Control Center concept worked very efficiently and will be used for future PPPL projects June 25 -26, 2002 D&D Lessons Learned Workshop 3

Engineering and Planning Ø Full scale mockups were important in developing procedures, techniques, identifying safety concerns, and provided a training tool for the construction team Ø SAFETY should be included in all planning activities and is the KEYSTONE to a successful project Ø Use Integrated Safety Management – Line management responsibility for safety June 25 -26, 2002 D&D Lessons Learned Workshop 4

Cost and Schedule Ø Ø Define critical paths upfront and keep in focus Establish cost contingency methodology and reserve Establish schedule contingency (Time) Resource loaded schedules Ø Work Authorization Process Ø Advanced procurement planning(hardware/materials) Ø Earned Value Concept Ø Monthly Status Meetings June 25 -26, 2002 D&D Lessons Learned Workshop 5

Safety Ø Establish your safety program prior to beginning activities- adequate staffing required – Construction Safety, Industrial Hygiene, Health Physics Ø Job Hazard Analysis (JHA) program for planning work activities. –This allows those that are familiar with the job, and the associated hazards, to evaluate the work to be performed and suggest controls. Ø Develop and implement training and qualification programs (PPE’s, ladder safety, electrical safety, equipment usage, etc. ) June 25 -26, 2002 D&D Lessons Learned Workshop 6

Safety Ø Use Safety Meetings- effective tool to maintaining safe working environment Ø Establish a Confined Space program –Training –Documentation control Ø Be prepared for the unexpected. In our case it was lead oxide –Strippable paint provided the most effective means of removing lead oxide surface dust –Reuse lead shielding by coating lead with Polyurethane paint$$$ savings June 25 -26, 2002 D&D Lessons Learned Workshop 7

Safety Ø Hazard Control – Use engineering and administrative controls FIRST – Personal Protective Equipment (PPE’s) only as a last resort (secondary control method ) when it is not feasible to make the work area free of all hazards. Ø Pre-plan the job to ensure that the necessary PPE’s to complete a job are readily available to workers June 25 -26, 2002 D&D Lessons Learned Workshop 8

Health Physics Ø Careful job planning and proper contamination control by Health Physics reduces the number of contamination areas and spread of contamination Ø Clean materials and equipment entering contamination areas should be controlled –Auxiliary Tool Crib in TC for contaminated tools, etc. Ø Seek alternatives to materials which can not be surveyed for tritium –Foam filling materials June 25 -26, 2002 D&D Lessons Learned Workshop 9

Electrical Safety Ø Test immediately prior to cutting cables/conduits, however, treat all cable cuts as live Ø Utilize Lockout/Tagout policy Ø Safety and productivity are enhanced by employing the same individuals to perform electrical removals for the duration of the job. Ø When possible, using a consistent procedure format helps enable electricians to better become the “last line of defense” June 25 -26, 2002 D&D Lessons Learned Workshop 10

Electrical Safety Ø Non-contact voltage sniffers do not detect DC current Ø Planning and procedure preparation require at least twice as much labor as the field electrician effort Ø Pre-identify and protect wiring/devices that must remain Ø DO NOT perform cuts on energized cables June 25 -26, 2002 D&D Lessons Learned Workshop 11

Field Activities Ø Oversight Supervision is required at all times Ø Develop a team work and a safe working environment ØDaily and weekly meetings with field team ØUse individual experience and talents wherever possible June 25 -26, 2002 D&D Lessons Learned Workshop 12

Field Activities Ø 100% use of procedures worked well, new ideas can be incorporated into procedures through revisions Ø Use of Job Hazard Analysis (JHA’s) ØPre and post job briefings to pass on lessons learned promptly ØPassed on in real time to persons preparing new procedures June 25 -26, 2002 D&D Lessons Learned Workshop 13

Field Activities Ø Pro-active approach to contamination control and decontamination – Covers over the Neutral beam boxes – Negative pressure on the vacuum vessel Ø Use the right tools for the job. Take the time and wait as needed to obtain/develop the proper tools Ø Actively involve your Health Physics technicians - they have years of experience working in nuclear facilities June 25 -26, 2002 D&D Lessons Learned Workshop 14

Field Activities Ø Establish teams to handle specific tasks – Example- lead removal team, diamond wire cutting team • More efficient • Less expensive • Less training Ø SAFETY must be involved in all aspects of field activities Ø Try to anticipate and plan for problem activities (they have cost and schedule impact) –Shield wall removal (blocks stuck together with RTV) –Lead contamination issues –Shear compression panel removals (nuts harder to backoff than expected) June 25 -26, 2002 D&D Lessons Learned Workshop 15

Vacuum Vessel Fill Ø The use of low density concrete provided: – Low fill weight – Stabilization of tritium. – Void fill as required for Rad Waste burial – Shielding from gamma. Ø The concrete was a very effective means of stabilizing the internal contamination. The filling/curing process did not liberate tritium from the graphite tiles. June 25 -26, 2002 D&D Lessons Learned Workshop 16

Vacuum Vessel Fill Ø The gas handling system was effective in controlling overpressure during the curing process. The result was NO slumping of the concrete. Ø The ability to route exhaust gasses, to systems with various levels of detritiation, allowed us to minimize the release of tritium, without unnecessarily burdening the tritium oxidation system. June 25 -26, 2002 D&D Lessons Learned Workshop 17

Diamond Wiring Cutting Ø Has been demonstrated to be an effective tool in the D&D arsenal – the ability to cut large metal structures containing softer metals, such as stainless steel, and one of the hardest metals, Inconel, in conjunction with a concrete-matrix. Ø Can be used in access limited configurations Ø Mitigation of contamination generation –Advantageous when compared to the significant health and safety concerns associated with the baseline technology of plasma torch cutting June 25 -26, 2002 D&D Lessons Learned Workshop 18

Diamond Wiring Cutting Ø CO 2 has been shown to be effective for cleaning and cooling the diamond wire Ø New cutting speeds and cable tension values have been established (significantly different from industry standards) Ø Potential for multiple uses in industry June 25 -26, 2002 D&D Lessons Learned Workshop 19

Tritium Handling Ø The secret to tritium handling is: – Engineering hardware • Elephant trunk stations • Drum Bubbler • Oil change carts • Gore-tex rope-gasket material for making seals – Trained, skilled personnel • Training program – Strict adherence to established procedures and protocol June 25 -26, 2002 D&D Lessons Learned Workshop 20

Waste Management Ø Packaging – Consider selecting two vendors – On-site QA is a plus – Specify and approve testing methods – Nuclear filters – not for Tritium – Ensure testing is integrated with assembly and welding plan – Visit your vendor – explain your needs – Identify package needs with engineering – Account for disassembly techniques June 25 -26, 2002 D&D Lessons Learned Workshop 21

Waste Management Ø Packaging-continued – Plan for voids and material to fill voids – Incorporate weight of void fillers into design. – Give yourself contingency • weight capacity • interior dimension –Void Filler • Low Density Concrete – Geofoam • Expanding Foam • Secondary waste – plastics, rags, metals, crushed glass • Radioactive Waste – the most desirable - $ June 25 -26, 2002 D&D Lessons Learned Workshop 22

Waste Management Ø Transportation – Plan and contract for multiple services • Overweight/Oversize/height concerns • Dump trailers – non-contaminated metals • Special services – Packaging- Reduce costs • Effective use of wrapping components instead of boxing (TF and PF coils) June 25 -26, 2002 D&D Lessons Learned Workshop 23

Summary Ø The D&D Project has been able to successfully complete the removal of the TFTR machine using a sound engineering plan, SAFETY, trained personnel, good communication and oversight Ø It is hoped that some of the lessons that we have learned and presented this week can be used in your future projects June 25 -26, 2002 D&D Lessons Learned Workshop 24