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 Kershaw2

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 HL LHC Remote Handling Keith Kershaw3

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 HL LHC Remote Handling Keith Kershaw4

Example : LHC collimators HL LHC Remote Handling Keith Kershaw5

LHC collimator remote exchange… Remotely operated crane for handling and transport Telemax for inspection and disconnection TIM for Inspection HL LHC Remote Handling Keith Kershaw6

Example : SPS Remote Vacuum connection (1978) HL LHC Remote Handling Keith Kershaw7

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. HL LHC Remote Handling Keith Kershaw8

ITER – Fusion Tokamak HL LHC Remote Handling Keith Kershaw9 After the first 7 years operation remote handling will be vital for maintenance Person for scale

ITER use JET RH experience HL LHC Remote Handling Keith Kershaw10 “Man in the loop”

Multi-purpose deployer with twin force reflecting manipulators HL LHC Remote Handling Keith Kershaw11 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) HL LHC Remote Handling Keith Kershaw12

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 HL LHC Remote Handling Keith Kershaw13

IRHCoP Example – Location Devices Parallel Dowel Pin Arrangement Ball-End Dowel Arrangement Axial & Azimuthal Flange Location HL LHC Remote Handling Keith Kershaw14

IRHCoP Example – Fasteners “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 HL LHC Remote Handling Keith Kershaw15

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) HL LHC Remote Handling Keith Kershaw16

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. HL LHC Remote Handling Keith Kershaw17

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 HL LHC Remote Handling Keith Kershaw18

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. HL LHC Remote Handling Keith Kershaw20

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 HL LHC Remote Handling Keith Kershaw21

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… HL LHC Remote Handling Keith Kershaw22