Water hydraulic manipulator for fail safe and fault tolerant remote handling operations at ITER

Department of Intelligent Hydraulics and Automation (IHA) of Tampere University of Technology has been involved in the European Fusion program since 1994 within the ITER reactor maintenance activities. In this paper we discuss the design and development of a six degrees of freedom water hydraulic manipulator with a force feedback for teleoperation tasks. The manipulator is planned to be delivered to Divertor Test Platform 2 (DTP2) during year 2008. The paper also discusses the possibility to improve the fail safe and redundant operation of the manipulator. During the design of the water hydraulic manipulator, special provisions have been made in order to meet the safety requirements such as servo valve block for redundant operation and safety vane brakes for fail safe operation.     

The remote handling systems for ITER

The ITER remote handling (RH) maintenance system is a key component in ITER operation both for scheduled maintenance and for unexpected situations. It is a complex collection and integration of numerous systems, each one at its turn being the integration of diverse technologies into a coherent, space constrained, nuclearised design. This paper presents an integrated view and recent results related to the Blanket RH System, the Divertor RH System, the Transfer Cask System (TCS), the In-Vessel Viewing System, the Neutral Beam Cell RH System, the Hot Cell RH and the Multi-Purpose Deployment System.     

Design for high productivity remote handling

As the central part of a programme of enhancements in support of ITER, the Joint European Torus (JET) is being equipped with an all-metal wall. This enhancement programme requires the removal and installation of 6927 tile carriers and tiles, as well as the removal and installation of embedded diagnostics and antennas. The scale of this operation and the necessity to maximise operational availability of the facility added a requirement for high productivity in the remote activities to the existing exigencies of precision, reliability, cleanliness and operational security. This high productivity requirement has been incorporated into the design of the components and associated installation tooling, the design of the installation equipment, the development of installation procedures including the use of a mock-up for optimisation and training.Consideration of the remote handling installation process is vital during the design of the in vessel components. A number of features to meet the need of the high productivity while maintaining the function requirements have been incorporated into the metal wall components and associated tooling including kinematic design with guidance appropriate for remote operation. The component and tools are designed to guide the attachment of the installation tool, the installation path, and the interlocking with adjacent components without contact between the fragile castellated beryllium of the adjacent tiles. Other incorporated ergonomic features are discussed.At JET, the remote maintenance is conducted using end effectors, normally bi-lateral force feed back manipulator, mounted on driven, articulated booms. Prior to the current shutdown one long boom was used to conduct the installation and collect and deliver components to the “short” boom [3] which was linked to the tile carrier transfer facility. This led to loss of efficiency during these movements. The adoption of a new remote handling philosophy using ‘point of installation’ delivery of components via an additional long boom and a sophisticated logistics system based on ‘task modules’ is described and operational efficiencies detailed. The enabling programs and software behind this new approach needed significant development. Systems such as a task module manager database, image visualisation, virtual reality simulation, operational document system and teach files, which have significantly evolved since their initial inception in 2002, will be elaborated.     

Design progress of the ITER blanket remote handling equipment

The ITER blanket (BL) is composed of about 400 modules in the vacuum vessel (VV). The BL has to be maintained by remote handling means due to high radiation levels in the VV after D-T operation. The remote handling (RH) equipment for BL maintenance consists of articulated rail, supports, a rail-mounted vehicle, a telescopic arm, an end-effecter, tools and related systems such as transfer casks and umbilical system.Towards the construction, the BL RH equipment design has been improved and developed in more detail, based on the 2001 FDR design. The overview of design results is introduced in this paper. The design of rail deployment system of the BL RH has been updated to enable the rail connection in the transfer cask in order to minimize occupation space at storage area. For this purpose, design work has been performed for concept, sequence and typical simulation of BL replacement in the VV and rail deployment/storage of the RH equipment in the cask, including cask docking. In particular, the technical issues of the rail connection in the cask are (1) tight tolerance of a pin at a hinge, (2) limited space for the connection inside a cask and (3) tight positioning accuracy. This paper summarizes the idea to solve these issues and the results of the design work. The paper also introduces new cable handling equipment, rail support equipment and BL module transporter.     

Breaking down the requirements: Reliability in remote handling software

Software requirements have an important role in achieving reliability for operational systems like remote handling: requirements are the basis for architectural design decisions and also the main cause of defects in high quality software. We analyze related recommendations and requirements given in software safety standards, handbooks etc. and apply them to remote handling control systems, which typically have safety-critical functionality, but are not actual safety-systems?for example the safety-systems in ITER will be hardware-based.Based on the analysis, we develop a set of generic recommendations for control system software requirements, including quality attributes, software fault tolerance, and safety and as an example we analyze ITER remote handling system software requirements to identify and present dependability requirements in a useful manner. Based on the analysis, we divide a high-level control system into safety-critical and non-safety-critical subsystems, and give examples of requirements that support building a dependable system.     

CAD supported remote handling systems for fusion reactors

Remote maintenance in fusion reactors poses new challenges that have not been met previously either in other nuclear environment nor in the area of industrial robot application. The high radiation levels caused by neutron radiation and superimposed by tritium contamination are the predominant characteristics. The geometric complexity is almost equally important. These features together call for the application of new techniques that aim at combining the best of two worlds: the servo-manipulator technology and the latest developments in industrial-robot technology.     

Simulation-based design process for the verification of ITER remote handling systems

The work behind this paper takes place in the EFDA's European Goal Oriented Training programme on Remote Handling (RH) “GOT-RH”. The programme aims to train engineers for activities supporting the ITER project and the long-term fusion programme. One of the projects of this programme focuses on the verification and validation (V&V) of ITER RH system requirements using digital mock-ups (DMU). The purpose of this project is to study and develop efficient approach of using DMUs in the V&V process of ITER RH system design utilizing a System Engineering (SE) framework. Complex engineering systems such as ITER facilities lead to substantial rise of cost while manufacturing the full-scale prototype. In the V&V process for ITER RH equipment, physical tests are a requirement to ensure the compliance of the system according to the required operation. Therefore it is essential to virtually verify the developed system before starting the prototype manufacturing phase. This paper gives an overview of the current trends in using digital mock-up within product design processes. It suggests a simulation-based process design centralized around a simulation lifecycle management system. The purpose of this paper is to describe possible improvements in the formalization of the ITER RH design process and V&V processes, in order to increase their cost efficiency and reliability.     

Preliminary definition of the remote handling system for the current IFMIF Test Facilities

A coherent design of the remote handling system with the design of the components to be manipulated is vital for reliable, safe and fast maintenance, having a decisive impact on availability, occupational exposures and operational cost of the facility. Highly activated components in the IFMIF facility are found at the Test Cell, a shielded pit where the samples are accurately located. The remote handling system for the Test Cell reference design was outlined in some past IFMIF studies. Currently a new preliminary design of the Test Cell in the IFMIF facility is being developed, introducing important modifications with respect to the reference one. This recent design separates the previous Vertical Test Assemblies in three functional components: Test Modules, shielding plugs and conduits. Therefore, it is necessary to adapt the previous design of the remote handling system to the new maintenance procedures and requirements. This paper summarises such modifications of the remote handling system, in particular the assessment of the feasibility of a modified commercial multirope crane for the handling of the weighty shielding plugs for the new Test Cell and a quasi-commercial grapple for the handling of the new Test Modules.     

High level integration of remote handling control systems at JET

To reduce the timescale of the JET Enhanced Performance 2 (EP2) shutdown, two multi-jointed Booms instead of one will be used for maintenance and upgrades inside the JET vessel. To fully utilize this new configuration, the control systems of the Booms have been modified at a high level to allow quick and safe interactions between them. This paper will discuss how the control systems of the Booms have been integrated to exploit the increased mechanical functionality of the Octant 1 Boom, and will demonstrate how this has improved safety, utility and efficiency for the remote handling operators during the EP2 shutdown. Other operational streamlining functions will be mentioned, as well as a look to the future of Remote Handling at JET.     

A remote handling rate-position controller for telemanipulating in a large workspace

This paper presents a new haptic rate-position controller, which allows manipulating a slave robot in a large workspace using a small haptic device. This control algorithm is very effective when the master device is much smaller than the slave device. Haptic information is displayed to the user so as to be informed when a change in the operation mode occurs. This controller allows performing tasks in a large remote workspace by using a haptic device with a reduced workspace such as Phantom. Experimental results have been carried out using a slave robot from Kraft Telerobotics and a commercial haptic interface as a master device. A curvature path following task has been simulated using the proposed controller which was compared with the force-position control algorithm. Results obtained show that higher accuracy is obtained when the proposed method is used, spending a similar amount of time to perform the task.     

Influence of visual feedback on human task performance in ITER remote handling

In ITER, maintenance operations will be largely performed by remote handling (RH). Before ITER can be put into operation, safety regulations and licensing authorities require proof of maintainability for critical components. Part of the proof will come from using standard components and procedures. Additional verification and validation is based on simulation and hardware tests in 1:1 scale mockups.The Master Slave manipulator system (MS2) Benchmark Product was designed to implement a reference set of maintenance tasks representative for ITER remote handling. Experiments were performed with two versions of the Benchmark Product. In both experiments, the quality of visual feedback varied by exchanging direct view with indirect view (using video cameras) in order to measure and analyze its impact on human task performance.The first experiment showed that both experienced and novice RH operators perform a simple task significantly better with direct visual feedback than with camera feedback. A more complex task showed a large variation in results and could not be completed by many novice operators. Experienced operators commented on both the mechanical design and visual feedback. In a second experiment, a more elaborate task was tested on an improved Benchmark product. Again, the task was performed significantly faster with direct visual feedback than with camera feedback. In post-test interviews, operators indicated that they regarded the lack of 3D perception as the primary factor hindering their performance.     

The remote handling compatibility analysis of the ITER generic upper port plug structure

The ITER diagnostics generic upper port plug (GUPP) is developed as a standardized design for all diagnostic upper port plugs, in which a variety of payloads can be mounted. Here, the remote handling compatibility analysis (RHCA) of the GUPP design is presented that was performed for the GUPP final design review. The analysis focuses mainly on the insertion and extraction procedure of the diagnostic shield module (DSM), a removable cassette that contains the diagnostic in-vessel components. It is foreseen that the DSM is a replaceable component – the procedure of which is to be performed inside the ITER hot cell facility (HCF), where the GUPP can be oriented in a vertical position.The DSM removal procedure in the HCF consists of removing locking pins, an M30 sized shoulder bolt and two electrical straps through the use of a dexterous manipulator, after which the DSM is lifted out of the GUPP by an overhead crane. For optimum access to its internals, the DSM is mounted in a handling device. The insertion of a new or refurbished DSM follows the reverse procedure.The RHCA shows that the GUPP design requires a moderate amount of changes to become fully compatible with RH maintenance requirements.     

Preliminary concept design of the divertor remote handling system for DEMO power plant

This paper is based on the remote maintenance system project (WPRM) for the demonstration fusion power reactor (DEMO). Following ITER, DEMO aims to confirm the capability of generating several hundred of MW of net electricity by 2050. The main objective of these activities is to develop an efficient and reliable remote handling (RH) system for replacing the divertor cassettes.This paper presents the preliminary results of the concept design of the divertor RH system. The proposed divertor mover is a hydraulic telescopic boom driven from the transportation cask through the maintenance tunnel of the reactor. The boom is divided in three sections of 4 m each, and it is driving an end-effector in order to perform the scheduled operations of maintenance inside the vacuum vessel.Two alternative design of the end effector to grip and manipulate the divertor cassette are also presented in this work. Both the concepts are hydraulically actuated, basing on the ITER previous studies. The divertor cassette end-effector consists of a lifting arm linked to the divertor mover, a tilting plate, a cantilever arm and a hook-plate.The main objective of this paper is to illustrate the feasibility of DEMO divertor remote maintenance operations.     

Development and application of high volume remote handling systems in support of JET and ITER

The Joint European Torus (JET) Remote Handling System has evolved from a small scale maintenance capability to one of high efficiency large volume installations. The Enhanced Performance 2 shutdown 2010–2011 for example, required the replacement of many thousands of components ranging from about 100 g to 130 kg in weight. The scale of this type of operation and the necessity to maximise operational availability intensified the demands for high productivity whilst maintaining the necessary high standards for precision, reliability, cleanliness, and operational security.This paper discusses the developments in design, control, maintenance, preparation and operation of the current state of the art remote handling facilities at JET. It explores how the experience of over 20,000 h of operations has developed the applied methodology and how this could be appropriate to ITER and other facilities requiring complex remote maintenance, where extensive, high productivity remote handling operations will be essential. It also discusses the advances that have been made in management and presentation of operational data within the command, control and human machine interfaces (HMI) systems, along with the supporting operational databases.     

Evolving the JET virtual reality system for delivering the JET EP2 shutdown remote handling tasks

The quality, functionality and performance of the virtual reality (VR) system used at JET for preparation and implementation of remote handling (RH) operations has been progressively enhanced since its first use in the original JET remote handling shutdown in 1998. As preparation began for the JET EP2 (Enhanced Performance 2) shutdown it was recognised that the VR system being used was unable to cope with the increased functionality and the large number of 3D models needed to fully represent the JET in-vessel components and tooling planned for EP2. A bespoke VR software application was developed in collaboration with the OEM, which allowed enhancements to be made to the VR system to meet the requirements of JET remote handling in preparation for EP2. Performance improvements required to meet the challenges of EP2 could not be obtained from the development of the new VR software alone. New methodologies were also required to prepare source, CATIA models for use in the VR using a collection of 3D software packages. In collaboration with the JET drawing office, techniques were developed within CATIA using polygon reduction tools to reduce model size, while retaining surface detail at required user limits. This paper will discuss how these developments have played an essential part in facilitating EP2 remote handling task development and examine their impact during the EP2 shutdown.     

Generic control system design for the Cassette Multifunctional Mover and other ITER remote handling equipment

A new suite of Remote Handling (RH) equipment, addressing the latest design of the divertor region, is currently being specified for ITER, with procurement of the Cassette Multifunctional Mover (CMM) scheduled for 2005–2006. This presents a unique opportunity to address a vital component of the RH system – the control system – and this paper introduces a number of concepts based on replication of design and implementation for functionally similar RH systems. Correctly implemented, this should improve equipment availability and reliability, reduce overall support requirements, and minimise the risks of serious failure.     

Concept for a vertical maintenance remote handling system for multi module blanket segments in DEMO

The anticipated high neutron flux, and the consequent damage to plasma-facing components in DEMO, results in the need to regularly replace the tritium breeding and radiation shielding blanket. The current European multi module segment (MMS) blanket concept favours a less invasive small port entry maintenance system over large sector transport concepts, because of the reduced impact on other tokamak systems – particularly the magnetic coils. This paper presents a novel conceptual remote maintenance strategy for a Vertical Maintenance Scheme DEMO, incorporating substantiated designs for an in-vessel mover, to detach and attach the blanket segments, and cask-housed vertical maintenance devices to open and close access ports, cut and join service connections, and extract blanket segments from the vessel. In addition, a conceptual architectural model for DEMO was generated to capture functional and spatial interfaces between the remote maintenance equipment and other systems. Areas of further study are identified in order to comprehensively establish the feasibility of the proposed maintenance system.