best practices for remote assembly and maintenance · best practices for remote assembly and...

Best Practices for Remote Assembly and Maintenance Keith Kershaw, Sources, Targets and Interactions Group Thanks to: Alessandro Tesini and Jim Palmer of ITER, Luca Dassa of EN-MME

Contents

• Why is it important to design for remote handling?

• CERN examples

• ITER Remote Handling Code of Practice

• Next steps

• Conclusions and discussion

HL LHC Remote Handling Keith Kershaw 2

Why is it important to design

for remote handling ? Why use remote handling?

• Maximise running time

• Reduce exposure of personnel to hazards (radioactivity, Oxygen deficiency etc…)

Why design for remote handling?

• Manipulator arms cannot do everything a human can

• Ensure remote maintenance is POSSIBLE

• Speed up remote maintenance

• Hands-on work will also be faster


CERN examples

CERN already has designed equipment to be compatible with remote handling. Examples include:

• LHC collimators

• SPS remote vacuum connection

Luca Dassa and Keith Kershaw are preparing short course for designers


Example : LHC collimators


LHC collimator remote exchange…

Remotely

operated crane

for handling and

transport Telemax for

inspection and

disconnection

TIM for

Inspection


Example : SPS Remote Vacuum

connection (1978)


The ITER Remote Handling

Code of Practice • Remote handling will be essential for ITER

maintenance.

• The ITER RHCoP is part of a management process to ensure “plant” is compatible with remote maintenance and to minimise downtime

• last year ITER issued CERN a Licence agreement to use the ITER RHCoP. It is not openly available.


ITER – Fusion Tokamak


After the first 7 years operation

remote handling will be vital for

maintenance Person for scale

http://www.iter.org/doc/www/content/com/Lists/WebsiteText/Attachments/47/in-cryostat overview 130116.jpg

ITER use JET

RH experience


“Man in the loop”

Multi-purpose deployer with twin

force reflecting manipulators


This is the “recovery” option

for times when purpose built

remote maintenance

equipment needs help

What is the ITER RHCoP?

There are two main documents:

• “ITER RHCoP” - (Technical guidelines)

• “ITER Remote Maintenance Management System” IRMMS - (Management processes)


ITER Remote Handling (RH) Baseline Strategy

RH Design Standards for:

• Location Devices

• Fasteners (incl. tooling)

• Welded Joints (incl. tooling)

• Electrical Connectors

• Fluid Connectors

Key principles for:

• Specification & design of RH equipment

• Preparation & implementation of RH Operations

IRHCOP defines and describes


IRHCoP Example – Location Devices

PIPE FLANGE

GUIDE SPIGOT

Parallel Dowel Pin Arrangement

Ball-End Dowel Arrangement Axial & Azimuthal Flange Location


IRHCoP Example – Fasteners

RETRACTED POSITIONENGAGED POSITION

EXTENDED SPRING

COMPRESSED SPRING

BOLT INBOLT IN

BOLT UNDER-FLUSH

WITH COMPONENT

SUPPORT STRUCTURE

THR

EA

DED

CA

PTI

VA

TIO

N

THR

EA

D

CLE

AR

AN

CE

COMPONENT

BOLT UNDERCUT TO

ROOT DIAMETER

CAPTIVATION OVER BOLT

KEY ACCESS

HEAD GUIDED

RETRACTED POSITION

ENGAGED POSITION

EXTENDED SPRING

COMPRESSED SPRING

BOLT IN

BOLT IN

BOLT UNDER-FLUSH

WITH COMPONENT SUPPORT STRUCTURE

COMPONENT

“Pop-up” captive bolts

captivation captivation at thread

captivation over the head

Tooling

Simple bolt runner

High torque tool with dove-tail feature

for local torque reaction


Includes:

• Organization of ITER RH Team

• Approach to RH classification

• Design & procurement process for RH equipment

• Method to ensure RH compatibility of ITER machine

• Organization and management of RH operations

ITER Remote Maintenance

Management System (IRMMS)


IRMMS - RH Classification (define at

start of design phase)

• RH Class1: Will need RH replacement / maintenance. Mock ups as part of design process

• RH Class 2: Only unscheduled maintenance. May involve mock ups for design process

• RH Class 3: failure probability < 1 in 200 years. Design for RH repair. RH equipment procured after assembly

• Non RH Classified: do not require remote maintenance.


IRMMS – Management (life cycle)

• Preparation and operations from concept to decommissioning

• Three key teams must work together through all stages of design and operation:

• ITER Plant

• ITER Remote Handling Equipment

• ITER Remote Handling Operations

• Reviews and iterations as part of process


More than 40 points

ITER remote

handling design

compatibility

checklist

Next steps

• We will start with short basic remote handling compatibility training courses for designers (EN MME and EN-STI)

• For the future we will need to develop our own code of practice and processes.

• This work will need to be based on realistic predictions of the capabilities of our remote handling equipment.


Conclusions & Discussion 1 • Where appropriate, beam line equipment

should be designed to be compatible with remote handling

• ITER RHCoP and IRMMS provide guidelines: • management aspects (collaboration of teams)

• design aspects

• Even if hands-on solutions are used, the same principles can offer benefits of reduced downtime and radiation exposure


Conclusions & Discussion 2

For every object: • Analyse - from the beginning - the installation, failure

and maintenance scenarios

• Analyse the big picture – do not rely on a magic remote handling device

Luca Dassa and Keith Kershaw are preparing a short course for designers on design for remote handling compatibility – please contact us with examples or input.

Thank you. Questions and discussion welcome…


best practices for remote assembly and maintenance · best practices for remote assembly and...

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