1. Remote Maintenance for Large Scale Physics Experiments Alan Rolfe 13 th April 2010

2. Presentation Introductions Example Physics Projects Preparation for Remote Maintenance Key points for RH on Large Scale Physics Projects 13th April 2010ThorEA Workshop - Trinity College, Oxford2

3. Introductions Alan Rolfe o 1973 – BSc; Mechanical Engineering (Bath) o 1976 – PhD; Fluid Power Control Systems (Bath) o 1978 – Normalair-Garrett, Yeovil o 1981 – Spar Aerospace Ltd, Toronto o 1984 – JET Project, Culham o 2000 – Oxford Technologies Ltd 13th April 2010ThorEA Workshop - Trinity College, Oxford3

4. Introductions Oxford Technologies Ltd Established in 2000 by staff and management of the JET Nuclear Fusion project Remote Handling Group HQ Based in Abingdon, UK Provides professional engineering services and bespoke products for remote handling projects 2008/9 Turnover:- €2M 25 professional engineers, 2 associates, 1 administrator ISO 9001:2000 certified (since 2005) 13th April 2010ThorEA Workshop - Trinity College, Oxford4

5. Example Projects with Remote Maintenance JET Joint Undertaking – Tokamak Fusion Experiment; Culham ITER – Tokamak Fusion Experiment; Cadarache MYRRHA – ADS for Nuclear Waste Experiments; Mol HiPER – Laser Fusion Experiment; Harwell 13th April 2010ThorEA Workshop - Trinity College, Oxford5

6. JET - Fusion Physics Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford6

7. JET - Fusion Physics Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford7

8. JET – Fusion Physics Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford8 2006

9. JET – Fusion Physics Experiment Remote maintenance arena  All components inside the Torus (All tasks outside the Torus are manual) Purpose of remote maintenance  Planned : In-situ inspection and repair to ensure continued m/c operation after failure during a 2yr active phase.  Actual: Modification to facilitate experimental programme in a 15- 20yr active phase 13th April 2010ThorEA Workshop - Trinity College, Oxford9 1983 19871996

10. JET – Fusion Physics Experiment Remote maintenance working environment  10mGy/hr inside the torus  Beryllium  Tritium Generic remote handling tasks  Removal & replacement of components (10gm to 350kg)  2D & 3D Metrology  Visual & Radiological Inspection  Swabbing/Sampling  Structural quality Welding  Vacuum quality Welding  Cutting  Cleaning  Cable & conduit handling  Recovery of failed RH equipment 13th April 2010ThorEA Workshop - Trinity College, Oxford10

11. ITER - Fusion Technology Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford11

12. ITER - Fusion Technology Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford12

13. ITER – Fusion Technology Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford13

14. ITER - Fusion Technology Experiment Remote maintenance arena  All components inside the Torus  All components inside the NBH Cell  All components inside the Hot Cell  Mixed Manual/Remote inside the Cryostat  Mixed Manual/Remote inside the access Galleries Purpose of remote maintenance  Removal and replacement of modular components  In-situ inspection/repair of components  Refurbishment of components  25yr active phase Remote maintenance working environment  200 Gy/hr inside the torus  20 Gy/hr inside the NB Cell and Hot Cell  Beryllium  Tritium 13th April 2010ThorEA Workshop - Trinity College, Oxford14

15. ITER - Fusion Technology Experiment Generic remote handling tasks  Removal & replacement of components ( 1kg to 11,000kg )  2D & 3D Metrology  Visual & Radiological Inspection  Swabbing/Sampling  Structural quality Welding  Vacuum quality Welding  Cutting  Cleaning  Recovery of failed RH equipment  Waste handling and Packaging 13th April 2010ThorEA Workshop - Trinity College, Oxford15

16. MYRRHA – ADS for Transmutation 13th April 2010ThorEA Workshop - Trinity College, Oxford16

17. MYRRHA - ADS for Transmutation MYRRHA Hall fly-through (c 2005) 13th April 2010ThorEA Workshop - Trinity College, Oxford17

18. MYRRHA - ADS for Transmutation Remote maintenance arena  All components inside the Machine Hall  Fuel handling & repairs beneath LBE Purpose of remote maintenance  Removal and replacement of modular components  In-situ inspection/repair of components  Refurbishment of components  25yr active phase Remote maintenance working environment  10 Gy/hr inside the machine hall  1 Gy/hr inside the Hot Cell  Polonium 13th April 2010ThorEA Workshop - Trinity College, Oxford18

19. MYRRHA - ADS for Transmutation Remote handling tasks  Cleaning  Removal & Replacement of Components ( 1kg to +/-18,000kg )  2D & 3D Metrology  Visual & Radiological Inspection  Swabbing/Sampling  Structural quality Welding  Vacuum quality Welding  Cutting  Recovery of failed RH equipment  Waste handling and packaging  Fuel Handling 13th April 2010ThorEA Workshop - Trinity College, Oxford19

20. HiPER – Laser Fusion Experiment 13th April 2010ThorEA Workshop - Trinity College, Oxford20

21. HiPER – Laser Fusion Experiment Remote maintenance arena  All components inside the Chamber  Beam-line components inside the Chamber Hall Purpose of remote maintenance  Removal and replacement of modular components  In-situ inspection/repair of components  25yr active phase Remote maintenance working environment  Tbd 13th April 2010ThorEA Workshop - Trinity College, Oxford21

22. HiPER – Laser Fusion Experiment Generic remote handling tasks  Removal & Replacement of Components ( up to 500kg )  2D & 3D Metrology  Visual & Radiological Inspection  Swabbing/Sampling  Welding  Cutting  Cleaning 13th April 2010ThorEA Workshop - Trinity College, Oxford22

23. Preparation for Remote Maintenance Design the Plant for RH compatibility  Include RH compatibility into the Project culture  Establish RH standards  Train designers in RH compatibility Adopt an Adaptable RH strategy Design & develop appropriate remote handling equipment, e.g:-  Dexterous manipulation  Transporters  Tooling  Control Room & HMI’s Prepare for remote handling operations  Operations procedures  Operations management  Mock-ups  Operator training 13th April 2010ThorEA Workshop - Trinity College, Oxford23

24. Dexterous Manipulation 13th April 2010ThorEA Workshop - Trinity College, Oxford24

25. Transporters 13th April 2010ThorEA Workshop - Trinity College, Oxford25

26. RH Tooling 13th April 2010ThorEA Workshop - Trinity College, Oxford26

27. RH Control Room & HMI’s 13th April 2010ThorEA Workshop - Trinity College, Oxford27

28. Full size physical mock-ups 13th April 2010ThorEA Workshop - Trinity College, Oxford28

29. Creation & Use of Virtual Mock-ups 13th April 2010ThorEA Workshop - Trinity College, Oxford29

30. Key Points for RH on Large Scale Physics Experiments 1. Design an Adaptable RH facility :- - long term; experiments always cause change of plant in unexpected ways - short term; unexpected conditions of plant after operation 2. Be aware that :- - failure to prepare for RH in the design of plant will increase downtime by an order of magnitude. - preparation for RH requires a conscious and significant project investment. - failure to prepare RH systems for recovery after failure risks a total loss of project. 13th April 2010ThorEA Workshop - Trinity College, Oxford30

31. End 13th April 2010ThorEA Workshop - Trinity College, Oxford31