D&D

"Final Tokamak Removal"

FAILURE MODES AND EFFECTS

ANALYSIS

(FMEA)

######### Rev.1 5/16/01

> **Prepared By:** \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ J.
> Chrzanowski (D&D Engineering Manager)
>
> \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ S. Raftopoulos (D&D
> Engineer)
>
> \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ R. Feder (D&D
> Engineer)
>
> \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ G. Gettelfinger (D&D
> Engineer)
>
> \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ R. Parsells (D&D
> Engineer)
>
> **Reviewed By:** \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ J.
> Levine (Safety Engineer)
>
> \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ Mike Viola (D&D
> Construction Manager)
>
> **Approved By:** \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ E.
> Perry (D&D Project Manager)

## Table of Contents

######## PREFACE 

**SCOPE
........................................................................................................................
5**

**SAFETY IMPLICATIONS
................................................................................................
5**

**LIST OF ACRONYMS**
**............................................................................................................**
**4**

1.  **Concrete Filling of Vacuum
    Vessel.......................................................................................**
    **7**

    1.  VV Ventilation system fails during concrete fill

    2.  VV window or component ruptures

    3.  Concrete overflows the vacuum vessel

    4.  Fill sight system fails

2.  **Vacuum Vessel Support
    System..........................................................................................**.
    **8**

    1.  Main Weight Bearing Rope Fails As System Is Adjusted to Full
        Design Tension

    2.  Main Weight Bearing Rope Fails As Vacuum Vessel Support Columns
        are Lowered

    3.  Horizontal Stop Wire Rope Fails At the Completion of Diamond
        Wire Cutting

3.  **Diamond Wire Cutting
    (DWC)...........................................................................................**
    **10**

    1.  Diamond Wire breaks during cutting operation

    2.  Diamond wire bead breaks off and becomes a projectile

    3.  Diamond wire gets bound in groove during cutting operation

    4.  Loss of liquid Nitrogen during cutting operation

    5.  Loss of liquid Nitrogen system during personnel entry into
        enclosure

    6.  Hydraulic system fails during DWC

    7.  Hydraulic fluid leak

    8.  Containment fails during DWC

    9.  HEPA filter system fails

    10. HVAC (elephant trunk) System Fails during DWC

    11. Following DWC large voids are found in the concrete exposing
        tiles

    12. AC Power interrupted during DWC operations

    13. Seismic Event during DWC operations

4.  **Lifting of TF Coil/ Vacuum Vessel Segment
    ........................................................................**
    **12**

    1.  TF nose surrogate fails during segment lift

    2.  Surrogate fails

    3.  Inboard lifting hardware failure during segment lift

    4.  Outboard lifting hardware during segment lift

    5.  Main hook fails to rotate

    6.  Main hook fails to move up/down

    7.  Trolley Drive Failure

    8.  Bridge Drive Failure

    9.  AC power interrupted

5.  **TF/VV Disassembly Activities
    .............................................................................................
    14**

    1.  Segment does not fit fixture

    2.  Tritium Leak

    3.  Fixture fails to swing

    4.  Sector stand motion is abrupt

    5.  Cannot rotate components

    6.  Rigging components fail

    7.  Fixture fails to swing open

### 

### LIST OF ACRONYMS

+--------+--------------------------+-------+-------------------------+
| # AC   | Alternating Current      |       |                         |
+--------+--------------------------+-------+-------------------------+
| *      | Decontamination and      |       |                         |
| *D&D** | Decommissioning          |       |                         |
+--------+--------------------------+-------+-------------------------+
| *      | Diamond Wire Cutting     |       |                         |
| *DWC** |                          |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Environmental            |       |                         |
| ERWM** | Restoration & Waste Mgt  |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Failure Modes & Effect   |       |                         |
| FMEA** | Analysis                 |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | High-Efficiency          |       |                         |
| HEPA** | Particulate Air          |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Heating/Ventilation/Air  |       |                         |
| HVAC** | Conditioning             |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Lock Out/Tag Out         |       |                         |
| LOTO** |                          |       |                         |
+--------+--------------------------+-------+-------------------------+
| *      | Most Intense Earthquake  |       |                         |
| *MIE** |                          |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Princeton Plasma Physics |       |                         |
| PPPL** | Laboratory               |       |                         |
+--------+--------------------------+-------+-------------------------+
| **TF** | Toroidal Field Coils     |       |                         |
+--------+--------------------------+-------+-------------------------+
| **     | Tokamak Fusion Test      |       |                         |
| TFTR** | Reactor                  |       |                         |
+--------+--------------------------+-------+-------------------------+
| **VV** | Vacuum Vessel            |       |                         |
+--------+--------------------------+-------+-------------------------+
| **V    | Vacuum Vessel Temporary  |       |                         |
| VTSS** | Support System           |       |                         |
+--------+--------------------------+-------+-------------------------+

# SCOPE

This version of the D&D Final Tokamak Removal FMEA reflects the
configuration of the vacuum vessel and facility as operations proceed in
performing the filling and segmenting procedures. The failures have been
identified to address the following.

1: Load Line failures during lifts.

2: Diagnostic & Control failures

3: Component failures.

4: Operational failures.

D&D will utilize the existing auxiliary systems of D-site. The TFTR FSAR
includes FMEA's for these systems, including effects of failures on the
auxiliary systems themselves. For D&D this document only addresses
failures that impact the D&D Final Tokamak Removal. The TFTR FSAR covers
effects of failures, on the auxiliary systems.

In general, single failure modes are addressed. In some cases, for
failures that would have severe consequences in terms of damage to
hardware or risk to personnel safety, multiple failures are addressed.

**SAFETY IMPLICATIONS**

Certain failures can increase the risk of injury to personnel. For any
particular failure, the level of risk of injury to personnel depends on
several factors including:

1)  The nature of the failure

2)  The presence or absence of features that mitigate the effect of the
    failure (e.g. redundancy, energy isolating barriers, etc.)

3)  The presence or absence of personnel in the area where the failure
    has occurred

4)  The level of training of the personnel

The FMEA addresses the first two items. The last two relate mainly to
administrative procedures that aim to prevent access to hazardous areas
or to limit access to personnel trained to conduct themselves safely in
potentially hazardous areas. This FMEA *does not* address administrative
procedures.

This FMEA addresses new systems to support the Tokamak removal, as well
as other D-site systems whose failure could cause damage during the
operations.

This FMEA *does not address* safety issues related to the conduct of
operations throughout the balance of the D-site facility. Considering
that the safety of operations of TFTR was documented and approved via
the TFTR FSAR, and demonstrated to be effective for more than a decade,
it would not add to the safety of D&D operations to repeat that
analysis.

**SUMMARY\
**

The critical elements that draw the attention of the engineer include:

**Load line failures** have high impact. Subsequently they have the most
conservative margin. The working load is the load indicating on the load
line element. The ultimate load is the load that accompanies failure.
The margin between the working load and the ultimate load is minimum
factor of five. The capacity for fabricated 304SS elements is based on
yield and ultimate strength. The minimum yield strength of 304SS is
30,000 psi. The minimum tensile strength is 75,000 psi. The allowable
shear strength of welds per AWS/AISC is 30% of yield. The allowable
tensile strength of welds per AWS/AISC is 60% of yield.

**Diagnostic and control failures** have high impact during concrete
fill operations. This is the phase that can produce tritium release in
the test cell. This is a personnel hazard rather that a site release
hazard. Area and portable monitors will detect the presence of tritium.
Operations will be suspended and recovery procedures will be
implemented.

**Failures of Components** share the same characteristic as control
failures. If a tritium boundary is ruptured, operations must be
interrupted until components are restored. Then the operations can be
resumed.

**Operations failures** that involve personnel are mitigated by
experience, training, walk-through, clear lines of responsibility, and
written procedures. Operations failures that involve equipment are
mitigated by redundancy, work-a-rounds or emergency response procedures
depending on the nature of the failure.

  --------- ----------------------- ---------------------------------------- ---- -- -- --
  Project   **[D&D]{.underline}**   **FAILURE MODES AND EFFECTS ANALYSIS**              

  --------- ----------------------- ---------------------------------------- ---- -- -- --

  --------- -------------------------------- ----------- ------------------------- ------ ---------
  Element   **[1.0 Concrete Filling of       Performed   **[Robert                 Date   1/25/01
            Vacuum Vessel]{.underline}**     By          Parsells]{.underline}**          

                                                                                          

                                             Reviewed By                           Date   
  --------- -------------------------------- ----------- ------------------------- ------ ---------

+---------+---------------+----------+----------+----------+----------+
| **Op    | #### Failu    | **System | **Fault  | **Comp   | **R      |
| erating | re Mode/Cause | Effect** | Detec    | ensating | emarks** |
| Mode**  |               |          | tion/Iso | prov     |          |
|         |               |          | lation** | isions** |          |
+---------+---------------+----------+----------+----------+----------+
| C       | VV            | Possible | Air flow | Suspend  |          |
| oncrete | ventilation   | release  | monitors | ope      |          |
| Filling | system fails  | of       | or       | rations, |          |
|         | during fill   | tritium  |          | Isolate  |          |
|         |               | in T/C   | Area/    | VV,      |          |
|         |               |          | Portable | Replac   |          |
|         |               |          | Monitors | e/repair |          |
|         |               |          |          | ven      |          |
|         |               |          |          | tilation |          |
|         |               |          |          | system.  |          |
|         |               |          |          | Use      |          |
|         |               |          |          | bubble   |          |
|         |               |          |          | as       |          |
|         |               |          |          | req'd.   |          |
+---------+---------------+----------+----------+----------+----------+
| C       | VV window or  | Concrete | Visual   | Suspend  | All      |
| oncrete | component     | leak,    |          | op       | windows  |
| Filling | ruptures      | Possible | Area/    | erations | and      |
|         |               | release  | Portable | &        | fragile  |
|         |               | of       | Monitors | cleanup. | co       |
|         |               | tritium  |          | Replac   | mponents |
|         |               | in T/C   |          | e/repair | covered  |
|         |               |          |          | window & | with     |
|         |               |          |          | resume   | metal    |
|         |               |          |          | op       | pr       |
|         |               |          |          | erations | otective |
|         |               |          |          |          | covers.  |
+---------+---------------+----------+----------+----------+----------+
| C       | Concrete      | See      | Visual   | Let      |          |
| oncrete | overflows the | previous |          | concrete |          |
| Filling | vacuum vessel |          |          | set &    |          |
|         |               |          |          | resume   |          |
|         |               |          |          | op       |          |
|         |               |          |          | erations |          |
+---------+---------------+----------+----------+----------+----------+
| C       | Fill level    | Suspend  | Visual   | Move     |          |
| oncrete | sight system  | op       |          | sight    |          |
| Filling | fails         | erations |          | system   |          |
|         |               |          |          | to       |          |
|         |               |          |          | a        |          |
|         |               |          |          | lternate |          |
|         |               |          |          | port.    |          |
+---------+---------------+----------+----------+----------+----------+
|         |               |          |          |          |          |
+---------+---------------+----------+----------+----------+----------+

  --------- ----------------------- ---------------------------------------- ---- -- -- --
  Project   **[D&D]{.underline}**   **FAILURE MODES AND EFFECTS ANALYSIS**              

  --------- ----------------------- ---------------------------------------- ---- -- -- --

  --------- -------------------------------- ----------- ---------------------- ------ ---------
  Element   **[2.0 Vacuum Vessel Temporary   Performed   **[Russell             Date   1/25/01
            Support System]{.underline}**    By          Feder]{.underline}**          

                                                                                       

                                             Reviewed By                        Date   
  --------- -------------------------------- ----------- ---------------------- ------ ---------

+----------+---------------+----------+----------+----------+----------+
| **O      | #### Failu    | **System | **Fault  | **Comp   | **R      |
| perating | re Mode/Cause | Effect** | Detec    | ensating | emarks** |
| Mode**   |               |          | tion/Iso | prov     |          |
|          |               |          | lation** | isions** |          |
+----------+---------------+----------+----------+----------+----------+
| Set      | Main Weight   | No       | Visual   | Vessel   | Safety   |
| VVTSS To | Bearing       | Effect   | and      | still    | Factor   |
| Full     | Support Wire  | on Load  | audible  | resting  | of 3 in  |
| Design   | Rope Fails    |          |          | on       | design.  |
| Tension  |               | Safety   |          | columns  | Stored   |
|          |               | Hazard   |          |          | Energy   |
|          |               | to       |          | Tension  | in Wire  |
|          |               | P        |          | can be   | Rope     |
|          |               | ersonnel |          | easily   |          |
|          |               |          |          | relieved | Ho       |
|          |               |          |          | to fix   | rizontal |
|          |               |          |          | problem  | stop     |
|          |               |          |          |          | ropes    |
|          |               |          |          |          | not      |
|          |               |          |          |          | e        |
|          |               |          |          |          | ffective |
|          |               |          |          |          | at this  |
|          |               |          |          |          | stage    |
|          |               |          |          |          | because  |
|          |               |          |          |          | whole    |
|          |               |          |          |          | torus    |
|          |               |          |          |          | self-    |
|          |               |          |          |          | supports |
|          |               |          |          |          | ho       |
|          |               |          |          |          | rizontal |
|          |               |          |          |          | loading. |
|          |               |          |          |          | Admini   |
|          |               |          |          |          | strative |
|          |               |          |          |          | controls |
|          |               |          |          |          | will be  |
|          |               |          |          |          | placed   |
|          |               |          |          |          | in       |
|          |               |          |          |          | inst     |
|          |               |          |          |          | allation |
|          |               |          |          |          | /testing |
|          |               |          |          |          | p        |
|          |               |          |          |          | rocedure |
|          |               |          |          |          | and      |
|          |               |          |          |          | warning  |
|          |               |          |          |          | will be  |
|          |               |          |          |          | noted of |
|          |               |          |          |          | p        |
|          |               |          |          |          | ersonnel |
|          |               |          |          |          | hazard.  |
+----------+---------------+----------+----------+----------+----------+
| Lowe     | Main Weight   | Load     | Visual   | R        | Safety   |
| r/Remove | Bearing       | from     |          | edundant | Factor   |
| Vacuum   | Support Wire  | failed   |          | design   | of 3 in  |
| Vessel   | Rope Fails    | fixture  |          | of       | design.  |
| Columns  |               | dis      |          | fixtures | Ho       |
|          |               | tributed |          | and      | rizontal |
|          |               | to other |          | hardware | stop     |
|          |               | fixtures |          |          | ropes    |
|          |               |          |          | 30 total | not      |
|          |               | Be       |          | fixtures | e        |
|          |               | lleville |          | to share | ffective |
|          |               | stack    |          | load     | at this  |
|          |               | disp     |          | with     | stage    |
|          |               | lacement |          | more     | because  |
|          |               | results  |          | than     | whole    |
|          |               |          |          | adequate | torus    |
|          |               |          |          | margin.  | self-    |
|          |               |          |          |          | supports |
|          |               |          |          |          | ho       |
|          |               |          |          |          | rizontal |
|          |               |          |          |          | loading  |
+----------+---------------+----------+----------+----------+----------+
| Diamond  | Horizontal    | Load     | Visual   | R        | Safety   |
| wire     | stop rope or  | Dis      |          | edundant | Factor   |
| cutting  | hardware      | tributed |          | design   | of 3 in  |
| of VV    | fails         | to Other |          | of       | design.  |
|          |               | F        |          | fixtures | There is |
| Or       |               | ixtures, |          | and      | no       |
|          |               | Bel      |          | hardware | ad       |
| Lifting  |               | levilles |          |          | ditional |
| segment  |               | Displace |          |          | loading  |
|          |               |          |          |          | on the   |
|          |               |          |          |          | main     |
|          |               |          |          |          | weight   |
|          |               |          |          |          | -bearing |
|          |               |          |          |          | fixture  |
|          |               |          |          |          | in this  |
|          |               |          |          |          | step.    |
|          |               |          |          |          |          |
|          |               |          |          |          | In the   |
|          |               |          |          |          | instant  |
|          |               |          |          |          | that     |
|          |               |          |          |          | each     |
|          |               |          |          |          | segment  |
|          |               |          |          |          | is cut   |
|          |               |          |          |          | free,    |
|          |               |          |          |          | the      |
|          |               |          |          |          | Ho       |
|          |               |          |          |          | rizontal |
|          |               |          |          |          | Stop     |
|          |               |          |          |          | Roped    |
|          |               |          |          |          | will     |
|          |               |          |          |          | load up  |
|          |               |          |          |          | for the  |
|          |               |          |          |          | first    |
|          |               |          |          |          | time.    |
+----------+---------------+----------+----------+----------+----------+
| Diamond  | Hard stop air | Ropes    | Pressure | Repair   | Con      |
| wire     | bag develops  | loose    | i        | or       | sequence |
| cutting  | leak          | tension, | ndicator | replace  | of       |
| of VV    |               | vessel   | i        | air bag  | failure  |
|          |               | moves    | ndicates |          | is       |
| Or       |               |          | loss of  |          | minor.   |
|          |               |          | p        |          | Loss of  |
| Lifting  |               |          | ressure, |          | pressure |
| segment  |               |          | bevel    |          | will not |
|          |               |          | washer   |          | lead to  |
| ***R1*** |               |          | stack    |          | loss of  |
|          |               |          | will     |          | control  |
|          |               |          | change   |          | of       |
|          |               |          | disp     |          | segment. |
|          |               |          | lacement |          |          |
+----------+---------------+----------+----------+----------+----------+

  --------- ----------------------- ---------------------------------------- ---- -- -- --
  Project   **[D&D]{.underline}**   **FAILURE MODES AND EFFECTS ANALYSIS**              

  --------- ----------------------- ---------------------------------------- ---- -- -- --

  --------- -------------------------------- ----------- ------------------------- ------ ---------
  Element   **[3.0 Diamond Wire Cutting of   Performed   **[Robert                 Date   1/25/01
            Vacuum]{.underline} Vessel       By          Parsells]{.underline}**          
            (DWC)**                                                                       

                                                                                          

                                             Reviewed By                           Date   
  --------- -------------------------------- ----------- ------------------------- ------ ---------

+---------+---------------+----------+----------+----------+----------+
| **Op    | #### Failu    | **System | **Fault  | **Comp   | **R      |
| erating | re Mode/Cause | Effect** | Detec    | ensating | emarks** |
| Mode**  |               |          | tion/Iso | prov     |          |
|         |               |          | lation** | isions** |          |
+=========+===============+==========+==========+==========+==========+
| Diamond | Diamond wire  | Several  | Audio    | The      | Analysis |
| wire    | breaks during | beads    | d        | e        | & field  |
| cutting | operation     | will     | etection | nclosure | tests    |
| of VV   |               | become   | and      | has been | have     |
|         |               | proj     | movement | designed | been     |
|         |               | ectiles. | of       | and      | p        |
|         |               |          | te       | pr       | erformed |
|         |               |          | nsioning | ototyped | to       |
|         |               |          | system.  | to       | verify   |
|         |               |          |          | contain  | i        |
|         |               |          |          | beads.   | ntegrity |
|         |               |          |          |          | of       |
|         |               |          |          |          | e        |
|         |               |          |          |          | nclosure |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Diamond wire  | Bead     | Audio    | The      | Analysis |
| wire    | bead breaks   | will     | d        | e        | & field  |
| cutting | off and       | become   | etection | nclosure | tests    |
| of VV   | becomes       | pro      | and      | has been | have     |
|         | projectile    | jectile, | movement | designed | been     |
|         |               | inc      | of       | and      | p        |
|         |               | remental | te       | pr       | erformed |
|         |               | di       | nsioning | ototyped | to       |
|         |               | minution | system.  | to       | verify   |
|         |               | of saw   |          | contain  | i        |
|         |               | cutting  |          | beads.   | ntegrity |
|         |               | ef       |          |          | of       |
|         |               | ficiency |          |          | e        |
|         |               |          |          |          | nclosure |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Diamond wire  | The wire | Visual   | Suspend  |          |
| wire    | becomes bound | slips on | de       | op       |          |
| cutting | in groove     | the      | tection. | eration. |          |
| of VV   |               | drive    |          | Free     |          |
|         |               | wheel or |          | wire or  |          |
|         |               | s        |          | r        |          |
|         |               | eparates |          | e-splice |          |
|         |               | at the   |          | coupling |          |
|         |               | coupling |          | if       |          |
|         |               |          |          | s        |          |
|         |               |          |          | eparated |          |
|         |               |          |          | & resume |          |
|         |               |          |          | ope      |          |
|         |               |          |          | rations. |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Loss of       | Heat     | Visual   | Suspend  |          |
| wire    | liquid        | build-up | d        | op       |          |
| cutting | nitrogen or   | in wire  | etection | eration. |          |
| of VV   | CO2 coolant   |          |          | Restore  |          |
|         | during DWC    |          |          | LN2 flow |          |
|         | ***R1***      |          |          |          |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Liquid        | P        | Visual   | Vacate   | Admini   |
| wire    | Nitrogen or   | ersonnel | d        | p        | strative |
| cutting | CO2 leak      | hazard   | etection | ersonnel | controls |
| of VV   | while         |          | and O2   | from     | (LOTO)   |
|         | personnel are |          | mo       | en       | will     |
|         | in enclosure  |          | nitoring | closure. | exclude  |
|         | ***R1***      |          |          | Close    | p        |
|         |               |          |          | LN2      | ersonnel |
|         |               |          |          | supply   | from     |
|         |               |          |          | valve.   | e        |
|         |               |          |          |          | nclosure |
|         |               |          |          |          | during   |
|         |               |          |          |          | cutting  |
|         |               |          |          |          | op       |
|         |               |          |          |          | eration. |
|         |               |          |          |          | E        |
|         |               |          |          |          | nclosure |
|         |               |          |          |          | is       |
|         |               |          |          |          | treated  |
|         |               |          |          |          | as       |
|         |               |          |          |          | Possible |
|         |               |          |          |          | O2/      |
|         |               |          |          |          | Confined |
|         |               |          |          |          | space.   |
|         |               |          |          |          | Confined |
|         |               |          |          |          | space    |
|         |               |          |          |          | permit   |
|         |               |          |          |          | and      |
|         |               |          |          |          | training |
|         |               |          |          |          | required |
|         |               |          |          |          | to       |
|         |               |          |          |          | enter.   |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Hydraulic     | Suspend  | Visual   | Repair   |          |
| wire    | drive system  | op       | d        | /replace |          |
| cutting | fails during  | erations | etection | unit &   |          |
| of VV   | cutting       |          |          | resume   |          |
|         |               |          |          | op       |          |
|         |               |          |          | erations |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Hydraulic     | Suspend  | Visual   | Repair   |          |
| wire    | fluid leak    | op       | d        | system,  |          |
| cutting |               | erations | etection | absorb & |          |
| of VV   |               |          |          | solidify |          |
|         |               |          |          | oil; and |          |
|         |               |          |          | resume   |          |
|         |               |          |          | o        |          |
|         |               |          |          | peration |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Containment   | Suspend  | Loss of  | Repair   |          |
| wire    | fails during  | op       | negative | system   |          |
| cutting | DWC           | erations | pressure | and      |          |
| of VV   |               |          |          | resume   |          |
|         |               |          |          | op       |          |
|         |               |          |          | erations |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | HEPA filter   | Suspend  | Visual   | Repair   |          |
| wire    | system fails  | op       | d        | system   |          |
| cutting |               | erations | etection | and      |          |
| of VV   |               |          | & loss   | resume   |          |
|         |               |          | of       | op       |          |
|         |               |          | delta-P  | erations |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | HVAC          | Suspend  | Loss of  | Repair   |          |
| wire    | (elephant     | op       | negative | system   |          |
| cutting | trunk) System | erations | pressure | and      |          |
| of VV   | fails during  |          |          | resume   |          |
|         | DWC           |          |          | op       |          |
|         | operations    |          |          | erations |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Following     | Suspend  | Visual   | Install  |          |
| wire    | DWC, large    | op       | d        | end caps |          |
| cutting | voids found   | erations | etection | &        |          |
| of VV   | in the        |          |          | bubbler. |          |
|         | concrete      |          |          | Foam     |          |
|         | exposing      |          |          | fill     |          |
|         | carbon tiles  |          |          | voids &  |          |
|         |               |          |          | resume   |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | AC power      | Shut     | Visual   | Repair   |          |
| wire    | interrupted   | down     | d        | system   |          |
| cutting | during DWC    | op       | etection | and      |          |
| of VV   | operations    | erations |          | resume   |          |
|         |               |          |          | op       |          |
|         |               |          |          | erations |          |
+---------+---------------+----------+----------+----------+----------+
| Diamond | Seismic event | Shut     | Visual   | Repair   | All      |
| wire    | occurs during | down     | d        | system   | systems  |
| cutting | the DWC       | op       | etection | and      | used for |
| of VV   | operations    | erations |          | resume   | DWC of   |
|         |               |          |          | op       | VV will  |
|         |               |          |          | erations | be       |
|         |               |          |          |          | sei      |
|         |               |          |          |          | smically |
|         |               |          |          |          | q        |
|         |               |          |          |          | ualified |
|         |               |          |          |          | by       |
|         |               |          |          |          | PPPL's   |
|         |               |          |          |          | Seismic  |
|         |               |          |          |          | Engineer |
|         |               |          |          |          | before   |
|         |               |          |          |          | being    |
|         |               |          |          |          | placed   |
|         |               |          |          |          | in       |
|         |               |          |          |          | service. |
+---------+---------------+----------+----------+----------+----------+

  --------- ----------------------- ---------------------------------------- ---- -- -- --
  Project   **[D&D]{.underline}**   **FAILURE MODES AND EFFECTS ANALYSIS**              

  --------- ----------------------- ---------------------------------------- ---- -- -- --

  --------- -------------------------------- ----------- ----------------------------- ------ ---------
  Element   **[4.0 Lifting of TF Coil/VV     Performed   **[Geoff                      Date   1/25/01
            Segment]{.underline}**           By          Gettelfinger]{.underline}**          

                                                                                              

                                             Reviewed By                               Date   
  --------- -------------------------------- ----------- ----------------------------- ------ ---------

+---------+--------------+----------+---+----------+----------+----------+
| **Op    | #### Failur  | **System | * |          | **Comp   | **R      |
| erating | e Mode/Cause | Effect** | * |          | ensating | emarks** |
| Mode**  |              |          | F |          | prov     |          |
|         |              |          | a |          | isions** |          |
|         |              |          | u |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | t |          |          |          |
|         |              |          | D |          |          |          |
|         |              |          | e |          |          |          |
|         |              |          | t |          |          |          |
|         |              |          | e |          |          |          |
|         |              |          | c |          |          |          |
|         |              |          | t |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | / |          |          |          |
|         |              |          | I |          |          |          |
|         |              |          | s |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | a |          |          |          |
|         |              |          | t |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | * |          |          |          |
|         |              |          | * |          |          |          |
+=========+==============+==========+===+==========+==========+==========+
| Lifting | Inter-TF     | Pot      | V |          | Ca       |          |
| of TF   | coil nose    | entially | i |          | pacities |          |
| Coil/VV | surrogate    | i        | s |          | of other |          |
| Segment | fails during | ncreased | u |          | su       |          |
|         | segment lift | loading  | a |          | pporting |          |
|         |              | on the   | l |          | e        |          |
|         |              | vacuum   | d |          | quipment |          |
|         |              | vessel   | e |          | will not |          |
|         |              | supports | t |          | be       |          |
|         |              |          | e |          | e        |          |
|         |              |          | c |          | xceeded. |          |
|         |              |          | t |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Upper        | Pot      | V |          | Ca       |          |
| of TF   | inter-TF     | entially | i |          | pacities |          |
| Coil/VV | coil         | i        | s |          | of other |          |
| Segment | outboard     | ncreased | u |          | su       |          |
|         | shear        | loading  | a |          | pporting |          |
|         | /compression | on the   | l |          | e        |          |
|         | surrogate    | vacuum   | d |          | quipment |          |
|         | fails during | vessel   | e |          | will not |          |
|         | segment lift | supports | t |          | be       |          |
|         |              |          | e |          | exceeded |          |
|         |              |          | c |          |          |          |
|         |              |          | t |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Catastrophic | Loss of  | V |          | Lift     | Safety   |
| of TF   | Failure of:  | load     | i |          | p        | Factor   |
| Coil/VV |              | support  | s |          | ractices | of 5 in  |
| Segment | Inboard      |          | u |          | co       | rigging  |
|         | Lifting Lug  |          | a |          | nsistent | c        |
|         | Bolt;        |          | l |          | with DOE | omponent |
|         |              |          | d |          | Hoisting | design.  |
|         | Inboard      |          | e |          | and      | Rigging  |
|         | Lifting Lug; |          | t |          | Rigging  | co       |
|         |              |          | e |          | Order    | mponents |
|         | Inboard      |          | c |          |          | tested   |
|         | Swivel Eye;  |          | t |          |          | at       |
|         |              |          | i |          |          | manuf    |
|         | Inboard      |          | o |          |          | acturer. |
|         | Sling;       |          | n |          |          |          |
|         |              |          | o |          |          |          |
|         | Inboard      |          | r |          |          |          |
|         | Shackle;     |          | d |          |          |          |
|         |              |          | e |          |          |          |
|         | or           |          | t |          |          |          |
|         |              |          | e |          |          |          |
|         | Inboard Load |          | c |          |          |          |
|         | Cell         |          | t |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | u |          |          |          |
|         |              |          | s |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | g |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | a |          |          |          |
|         |              |          | d |          |          |          |
|         |              |          | c |          |          |          |
|         |              |          | e |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | s |          |          |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Outboard     | Shift of | V |          | Lift     | Safety   |
| of TF   | Lifting Lug  | load.    | i |          | p        | Factor   |
| Coil/VV | Bolt;        |          | s |          | ractices | of 5 in  |
| Segment |              |          | u |          | co       | rigging  |
|         | Outboard     |          | a |          | nsistent | c        |
|         | Lifting Lug  |          | l |          | with DOE | omponent |
|         | ;            |          | d |          | Hoisting | design.  |
|         |              |          | e |          | and      | Rigging  |
|         | Outboard     |          | t |          | Rigging  | co       |
|         | Swivel Eye;  |          | e |          | Order    | mponents |
|         |              |          | c |          | Ca       | tested   |
|         | Outboard     |          | t |          | pacities | at       |
|         | Sling;       |          | i |          | of other | manuf    |
|         |              |          | o |          | su       | acturer. |
|         | Outboard     |          | n |          | pporting |          |
|         | Shackle;     |          | o |          | e        |          |
|         |              |          | r |          | quipment |          |
|         | Outboard     |          | d |          | will not |          |
|         | Chain Hoist; |          | e |          | be       |          |
|         |              |          | t |          | exceeded |          |
|         | or           |          | e |          |          |          |
|         |              |          | c |          |          |          |
|         | Outboard     |          | t |          |          |          |
|         | Load Cell    |          | i |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | u |          |          |          |
|         |              |          | s |          |          |          |
|         |              |          | i |          |          |          |
|         |              |          | n |          |          |          |
|         |              |          | g |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | o |          |          |          |
|         |              |          | a |          |          |          |
|         |              |          | d |          |          |          |
|         |              |          | c |          |          |          |
|         |              |          | e |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | l |          |          |          |
|         |              |          | s |          |          |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Main hook    | Loss of  |   | Visible  | I        |          |
| of TF   | fails to     | load     |   | d        | mplement |          |
| Coil/VV | rotate       | ori      |   | etection | custom   |          |
| Segment |              | entation |   | by       | recovery |          |
|         |              | control  |   | operator | p        |          |
|         |              |          |   |          | rocedure |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Main hook    | Loss of  |   | Visible  | I        | Main     |
| of TF   | fails to     | ability  |   | d        | mplement | hoist    |
| Coil/VV | move U/D     | to       |   | etection | custom   | drive    |
| Segment |              | change   |   | by       | recovery | de-e     |
|         |              | load     |   | operator | p        | nergizes |
|         |              | e        |   |          | rocedure | to       |
|         |              | levation |   |          |          | "parked" |
|         |              |          |   |          |          | mode     |
|         |              |          |   |          |          | (brakes  |
|         |              |          |   |          |          | held on  |
|         |              |          |   |          |          | by       |
|         |              |          |   |          |          | f        |
|         |              |          |   |          |          | ail-safe |
|         |              |          |   |          |          | me       |
|         |              |          |   |          |          | chanical |
|         |              |          |   |          |          | springs) |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Trolley      | Loss of  |   | Visible  | I        |          |
| of TF   | drive        | ability  |   | d        | mplement |          |
| Coil/VV | failure      | to move  |   | etection | custom   |          |
| Segment |              | load     |   | by       | recovery |          |
|         |              | Nor      |   | operator | p        |          |
|         |              | th/South |   |          | rocedure |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | Bridge drive | Loss of  |   | Visible  | I        |          |
| of TF   | failure      | ability  |   | d        | mplement |          |
| Coil/VV |              | to move  |   | etection | custom   |          |
| Segment |              | load     |   | by       | recovery |          |
|         |              | E        |   | operator | p        |          |
|         |              | ast/West |   |          | rocedure |          |
+---------+--------------+----------+---+----------+----------+----------+
| Lifting | AC power is  | Inte     |   | Visible  | Suspend  | Main     |
| of TF   | interrupted. | rruption |   | d        | lift     | hoist    |
| Coil/VV |              | of crane |   | etection | until    | drive    |
| Segment |              | service  |   | by       | power    | de-e     |
|         |              |          |   | operator | system   | nergizes |
|         |              |          |   |          | res      | to       |
|         |              |          |   |          | toration | "parked" |
|         |              |          |   |          |          | mode     |
|         |              |          |   |          |          | (brakes  |
|         |              |          |   |          |          | held on  |
|         |              |          |   |          |          | by       |
|         |              |          |   |          |          | f        |
|         |              |          |   |          |          | ail-safe |
|         |              |          |   |          |          | me       |
|         |              |          |   |          |          | chanical |
|         |              |          |   |          |          | springs) |
+---------+--------------+----------+---+----------+----------+----------+