Tie workshops together where possible:

Workshop 1 -- Develop CRAD (use "Engineering" Subject Matter Expert
base)

Workshop 2 -- (Short) Selecting Documents to review and Activities to
Observe: Using performed based principles and the CRAD as a basis,
select the Documents to Review and Activities to Observe. (This may be a
two part workshop.)

Workshop 3 -- Performance-Bases Document Review - Review Fuel Grappler
design documents and provide areas for further "pulling the string."
Include wrap up with suggested ways to follow up on the areas
identified.

Workshop 4 -- See if we can develop an "interview video" Possible option
is to make a "level of knowledge" interview or possibly a follow-up
interview on Workshop 3 where we interview the Engineering Manager and
Responsible Engineer. We could make two, one where they respond
appropriately and another where they do not take the engineering issue
seriously.

**WORKSHOP 3 -- PERFORMANCE-BASED DOCUMENT REVIEW**

**INSTRUCTOR GUIDE (Draft 1 dated 3/31/07)**

Using performance based principles you have determined that the Fuel
Grappler is a new piece of equipment critical to the upcoming activity
that is the subject of this ORR.

BACKGROUND INFORMATION

The original fuel handling device that came with the fuel when it was
first delivered is "long gone" and there are no drawings available for
the original grappler. We must design and locally manufacture a fuel
handling device (Fuel Grappler):

1.  That can be picked up by a crane main hook,

2.  Positively engage the lifting holes at the top of the fuel element,
    (show sketch)

3.  Lift the fuel element from the fuel pool,

4.  Traverse over the open area (at times it will be 30 feet above the
    floor) a horizontal distance of approximately 100 feet

5.  Lower the fuel element into the dry storage cask

6.  Disengage from the fuel element

7.  Return to the fuel pool for another element.

All these actions must be performed remotely with the crane operation
performed using video cameras once the fuel element lift is started. As
long as the fuel is still in the pool, the crane hook can be attached to
the Fuel Grappler and the engagement of the element can be performed
locally by an appropriately trained operator who can enter the fuel
storage pool area. He must leave the fuel storage area and cannot enter
the area if a fuel element is not fully inserted into its storage
location in the fuel pool. Disengaging the fuel grappler from the fuel
element must be done remotely.

The crane operator must operate the crane remotely via closed circuit
television feed with an operating station that is isolated/shielded from
the fuel element once the lift is started.

Closed circuit television cameras are located so as to provide coverage
of the move. In particular a camera is located above the fuel pool which
allows observation and inspection of the fuel element as it is lifted
from the fuel pool.

A design criterion for the fuel grappler is that all load carrying
components must maintain a safety factor of at least 4 for the lift. The
rated capacity of the grappler will be based on maintaining this safety
factor.

DIVIDE THE CLASS INTO GROUPS OF 4 TO 6 PERSONS. WHERE THERE IS A MIXED
GROUP OF STUDENTS TRY TO BREAK UP EXPERTISE, ORGANIZATIONS, COMPANY
AFFILIATIONS, MANAGERS, ETC TO ENSURE THAT THE GROUPS ARE NOT DOMINATED
BY A SINGLE ORGANZATION. WHERE POSSIBLE MAKE SURE EACH GROUP HAS AN
ENGINEERING TYPE IN THE GROUP.

The following introduction is then provided to all the groups at the
same time to provide the starting point for the continued exercise:

USING PERFORMANCE-BASED CRITERIA YOU HAVE DETERMINED THAT THE DESIGN AND
MANUFACTURE OF THE FUEL GRAPPLER IS SIGNIFICANT TO SAFETY. ITS FAILURE
COULD RESULT IN DROPPING OF THE FUEL ASSEMBLY AND/OR INABILITY TO
PERFORM THE STATED OPERATION IN A SAFE MANNER.

Discuss with the group the impact of dropping a fuel assembly. (release,
although the assemblies are very robust: probably most significant is
that the dose rates in proximity of the fuel would preclude personnel
entry to re-grab the assembly and we are not prepared to manage the
situation of a dropped assembly. The facility ventilation system and
safety systems could handle the event, including calculated releases to
the area, however we would be hard pressed to pick up the dropped
assembly with current equipment)

Three fuel grapplers were manufactured for this operation. Each is
available in an adjacent storage/laydown area for inspection.

You are able to physically observe the fuel grapplers and note the
following conditions:

1.  Each grappler appears to be made in a "workmanlike" manner and
    appears to be stainless steel.

2.  All welds appear to be workmanlike and ground smooth where
    appropriate.

3.  The approximately ¼ inch fillet welds around the "upper bails" cover
    about ¾ of the total visible surface area of the circumference of
    the inserted bail (provide sketch) The gussets are fillet welded
    along their entire edges.

4.  Each grappler is clearly marked with a stainless steel tag that
    indicates the ID number of the grappler and states the rated
    capacity of the fuel grappler assembly is 2000 lbs. The tag also has
    a date when re-inspection is required.

5.  Each grappler has a unique identification number stamped on the
    grappler barrel and that number matches the tags attached..

6.  Each grappler has a QC Accept tag attached with the name of the
    inspector, inspector signature, date, equipment Id number, and a
    reference to the QC inspection report number associated with the
    grappler.

7.  As far as you can tell, the grappler is in accordance with the
    as-built drawing (provide drawing to each group)

Answer any questions posed from the groups. If asked.

-   The storage area is inside an area adjacent to the maintenance
    workshop that is heated and cooled.

-   The grapplers are appropriately protected from damage or
    deterioration.

-   The ¼ welds mentioned in 3 above are not exactly the same on all
    three grapplers. From observation, some seem to have a larger
    portion of the circumference welded. Some are a little more than ¾
    of the circumference, some are a little less. One grappler looks
    like it may actually be closer to a little over ½ of the visible
    surface area of the circumference. The welds look good and are not
    "tack" welds but they are not full circumference welds either.

-   The grapplers look "pretty good" An operator with you is able to
    turn the operating mechanism and it turns freely and extends the
    "pawls" easily. Each pawl has chamfered corners. The 12 small cap
    screws at the very bottom of the assembly look awfully small but
    they are in accordance with the drawing.

Have the groups discuss the primary "load bearing path" of the grappler
using the drawing as a reference.

Crane hook attaches to the bail

Bail is welded to the collar

Collar is attached to the "cylinder" (check on this for final)

Cylinder is welded to Top Plate assembly

Bottom plate is fastened to the Top Plate by 12 cap screws

Bottom Plate supports the 4 pawls that extend and engage the fuel
assembly

4 Pawls engage the holes in the top of the fuel assembly.

Force on the pawls includes direct linear load and "torque"

Non load bearing portions include

Bail block that ensures pawls do not disengage

Shaft that extends inside cylinder to engage the pawls

Pawl wheel

YOU HAVE ACCESS TO THE ENGINEERING CALCULATION FOR THE GRAPPLER. AS IT
REPRESENTS A SAFETY SIGNIFICANT ELEMENT IN THE SUCCESSFUL PERFORMANCE OF
THE ACTIVITY UNDER REVIEW IT IS APPROPRIATE FOR REVIEW.

During the course of this workshop the instructor may take on many
roles. These include acting as the instructor (guiding or advising the
team on areas of potential interest) or role play as any member of the
facility staff. If you wish to "speak to" any staff member for a
question you must tell the instructor who you wish to "speak to" so that
he can take on the appropriate role.

The facility engineer is available during the review and you may ask him
any questions relating to the design. Understand that he is not the
engineer who did the design but is in the "design authority" chain for
the facility. (The instructor will role play as appropriate and respond
based on the tone/type of questions you ask) Other documents may or may
not be readily available. Where the limitation of the workshop precludes
providing them to you, the instructor will so inform you and give you
the information verbally. If you do not ask, the instructor will not
volunteer information.

If you feel the need to conduct further interviews to follow up on
potential issues, identify who you will need to interview and develop
your lines of inquiry.

If you need to look at the grapplers physically, or observe some other
activity, let the instructor know. Depending on the circumstances, the
instructor will either provide you with the "results" of your
observation or ask you to provide what information you are trying to
gain by the observation and respond accordingly.

Pass out the Fuel Grappler Design Document:

USING PERFORMANCE BASED TECHNICQUES, REVIEW THE DESIGN DOCUMENT.

AT THE END OF THIS WORKSHOP -- BE PREPARED TO:

DISCUSS POTENTIAL ISSUES

DISCUSS YOUR ACTIONS

IDENTIFY HOW YOU WOULD GO ABOUT "PULLING THE STRING"

IDENTIFY WHAT METHODS MAY BE USEFUL TO VALIDATE THE ISSUES IDENTIFIED

RANK THE SAFETY SIGNIFICANCE OF THE POTENTIAL ISSUES

IDENTIFY ANY ISSUES THAT MAY BE "PRE-RESTART ISSUES"