DIII-D Safety Program – Supporting Fusion Science at All Levels

1. DIII-D Safety Program – Supporting Fusion Science at All Levels By R. Lee for the DIII-D Team Presented at the DOE Accelerator Safety Workshop SLAC Menlo Park, CA August 21-23, 2018 Work supported by U.S. DOE under DE-FC02-04ER54698.

2. Outline • Overview of the DIII-D Facility • DIII-D Safety Program • Major Upgrades to DIII-D Science Capabilities Demand Proactive Safety Management • Ongoing improvements to DIII-D Safety Program

3. Outline: Part 1 • Overview of the DIII-D Facility • DIII-D Safety Program • Major Upgrades to DIII-D Science Capabilities Demand Proactive Safety Management • Ongoing improvements to DIII-D Safety Program

4. DIII-D is a Key Component in the Worldwide Strategy to Make Fusion on Earth a Reality • The mission of the DIII-D Research Program is to establish the scientific basis for the optimization of the tokamak approach to fusion energy production. The DIII-D Program is a cornerstone element in the national fusion program strategy. • The GA Energy/Fusion Group has been a pioneer in pursuing an increased understanding of high-temperature plasma physics within the toroidal magnetic confinement device called a tokamak. DIII-D operates under a DOE Cooperative Agreement. • ITER is a multinational fusion effort under construction in France. DIII-D, with its non-circular cross-section and versatile experimental capability, has had a profound impact on the design of ITER, including the development of the physics basis for key ITER issues and advanced ITER operation.

5. Aerial View of DIII-D Facility, Located in San Diego, CA 138kVAC/480VAC Substation 5MW West Substation (Fed from Dunhill) Low & High Pressure Deionized Water Pumping Systems Two RF Transmitter PSs 30kVDC, 125A Helium Gas Storage Five Gyrotron PSs 105kVDC, 90A Diagnostics Lab Eight Neutral Beam PSs 120kVDC, 100A Control Room 12.47kVAC Switchgear (from 138kVAC Line) Dunhill Substation 138KVAC & 69kVAC Substations DIII-D Machine Three Cooling Towers 525MVA Motor Generator

6. DIII-D Tokamak System Capabilities DIII-D Tokamak Vacuum Vessel Volume = 35 m3, material: Inconel 625 (Ni, Cr, Mo, Nb+Ta) Confined plasma current, Ip ≈ 1.6 MA Magnetic field coils for breakdown and control 144-turn, 127 kA toroidal field coil (2.2 T axial field) 140 kA ohmic heating coil (transformer primary) 18 poloidal field shaping coils 6 external coils, 12 internal coils Plasma Control Computer System • 18 CPUs, 40 GB real-time CPU network Heating and Current Drive (injected power/pulse) • Neutral Beams: 8 sources; ≈ 16 MW (80 keV deuterium) • Electron Cyclotron (Microwaves): 6 gyrotrons @110 GHz; 3.5 MW (5 s)

7. DIII-D Tokamak System Capabilities (cont’d) Wall conditioning & density control • ATJ graphite (porous, can trap D2 fuel, impurity gases) • 350 °C bake, boronization, He glow discharge between pulses • 3 LHecryopumps; 15–20,000 l/s Special attributes • Beamline tilting, swinging • Diagnostics (> 70); passive and active • Remote control via PLCs, PCS Typical plasma parameters • Plasma species: deuterium • Plasma temperature ≈ 10 keV (≈ 116,000,000 K) • Density ≈ 3 e14 cm-3 • Neutron rate ≈ 1e15n/s

8. Strong Involvement of Collaborators is Essential to the Excellence of the DIII-D Diagnostic Set • UF-CHERS (UW) • Coherence imaging (LLNL/ANU) • DISRAD (UCSD) •VUV camera (LLNL) • FIDA (UCI) • NPAs (UCI) • ASDEX gauge (ORNL) • SXR (UCSD) Pellet Inj (ORNL) • • BES (U Wisc) • FIR & w scattering (UCLA) • MSE (LLNL) • Fast framing camera (UCSD) • Vertical scan probe (UCSD) • ECE (UT,U Md) • CP swing probes (U Tor./GA) 4/2013 • Fast ion collectors (UCI) • MDS spectrometer (ORNL) • ECEI & MIR (UCD) • DBS & CECE (UCLA) • Neutrons (UCI) • Gamma detectors (UCSD) • Langmuir probes (SNL) • Phase contrast imaging (MIT) • Filterscopes (ORNL) • Radial scanning probe (UCSD) • Reflectometers (UCLA) •Visible cameras (LLNL)

9. Inside View of DIII-D: Diagnostics, Heating, Pumping

10. Multiple Hazards Exist at DIII-D • Ionizing radiation (neutrons, gamma rays, X-rays), tritium • Electrical (138 kV AC, >100 kV DC); high current (>100 kA) • Microwave (110 GHz >2MW) • Magnetic fields (< 5 T) • Lasers (visible and IR, Class I – IV, pulsed and steady-state) • Cryogens (LHe/LN2) • Explosive, toxic, and asphyxiating gases (H2, D2, CD4, diborane, Ar, Ne, Xe, and CCl2F2) • High pressure fluids: water < 300 psi, hydraulic < 5000 psi, gases <2200 psi • High noise levels • Mixed waste • High temperature surfaces (350 ˚C) • Confined spaces • Common hazards: fall, slip, trip, ladder, machinery, etc.

11. Outline: Part 2 • Overview of the DIII-D Facility • DIII-D Safety Program • Major Upgrades to DIII-D Science Capabilities Demand Proactive Safety Management • Ongoing improvements to DIII-D Safety Program

12. Overview of the DIII-D Safety Program • The Safety Program at DIII-D is based on Integrated Safety Management (ISM). It has been a successful system for assuring safe and efficient operations. • Hazards are identified for each task and engineered controls are put in place to protect personnel & equipment • Safety training for all personnel is regularly evaluated, provided on an on-going basis, and tracked • Processes and procedures are in place to control work • Lessons learned from incidents/near-misses are used to strengthen our Safety Program • The DIII-D team has created an environment with relative freedom from danger, risk, or threat of harm, injury, or loss to personnel and property.

13. The DIII-D Safety Program is Supported by General Atomics Corporate Safety Organizations • The DIII-D program is supported by General Atomics Corporate Environmental Safety & Health Group and Health Physics Group • DIII-D Safety Committee and Energy Group Safety Officer (employee of GA ES&H Group) • Externally regulated by Cal-OSHA and other state and local regulations • Radiological exposure is governed by State of California Radiation Control Regulations (Title 17). DIII-D procedures and ALARA program set targets below legal limits. • DIII-D has a dedicated on-site Emergency Response Team of trained members of the operations group.

14. Training of Personnel Plays a Critical Role in Safety • All new workers entering the DIII-D site to perform work receive a safety check-in sheet and safety indoctrination • DIII-D employees, GA maintenance staff, students, post docs, collaborators, contractors • DIII-D Safety training complements General Atomics safety training • Job classification and functions for each person are developed jointly with supervisor based on assigned tasks and responsibilities • Required training is identified for each job classification • Classes, hands-on, and on-line training are available • Supervisor and employee review job classification and required training annually • Web-based program is used to assign, track, & register training • Automatic reminders are sent to staff and supervisors

15. DIII-D Safety Training is Broad-based • Number of safety classes offered • ≈ 30 on-line classes are available • ≈ 20 are instructor-led • Classes are customized for the type of work being completed • Verifications are required for confined space entry, forklift & crane use, electrical work, and lockout/tagout procedures • Recent on-line vs instructor-led classes • 1263 training events (person-class) attended since January 2018 • 642 on-line training events (person-class) completed • 95% of required training is completed to date • DIII-D training database information • GA is transitioning to a Learning Management System database for safety training to include all GA and Affiliates. The Energy Group will continue to use the current training database until a system is in place to accommodate collaborators, include job classifications, and implement a method to have Management assign classes.

16. DIII-D Safety Statistics Shows Relatively Low Injury Rate* *injuries per 100 employees Injuries have remained low in the past 5 years. This is due to: • Improved and continual investigations and communication • Frequent targeted safety topic presentations • Improved safety awareness Near Miss reporting • Proactive method involving employees in safety • Employees are encouraged to report an unsafe act or condition • Near miss reporting helps to reduce injury incidents

17. DIII-D Safety Program – Most Injuries are Associated with Normal Work Activities • Engineering controls are in place for high hazard areas such as high voltage and laser rooms to ensure that injuries do not occur • Most injuries to personnel have occurred due to muscle strain, cuts, and bumps from normal work activity • Electrical shocks occurred from low voltage power supplies

18. Outline: Part 3 • Overview of the DIII-D Facility • DIII-D Safety Program • Major Upgrades to DIII-D Science Capabilities Demand Proactive Safety Management • Ongoing improvements to DIII-D Safety Program

19. Neutral Beam Reconstruction and RF Systems Installation Increases DIII-D Versatility and Safety Vigilance • Eight neutral D2 beams are used to heat D2 plasma to fusion-relevant temperatures in excess of 100,000,000 K. • Initial injection geometries were paired to provide good beam-plasma interaction along the mid-plane axis of the vessel • 4 beamlines, each consisting of a pair of tangential and radial injectors (at toroidal angles of 30˚, 150˚, 210˚, 330˚) • Past modifications were made to increase physics understanding • Rotation of 210˚ beamline • Modification of 150˚ to allow off-axis (‘downward’) injection • Present modifications include ground-breaking design: reconstruct 210˚ beamline to allow for both rotation AND off-axis injection • Additional in-vessel work to include in-vessel helicon installation is ongoing during the Long Torus Opening (LTO) lasting about 11 months

20. LTO Activities Require Many Personnel and Pose Unusual Hazards • 43 personnel from various contractors have been on site in the past few months for excavation and removal of concrete and to perform other electrical & mechanical tasks • Every contractor receives a mandatory safety orientation prior to working on site. • Daily inspections are performed by the Fusion Safety Officer • Daily safety briefings describing the task, hazards and mitigation are completed each day for every main task • 8:05 meetings are held describing the overall tasks for the day and any safety concerns are discussed • Major crane work, removal of equipment close to DIII-D vessel impacts ongoing maintenance and other new work • Requires use of Hazardous Work Authorizations, travelers, or other task-specific & management-reviewed documents

21. Hazards are Identified for Each Task and Mitigation is Developed • Each task is examined and the hazards are identified • Hazardous Work Authorization (HWA) is prepared by Responsible Project Lead • Task and system description • Description of hazards • Identifies the methods of mitigation, PPE, and required training • Lists personnel involved in each subtask • Lists permits required, hazardous chemicals, lasers, etc. involved • Specifies emergency response, if specialized for system • Specifies lockout/tagout procedures • Draft plan for safe operation of system presented at first design review • HWAs are reviewed by DIII-D and GA line and safety management • Reviewed and approved prior to performing work • Specialized subcommittees of DIII-D Safety committee provide review of HWA as needed (electrical, laser, chemical) • Updated annually or after changes

22. Proactive and Consistent Safety Assessments and Plans Provide Awareness & Communication for Workers • Tasks are planned & reviewed well ahead of schedule • Daily task safety checklist • Include all sub-tasks associated with main task • Computer & paper form • Located at jobsite; lists all persons on a task • Archived by management • Travelers • List tasks specific to overall project • May be procedures for mechanical or electrical work

23. Outline: Part 4 • Overview of the DIII-D Facility • DIII-D Safety Program • Major Upgrades to DIII-D Science Capabilities Demand Proactive Safety Management • Ongoing improvements to DIII-D Safety Program

24. Group-Wide Safety Meetings Strengthen Safety Culture Through Awareness & Communication • Group-wide input is requested regarding safety issues. A list of action items is developed and pursued. • Improve the training of non-DIII-D personnel, including short-term custodians, Security personnel, and contractors • Revise existing Lock-Out/Tag-Out DIII-D procedures. New procedure should require: • Improved written, system specific procedures written and approved • Easy availability of system-specific procedures (local & on-line) • A Task Group was formed to update the After Hours Work/Lone Worker procedures. • A Task Group was formed to update the “Pit Run” procedures. • DIII-D runs pulsed shots. Brief access to the Machine Hall “Pit” is allowed between shots to adjust experimental hardware.

25. Safety Upgrades in an Older Facility • Primary hazards for personnel while operating include: moving machinery, high voltage, and radiation. • Access Control for hazardous areas is accomplished through locks and Kirk Key Control. Daily walk-through by operators prior to securing these areas ensure no personnel are present. • In many cases, areas are divided into sections with interlocks wired in series with a single interlock for each area running to the Main Control Room. This interlock is OR’ed and then sent to an Emergency Crash System (ABORT) which turns off power supplies and opens breakers. • Wiring is old (>30 years) and not well documented. Adding on new areas can be difficult. Serial wiring makes troubleshooting difficult. • Investigating Distributed Safety System to incrementally add-on and begin piecemeal replacement. • Versafe from GE as add-on to existing Profinet linked PLC drops • SIL-3 rated hardware • Programmable functionality. Increased Diagnostics.

26. Summary • DIII-D has a successful system for assuring safe and efficient operations • Hazards identified for each task and mitigation is put in place to protect personnel & equipment • Safety training for all personnel is regularly evaluated, provided on an on-going basis, and tracked • Processes and procedures are in place to control work • Lessons learned from investigations of both injuries and ‘near miss’ incidents have significantly improved the safety program • Wide use of engineered controls are key to strong safety record at DIII-D • Awareness and communication are paramount to safe & efficient operations DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.