robotic inspection tool development for double shell tanks...

ROBOTIC INSPECTION TOOL

DEVELOPMENT FOR DOUBLE

SHELL TANKS AT HANFORD

Dwayne McDanielFlorida International University

RCNET Workshop & Professional Development

July 13th – July 14th

TEAM MEMBERS

PRINCIPLE INVESTIGATOR: Leonel Lagos, Ph.D., PmP

PROJECT MANAGER: Dwayne McDaniel, Ph.D., P.E.

TECHNICAL STAFF: Anthony Abrahao, William Tan, Ph.D.

DOE FELLOWS: Michael DiBono, Ryan Sheffield, John Conley, Sebastian

Zanlogo

Work supported by: U.S. Department of Energy Office of

Environmental Management under Cooperative

Agreement # DE-EM0000598

Advancing the research and academic mission of Florida International University

OUTLINE

Background

Proposed Inspections

Pneumatic Crawler

Testing and Evaluation

Magnetic Miniature Rover

Testing and Evaluation

Path Forward


TASK DESCRIPTION


1.) Refractory

Air Slots through

the Annulus

2.) 6” Leak

Detection

Piping

3.) 4” Air

Supplying

Piping

PROPOSED INSPECTION


AIR SUPPLY LINE INSPECTION TOOL

Remote controlled

Video feedback recorded for future analysis

Radiation hardened (~80 rad/hr)

High temperature environment (~170 ° F)

To be used in pipes and fittings with 3” and 4” diameters

Will need to turn through elbows, bends, and transitions

Will need to crawl through vertical runs


OBJECTIVE: To develop an inspection tool that crawls through the air supply pipe that leads to the central plenum of the primary tank of the DSTs at Hanford and provides video feedback

DESIGN PARAMETERS:

INSPECTION PATH (AY-102)


The proposed

inspection distance

will be approximately

100 feet with a

significant portion

being gravity fed

The path is made up

of 40 pipes which are

3” and 4” in diameter,

with reducers and

several elbows

CONCEPTUAL DESIGN


Modular design composed of

interchangeable modules

connected with rigid links

This gives potential to

be customized for

specific tasks with the

addition of extra

modules

Examples include:

-Instrumentation

-Material Sampling

-Pipe Repair

OVERALL SYSTEMS

Front camera

Front and back grippers

Two middle movers


The basic design is composed of five modules:

Fully automated movement, remotely controlled by a handheld device

Fully customizable programmable control interface

THE DESIGN


Pneumatic Actuators to emulate the

contractions of the peristaltic movements

Movement does not require embedded electronics and

electric actuators

Suitable for highly radioactive environments with potential

exposure to flammable gases

GRIPPER MODULE


Maximizing the strength of the gripper is a major

factor in the design

Stronger grip would allow the device to carry additional

modules, and to inspect longer pipelines

BENCH SCALE TESTBED


The current grippers are

able to provide a

maximum gripping

force of ~40 lbs

This is also the maximum force

with which the mover modules

can propel the crawler in the

forward direction

BENCH SCALE TESTBED


Based on

maneuverability

bench scale

tests, the crawler

has great

potential to

accomplish the

proposed

inspection

MOVING FORWARD

INSTRUMENTATION MODULE

An embedded computer

A tether load cell

Other sensors (temperature, humidity, and radiation)


Monitor the dynamic performance during full

scale tests

Design additional modules carrying: Plant force sensitive resistors

in the pads of the gripping

mechanism

+ +=

REFRACTORY SLOT INSPECTION TOOL

Travel through small cooling channels with dimensions as small as 1.5” x 1.5”

Remote controlled

Inserted through a riser to the annulus floor

Live video feedback

Radiation hardened (~80 rad/hr)

High temperature environment (~170 ° F)

Must not subject the channel walls to pressures greater than 200 psi (the compression strength of the refractory material)

Navigate ~ 50 feet to the tank center, while maneuvering four 90 ° turns (first phase – 17 feet, no turns

Tethered


OBJECTIVE: To develop an inspection tool that navigates through the refractory pad air channels under the primary liners of the DST’s at Hanford while providing live video feedback

DESIGN PARAMETERS:

INITIAL DESIGNS

Use of tank-tracks for increased maneuverability

Upside down travel to avoid refractory debris (via magnets)


GENERAL APPROACH

Insufficient pulling force

Inadequate clearance with tank surface

Cumbersome reassembly

Difficulty overcoming obstacles (small wheels)

EARLY PROTOTYPES

BENCH SCALE TESTING

Device weight: 0.18 lb

Average pull force: 4.75 lb

Tests performed at: 5V

Power/Weight ratio: 26

Motor rated for 3-9 V

Maximum Pull

Force


CURRENT PROTOTYPE

BENCH SCALE TESTING


FIRST 17 FEET

2 90 DEGREE TURNS

8” BETWEEN EACH TURN

1.5” X 1.5”

ALTERNATIVE DESIGN

Explore first 17 feet


Make 90 degree turn

CABLE MANAGEMENT

Goal: To design a system to let out/recover the tether of the rover with

precision


MOVING FORWARD

SEMI-AUTONOMOUS DRIVING


SECTIONAL FULL-SCALE MOCKUP


Objective: To design a full-scale sectional

mockup of the DST to evaluate inspection

technologies and robotic devices.

Modular design: various refractory and drain line

configurations, different plate thicknesses,

predefined defects.

Dimensions 38’ length x 8’ width x 12’ height

Simulate inspections of refractory pad,

primary liner, drain slots, secondary liner

and central plenum.

Evaluate tank integrity – corrosion, wall

thickness, defects, welds, cracks

MOVING FORWARD

Develop full-scale mock up test bed

Develop delivery mechanism for easy development

Provide feedback of other inspection parameters (temperature, relative humidity,

radiation, etc.)

Redesign a radiation hardened version

Scale the design for smaller pipe sizes


Develop full-scale mock up test bed

Develop delivery mechanism for easy development

Provide feedback of other inspection parameters (temperature, relative humidity, radiation, etc.)

Redesign a radiation hardened version

Autonomous deployment/maneuvering of inspection tool

Crawler

Rover

SENSOR INTEGRATION


Crawler

Incorporation of temperature

and humidity sensors into the

front module.

Creation of a new module that

will be capable of surface

mapping, ultrasound and

radiation sensing.

SENSOR INTEGRATION


Rover

Development of a removable

hood for the system that can be

customizable to incorporate

temperature, humidity and

radiation sensors. iButton sensor for temperature and humidity

Radiation sensor for measuring beta and gamma radiation

robotic inspection tool development for double shell tanks...

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