Summary of the D&D Engineering Operations
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1 Summary of the D&D Engineering Operations Keith Rule Princeton Plasma Physics Laboratory
2 Project Attributes! Schedule: October 1999 through September 2002! Original Estimated Project Cost: $40.3M! Project Cost at Completion: $36.8M!! Objectives:! Remove activated and/or contaminated components from the TFTR Test Cell and adjacent support areas.! Provide data for the decommissioning of future fusion projects.!! Scope! 2398 cubic meters of low level radioactive waste.! 1995 metric tons! 440 standard containers (IP-1, ~3 m 3 volume)! 72 specific design containers (Type A, 22 m 3 to ~42 m 3 )! Dose rate 50 mrem/hr (0.5mGy) contact with vacuum vessel! Approx. 10,000 curies (370 TBq) of tritium disposed!
3 TFTR - 3 year D&D
4 Radiation Protection Facts! 0 Zero reportable occurrence reports due to health physics related issues based on regulatory requirements.! < 100 mrem (1 mgy) combined dose from internal exposure due to tritium for all HP technicians and workers monitored for D&D operations! Maximum single individual external dose of 573 mrem (5.73 mgy) attributed to the sheer compression panel removals.! 0 Zero detectible internal exposures due to activated metals.! More than 150,000 individual liquid scintillation vial samples analyzed.! Just over 530 Ci (19.6 TBq) of tritium total for the site released up the stack.! 1.4 mrem (0.014 mgy) maximum cumulative off-site EDE.
5 Conduct of Operations Worker safety highest priority! Protecting environment from tritium release! Very different set of hazards than TFTR operations! Centralized control of work activities! Procedure compliance mandatory! Clear responsibility and accountability!!
6 Conduct of Operations D&D Construction WBS Mgr. D&D HP/ Rad Waste WBS Manager D&D Project Manager D&D Engineering WBS Manager D-Site Shift Supervisor Field Supervisors Lead Tech. & Crews Health Physics Supervisor Work Control Center Manager WORK CONTROL CENTER Industrial Hygiene Construction Safety HP/Rad Waste Coordinator K. Rule WCC Planners Scheduler Clerical Support Quality Control D&D Work Control Center Organizational Chart
7 Work Planning Process! Safety for workers and environment! Reduce exposure to hazards including radioactivity!! Three step process for worker protection! Engineering controls! Administrative controls procedures, work planning! Personnel Protective Equipment!! Engineering!! Define work scope!! Conduct Peer Reviews and Design Reviews!! Prepare installation/removal procedure!! Define prerequisites for field work!! Update or void drawings after removal is complete!
8 Work Package Process! Work Control Center!! Review Engineering Package for completeness!! Ensure prerequisites are completed prior to issuing package for work!! Arrange for all permits!! Release work package to field per schedule!! Arrange for resolution of field problems!! Return completed work package to Engineering for drawing update/voiding!! Construction!! Verify and/or perform safing and lockout/tagout per PPPL procedures as required!! Perform field work per procedure!! Return completed work package to Work Control Center!
9 Radioactive Waste Integrated to Schedule! Information integrated into Master Schedule! Volume, containers, shipments, and cost.! Any change to schedule reflects impact to waste management
10 VV Segment Container
11 Characterization! In-Situ Object Counting System - Portable Gamma Spec system! Liquids sample and analyze! Surface contamination measurements! Radioactivity values for major components Code calculations L.P. Ku
12 Disposal Sites! Hanford (DOE) Washington State Lengthy approval process to ship each load. Waste is routinely analyzed at Hanford Actual costs averaged to $22/ft 3 (surcharges)! Nevada Test Site (DOE) Lengthy approval process to become an approved generator. ~ 1.5 years Emphasis is placed on procedures and generator documentation Cost - $6/ft 3, no surcharges
13 Final Analysis! 1995 estimate - 84,703 ft 3! Deleted scope 30,525 ft 3 54,178 ft 3! Added scope - Moratorium - 15,440 ft 3 69,618 ft 3 9,940 in dump trailers cost of $260,680 5,500 used for void filling saved $145,000! Disposed at Hanford 27,312 ft 3! Disposed at NTS 21,918 ft 3! Total disposed 49,230 ft 3
14 Waste Packaging Container Design! Standard Containers 6 & 8 feet long! Weight capacity 10,000 pounds! Closure types clip down and bolt down! Use sealants and bolt down lid for tritium
15 TFTR Vacuum Vessel
16 ! Eliminates vapors and fumes associated with burning techniques.! Keeps workers further away from hazards.! Proven to be the least time consuming. Diamond Wire Cutting
17 Diamond Wire Cutting! VV filled with lowdensity concrete.! Reduced T2 emissions.! Lower dose rate.! Cutting rate greatly increased.! VV segmenting duration shortened.! Personnel exposure to hazard from enclosure entries minimized.
18 Diamond Wire Cutting
19 Diamond Wire Cutting
20 Progress October 1999 November 2000 April 2002 Summer 2001
21 Conclusion! TFTR D&D was a very successful project for the fusion community. Management - Work Planning and control. Engineering- Diamond wire cutting Radiological low exposures, workers and environment Performance! R&D with existing technology! Involve peers and hands-on techs! Take the time to find technology! Learn from others! Train, practice, mock-ups
22 Project Management! Cost - Performance Measurement System employed utilizing earned value techniques!! Schedule - PC based Primavera System!! 1.0!Engineering!! 2.0!Field Operations!! 3.0!Project Management!! 3.1!Project Office!! 3.2!Work Control Center!! 3.3!Configuration and Document Control!! 4.0!Health Physics and Safety!! 5.0!Radioactive Waste Management!
23 Diamond Wire Cutting Upper and lower pulley is mounted on adjustable gear rack. Pulley is re-positioned to ensure that wire does not bend sharply around edge of cut. Camera provided real-time visual feedback to DWC saw operator for accurate positioning of pulleys.
24 Champion Cutting Tool! Plunging blade! Inherently safe! Multiple endeffectors
25 Wachs Clamshell Cutter! 15 Models for ½ to 36 pipe! Machine splits for quick mount! Pneumatic motor drive! auto feed! Cuts carbon, stainless, and harder alloys
26 Wachs Guillotine Saw! Used to cut copper coils and umbrella structure! 4 models available! 2 to 24 diameter! Chain pipe vise attachment! Pneumatic driven! Auto and manual feed control
27 Waste Packaging Filling voids! Low density concrete contains tritium and other contamination pounds per cubic foot Provides shielding Exceeds all disposal facility criteria
28 Waste Packaging Special Containers! Identify package needs with engineering.! Account for disassembly techniques! Plan for voids and material to fill voids! Incorporate weight of void fillers into design.! Give yourself contingency weight capacity interior dimension
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