Remote Handling Activities and Overview

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Remote Handling activities and overview17th November 2013 (Madrid, Ciemat)By Elena V. Rosa Adame

ITER-DEMO-ISFNT 2013WP10-GOT-GOT RH-WP1.2

1My name is Elena Rosa from CIEMAT; CIEMAT is one of the participating European Association.In this work, EFDA promotes the GOT RH Programme and

I'm the trainee of the task 2 within the WP1

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WP10-GOT-GOT RH-WP1.2

What do we mean by Remote Handling?

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Maintenance.WP10-GOT-GOT RH-WP1.2Thermal loadsFrom plasma From neutronsFrom instrument losses Particle fluxesRe-deposition of eroded material on optics, mirrorsElectro-magneticDisruptions: significant displacements of instruments.NeutronsDegradation of materials

Why RH?ITER operation contaminates components.Beryllium depositionTritiumActivation (gamma)

What do we mean by Remote Handling?

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What do we mean by Remote Handling?The RH is not only manipulators it is much more(human, interfaces)Remote Handling is designed to enable an operator to undertake manual handling work at a particular work site without being physically present at that location. Unlike conventional robotics, Remote Handling always involves a human being within the process. The main handling device is a manipulator, not a robot, because the majority of Remote Handling tasks need the intuition and intelligence of a human.RH Group at JETThe Remote Handling system used for maintenance at the nuclear fusion experiment includes, transporters, servo manipulators, advanced human machine interfaces, Virtual Reality, television and a wide range of specialist tools. The technological expertise required of the personnel to design and operate these types of systems covers mechanical, electrical and electronic engineering, software, real time control, ergonomics, pneumatics, hydraulics, welding and cutting.

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WP10-GOT-GOT RH-WP1.2Things become more complex when the components to manipulate are heavy and: ITER is huge 10 times larger than JET (estimated 15E6 components, scale of RH unprecedented, diversity of RH system)ITER is a pressurised nuclear facilityITER is a new, international scientific cooperation

What do we mean by Remote Handling?The RH is not only manipulator it is much more(human, interfaces)

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Starting point: Maintenance Strategy-Input from RAMIWhen: Planned or not plannedWhat: Which componentsWhere: VV, port, maintenance facilityHow: manual or with RHPerform analysis with CAD, VR. Check feasibility, resource usageEffort (time) and maintenance facility occupationSpare parts to be kept in stock Tooling Intermediate storage & logistics, wasteInput to formal RH compatibility reviewIterate to increasing detail corrsponding to design review goals OSD validation using virtual mockupRH Compatibility Analysis

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WP10-GOT-GOT RH-WP1.2PDF:Provide context Design referenceHigh level descriptionPhysical properties Plant conditionPlant interfacesRH featuresTask overviewCritical issuesRevision historyApproval TDF:ObjetiveStart pointEnd pointAssumptionsSequence (access, stability)Tool conceptsIssuesApproval OSD:Sequence detail, time estimates Operator roles, synchronization pointsTool concepts, hazards and safety issuesRH Compatibility Analysis

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WP10-GOT-GOT RH-WP1.2ISFNT 2013Plenary sessions: Road Map and DEMO mainlyParallel sessions: Blankets technology (50 % ITER, 50 % DEMO)VV (70 % ITER, 30% DEMO) Safety issues and waste management (50 % ITER, 40% DEMO, JT60SA) Material engineering for FHT (ITER, DEMO and fusion in general)Nuclear System DesignFirst wall technology Inertial confinementRepair and Maintenance (50%ITER, 50% DEMO)Poster session (Reair and Maintenance): 50 % ITER, 35 % DEMO, 15 % IFMIFAMF in DEMO (logistic, timing, cost)Pipe connections (JET /DEMO)IVVS (ITER)Divertor/blankets maintenaceUpper port plug (ITER / DEMO)

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Reports , additional training and dissemination of the resultsWP10-GOT-GOT RH-WP1.2IDNameExpected Date (from 1st December 2011)D1.1Technical Specification Document (TSD)1-2 monthsD1.2Quality Plan (QP)4 monthsD1.3System Requirements Documents (SRD)10 monthsD1.4Conceptual Design Document including Digital Mock-up16 monthsD1.5Detailed Design Document34 monthsD1.6Final Report of Design 36 months

Publications/ConferencesFunctional Requirements and Alignment of the UPP and CPEHS for ITER. Technofusin (June 2012, Madrid) Progress on the interface between UPP and CPRHS Tractor/Gripping Tool for ITER, in Fusion and Engineering and Design (Elsevier). Reference FUSION6744. SOFT conference (September 2012) Gripping tool for the ITER UPP RH. ISFNT conference (September 2013, Madrid) Courses/Workshops Project Management and Quality Assurance and Mechanical Design and Control (March 2012, Tampere). 6th Karlsruhe International School on Fusion Technologies (September 2012, Karlsruhe). PUREsafe workshop (October 2012, Madrid). Robotics, Telerobotics and Interfaces for RH (March 2013, Paris).

GOT-RH-Programme. ITER

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WP10-GOT-GOT RH-WP1.2According to the TSD, QP, SRD and CDD, the object of the project is: To design the RH tools acting in the interface between UPP and CPRHS and their related mechanical interfaces when the TCS is docked in the docking pins of the building and the bioshield is already extracted. That is the confinement between the cask envelope and the port duct extension is guaranteed and the tractor has access to the plugs bottom and the plugs flange.


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WP10-GOT-GOT RH-WP1.2After our last meeting with Darren Locke (F4E) the goal is rethought: The object of the project is: To design several RH gripping tools acting in the interface between UPP and CPRHS and their related mechanical interfaces. Why?: because it is currently assumed that the cutting, sealling and bolting operations will be carried out manually.The gripping operation is the only one that is going to be carried out remotely due to the cask/tractor/gripping tool would not allow access of a human operator to manually connect/disconnect plug and tractor.

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The conceptual design of the interface between UPP and tools for plug RH insertion/extraction.Extraction Force: 100kNInsertion Force: 30 kNGOT-RH-Programme. ITER

12As everybody knows:

The goal of this programme is to train engineers for supporting the ITER Project in RH task.

Within the programme there are 3 WP with different projects. I'm working in project 2 of WP1, that is oriented in the field of the mechanical engineering oriented.

The goal of project 2 is to carry out the conceptual design of interfaces between UPP and cask and tools for UPP RH operations

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WP10-GOT-GOT RH-WP1.2Data input/kinematic and friction study conclutions

To absorb the the 01 of misalignment between the port duct and port cell rails, there is a total clearance of 10mm between skids and rails. Adjustable wedges are manually installed according the ITER documentation. The assumed friction coefficient between skids and rails is 03.After the kinematic/friction study, the highest relative misalignment between plug axis and tractor axis is 0523 in the rail plane. That is, the tractor sees the relative displacements of 165 mm and 41 mm of the point centered at the plug bottom interface.

The friction forces on the xy plane (Fix) due to the misaligment of foces are small in comparison to the friction forces due to the plug weight (Fixy).

It is recommended to reduce the tolerance of the skids to 5mm. The 38 mm is the minimum required tolerance to absorbe the misalignment between rails. In addition, the distance between plug wall and VV port components is 25 mm . Also, it is recommended to give a curved shape to the inner side of skids to avoid cutting edges and facilitate extraction. The installation of adjustable wedges could be avoided if there is a good connection between rails.

Double curvature on inner side of skidsSkid to limit the plug turningSkid to align the plug on the rails


13As everybody knows:

The goal of this programme is to train engineers for supporting the ITER Project in RH task.

Within the programme there are 3 WP with different projects. I'm working in project 2 of WP1, that is oriented in the field of the mechanical engineering oriented.

The goal of project 2 is to carry out the conceptual design of interfaces between UPP and cask and tools for UPP RH operations

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Previous concepts for the gripping toolWP10-GOT-GOT RH-WP1.2

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Joint between GT and plug interface Joint between GT and tractor interface Gripping Point (GP)Only one gripping point. This reduces the risk of jamming during extraction/insertion and makes connection/disconnection faster. Analogy with railway couplings (one connector between train cars instead of two).The gripping tool is composed of three parts: - the gripping tool part connected to the plug interface - the gripping point - the gripping tool part connected to the tractor interfaceThe part of the grippint tool placed in the plug interface is connected hand on. (F4E input)The gripping tool has to allow y/z displacements in the gripping point ( 20 mm, 5 mm) and it has to support 100/30 kN in the plug extraction/insertion.The gripping tool should avoid the need for force feedback.The 01 of misalignments between port duct and port cell does not produce lineal traslation in the GP. The gripping tool should allow small relative torsional movement between plug and tractor. This is achieved by tolerances in the GP.The number of sensor onboard the TCS is very resticted. The gripping tool should rely on visual control as much as possible.GOT-RH-Programme. ITER

14In this table it is shown the situation of my project within of the programme

As I have said, Im the trainee and my mentors are Luis Ros and Vicente Queral from CIEMAT. We work in Project 2 within WP1 of WP10 goal oriented training for RH.

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WP10-GOT-GOT RH-WP1.2 GT 1: TowHitch

The tool connection/disconnection is carried out in the horizontal plane.The GP displacements in the horizontal plane are allowed by two turning joints.The GP displacements in the vertical plane are allowed by tolerances between hitch and and end-effector.GOT-RH-Programme. ITER

15There are 6 documents foreseen to submit, two of them have just been submitted (TSD and QP), and the next will be SRD. The number of presentation, publication and courses of the trainee are shown in that table:This presentation is the first of the year. The second presentation is foreseen in the summer school in karlsruheIm trying to submit a publication for SOFT. The deadline for submitting the abstract is on 2th of April.

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WP10-GOT-GOT RH-WP1.2 GT 1: TowHitch

5mmThe tractor rested on the rails approaches the plug and the cone structure of the end-effector pushes slightly the end of the articulated arm (hitch).The cone structure drives the hole of the hitch to the GP and the shock absorber buffers the push.The hitch is in the right position for the rod to be lowered. This position can be verified and validated through visual control (e.g. marks on the hitch) or, if possible, through a force and/or position sensor.The stepper motor 1 turns the cam and the rod goes down locking the hitch. The motor shaft is locked (holding torque). It is checked that the rod is lowered either trough visual inspection (no cover can be installed in this case) or, if possible, by a position sensor. This means the hitch is locked by the rod and the tractor is ready to push the plug. The tractor starts to pull from the plug and the shock absorber buffers the pull.The sensor force (if available) verifies the tractor is pulling the plug and it gives information about the load during the extraction. GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 GT 2: Mushroom-Hoop

The tool connection/disconnection is carried out in the vertical plane.The GP displacements in the vertical/horizontal plane are reached by tolerances in the end-effector. GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 GT 2: Mushroom- Hoop

The tractor approaches the plug until the painting marks that indicate the right tractor position to start the connection are reached (visual control).Visual control of the mushroom grip under the Hoop rear part and turning the motor 1 (turning the Hoop).After introducing mushroom grip through the rear part of the Hoop, tractor moves backward until mushroom grip reaches the front part of the Hoop. Visual validation of the right connection in the GP.The tractor starts to pull from the plug and the sensor force, if available, verifies the right plug extraction.GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 GT 3: TwistLockThe tool connection/disconnection is carried out in the horizontal plane.The GP displacements in the vertical/horizontal plane are allowed by clearances between end-effector and plug.



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WP10-GOT-GOT RH-WP1.2 GT 3: TwistLock

The tractor approaches the plug until the painting marks that indicate the right tractor position to start the connection are reached (visual control).The tractor introduces the twist-lock inside the hole.The shock absorber buffers the push and the sensor force, if availabe, provides information on the pushing force. The gripping position is verified and validated visually with the help of painting marks and, if available, through a sensor position.The motor twists and locks the twistlock shaft. This position is verified and validated visually and by the motor command signal.The tractor starts to pull from the plug and the shock absorber buffers the pull. The sensor force, if available, gives information about the pulling force.GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 GT 4: Mushroom-Plate

The tool connection/disconnection is carried out in the horizontal plane.The GP displacements in the horizontal plane are allowed by two turning joints.The GP displacements in the vertical plane are allowed by tolerances in the end-effector. GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 GT 3: Mushroom-Plate

The tractor approaches to the plug and pushes the plug. The wedge shaped feature in the articulated plate drives the mushroom grip to the GP. The shock absorber buffers the push and the force sensor, if available, identifies if the applied tractor force is suitable. It is checked that the grip is in the connection position through visual inspection or, if possible, by a position sensor. The motor turns the cam and the rod locks the mushroom grip. It is checked that the rod is engaged through visual inspection, through the motor signal and, if possible, trhough a position sensor. The tractor pulls the plug and the shock absorber buffers the pull. The sensor force, if available, gives information about the load extraction.GOT-RH-Programme. ITER


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WP10-GOT-GOT RH-WP1.2 Conclutions and further works:

RAMI analysis of the gripping tool. For that, the reliability requirement for the UPP is needed as input.Structural evaluation of the tools. Assessment of whether the disadvantage of excentricity of the load in the GP is more important than the advantage of fast connection and simplicity associated to clearances in the GP (no need for alignment in the end-effector).Dynamic study of the tool .



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WP10-GOT-GOT RH-WP1.2 Other Concepts of Gripping Tools that have been rejected:

The displacements in the tool GP (20mm, 5mm) are reached by clearances. The tool connection/disconnection and the movement of the fastener is carried out in the same plane (horizontal). Therefore the geometry of this tool is quite simillar to GT4 Rod-Plate. In contrast, The closing system based on springs and cables is less reliable than the rod and cam and the closer trajectory needs much space.


24And finally Progress and next step

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The displacements in the tool GP (20mm, 5mm) are reached by double turning joints, like GT1 and GT4.The tool connection/disconnection and the movement of the fastener is carried out in different planes.Tool more complex than GT1 without offering a significant advantage. The GP needs double alignment (in horizontal and vertical plane)



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The displacements in the tool GP (20mm, 5mm) are reached by two turning joints.The tool connection/disconnection and the movement of the fastener is carried out in the same plane (vertical). The GP has to be aligneed in the horizontal/vertical planes. Tool more complex than GT2 without offering a significant advantage.



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This concept (Janney or other train couplers) was not selected due to the complexity associated to inserting a pin in the GP locking tractor and plug. In addition, recovery from failure (e.g. jamming) in the pin actutation system would be complex.The tool is more complex than the presented ones without offering any significant advantage.



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RH Group at Ciemat: Elena V. RosaWP13-DAS07-RH Task 08: Active Maintenace Facility WP13-DAS07-RH Task 09: Service Joining Technology (in cooperation with Ivn Fernndez)WP13-DAS07-EFDA tasks. DEMORH Activities and Overview

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WP13-DAS07-Task 08: AMF. DEMO

RH Activities and Overview

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Reference document: Thomas J., DEMO Active Maintenance Facility. EFDA_D_2L6NLS. Final report for WP12-DAS06-T04 (2013).RH Activities and Overview

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RH Activities and OverviewWP13-DAS07-Task 08: AMF. DEMO

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Description of the individual components (WCLL)WCLL blanket modules design developed by CEA (Aubert J., In-Vessel Components Design and Integration. EFDA_D_2JNFUP. Final report for the WP12-DAS02-T03 (2013)).

The blanket modules weight estimated in EFDA_D_2L6NLS does not correspond with the estimated value in this task (even considering a packaging factor of 0.8)RH Activities and Overview

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Ciemat Activities and RH OverviewWP13-DAS07-Task 08: AMF. DEMODescription of the individual components (WCLL)WCLL outboard module 2 (equatorial plane).

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WP13-DAS07-Task 08: AMF. DEMOPacking factor: 0.8 (the module 2 is the highest module. A reduction factor to correct the MMS weight is considered ).

Eurofer density: 7750 kg/m3Tungsten density: 18700kg/m3 RH Activities and Overview

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WP13-DAS07-Task 08: AMF. DEMOThe main goal of the active components disassembly is to automate the operations as much as possible: Fixed and controlled geometrical positions (components and RH systems) in the maintenance room (like in an automatized production line).For blanket dismantling, a workbench preliminary design is proposed:


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WP13-DAS07-Task 08: AMF. DEMORH equipment. Blanket working bench.


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WP13-DAS07-Task 08: AMF. DEMOBlanket dismantling operationsPlacing of the MMS in a workbench to be manipulated (possible adaptation of the design to be inserted as part of the workbench) . Disconnection of the plugs of the upper pipes of the blanket.Extraction of the remaining water from the pipes and manifolds (e.g. using vacuum or pressurized He) (tritiated water must be stored and processed).Cutting of the back support structure.Cutting of the welded joints between the modules iv_1, iv_2, iv_3, iv_4 and the back support structure (we assume that the design of this cover will allow being disassembled). Extraction of the cut back support structure and insertion in the storage package to be transported to the waste and recycling room.Repetition of the process until the complete disassembly of the back support structure.Cutting of the inlet/outlet pipes of each module and insertion in the package to be transported (according to the tables, each OB blanket module has 48 pipes).Cutting of the manifolds and insertion in the storage package to be transported to the waste and recycling room.Individual modules operations. They can be carried out in parallel or one after the other (the dismantling of the module maybe could be carried out in the waste and recycling facility (TBD).


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WP13-DAS07-Task 09: Service Joining Technology. DEMO

Main issue:Spring reliability (possibility of embrittlement due to high neutron & gamma doses; performance at high temperature).


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WP13-DAS07-Task 09: Service Joining Technology. DEMOSprings vs. radiation accumulated doseDEMO operational concept description (2LCY7A):

3.9-5.5 fpy 13-18.3 CYNeutronic study to shield the UPP of DEMO (EFDA_D_2D5TAJ):Shielding of 0.2 m: fluence rate decreases from 21012 n cm-2 s-1 to 21011 n cm-2 s-1. Shielding material: based on stainless steel borated 2% (ASTM-A887-89) to 60 % plus H2O to 40 %. Considering an average time of 10 y between blanket replacement, the specific neutron dose in the connector location is 6.30721023 n/m2 < 1025 n/m2 (rough approximation). The accumulated radiation dose (absorbed) must be compared with the maximum radiation dose accepted by COTS springs.

10 yearsRH Activities and Overview

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WP13-DAS07-Task 09: Service Joining Technology. DEMOSprings vs. temperatureThermal compatibility of candidate materials 10 y).

Out of the auxiliary system


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WP13-DAS07-Task 09: Service Joining Technology. DEMO


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WP13-DAS07-Task 09: Service Joining Technology. DEMOCapillary flow modelingFirst stage: 2D axisymmetric analyses.FEM model: geometry focused on the gap between the upper and the lower Ni-200 parts (0.1 mm, according to the American Welding Society recommendation).Initial conditions: temperature map from previous electromagnetic-thermal analysis (theating=20 s).


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WP13-DAS07-Task 09: Service Joining Technology. DEMOR&D needs towards manufacturing and testing a mock-upPreliminary identification of requirements for a detailed design.Development of experimental work to characterize key parameters affecting the performance of the connector:Eurofer/Ni-200 brazability.Filler metals spreadability.Magnetic & thermal properties.Tritium transport parameters.Temperature maps (nuclear heating) in the upper ports.To fix reliability objectives.Influence of high neutron dose (accumulated & rated) on the materials behaviour.Assessment on manufacturing methods detailed design phase.Further development in the Final Report.


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Thanks457 th November 2013 (Ciemat, Madrid)

Elena V. Rosa Adame ([email protected])Acknowlwdgements to Gerardo Veredas for his technical support in Catia. www.ciemat.es


45I would like to tell you that I have internal progress meeting with my mentors Luis and Vicente every week more or less.

Thank you for your attention.