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TFTR D&D Status

July 24, 2001

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Project StatusThe TFTR D&D Project

will be completed on time and within budget

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Project Status

Reviews since 12/00:

• DOE Cost and Schedule Review, 12/00

• PPPL Audit of D&D Project, 12/00 - 1/01 - no findings

• DOE-PG Unified Safety Review, 4/01 - no findings

• DOE-CH Review of Sector Lift Procedure, 5/01 - approved

• ALARA Review of Vessel Segmentation, 5/01 - approved

• DOE EH-24 Review, 5/01 - awaiting report

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Project Status cont

Engineering:

• Vessel Segmentation FMEA approved

• Successful Final Design Review for Vessel Segmentation

• Last of the removal procedures are being prepared

• Temporary vessel supports, for vessel segmentation, have been designed, fabricated, tested, and are currently being installed

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Project Status cont

Engineering cont:

• A sector disassembly fixture has been designed, fabricated and tested - a second fixture is currently in fabrication

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Project Status cont

Engineering cont:

• A special vertical bandsaw has been tested and procured for cutting the TF coils in half to reduce the cost of shipping them for burial

• Contamination barriers for the annulus between the vacuum vessel and the TF coils have been designed, tested, and are currently being installed

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Project Status cont

Engineering cont:

• Continuing to spend more time on engineering (especially Diamond Wire Cutting) because it improves overall safety and efficiency

• Continuing to pay attention to the principles of Integrated Safety Management

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Project Status cont

Diamond Wire Cutting Engineering:

• Cutting of the vacuum vessel will be done using a diamond wire rope technology that has been specifically developed for this purpose

- reduced airborne contamination

- reduced worker exposure

- reduced cost

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Project Status cont

Diamond Wire Cutting Engineering cont:

• When each vessel segment is removed, two TF coils will be lifted with it

• A disassembly fixture will be used to support the vessel segment while the TF coils are rotated off of it

• The vessel segments will be placed in special shipping/burial containers and immediately shipped

• A special vertical bandsaw will be used to cut the TF coils in half to reduce the cost of shipping them for burial

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Project Status cont

Diamond Wire Cutting Engineering cont:

• Diamond Wire Cutting trials have developed the process into a mature state

• Results indicate that we can do a through-cut in a day

• Process has been refined to reduce the chance of a broken wire and reduce worker exposure should a wire need to be replaced

• Process for gas cooling/cleaning of the wire has been developed to reduce tritium contaminated waste

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Project Status cont

Diamond Wire Cutting Engineering cont:

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Project Status cont

Field Work:

Vacuum Pumping Ducts have been removed

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Project Status cont

Field Work cont:

Lintels and columns and Shear Compression Panels have been removed

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Project Status cont

Field Work cont:

Ducts connecting Neutral Beamlines to the vacuum vessel have been removed

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Project Status cont

Field Work cont:

Vacuum vessel appendages have been removed and all windows have been reinforced

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Project Status cont

Field Work cont:

Vacuum vessel has been filled with lightweight concrete

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Project Status cont

The TFTR D&D Project is continuing on a path which will assure that it will be completed on time and within budget

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TFTR D&D Cost Performance(baseline revised to include change notice 5 & 6)

$0

$500

$1,000

$1,500

$2,000

$2,500

$3,000

$3,500

$4,000

$4,500

O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A SFY00 FY01 FY02

$K

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

$40,000

$45,000

$K

DOE MANAGEMENT RESERVEBASELINE FUNDING (BA)BCWS (monthly)BCWP (monthly)ACWP (monthly)BCWS (cumulative)BCWP (cumulative)ACWP (cumulative)

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TFTR D&D**** Fiscal Year 01 only ****

JUNE FY01CURRENT PERIOD CUMULATIVE TO DATE AT COMPLETION

Budgeted Cost Budgeted Cost VARIANCES Budget Current

BCWS BCWP ACWP (1) BCWS BCWP ACWP Sch Var SPI Cst Var CPI (Dec00 baseline) Estimate Variance

WBS 1 Engineering 129 130 100 1,465 1,412 1,536 -53 .96 -124 .92 1,933 1,933 0* T100/T101 Mech Engr Oversight & planning 45 82 55 877 864 1,017 -13 .99 -153 .85 1,089 * 1,089 0

* T115 Electrical Engr Oversight & Planning 85 49 45 589 548 520 -40 .93 29 1.06 844 * 844 0WBS 2 Field Operations 954 624 815 6,356 5,588 5,123 -768 .88 465 1.09 8,639 8,639 0

T211 Field Ops Suprvision 51 52 39 456 456 411 0 1.00 45 1.11 615 615 0T212 Field Ops Support Crews 63 63 44 559 559 589 0 1.00 -30 .95 754 754 0T213 Equipment, Tools & Rigging 94 40 42 798 529 410 -268 .66 119 1.29 1,087 1,087 0T214 Design & Development Support 0 0 0 0 0 0 0 - 0 .00 0 0 0

* T215 Electrical Removals and Mods 48 22 21 413 265 152 -148 .64 113 1.74 633 * 633 0

* T220/T222 Non-Tokamak Removals 383 20 26 1,131 727 501 -403 .64 226 1.45 1,776 * 1,776 0T221 D-Site TRECAMS Upgrade 0 0 -2 87 87 104 0 -17 .84 87 87 0T240 Tokamak Removals 6 7 116 1,222 1,199 1,245 -24 .98 -46 .96 1,236 1,236 0

* T241 DWC & Vessel Fill 310 420 529 1,691 1,766 1,710 75 1.04 56 1.03 2,451 * 2,451 0WBS 3 Project Office 107 108 131 951 965 793 14 1.01 172 1.22 1,300 1,300 0

T310 Project Office/T311 EH Safety Followup 46 46 98 407 421 434 14 1.04 -13 .97 565 565 0T320 Work Control Center 46 46 27 406 406 314 0 1.00 92 1.29 548 548 0T330 Configuration & Document Control 16 16 6 138 138 45 0 1.00 94 3.09 187 187 0

WBS 4 HP and Safety 107 103 148 950 928 947 -22 .98 -19 .98 1,283 1,283 0T410 HP Oversight 101 100 147 889 893 871 4 1.00 22 1.02 1,200 1,200 0T420 Safety Oversight 7 3 1 61 35 76 -26 .57 -40 .46 83 83 0

WBS 5 Radwaste 165 159 150 1,202 1,268 911 66 1.05 357 1.39 1,713 1,713 0T510 Radwaste Management 28 34 25 297 270 242 -28 .91 28 1.11 384 384 0T520 Containers & Misc Supplies 51 3 36 320 410 218 89 1.28 191 1.88 477 477 0T530 Waste Transportation & Disposal 78 114 90 511 515 448 4 1.01 67 1.15 753 753 0T540 Mixed Waste 8 8 0 73 73 3 0 1.00 71 27.21 99 99 0

0Subtotal 1,463 1,125 1,345 10,925 10,161 9,310 -764 .93 851 1.09 14,868 14,868 0

CONTINGENCY 298 298 0* Baseline revised to reflect change notice 5 and 6

TOTAL FY00 15,166 15,166 0

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PrincetonUniversity Plasma Physics LaboratoryPPPL COST PERFORMANCE REPORT WORKBREAKDOWN STRUCTURE

TFTR D&DTOTAL PROJECT (FY00-FY02)

JUNE FY01CURRENT PERIOD CUMULATIVE TO DATE AT COMPLETION

Budgeted Cost Budgeted Cost VARIANCES Budget CurrentBCWS BCWP ACWP BCWS BCWP ACWP Sch Var SPI Cst Var CPI (Dec00 baseline) Estimate Variance

WBS 1 Engineering 129 130 100 3,476 3,423 3,547 -53 .98 -124 .97 5,319 5,319 0* T100/T101 Mech Engr Oversight & planning 45 82 55 2,404 2,391 2,544 -13 .99 -153 .94 3,247 * 3,247 0* T115 Electrical Engr Oversight & Planning 85 49 45 1,072 1,032 1,003 -40 .96 29 1.03 2,071 * 2,071 0

WBS 2 Field Operations 954 624 815 11,529 10,761 10,296 -768 .93 465 1.05 18,279 18,279 0T211 Field Ops Suprvision 51 52 39 763 763 719 0 1.00 45 1.06 1,594 1,594 0

T212 Field Ops Support Crews 63 63 44 1,249 1,249 1,279 0 1.00 -30 .98 2,301 2,301 0

T213 Equipment, Tools & Rigging 94 40 42 2,455 2,186 2,067 -268 .89 119 1.06 3,074 3,074 0

T214 Design & Development Support 0 0 0 163 163 163 0 1.00 0 1.00 163 163 0* T215 Electrical Removals and Mods 48 22 21 656 508 395 -148 .77 113 1.29 1,505 * 1,505 0* T220/T222 Non-Tokamak Removals 383 20 26 1,992 1,588 1,362 -403 .80 226 1.17 3,577 * 3,577 0

T221 D-Site TRECAMS Upgrade 0 0 -2 468 468 485 0 1.00 -17 .96 468 468 0

T240 Tokamak Removals 6 7 116 2,091 2,068 2,114 -24 .99 -46 .98 2,464 2,464 0* T241 DWC & Vessel Fill 310 420 529 1,691 1,766 1,710 75 1.04 56 1.03 3,133 * 3,133 0

WBS 3 Project Office 107 108 131 2,181 2,196 2,023 14 1.01 172 1.09 3,963 3,963 0T310 Project Office/T311 EH Safety Followup 46 46 98 943 958 971 14 1.02 -13 .99 1,713 1,713 0

T320 Work Control Center 46 46 27 971 971 879 0 1.00 92 1.10 1,729 1,729 0

T330 Configuration & Document Control 16 16 6 267 267 174 0 1.00 94 1.54 522 522 0WBS 4 HP and Safety 107 103 148 2,346 2,324 2,343 -22 .99 -19 .99 4,093 4,093 0

T410 HP Oversight 101 100 147 2,206 2,209 2,188 4 1.00 22 1.01 3,849 3,849 0T420 Safety Oversight 7 3 1 140 114 155 -26 .81 -40 .74 244 244 0

WBS 5 Radwaste 165 159 150 1,586 1,652 1,296 66 1.04 357 1.28 4,652 4,652 0T510 Radwaste Management 28 34 25 481 453 426 -28 .94 28 1.07 947 947 0

T520 Containers & Misc Supplies 51 3 36 379 469 277 89 1.24 191 1.69 768 768 0

T530 Waste Transportation & Disposal 78 114 90 651 655 588 4 1.01 67 1.11 2,720 2,720 0

T540 Mixed Waste 8 8 0 75 75 5 0 1.00 71 15.72 217 217 0

0Subtotal 1,463 1,125 1,345 21,119 20,355 19,504 -764 .96 851 1.04 36,306 36,306 0

CONTINGENCY 3,989 * 3,989 0* Baseline revised to reflect change notice 5 and 6

TOTAL PROJECT 40,295 40,295 0

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FY01 Accomplishments

TaskRemove Umbrella Structure (milestone #18)ICRF Platforms/line Removed (milestone #13)DPI/LPI Removed (milestone #14)Diagnostics Removal Procedure (milestone #11)Remove Pump Ducts (milestone #17)Remove Columns & Lintels (milestone #19)Fill Vacuum Vessel with Concrete (milestone # 20)Begin Full Scale DWC Mockup Training (milestone #22)Begin Penetration removal & fillRemove Shear Compression PanelsFabricate & Test Disassembly FixtureProcure, Fabricate, Assemble & Test DWC EquiptTest TF Coil Segmenting

PlanJun 01Dec 00Jan 01Feb 01Mar 01Feb 01June 01Apr 01Sept 01May 01Feb 01Feb 01-

ActualNov 00Dec 00Jan 01Apr 01Feb 01Feb 01June 01May 01June 01May 01Feb 01Feb 01Jan 01

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FY01 Remaining

Relocate TPS to Test Cell Basement Begin vacuum system piping removal Continue penetration removal & fill Prep for DWC ops Training Setup equipt and enclosure “Feder” supports DWC operations – remove 2 segments Segment disassembly incl TF coil size reduction TF coil test program (coil #3)

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FY02 Planned

Complete DWC operations Complete all test cell basement vacuum piping removals Disassembly and disposal of vessel segments and TF coils Remove ISS Remove Center plug Complete all penetration removals and fill Shot blast test cell floor Final Radiological survey Complete TF coil test program

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Radwaste StatusShipments

FY00

FY01 October November December January February March April MayFY01 to date

Project to Date

Generated waste to be shipped FY01

Volume (ft3)

5,978

1,4300

1,2392,411

00

3,565415

9,060

15,038

6,828