The Savannah River Site's (SRS) Defense Waste Processing Facility (DWPF) requested development of tooling for remote replacement of gaskets in mechanical Hanford connectors. The facility has compressed air supply, two master-slave manipulators (MSM's) and a lightweight robotic arm for operation of the remote tools. The Savannah River National Laboratory (SRNL) developed and tested multiple tools to perform the gasket replacement tasks. Separate pneumatic snap-ring removal tools that use the connector skirt as a reaction surface were developed for removal of the snap ring and spent gasket on both vertical and horizontal Hanford connectors. A pneumatic tool that clamps and centers on the jumper pipe ID was developed to simultaneously install the new gasket and snap ring. A pneumatic snap-ring-loading tool was developed that compresses the snap ring and places it in a groove in the installation tool. All of the tools are located on a custom work table with a pneumatic valve station that directs compressed air to the desired tool and vents the tools as needed. The entire system has been successfully tested using MSM's to manipulate the various tools. Deployment of the entire system is expected during FY08. The Hanford connector gasket replacement tooling has been successfully tested using MSM's to manipulate the various tools. Nitric acid is used in many of the decontamination processes performed in the REDC, where the tooling will be deployed. Although most of the tool components were fabricated/purchased with nitric acid and radioactive service in mind, some of the prototype parts must be replaced with parts that are more compatible with nitric acid/radioactive service. Several modifications to the various tools are needed to facilitate maintenance and replacement of failed components. Development of installation tools for replacement of 1-inch, 2-inch and multi-hole gaskets is being considered. Deployment of the existing system in the DWPF REDC is expected during FY08
