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Upper port handling

Equatorial port handling

In-vessel viewing system

Divertorhandling

Blanket handling

ITER Remote Handling

Upper port handling

Equatorial port handling

In-vessel viewing system

Divertorhandling

Blanket handling

Upper port handling

Equatorial port handling

In-vessel viewing system

Divertorhandling

Blanket handling

ITER Remote Handling

Why Is Full Remote Handling an Area of Unfilled DEMO R&D Gap?Tom Burgess for NCT Discussion Group

What Is Full Remote Handling, required by Demo?• Full remote handling uses robotic handling systems supported by component,

device, and facility designs to enable efficient maintenance of all activated components, minimize mean time between failure, and maximize availability

What Is the gap in Fusion Full Remote Handling?• Exceptionally challenging remote handling environment with competing requirements:

• Large handling payloads, precise positioning / alignment, high radiation, poor accessibility, complex fusion core components, and tightly constrained spaces.

• Far beyond available knowledge base (fission, accelerators, fusion, etc.)

Contributions from ITER• First reactor-size remote handling• Severe constraints in design

• Limited access • Many modules in small sizes• Lengthy maintenance cycles• Low availability • major changes in approach

anticipated for DEMO

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A NCT Facility Fills this Gap in Unique Ways

Envisioned NCT Challenges and Capabilities

• Must achieve an availability of 30%, an order of magnitude above ITER goal

• Demo-level high radiation

• Frequent scheduled and unscheduled component exchanges

• High degree of component modularization

• Time and cost effective solutions

• Vertical Access:CTF Vertical May 31, 2007.avi

• Mid-plane Access: CTF Midplane May 16, 2007.avi

Midplane port assembly

handling cask

Vertical port handling cask

In-cell servomanipulator

CTF Remote Handling

Activated component hot cell

Vertical cask docking port

Midplane cask docking port

Midplane port assembly

handling cask

Vertical port handling cask

In-cell servomanipulator

CTF Remote Handling

Activated component hot cell

Vertical cask docking port

Midplane cask docking port

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Back-up Slides

Fission and Nuclear Accelerator Examples

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Fission Reactor Remote Handling is Simple by Comparison

ORNL High Flux Isotope Reactor Fuel Pool

Power Reactor Fuel Handling

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Fission’s Fuel Reprocessing Is More Challenging

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SNS Target FacilityCutaway of TargetBuilding

Spallation Neutron Source Target Facility: A Modern, Accelerator-based Example

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SNS Target Process Hot Cell

Size: 103 Ft Long x 14 ft Wide x 30 feet High

A US science frontier facility

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SNS Hot Cell Interior Looking Towards TargetAn inaccessible area where all process systems are fully remotely maintained with state-of-the-art robotic remote handling system

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Remote Handling Design Development for Rare Isotope Accelerator (RIA)

ORNL in collaboration with ANL, LLNL and MSU, developed the conceptual design of RIA target stations and facilities

Sponsored by DOE Office of Science - Nuclear Physics

Accelerates ion beams from hydrogen through uranium at power levels up to 400 kW with primary targets of liquid lithium and water-cooled tungsten

RIA R&D and design was completed in 2006. DOE has rescoped and defined as the Facility for Rare Isotope Beams (FRIB), with ~ 5 year delay in construction schedule.

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Remote Handling Design Development for Archimedes Filter Plant

Archimedes Filter Plant will reduce

HLW mass by 75% to 90%

Remote Systems completed tasks:

Trade-off Study to evaluate

and select the optimum

remote handling approach for

the multi-filter plant

Conceptual Design and Cost

Est. of the AFP Remote

Handling System and

supporting documents

For Hanford Waste, operation with reduced ionization fraction allows: Highest effective throughput unit Smallest number of separators Minimum power requirements

Waste Stream Input Light Ions

Non-ionized gas bypass

Heavy Ions

Low Activity Waste Collectors

High Level Waste Collector

Archimedes Nuclear Waste, LLC, is developing a proprietary

process for plasma mass separation of HLW stored at DOE-Hanford

AFP RemoteHandling System Concept Design

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Back-up Slides

NCT Component Test Facility (CTF) Remote Handling Specific

CTF Builds On ITER Remote Maintenance Approach

ITER remote handling (RH) design and experience leveraged and applied

Hands-on maintenance employed to the fullest extent possible

Activation levels outside vacuum vessel low enough to permit hands-on maintenance

Upper port handling

Equatorial port handling

In-vessel viewing system

Divertor handling

Blanket handling

ITER Remote Handling Systems

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MachineAssembly / Disassembly

Schematic

•Disconnect upper piping•Remove sliding electrical joint•Remove top hatch

•Remove upper PF coil•Remove upper diverter•Remove lower diverter•Remove lower PF coil

•Extract NBI liner•Extract test modules•Remove upper blanket assembly•Remove lower blanket assembly

•Remove centerstack assembly •Remove shield assembly

Upper PipingElectrical JointTop Hatch

Upper PF coilUpper DiverterLower DiverterLower PF coil

Upper Blanket AssyLower Blanket Assy

CenterstackAssembly

ShieldAssembly

NBI Liner

Test Modules

CTF Vacuum Vessel, Blanket and Port Assembly Shielding Allows Ex-Vessel Hands-on Access

VV, blanket and port shielding

(steel & water)

In-vessel components removed as integral assemblies and transferred to hot cell for repair or processing as waste

In-vessel contamination controlled and contained by sealed transfer casks that dock to VV ports

Remote operations begin with hands-on disassembly and preparation of VV closure plate at midplane port or top vertical port

Midplane ports provide access to test blanket modules, heating, and diagnostic systems housed in standard shielded assemblies that are remotely removed

Midplane Port RH Cask

Test Blanket Module

Hot Cell

Cask Docking Ports

Activated Components Transferred Between Machine and Service Hot Cell by RH Casks

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Top Vertical Port Facilitates Large Component Replacement To Minimize Maintenance Time

To reduce maintenance time / significantly increase machine availability (30 % duty factor), a large in-vessel component module approach with vertical replacement is being investigated.

Remote Handling Classification of Components

Class 1 (Relatively frequent)

Class 2 (Relatively infrequent)

Class 3 (Not expected but possible)

Class 4 (Hands-on)

Upper and Lower Divertor Modules / Coils Midplane Port Assemblies: Test Blankets, RF Heating, Diagnostics Neutral Beam Ion Source Cleaning In-vessel Inspection (viewing/metrology probe)

Upper and Lower Breeder Blanket Center Stack Neutral Beam Components

Vacuum Vessel Sector / TF Coil Leg Shield Blanket

Poloidal Field Coils Ex-vessel Services

Remote maintenance is an important design and interface requirement, particularly for frequently handled items

Components are given a classification to guide the level of design optimization for ease and speed of replacement

Component Maintenance Frequency and Time EstimateComponent or Operation RH

Class Expected Frequency

Maintenance Time Estimate*

Divertor Module TBD, replacement rate ~ at least once every 2 years?

Upper module: ~ 4 weeks Upper and lower: ~ 6 weeks (assuming center stack not removed)

Midplane Port Assemblies 1 ~ 3 weeks per port assembly

Neutral Beam Ion Source Cleaning ~ 1 week per NBI

In-vessel Inspection (viewing/metrology probe)

1

Frequent deployment

Single shift (8-hr) time target (deployed between plasma shots, at vacuum & temp.)

Upper and Lower Breeder Blanket

TBD, replacement

rate ~ several times in life of machine ?

Upper: ~ 6 weeks Upper and Lower: TBD (significant if all midplane port assemblies must be extracted)

Center Stack (Class 1?) 2 ~ 6 weeks Neutral Beam Internal Components TBD, ~ 2 to 4 weeks

Vacuum Vessel Sector / TF Coil 3

Replacement not expected

TBD, replacement must be possible and would require extended shutdown period

Shield Blanket

* Includes active remote maintenance time only. Actual machine shutdown period will be longer by ~ > 1 month.Time estimates are rough approximations based on similar operations estimated for ITER and FIRE.

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ITER equatorial port assembly remote handling system

Port assembly installed

Port assembly RH tractor

RH caskVV port

Port assembly and RH cask interface to VV

Port assembly removed to cask

VV

Blanket

PFTF

Cryostat

Port bellows

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ITER VV port access clearance requirements

Port assembly and RH cask interface requires > 50 cm clearance measured from nearest component to inside port opening

Space drivers:

•Cask maneuvering clearance

•Cask enclosure wall

•Cask-to-port seals

& docking clamps (not shown)

•Double-seal door seals

•Port assembly seal welds

•Port assembly attachment keys

Note: Design has been optimized to minimize space, requires R&D to verify, and is subject to increases

60 cm

60 cm