Interactive virtual mock-ups for Remote Handling compatibility assessment of heavy components

ITER standards Tesini (2009) require hardware mock-ups to validate the Remote Handling (RH) compatibility of RH class 1- and critical class 2-components. Full-scale mock-ups of large ITER components are expensive, have a long lead time and lose their relevance in case of design changes. Interactive Virtual Reality simulations with real time rigid body dynamics and contact interaction allow for RH Compatibility Assessment during the design iterations. This paper explores the use of interactive virtual mock-ups to analyze the RH compatibility of heavy component handling and maintenance. It infers generic maintenance operations from the analysis and proposes improvements to the simulator capabilities

Analysis of ITER upper port plug remote handling maintenance scenarios

The ITER tokamak has a modular design, with port plugs, blanket modules and divertor cassettes. This set-up allows for maintenance of diagnostics, heating systems and first wall elements. The maintenance can be done in situ, or in the Hot Cell. Safe and effective remote handling (RH) will be ensured by the RH requirements and standards. Compliance is verified through remote handling compatibility assessments at the ITER Design Review milestones. The Remote Handling Study Centre at FOM Institute DIFFER is created to study ITER RH maintenance processes at different levels of complexity, from relatively simple situational awareness checks using snap-shots in the CAD system, time studies using virtual reality (VR) animations, to extensive operational sequence validation with multiple operators in real-time. The multi-operator facility mimics an RH work-cell as presently foreseen in the ITER RH control room. Novel VR technology is used to create a realistic setting in which a team of RH operators can interact with virtual ITER environments. A physics engine is used to emulate real-time contact interaction as to provide realistic haptic feed-back. Complex interactions between the RH operators and the control room system software are tested. RH task performance is quantified and operational resource usage estimated. The article provides a description and lessons learned from a recent study on replacement of the Steering Mirror Assembly on the ECRH (Electron Cyclotron Resonance Heating) Upper Launcher port plug

Feasibility of Upper Port Plug tube handling

Central, retractable tubes are proposed in several Upper Port Plugs (UPPs) designs for ITER, to enable fast exchange of specific components of diagnostics housed in these UPPs. This paper investigates into possible designs to enable the efficient handling of tubes. The feasibility of tube handling is analysed by first reviewing the designs drivers. Several concepts for handling of the tube are proposed, exploring the limits described by the design drivers. Suggestions are presented for tube integration into the UPP design, concerning the tube mounting into the UPP, the load takeover and coping with the thermal elongation. It is found that the handling of tubes is feasible but still requires a lot of system level integration. Also, the added value of a tube as a feature in an UPP design to the availability of the subsystem the UPP is a part of, is questionable and needs further assessment on ITER system level. (C) 2011 Elsevier B.V. All rights reserved

Analysis and validation center for ITER RH maintenance scenarios in a virtual environment

A facility for detailed simulation of maintenance processes in the ITER Hot Cell Facility (HCF) has been taken into operation. The facility mimics the Remote Handling (RH) work-cells as are presently foreseen. Novel virtual reality (VR) technology, extended with a physics engine is used to create a realistic setting in which a team of Remote Handling (RH) operators can interact with a virtual Hot Cell environment. The physics engine is used to emulate the Hot Cell behavior and to provide tactile feed-back of the (virtual) slave. Multi-operator maintenance scenarios can be developed and tested in virtual reality. Complex interactions between the RH operators and the HCF control system software will be tested. Task performance will be quantified and operational resource consumption will be estimated. (C) 2011 Elsevier B.V. All rights reserved

Applying HAZOP analysis in assessing remote handling compatibility of ITER port plugs

This paper describes the application of a Hazard and Operability Analysis (HAZOP) methodology in assessing the criticality of remote handling maintenance activities on port plugs in the ITER Hot Cell facility. As part of the ECHUL consortium, the remote handling team at the DIFFER Institute is developing maintenance tools and procedures for critical components of the ECH Upper launcher (UL). Based on NRG's experience with nuclear risk analysis and Hot Cell procedures, early versions of these tool concepts and maintenance procedures were subjected to a HAZOP analysis. The analysis identified several weak points in the general upper port plug maintenance concept and led to clear recommendations on redesigns in port plug design, the operational sequence and ITER Hot Cell equipment. The paper describes the HAZOP methodology and illustrates its application with specific procedures: the Steering Mirror Assembly (SMA) replacement and the exchange of the Mid Shield Optics (MSO) in the ECH UPL. A selection of recommended changes to the launcher design associated with the accessibility, maintainability and manageability of replaceable components are presented

The Engineering Analysis In Support Of The Iter Electron Cyclotron Heating And Current Drive Transmission Lines

An engineering study has been poformed on the ITER electron cyclotron transmission lines with the aim of optimizing its conceptual design. The support types and optimum spacing, cooling, vacuum, seismic, and gravitational effects were reviewed. For the vacuum system it was shown that two pumps per line, with a capacity of 50 l/s, are sufficient. It was explained that the temperature variation inside the building is the predominant factor that influences the thermal expansion of the lines. The support strategy is one of minimizing the number of constraints. Variation in support interspacing reduces the degree of harmonic disturbances. The section of transmission line inside the ITER port cell was identified as critical with regards to occurrence of deformation and stresses. Potential solutions are described. The use of seismic breaks is discussed in light of the differences in foundation and structure of the ITER tokamak building and assembly hall. It is proposed that this interface be studied in more detail, after more data is available on the behavior of these buildings. The geometry of individual supports should be simple, with the fewest possible adjustments. The supports are designed to allow small movements of the waveguide to compensate for the thermal expansion or contraction. The transmission line system can be made for optimum alignment during nominal operating temperatures by prestressing during installation

The ITER EC H&CD Upper Launcher: Maintenance concepts

Maintenance of the ITER EC H&CD Upper Launcher (UL) shall be performed through the use of Remote Handling (RH) in the ITER Hot Cell Facility (HCF). The UL design will have to be fully compliant with ITER RH maintenance requirements and the set of RH tooling and services available in the HCF. This paper describes the development of an overall maintenance strategy for the UL, starting from a listing of all conceivable maintenance operations, including hands-on tasks. Components for which design concepts are discussed in this paper are the Blanket Shield Module (BSM), the steering mirror (M4), the mid optics (M1, M2) and the waveguide (WG) feed-through plate. Aspects related to RH documentation, overall maintenance strategy and design concepts for optimizing the maintainability of the UL are presented

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

The ITER EC H&CD upper launcher: Analysis of remote handling compatibility

The present design of the ECH (Electron Cyclotron Heating) upper port launcher has been evaluated in light of the ITER remote handling (RH) requirements. Changes to the launcher design associated with the accessibility, maintainability and manageability of replaceable components are presented. Captive bolts were placed along the flange of the Blanket Shielding Module (BSM). A hinge mechanism was integrated to simplify the (dis-)mounting of the BSM and a frame with incorporated cooling and actuation lines was suggested for simplified mounting and replacement of the steerable mirrors. Rotating the upper port plug upside-down improves maintenance access and component handling. Tools are proposed for manipulation of the port plug and its sub-components. The RH compatibility analysis can improve a design. Early consideration of RH requirements and implementation of necessary features is therefore vital. (C) 2011 Elsevier B.V. All rights reserved