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ITER remote maintenance system configuration model overview
Fusion Engineering and Design 86 (2011) 1903–1906
Contents lists available at ScienceDirect
Fusion Engineering and Design journal homepage: www.elsevier.com/locate/fusengdes
ITER remote maintenance system configuration model overview夽 J.P. Friconneau a,∗ , C. Conesa a , C.H. Choi a , A. Dammann a , I. Kuehn a , B. Levesy a , J.P. Martins a , M. Nakahira a , J. Palmer a , G. Rigoni a , A. Tesini a , C. Damiani b , C. Gonzalez Gutierrez b , D. Locke b a b
ITER Organization, CS 90 046, 13067 St. Paul Lez Durance Cedex, France Fusion for Energy, c/Josep Plá n.2, Torres Diagonal Litoral B3 – 9th Floor, 08019 Barcelona, Spain
a r t i c l e
i n f o
Article history: Available online 21 September 2011 Keywords: ITER Maintenance Remote handling Design integration
a b s t r a c t A challenge for the ITER project is to manage the design of many systems being developed in parallel. In order to control the machine configuration and ensure proper design integration, the ITER project has implemented the so-called “configuration management models” (CMMs), aimed at controlling and managing the machine systems’ interfaces. Specific issues are raised for modelling the ITER remote maintenance system (IRMS). That system shall provide the mean to support the remote maintenance operations for in-vessel components, remote transfer of activated components between the vacuum vessel (VV) and the hot cell facility and remote repairing, refurbishing and/or processing operations in the hot cell facility. The IRMS are dynamic, constantly changing morphologies, working envelopes and locations within the plant. This raises the issue of how to integrate the dynamic nature of this equipment into the CMM required for design integration. This paper describes the design methodology that is being developed to address the specific nature of the IRMS in the building of the CMM and gives examples to demonstrate the benefits to be gained by adopting this approach. © 2011 ITER Organization. Published by Elsevier B.V. All rights reserved.
1. Introduction
2. Configuration management system
The ITER project consists of complicated, heavy and delicate plant systems and components which have to be assembled on site with high accuracy through precisely defined interfaces (Fig. 1). Each component has its own design specifications and tolerances for manufacturing, assembly, commissioning and operation s. The configuration management models (CMMs) are used to control and manage the configuration of the ITER reference technical database, called the baseline. They are also used to provide reference technical data, including interfaces with other systems. For CAD modelling required during design integration activities, the IRMS CMM represents a special case due to dynamic nature of the system: changing working volumes, displacements, multiple work areas. This paper describes how the requirements for the IRMS CMM are defined and how the CMM is developed.
2.1. Configuration management overview The CMMs define the physical configuration of the plant systems and components and are used in the change management process to assess the compatibility between systems. This has to be ensured at all stages of the design process. The CMM is one part of the configuration control process and is a reference model for the management of the configuration in the ITER baseline. During design integration checking, 3D models of systems must be validated against the existing CMMs. A CMM describes the physical envelopes or/and space maintenance allocation of all systems in ITER. It is developed according to the plant breakdown structure (PBS) and contains the following information: • Physical interfaces of the components (e.g., welded or bolted surfaces, connecting pipes, embedment, supports, hangers, etc.). • Functional interfaces. • Space allocation for assembly, maintenance and inspection and in-service inspection.
夽 The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. ∗ Corresponding author. Tel.: +33 04 4217 6918. E-mail address: [email protected] (J.P. Friconneau).
The plant system interfaces are completely described by a complete set of interface control documents.
0920-3796/$ – see front matter © 2011 ITER Organization. Published by Elsevier B.V. All rights reserved. doi:10.1016/j.fusengdes.2011.01.118
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J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
Fig. 1. Isometric view of the ITER Tokamak complex.
3. IRMS configuration management model
Fig. 2. ITER RHE type of mechanisms and operational space.
3.1. IRMS overview Maintenance of ITER systems located within the ITER Tokamak building will depend to a very significant extent on the ITER remote handling capability [1,2]. Wherever possible manual maintenance methods will be used, however all of the in-vessel components must be remotely handled and maintained using a set with the exception of NB cell which has a dedicated IRMS equipment, all other remotely maintainable ITER plant items will be removed from the Tokamak building and taken to the ITER hot cell for remote maintenance and repair. The in vessel transporter (IVT) is used for the vacuum vessel (VV) blanket remote removal [3]. IVT is composed of rail structures deployed from the cask remote handling system [4] attached to VV ports. The cask and plug remote handling system (CPRHS) [4] is used as well to transfer the blanket module from and to the hot cell building. By definition, the IRMS must be capable of movement. For example the transfer casks move from the port cells in the Tokamak building to the hot cell building through the galleries and the lift, and then occupy different hot cell work areas during different operational phases. Also, during remote operation, at a given position relative to the building, the IRMS configurations will change because of the system kinematics – for example the in vessel transporter (IVT) or the multi purpose deployer (MPD) systems’ configurations change in time during their deployment in the VV or in the hot cell remote handling test facility (RHTF). IRMS are significantly different from other ITER equipment. This means that there will be a number of configuration models for each IRMS and specific characteristic of the IRMS must be taken into account in their CMMs. 3.2. Mechanism and operational space of IRMS CMM IRMS equipment is able to move object in three-dimensional space and belongs to the robotic type of equipment [5]. IRMS kinematic configuration changes in time and is able to perform continuous movement along a set of trajectories. The operational space defines the volume occupied by the mechanism in all kinematics configurations when following all possible trajectories. The model to represent the IRMS is usually composed of static model representing the mechanism in a limited number of key configurations and a volume to represent the operational space. Two types of mechanisms have to be considered: the manipulator type mechanism representing most the IRMS and the mobile robot type specific for the cask RH system (see Fig. 2). The manipulator type is used to model IRMS consisting of a set of mechanisms build in series such like manipulators arms,
transporters or other handling mechanisms. Each mechanism consists of nearly rigid links which are connected by joints that allow relative motion of neighbouring links. The number of degree of freedom (d.o.f) describes the complexity of the mechanisms, e.g. the IVT, used for the maintenance inside the vacuum vessel, is made of more than 10 d.o.f. The mobile robot type is used to model the IRMS able to travel along the buildings. The operational space of the transfer cask represents the volume occupied by the cask during the travelling, therefore is extended to all necessary buildings and building levels. 3.3. IRMS CMM operational space details Even when the nominal geometrical configuration of operational space is defined, it may be necessary to take into account in the CMM additional space allocations for different sources of geometrical deviation. Each component has manufacturing or assembly tolerances. The maximum manufacturing tolerance values have to be considered and may be implemented in the CMM as additional layers and merged in the model. Additional space booking may be required to take into account the effects of bending or deflection under gravity or due to payloads. This is particularly important given the mass of some of the components to be remotely handled – for example the cask systems handle port plugs of 45 tonnes whilst the IVT replaces blanket modules of 4 tonnes in a full cantilever configuration. The accuracy and repeatability of IRMS trajectories have limits and the CMMs must take this into account. For example the uncertainties concerning the precise position of a transfer cask on its trajectory through the Tokamak building. These uncertainties are due to both technological limitations and operational constraints – the transfer cask speed is lower and hence the positional accuracy greater during the final approach to docking in the port cells than during transit through the galleries en route for the hot cell building. In addition to positional uncertainty, the speed of movement affects the stopping distance. The stopping distance must also be included in the CMMs – again this is particularly important for the transit of casks through the Tokamak and hot cell buildings. Equally to avoid collisions during seismic events, it is necessary to make the required space reservations in the CMM. Further volumes may require integration into the IRMS CMMs to take into account specific operations – for example the required volume for man access to and around the equipment during equipment maintenance operations. A further very important example
J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
1905
Fig. 3. Recommendation for RHE CMM modelling.
Fig. 4. IVT mechanism configurations.
will be the space required for the deployment of IRMS rescue tooling and procedures subsequent to a major failure of the IRMS and the need to recover it from the VV. The following table (Fig. 3) summarises the recommendations for building the IRMS CMM’s for mechanism and operational space models. 3.4. RHE operational state configuration During the ITER machine shutdown, the IRMS is deployed inside the VV to perform the scheduled maintenance operations. The configuration of the system and the initial position varies according to the task to perform. For example, two specific mechanism configurations are necessary to represent the IVT deployed in VV: one for the 100◦ configuration, another for the 180◦ (Fig. 4). To describe the cask configurations when docked to the port cells in the Tokamak building, a set of mechanisms is required to represent the different cask typologies (IVT casks, plug handling casks, etc.) and a set of reference positions to capture cask locations for all appropriate port cells (Fig. 5). During the maintenance of the IRMS, a specific set of trajectories is required to model the space requirement for IRMS cleaning operations. The trajectories to consider during the IRMS testing phase after repair are specific as well. In summary, IRMS is deployed in various different positions within the Tokamak, the NB and hot cell buildings and in different
Fig. 5. Cask mechanisms and reference position in TKM building level B1.
Fig. 6. MPD model configuration partial overview.
mechanism configurations. Each physical location of the mechanism and its associated operational space must be clearly identified. To capture all the different situations and associated configurations CMMs must be developed for each “state” of the IRMS and defined in terms of an initial configuration for the mechanism at a given reference position in the ITER machine for a given set of trajectories. A configuration matrix is required to monitor and register all states of each IRMS (see Fig. 6 of MPD partial example). 4. Example of application 4.1. IVT configuration model in RHTF For deployment of the IVT during tests in the remote handling test facility (RHTF), due to building space constraints, IRMS space allocation has been reduced to less than that available in the VV (Fig. 7). Testing requirements involve the test of each individual joint over its full range and load tests in the most critical configurations. As the IVT is deployed from a cask, the cask model is associated to the IVT CMM.
Fig. 7. IVT CMM in hot cell RHTF.
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J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
Fig. 8. Cask mechanism configurations.
Fig. 10. Full CPRHS CMM in TKM building.
Fig. 9. CPHRS operational space.
In addition to the IVT and cask, the CMM includes the supports required by the test mock-up and for the cask to simulate the conditions in the VV. 4.2. Cask configuration model overview The cask and plug remote handling system (CPRHS) is composed of 9 different casks to transfer component and equipment from the VV to the hot cell. For a given cask the mechanism shall represent both the travelling trajectory configuration, (e.g. from a docking station in HCF to a given port cell in TKM building) and the docking to the port cell (where the cask is aligned) before and after removal of the cask transfer system (CTS). In summary, the CPRHS configuration model is composed of: • 9 CPHRS mechanisms to represent the different casks typologies, • 3 mechanism configurations for each CPRHS (Fig. 8.). • 54 mechanism reference position in the Tokamak building and 32 in the hot cell building. • 182 operational spaces for the travelling trajectories and 9 for docking trajectories (Fig. 9). • A set of specific trajectories for the rescue system and the transfer system removal. • Additional operational space for man access in the CPRHS storage.
For each building, all theses individual models are merged in a single CAD model that constitutes the CPRHS CMM (Fig. 10). 5. Perspectives The CMM is a key tool for controlling design integration and managing system design activities. CAD modelling of the IRMS requires that the dynamic characteristics of the IRMS be correctly integrated into the static CMM. A methodology has been developed for addressing this issue and has been successfully implemented in a first series of study cases. It is now proposed to implement this methodology to all the IRMS. Acknowledgments The design activities related to Cask system have been performed under a task agreement with in the Fusion for Energy. References [1] A. Tesini, A.C. Rolfe, The ITER remote maintenance management system, Fusion Eng. Des. 84 (2009) 236–241. [2] A. Tesini, J. Palmer, The ITER remote maintenance system, Fusion Eng. Des. 83 (2008) 810–816. [3] M. Nakahira, et al., Design progress of the ITER blanket remote handling equipment, Fusion Eng. Des. 84 (2009) 1394–1398. [4] A. Tesini, et al., ITER in-vessel components transfer using remotely controlled casks, Fusion Eng. Des. 58–59 (2001) 469–474. [5] J. Craig, Introduction to Robotics: Mechanics and Control, third ed., Pearson, 2005.
Contents lists available at ScienceDirect
Fusion Engineering and Design journal homepage: www.elsevier.com/locate/fusengdes
ITER remote maintenance system configuration model overview夽 J.P. Friconneau a,∗ , C. Conesa a , C.H. Choi a , A. Dammann a , I. Kuehn a , B. Levesy a , J.P. Martins a , M. Nakahira a , J. Palmer a , G. Rigoni a , A. Tesini a , C. Damiani b , C. Gonzalez Gutierrez b , D. Locke b a b
ITER Organization, CS 90 046, 13067 St. Paul Lez Durance Cedex, France Fusion for Energy, c/Josep Plá n.2, Torres Diagonal Litoral B3 – 9th Floor, 08019 Barcelona, Spain
a r t i c l e
i n f o
Article history: Available online 21 September 2011 Keywords: ITER Maintenance Remote handling Design integration
a b s t r a c t A challenge for the ITER project is to manage the design of many systems being developed in parallel. In order to control the machine configuration and ensure proper design integration, the ITER project has implemented the so-called “configuration management models” (CMMs), aimed at controlling and managing the machine systems’ interfaces. Specific issues are raised for modelling the ITER remote maintenance system (IRMS). That system shall provide the mean to support the remote maintenance operations for in-vessel components, remote transfer of activated components between the vacuum vessel (VV) and the hot cell facility and remote repairing, refurbishing and/or processing operations in the hot cell facility. The IRMS are dynamic, constantly changing morphologies, working envelopes and locations within the plant. This raises the issue of how to integrate the dynamic nature of this equipment into the CMM required for design integration. This paper describes the design methodology that is being developed to address the specific nature of the IRMS in the building of the CMM and gives examples to demonstrate the benefits to be gained by adopting this approach. © 2011 ITER Organization. Published by Elsevier B.V. All rights reserved.
1. Introduction
2. Configuration management system
The ITER project consists of complicated, heavy and delicate plant systems and components which have to be assembled on site with high accuracy through precisely defined interfaces (Fig. 1). Each component has its own design specifications and tolerances for manufacturing, assembly, commissioning and operation s. The configuration management models (CMMs) are used to control and manage the configuration of the ITER reference technical database, called the baseline. They are also used to provide reference technical data, including interfaces with other systems. For CAD modelling required during design integration activities, the IRMS CMM represents a special case due to dynamic nature of the system: changing working volumes, displacements, multiple work areas. This paper describes how the requirements for the IRMS CMM are defined and how the CMM is developed.
2.1. Configuration management overview The CMMs define the physical configuration of the plant systems and components and are used in the change management process to assess the compatibility between systems. This has to be ensured at all stages of the design process. The CMM is one part of the configuration control process and is a reference model for the management of the configuration in the ITER baseline. During design integration checking, 3D models of systems must be validated against the existing CMMs. A CMM describes the physical envelopes or/and space maintenance allocation of all systems in ITER. It is developed according to the plant breakdown structure (PBS) and contains the following information: • Physical interfaces of the components (e.g., welded or bolted surfaces, connecting pipes, embedment, supports, hangers, etc.). • Functional interfaces. • Space allocation for assembly, maintenance and inspection and in-service inspection.
夽 The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. ∗ Corresponding author. Tel.: +33 04 4217 6918. E-mail address: [email protected] (J.P. Friconneau).
The plant system interfaces are completely described by a complete set of interface control documents.
0920-3796/$ – see front matter © 2011 ITER Organization. Published by Elsevier B.V. All rights reserved. doi:10.1016/j.fusengdes.2011.01.118
1904
J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
Fig. 1. Isometric view of the ITER Tokamak complex.
3. IRMS configuration management model
Fig. 2. ITER RHE type of mechanisms and operational space.
3.1. IRMS overview Maintenance of ITER systems located within the ITER Tokamak building will depend to a very significant extent on the ITER remote handling capability [1,2]. Wherever possible manual maintenance methods will be used, however all of the in-vessel components must be remotely handled and maintained using a set with the exception of NB cell which has a dedicated IRMS equipment, all other remotely maintainable ITER plant items will be removed from the Tokamak building and taken to the ITER hot cell for remote maintenance and repair. The in vessel transporter (IVT) is used for the vacuum vessel (VV) blanket remote removal [3]. IVT is composed of rail structures deployed from the cask remote handling system [4] attached to VV ports. The cask and plug remote handling system (CPRHS) [4] is used as well to transfer the blanket module from and to the hot cell building. By definition, the IRMS must be capable of movement. For example the transfer casks move from the port cells in the Tokamak building to the hot cell building through the galleries and the lift, and then occupy different hot cell work areas during different operational phases. Also, during remote operation, at a given position relative to the building, the IRMS configurations will change because of the system kinematics – for example the in vessel transporter (IVT) or the multi purpose deployer (MPD) systems’ configurations change in time during their deployment in the VV or in the hot cell remote handling test facility (RHTF). IRMS are significantly different from other ITER equipment. This means that there will be a number of configuration models for each IRMS and specific characteristic of the IRMS must be taken into account in their CMMs. 3.2. Mechanism and operational space of IRMS CMM IRMS equipment is able to move object in three-dimensional space and belongs to the robotic type of equipment [5]. IRMS kinematic configuration changes in time and is able to perform continuous movement along a set of trajectories. The operational space defines the volume occupied by the mechanism in all kinematics configurations when following all possible trajectories. The model to represent the IRMS is usually composed of static model representing the mechanism in a limited number of key configurations and a volume to represent the operational space. Two types of mechanisms have to be considered: the manipulator type mechanism representing most the IRMS and the mobile robot type specific for the cask RH system (see Fig. 2). The manipulator type is used to model IRMS consisting of a set of mechanisms build in series such like manipulators arms,
transporters or other handling mechanisms. Each mechanism consists of nearly rigid links which are connected by joints that allow relative motion of neighbouring links. The number of degree of freedom (d.o.f) describes the complexity of the mechanisms, e.g. the IVT, used for the maintenance inside the vacuum vessel, is made of more than 10 d.o.f. The mobile robot type is used to model the IRMS able to travel along the buildings. The operational space of the transfer cask represents the volume occupied by the cask during the travelling, therefore is extended to all necessary buildings and building levels. 3.3. IRMS CMM operational space details Even when the nominal geometrical configuration of operational space is defined, it may be necessary to take into account in the CMM additional space allocations for different sources of geometrical deviation. Each component has manufacturing or assembly tolerances. The maximum manufacturing tolerance values have to be considered and may be implemented in the CMM as additional layers and merged in the model. Additional space booking may be required to take into account the effects of bending or deflection under gravity or due to payloads. This is particularly important given the mass of some of the components to be remotely handled – for example the cask systems handle port plugs of 45 tonnes whilst the IVT replaces blanket modules of 4 tonnes in a full cantilever configuration. The accuracy and repeatability of IRMS trajectories have limits and the CMMs must take this into account. For example the uncertainties concerning the precise position of a transfer cask on its trajectory through the Tokamak building. These uncertainties are due to both technological limitations and operational constraints – the transfer cask speed is lower and hence the positional accuracy greater during the final approach to docking in the port cells than during transit through the galleries en route for the hot cell building. In addition to positional uncertainty, the speed of movement affects the stopping distance. The stopping distance must also be included in the CMMs – again this is particularly important for the transit of casks through the Tokamak and hot cell buildings. Equally to avoid collisions during seismic events, it is necessary to make the required space reservations in the CMM. Further volumes may require integration into the IRMS CMMs to take into account specific operations – for example the required volume for man access to and around the equipment during equipment maintenance operations. A further very important example
J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
1905
Fig. 3. Recommendation for RHE CMM modelling.
Fig. 4. IVT mechanism configurations.
will be the space required for the deployment of IRMS rescue tooling and procedures subsequent to a major failure of the IRMS and the need to recover it from the VV. The following table (Fig. 3) summarises the recommendations for building the IRMS CMM’s for mechanism and operational space models. 3.4. RHE operational state configuration During the ITER machine shutdown, the IRMS is deployed inside the VV to perform the scheduled maintenance operations. The configuration of the system and the initial position varies according to the task to perform. For example, two specific mechanism configurations are necessary to represent the IVT deployed in VV: one for the 100◦ configuration, another for the 180◦ (Fig. 4). To describe the cask configurations when docked to the port cells in the Tokamak building, a set of mechanisms is required to represent the different cask typologies (IVT casks, plug handling casks, etc.) and a set of reference positions to capture cask locations for all appropriate port cells (Fig. 5). During the maintenance of the IRMS, a specific set of trajectories is required to model the space requirement for IRMS cleaning operations. The trajectories to consider during the IRMS testing phase after repair are specific as well. In summary, IRMS is deployed in various different positions within the Tokamak, the NB and hot cell buildings and in different
Fig. 5. Cask mechanisms and reference position in TKM building level B1.
Fig. 6. MPD model configuration partial overview.
mechanism configurations. Each physical location of the mechanism and its associated operational space must be clearly identified. To capture all the different situations and associated configurations CMMs must be developed for each “state” of the IRMS and defined in terms of an initial configuration for the mechanism at a given reference position in the ITER machine for a given set of trajectories. A configuration matrix is required to monitor and register all states of each IRMS (see Fig. 6 of MPD partial example). 4. Example of application 4.1. IVT configuration model in RHTF For deployment of the IVT during tests in the remote handling test facility (RHTF), due to building space constraints, IRMS space allocation has been reduced to less than that available in the VV (Fig. 7). Testing requirements involve the test of each individual joint over its full range and load tests in the most critical configurations. As the IVT is deployed from a cask, the cask model is associated to the IVT CMM.
Fig. 7. IVT CMM in hot cell RHTF.
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J.P. Friconneau et al. / Fusion Engineering and Design 86 (2011) 1903–1906
Fig. 8. Cask mechanism configurations.
Fig. 10. Full CPRHS CMM in TKM building.
Fig. 9. CPHRS operational space.
In addition to the IVT and cask, the CMM includes the supports required by the test mock-up and for the cask to simulate the conditions in the VV. 4.2. Cask configuration model overview The cask and plug remote handling system (CPRHS) is composed of 9 different casks to transfer component and equipment from the VV to the hot cell. For a given cask the mechanism shall represent both the travelling trajectory configuration, (e.g. from a docking station in HCF to a given port cell in TKM building) and the docking to the port cell (where the cask is aligned) before and after removal of the cask transfer system (CTS). In summary, the CPRHS configuration model is composed of: • 9 CPHRS mechanisms to represent the different casks typologies, • 3 mechanism configurations for each CPRHS (Fig. 8.). • 54 mechanism reference position in the Tokamak building and 32 in the hot cell building. • 182 operational spaces for the travelling trajectories and 9 for docking trajectories (Fig. 9). • A set of specific trajectories for the rescue system and the transfer system removal. • Additional operational space for man access in the CPRHS storage.
For each building, all theses individual models are merged in a single CAD model that constitutes the CPRHS CMM (Fig. 10). 5. Perspectives The CMM is a key tool for controlling design integration and managing system design activities. CAD modelling of the IRMS requires that the dynamic characteristics of the IRMS be correctly integrated into the static CMM. A methodology has been developed for addressing this issue and has been successfully implemented in a first series of study cases. It is now proposed to implement this methodology to all the IRMS. Acknowledgments The design activities related to Cask system have been performed under a task agreement with in the Fusion for Energy. References [1] A. Tesini, A.C. Rolfe, The ITER remote maintenance management system, Fusion Eng. Des. 84 (2009) 236–241. [2] A. Tesini, J. Palmer, The ITER remote maintenance system, Fusion Eng. Des. 83 (2008) 810–816. [3] M. Nakahira, et al., Design progress of the ITER blanket remote handling equipment, Fusion Eng. Des. 84 (2009) 1394–1398. [4] A. Tesini, et al., ITER in-vessel components transfer using remotely controlled casks, Fusion Eng. Des. 58–59 (2001) 469–474. [5] J. Craig, Introduction to Robotics: Mechanics and Control, third ed., Pearson, 2005.