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UKAEA - RACE
Introduction to Remote Maintenance
Oliver Crofts
5th IAEA DEMO Programme Workshop
Daejeon, Korea – 7th to 10th May 2018
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UKAEAUK fusion research and development
RACE and CCFE are both
parts of UKAEA
RACE conducts all the remote
handling research and development
within UKAEA, including control
system development and working
with autonomous vehicle developers
RACE – Remote applications in
challenging environments
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20182
Autonomous vehicle
outside RACE
MAST
tokamak
JET tokamak remote maintenance system
Mascot manipulator operating in JET
Remote vehicle
testing at
RACE
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The maintenance challenge
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20183
Remote maintenance risks, gaps and development needs
The maintenance system is critical for the success of a fusion
power plant:
Must operate rapidly
Requires novel technologies
Will be large and complex
5 maintenance sub-topics address these challenges
| Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20184
ITER NB Cell layout development
Increasing Complexity
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Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20185
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
Maintenance system strategy and design
Plant layout and component design
Fusion development is moving from
experimental devices power plants
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Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20186
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
K DEMO in-vessel component
segmentationKeeman Kim et al,
FPCC Paris, France 2016/1/27
Fusion development is moving from
experimental devices power plants
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Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20187
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
EU DEMO vessel inspection
deployment systems by CEA
Fusion development is moving from
experimental devices power plants
|
Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20188
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
Laser bore pipe cutting and
welding
Laser bore cutting and welding
Pipe alignment and deployment
Thermal compensation
Non-destructive testing
Fusion development is moving from
experimental devices power plants
|
Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 20189
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
ITER hot-cell
Large range of functions
Significant cost driver
Storage
Commissioning
Dismantling
Waste
Fusion development is moving from
experimental devices power plants
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Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201810
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
JET standard remote interface
Mechanical interfaces
Pipe connections
Deployment systems
Tools
Design, testing, manufacture, spares
Space for access and tools
Fusion development is moving from
experimental devices power plants
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Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201811
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
Dropped loads
Containment and confinement
Inspections
Recovery and rescue
Accident conditions
Seismic events
Fusion development is moving from
experimental devices power plants
|
Maintenance is design driving
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201812
Step change in the availability requirements
compared to experimental devices
Demonstrate power plant feasibility
Short maintenance durations
Balance maintenance cost with availability and performance
Makes the maintenance system a design driving activity
Maintenance requirements will drive some aspects of the
plant design
Early integration of maintenance into the plant design
Developing maintenance oriented strategies
Understand maintenance space constraints
Develop enabling technologies
Minimise the cost of the supporting facilities
Develop standard tools, interfaces and deployment systems
Understand how safety can affect maintenance
Consider the benefits of advanced control techniques
CFETR blanket handling
Fusion development is moving from
experimental devices power plants
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Fewer TF coils
Fewer but heavier components to handle
Bigger vertical ports (radially outwards)
Reduced magnet performance (ripple)
More space for stronger, stiffer handling
Direct lifting of some blankets
Smaller number of components
Maintenance access through all ports
Removal of other in-port equipment
Visibility of components through the ports
Handling system deployed in the port
No toroidal pipe sections inside the vessel
Space for inspection
Increased radial build to inspect vessel
Access within the cryostat
Tokamak architecture
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201813
Trade-off between practical maintenance and plant designDefined and agreed early
RM Sub-topic 1 – Tokamak architecture
Presented by Eric Villedieu of CEA, France
EU blanket kinematics
JA DEMO and EU DEMO
Straight pipe connections
CFETR blanket handling
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Service joining technology
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201814
Service joining is an important part of maintenance and an enabling technology
Plasma facing component fluid connections are design driving
Valuable information and experience is being developed
DEMO will need to push the technology further
Higher demand for rapid maintenance
Harsher environment; radiation tolerance, rescue
Larger pipes with thicker walls
Includes pipe alignment and pipe deployment,thermal compensation, non-destructive testingand meeting the requirements of the regulator
RM Sub-topic 2 – Service joining technology
Presented by Satoshi Kakudate of QST, Japan
Current development status
JA DEMO pipe layout and handling
EU DEMO laser cutting and welding
ITER comparison between laser and TIG, fitting errors, life, mechanical cutting, non-destructive
testing and radiation hard components
Future actions to fill the gaps in the development by exiting fusion devices and industry
Do we have the service joining technology required for DEMO?
In-bore pipe cutting and welding,
close to the blanket
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Maintenance support facility
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201815
Large range of tasks lead to large size and high cost
Storage of new components and line replaceable items
Decontamination, storage, maintenance, commissioning and
upgrade of remote handling equipment
Storage and dismantling of used components
Segregation and size reduction of waste
What are the scope, size and cost implications for DEMO?
RM Sub-topic 3 – The role of the hot-cell in achieving fusion power
Presented by Nick Sykes of RACE, UK
Options
Minimise the burden on the facility
Automation, radiation tolerance
Standardisation of plant and operations
ITER
hot-cell
EU DEMO
Maintenance
facility
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The impact of safety on maintenance
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201816
Safety implications can have a large impact on the maintenance strategy and some may not be acceptable to a regulator, particular issues are:
Lifting large components significant distances above containment structures
Moving confinement barriers for maintenance
Impact between components during accidents
Investment protection
Serious damage to the plant cannot be tolerated,even where there are no direct safety implications
Regulator involvement
Regulator will not be involved until the design is mature
Anticipate what could be approved
Consider stakeholder requirements
Limit the risk of significant redesign
DEMO designs have similar safety risks
Lessons learned from ITER Divertor Remote Handling System
Regulation, nuclear safety and investment protection
What impact can safety have on technologies and strategies?
RM Sub-topic 4 – The impact of safety on DEMO remote maintenance
Presented by Gary Reed of Assystem, UK
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Intelligent maintenance
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201817
DEMO remote maintenance has a unique conjunction of control challenges
Rapid and precise handling of components throughout the complex trajectory
Uncertainty in models and measurements
Degradation of the payload
Limited sensor availability
Heavy and flexible payloads
Safety issues
Automated control
Principally to speed up operations
‘Smart’ to adapt to changing conditions
Limited development in industry
Worldwide development
Understand the benefits
Task optimisation and efficiency
Input into DEMO design
Strategy study on Intelligent Maintenance; motivations, realisation issues, gaps and uncertainties.
Implementation on CFETR, focusing on information management and artificial intelligence
What benefits may be achieved with advanced control techniques?
RM Sub-topic 5 – Intelligent maintenance for fusion reactors
Presented by Yong Cheng of ASIPP, China
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EU DEMO Remote Maintenance work byRACE and CEA is part funded by EUROfusion
Safety impact assessment by Assystem UK
JA DEMO work by QST Rokkasyo Fusion Institute
and Naka Fusion Institute
CFETR work by ASIPP
Contributors
Oliver Crofts – 5th IAEA DEMO Programme Workshop – Daejeon, Korea – 7th to 10th May 201818