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machine. Highly irradiated and contaminated auxiliary com-ponents of the fusion device, such as diagnostics, rf heating,and fueling systems scheduled for repair or replacement, willbe removed from the test cell through shielded doors on a carttransfer system. The general sequence of operations for compo-r> nt maintenance is shown in Fig. 2. The main path for failedcomponents is remote removal and transport to a shielded fa-cility for decon, followed by transfer to the hot cell for repair. Ifrepairs cannot be made, the component will be scrapped. Theradioa. tive components will be remotely processed by specialtools to reduce the volume of scrap before it is placed in sealedcontainers, which are then stored to await possible off-site ship-ment.

boom or a rigid mast and floor-based systems including tixed-mount and mobile manipulators.

The prime candidates evolving from these studies were thebridge-mounted manipulator with telescoping mast (Fig. 3)and a floor-mounted system with an articulated boom (Fig. 4).The overhead system was selected for the baseline configura-tion. This resulted from a comparison of the two systems andalso the modification of the arrangement cf the igloo shieldto provide unrestricted manipulator access. The overhead sys-tem provides full test cell coverage without interference fromfloor-mounted machine components.

FAILED COMPONENTQN FUSION DEVICE

OR DIAGNOSTICEQUIPMENT

REMOTEREPAIR INTEST CELL

INSTALL NEWOR REPAIREDCOMPONENT

4DEMOTE

CETACHMENT{. TRANSFER

i

NEWCOMPONENT

GROSSOECONCELL

TRANSFERTD REPAIR

CELL

TRANSFERTO DECONCELL

REMOTEREPAIR

DECON ANDCONTACTPFPAIR

REPAIREDEQUIPMENT

STORAGE

SCRAPCUTUP AND

PACKAGE

RAO-WASTESTORAGE OR

DISPOSAL

Fig. 2 Equipment maintenance sequence.

The major thrust of the work for FY 1987 was to definemaintenance requirements to a degree sufficient to identify ma-jor impacts on the facility configuration. These studies in-cluded evaluation of remote handling and manipulator trans-port system arrangements, access to machine components re-quiring remote maintenance, and requirements for transport,decontamination, and repair or disposal of failed components.The progress of this work is described here.

Assessment of Manipulator Systems

Remote handling and manipulator transport systems havea major impact on cell configuration and equipment layout.This study investigated the best way to provide manipulatorcoverage of the tokamak and associated cell equipment. Al-te. iatives included overhead systems with either a telescoping

IMWUIATOHFUU.YRETRACTED

0B.L

0 9 10SCALE (It)

Fig. 3. Bridge-mounted manipulator for CIT test cell.

MANIPULATOR

j BOOM HOIST: MOVABLE BASE

0 5 10SCAiE iltl

Fig. 4. Elevation view of CIT cell with typical floor-mountedmanipulator positions.

CV>mput -r Modeling of Manipulator Tasks

The repair of the ex-v aa.'l auxiliary machine componentsinvolves gaining access to the vertical ports on top uf or be-neath the machine and to the 18 midplane ports on the side ofthe machine. Each of these tasks requires insertion of the ma-nipulator slave with its TV viewing cameras and auxiliary hoistinto the opening made by removing a shield module. Three-dimensional, CATIA-developed kinematic models of manipu-lators and solid models of the upper diagnostic and midplaneport areas of the CIT machine are proving to be a powerfultool to evaluate access and reach requirements. Figures 5 and6 are examples of the CATI\ system models. In these models,it was shown that the original shield limited lateral movementof the manipulator to essentially a head-on radial approachto each port. This created remote handling problems for thecomponent designer and imposed some abnormal requirementsfor the slave-arm configuration and motions. Severe restraintswere also imposed on the viewing systems and the means forproviding auxiliary hoisting assistance.

Fig. 5. CATIA plan view of upper ports and manipulator sys-tem.

As a result of this study, the shield designers revised theigloo design to provide acceptable manipulator access. Thebridge-mounted manipulator now has free access to all theports except those underneath the machine. The overheadtransport system can position the manipulator slave arms andviewing equipment in and around each diagnostic port and rfheating port to perform the intricate tasks of disconnectingand replacing vacuum, electrical, and cooling interfaces. Ad-ditional CATIA modeling is planned for FY 1988.

Remote Maintenance Demonstrations

Demonstrations uf CIT ex-vessel maintenance tasks havebeen under way to determine capabilities and equipment re-

Fig. 6. CATIA elevation view of upper ports and manipulatorsystem.

quirements for the ex-vessel maintenance system. Thesedemonstrations are conducted on full-scale, partial mock-upsof the CIT machine at ORNL's ROMD Facility with a Cen-tral Research Laboratory model M-2 manipulator. The firstdemonstration simulated various tasks required to maintaindiagnostic hardware and associated vacuum piping located onthe upper surface of the CIT. The mock-up demonstration in-vestigated vision requirements (camera locations) and manip-ulator access to this equipment. Conventional, bolted vacuumflanges were used. The vacuum pipe flange now being con-sidered for CIT use is the "Cefilac" coupling, manufactured bythe Helicoflex Company, and is specifically designed for remotehandling. It is the type specified for use on the Joint EuropeanTorus (JET) in the European Fusion Program. Methods andprocedures for remotely assembling these vacuum joints will betested and refined during FY 1988.

A second demonstration is under way to help in under-standing the viewing needs for maintaining the rpper and mid-plane diagnostics. Because of the compact, complex arrange-ment of the diagnostics and their associated vacuum pipingand the physical constraints of the igloo shield and the pressframe, there is not much space for TV cameras. Ideally, theoperator would prefer a belly-mount view as well as upper rightand left views. It [s not apparent that all of these views canbe provided, since the location of cameras could interfere withmachine components.

A third mock-up has been designed to demonstrate theremoval and installation of the rf module, which is mounted inseveral midplane ports. The ex-vessel maintenance system willbe required to remotely detach and remove the rf module fromthe CIT device for refurbishment in the hot cell. Tasks thatwill be performed remotely in FY 1988 include:

Removing and installing the igloo shield sections. Aligning and supporting the rf coaxial pipes during removal

and installation. Making and breaking connections at the rf coaxial pipes

and midplane port (flange bolts, electrical connectors, anrlcoolant connectors).

^ Pushing and pulling the rf module into and out of the mid-plane port.

Remote Maintenance Design Guide

A manual that provides basic guidelines for the design ofequipment to be remotely maintained is being developed forissuance to equipment designers responsible for such systemsas the diagnostic, fueling, and rf heating systems. The guide-lines will be based on proven techniques used at other facili-ties for design of similar equipment. Designs specific to CITwill be incorporated from the remote maintenance demonstra-tion mock-ups of the CIT machine components conducted atGRNL.

Activities for FY 1988

The work planned for FY 1988 focuses on R&D activi-ties to support the development of a manipulator system pro-totype; the manipulator transporter; inspection and viewingequipment; and various fasteners, flanges, and connectors forremote handling. Some work will be done on cutting and weld-ing equipment. In addition, work will be started for designinga full-scale quadrant mock-up of the machine, to be located atthe Princeton site. The design-related work will be more lim-ited and will concentrate on the preliminary design of deconand waste-handling equipment, the hot cell equipment, and theremote maintenance control room.

Upgrading the existing mock-ups at ORNL to reflect thefinal machine configuration will be a priority activity. Themock-up of the upper vacuum pipes was based on an earlyversion of the machine size and the igloo structure. The rf

mock-up will be modified to study access and reach for variousdiagnostic modules. A new mock-up of the vacuum pipes underthe machine is planned for the second half of 1988.

Conclusions

The CIT is providing the impetus to apply existing re-mote handling technology to fusion device maintenance and tudevelop new approaches where needed. The activities for thepast year focused on developing maintenance requirements andconceptual designs of maintenance equipment. The early useof partial mock-ups has been invaluable in studying problemsof access and reach and has had an impact on the develop-ment of the machine configuration. The work for FY 1988 willemphasize manipulator system development, preliminary de-sign of facilities-related equipment, and the continued use offull-size mock-ups.

Acknowledgments

The authors wish to acknowledge the contributions to thework presented in this paper by our colleagues K. C. Bills, R. E.DePew, and J. D. Snider of the Remote Systems EngineeringGroup at ORNL, led by D. P. Kuban.

Reference

111 F. Puhn, R. Gallix, and E. Hager, "Conceptual Design ofthe Plasma Chamber and Remote Maintenance System forthe Compact Ignition Tokamak," paper presented at the12th Symposium on Fusion Engineering, Monterey, Cali-fornia, October 1987.

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the United^StatesGovernment. Neither the United States Government nor any agency thereof.nor any of thremployees makes any warranty, express or implied, or assumes any legal habihty or respons.b S T t h e a c c u r a i , comp.etencss, or usefulness of any information apparatus, prcducM*process disclosed, or represents that its use would not uifnnge pnvately owned "8-W * encTTerein to any specific commercia. product, process, or service by . |"de " a m e jmanufacturer, or otherwise does not necessarily const.tute or unply .ts u Mmendation, or favoring by the United States Government or any agency * " J V and opinions of authors expressed herein do not necessarily state or reflect those of theUnited States Government or any agency thereof.