TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 1 06 December 2009 EFDA ITER - Goal Oriented Training Program Port Plug Engineering - Maintainability associated to ITER Component Lifecycle - Tutor : Jen-Pierre MARTINS EFDA ITER - Goal Oriented Training Program Port Plug Engineering - Maintainability associated to ITER Component Lifecycle - Tutor : Jen-Pierre MARTINS EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 2 06 December 2009  Objectives of my program  Short presentation of an Eq port plug  Kinematic & FE Analysis on the Transfer Cask System with Samtech  Maintenance of the TBM with HAS EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 3 06 December 2009  Objectives Background Cause = nuclear fusion reactions for long term  high magnetic fields  produces high energy neutron  generates very high temperatures Consequence = maintenance in nuclear environment  make first wall components highly constrained and causes its wear  many parts of this region must be replaced or refurbished during the reactor’s life  maintenance of a reactor in exploitation is a critical point, because it directly affects the availability of the machine and its economical productivity Program motivations  Even if the goal of ITER is not to be an industrial reactor, it is essential to consider its maintainability for at least two major reasons:  To have powerful available experimental equipment  To demonstrate that the maintenance by remote handling is possible for the further steps (DEMO)  Because remote handling is one of the most important technical issues of the whole project EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 4 06 December 2009 Dimension : 3.5m x 2.2m x 1.7m Weight : 45t First Wall Component (= high activation)  Equatorial Port Plug EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 5 06 December 2009  Kinematic & FE Analysis on the Transfer Cask System with Samtech Collaboration with SAMTECH :  Collection of input data  Definition of the analysis methodology and study cases  Setup and delivery of the CATIA V5 configuration models for the study  Idealization of the CAD geometry, in order to have a model that will be more oriented to computation  Delivery of the specifications the simulation activity EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 6 06 December 2009  Transfer Cask System (TCS) : Ports dedicated maintenance platform. It has to carry the first wall component to the Hot Cells (nuclear maintenance room). Envelope : it docks to the port and provide the confinment. Pallet : it permits to align the envelope with the port. Air cushion : it moves the all system inside the building. EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 7 06 December 2009  Initial models Transferred by the DET Environment + current TCS model roughly positioned Last studies results were also implemented EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 8 06 December 2009  Geometry preparation Simplification, replacement or creation of 3D entities Methodology for transfers from CATIA to inside SAMCEF operational Cask envelope Pallet system Building VV Port Rails CAS End-effector Tractor Port plug EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ 9 06 December 2009  Geometry preparation Positions checking and corrections PLUG flange bolting face center TCS front face art floor level TCS CONTAINER Horizontal floor plane TCS PALLET / CONTAINER Horizontal interface plane EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Boundary conditions Localization of surfaces for forces reactions on the structure Identification of the surfaces in contact EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Loading conditions Postion and value for the center of gravity of the main objects to take into account Rear rescue door center of gravity Closed double door center of gravity Mover center of gravity Opened double door center of gravity Port plug center of gravity EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Kinematics 3D elements for mechanisms simulation TCS skeleton for main elements positions and interfaces ALL DOCKED EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Kinematics Diagram of the mechanical links between the different subsystems EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Conclusion Geometry is fixed Boundary and loading conditions are defined Kinematics preparation is fully operational in CATIA The report finalizing the 80% of the CEA contribution is about to be officially delivered to SAMTECH EFDA Goal Oriented Training Program Port Plug Engineering

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  TBS Layout Main technical components of the TBM system  TBMs ( 2 vertical modules per equatorial port plug)  Plug frame, ultra high vacuum sealing, mechanical attachment and cooling pipes (IF2a)  Manifold set for TBM feeding (Pipe forest)  Bioshield  Ancilary Equipment Unit (AEU) : PbLi-loop, measurement equipment, valves, tanks, …  Tritium plant dedicated area Main components of the installed TBM system in port cell (EU current study) Port Duct Port Extension Port Cell Bioshield Port Cell Door Vacuum Vessel AEU IF1IF2aIF2bIF3 Tritium plant equipment + VV Port Cell T Plant VVPort Cell T Plant TBM -TG04 Kick off Meeting Task 19 : Design and development plan of the port cell dis-/assembly RH system

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Maintenance conditions hypothesis for the current study Interface 2a is accessible even if AEU is connected => robot carriage must be installed in AEU structure A maintenance corridor is available on the side to allow human / machine access to the interfaces The bio-shield contains a dedicated maintenance door to give access to the pipe forest The cutting task is considered prior to the welding operation, because this is the most critical operation in terms of exposure TBM -TG04 Kick off Meeting Task 19 : Design and development plan of the port cell dis-/assembly RH system

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Pipe Forest preliminary design Pipe forest integration taking into account maintenance access (man / robot) Pipes insulation thickness = 100mm TBM -TG04 Kick off Meeting Task 19 : Design and development plan of the port cell dis-/assembly RH system

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Robotic simulations first results Industrial arm mounted on a commercial based elements 4 dofs platform designed by HAS After some modifications on the pipes and robotic tool design, first preliminary result have not revealed any killing issue TBM -TG04 Kick off Meeting Task 19 : Design and development plan of the port cell dis-/assembly RH system

TORE SUPRA Association EURATOM-CEA 2 nd GOTA-PPE meeting Julien WAGREZ December 2009  Remaining work and outlook First test with one dexterous industrial robot arm have been performed for cutting accessibility A more realistic cutting tool coming from HAS work is about to be integrated in order to replace the current simplified shape The remote removal of the insulation “half-shells” is about to start Other industrial robotic arms will be implemented in order to check the feasibility with different kind of robot providers. This is in order to avoid any exclusive robotic arm architecture and provider. An important handling equipment is required to transport the pipe forest during maintenance operations. A first assessment of this tool is starting. A preliminary design of the bio-shield will specify it’s main interfaces TBM -TG04 Kick off Meeting Task 19 : Design and development plan of the port cell dis-/assembly RH system