Remote Handling design progress for the Collimation Upgrade project

Remote Handling design progress for the Collimation Upgrade project

Keith Kershaw EN-HE 6 June 2011

Collimation Working Group 6 June 2011 Keith Kershaw EN-HE

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Contents

• Introduction – refresher (on-going process)• Four areas of work as proposed and agreed in

2010


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First mock up tests – remote handling of collimator

Dummy collimator installed on base using modified truck loader crane fitted with hoist and spreader rotation. Operation with only camera viewing and remote controls


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Reserved space for collimator handling LHCHMUMC_0001

Implications for infrastructure

Implications for collimator dimensions

It was necessary to modify water pipes


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Installation using specially designed trailer crane


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Plug – ins:

Careful guidance during LHC installation (not ideal for the future)


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Plug-in behaviour tests 2010

Practical investigations in LHC tunnel mock-up by EN-STI, EN-MME and EN-HE.


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Water plug - ins


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Infrastructure P7 (need to pass via TZ76)


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Passage at point 7-

Improvement of entry to UJ 76. Need to move grille

Shorter push-pull bar and push attachment point on Palfinger


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Palfinger 1000kg trailer - crane

Stability tests at 125%

Safety checks at the factory

•Custom design for collimator handling•Increased capacity (2x previous)•Better control with radio control•Flat loading surface (pump underneath)•Operation zone at “rear”end of trailer•Asymmetric stabilizers to reduce width

Spreader beam load test


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EN-HE radioactive collimator handling equipment development work 2010 onwards

1. Optimisation of collimator transfer etc2. Remote collimator exchange crane vehicle3. Vacuum disconnection mobile robot4. Remote Survey (HE part - see Patrick

Bestmann’s presentation)


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1) Optimisation of collimator transfer• Improve remote controls on the two existing

500 kg trailer cranes. • Compact shielded tractor units to tow the

trailer cranes • Partially shielded trailers for transporting the

collimators (weight of shielding restricted by LHC point 7 lift capacity of 1 tonne)

• Additional 1000kg capacity trailer crane • Minor infrastructure modifications to

improve passage.


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2) Remote collimator exchange crane vehicle

• Two remote control vehicles fitted with 1 tonne crane (One + option)

• Camera viewing system • Accessories, mock up tests, infrastructure

preparation


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Collimator remote crane design features

• 1000kg crane load capacity • Support platform for collimator transfer• Dimensions compatible with LSS7• Remote control of all movements• Powered rotation of spreader • Powered extension of stabilisers• Powered traction• Powered steering• Supports to add shielding• Manoeuvrability compatible with chicanes at point 7• Powered from monorail in tunnel (MAFI-type trolley)• Possible to tow out in event of breakdown


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Power from monorail

Notes : New trolley design needed to allow mounting on continuous monorail Use trolley for overview camera mounting

LHC Cryomagnet transport vehicle power trolley and push-pull bar.


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Collimator remote crane - status

• Market survey currently with specification committee – out this week

• Conceptual design for specification in progress• Specification based on previous trailer cranes• Aim for December 2011 Finance committee (1

+ option is borderline for FC threshold) • Delivery end 2012


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3) Vacuum disconnection mobile robot

Main items in cost estimate• Test equipment and trials • Robot with force reflecting master arm• Vehicle • Cable handling and accessories

• Plan is based on studies and tests in 2011- 1012 then major purchases of equipment in 2013-2014


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Collimator connections

Turn nuts to release

“unstructured” environment


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Bellows compressor


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Vacuum disconnection mobile robot

CEA pictures from: Overview of remote handling technologies developed for inspection and maintenance of spent fuel management facilities in France: Philippe DESBATS (CEA-LIST), Gérard PIOLAIN (COGEMA-HAG/DMCO),

Basic idea for cost estimation: Industrial robot controlled using force-reflecting master arm mounted on remote control vehicle

CEA LIST Master arm used with Staubli robot

Remote control vehicle (Kuka shown)


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Collimator remote disconnection development issues

• Determine level of remote handling sophistication and viewing necessary for task

• Determine geometrical requirements• Navigation and communication issues• Review – radiation dose implications, risks etc


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Determine level of remote handling sophistication necessary for task

• Practical mock-up tests with different remote handling techniques: e.g. master slave force reflecting manipulator , joystick control


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Determine geometrical requirements

• Inventory of collimators, 3D models, photos. (eg alignment of flange release nuts)

• Collect details of tooling • Define geometrical restrictions and check

against commercial manipulator /robot arms• Catia studies


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Solve mobile platform navigation and communication issues

• We have obtained EU Marie Curie funding to look into mobile platform issues specific to CERN’s radiation environment

• We are currently designing and will build a mobile test platform for this

• It will be possible to equip the mobile platform with an arm


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Disconnection review – radiation dose implications, risks etc

• We have a joint project with RP and have obtained EU Marie Curie funding to look into radiation dose implications of handling scenarios. The collimator exchange will be a major case for this work.

Report at end of 2011 bringing together test and study outcomes with intermediate conclusions and way ahead.


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Remote Survey (HE part)

Please see Patrick Bestmann’s presentation)


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Any Questions?


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Extra slides


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ITEM No 2011 2012 2013 2014 2015 totalOPTIMISATION OF COLLIMATOR TRANSFER ETCPurchases PurchasesImprove remote controls on the two existing 500 kg trailer cranes. 2 20 30 50Compact shielded tractor units to tow the trailer cranes 3 50 100 150Partially shielded trailers for transporting the coll imators (note1) 3 60 60additional 1000kg capacity trailer crane 1 20 100 120Minor infrastructure modifications to improve passage. 1 25 25 50Accessories and tests 1 25 25 50Total purchases 200 280 0 480 kchfManpower. Manpower1.5 man years 0,5 0,5 0,5 1,5 man-years

REMOTE COLLIMATOR EXCHANGE CRANE VEHICLE ETCPurchases Purchases

Two remote control vehicles fitted with1 tonne crane (note 2) 2 40 450 20 40 350 9001 camera viewing system 1 100 200 300Accessories,mock up tests, infrastructure preparation 1 100 100 100 300Total purchases 40 450 120 240 650 1500 kCHFManpower Manpower6 man years 1 1 1 1,4 1 5,4 man-years

VACUUM DISCONNECTION MOBILE ROBOTPurchases PurchasesTest equipment and trials 75 75robot with force reflecting master arm 1 100 800vehicle 1 100 300cable handling and accessories 1 100 100total purchases 75 75 100 1000 400 1650 kCHFManpower Manpower3 man years 0,6 0,75 0,75 0,75 0,75 3,6 man-yearsSpares 50 50 50 200 350

REMOTE SURVEY (HE part including support to operation)Purchases 15 20 20 15 15 85Manpower 0,4 0,3 0,3 0,3 0,3 1,6

OVERALL TOTALS (note 3) TOTAL PURCHASES 330 875 290 1305 1265 4065 kCHF

TOTAL MANPOWER 2,5 2,55 2,55 2,45 2,05 10,5 man-years

2011 2012 2013 2014 2015 totalNotes1) weight of shielding restricted by LHC point 7 l ift capacity of 1 tonne2) powered hook rotation and stabil izers (costs include studies and contract follow up)3) Vacuum disconnection first phase is ALARA studies + optimisation4) General note - does not include operation costs

Prepared: 9/3/2011 K Kershaw et al.

RADIOACTIVE COLLIMATOR EXCHANGE HANDLING EQUIPMENT DEVELOPMENT RESOURCES


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Documents

Remote Handling design progress for the Collimation Upgrade project