Target Area Overhead Crane: -Updated Layout -Fault Analysis -Recommendations for Remote Handling...

Target Area Overhead Crane:- Updated Layout- Fault Analysis

- Recommendations for Remote Handling (ITER)

R. Rinaldesi, K. Kershaw – HE Group

2

Updated layout

Main characteristics:

• Capacity: 40 ton• Span: increased from 22600 mm to 25100 mm• Lifting height: 24 m• Lifting speed: reduced from 10 m/min to 5 m/min• FEM classification: A4 - M4 (exception for gearbox)

Aug. 1st 2013Target Area Overhead Crane

3

Updated layout

Hook lateral approach:


4

Updated layout

Hook lateral approach:


5

Updated layout

Hook longitudinal approach:


6

Updated layout

Overall height:


7

Updated layout

Wheel loads:


8

Updated layout

Festoon along one walkway:


9

Fault AnalysisMechanical Faults

Hoist (lifting movements)


10




Fault Probability

Effect

Intervention

Duration of intervention on

crane *Preventive action

Price increas

e

Breakdown

position

Parking

zone

Main motor -short-circuit between phases

Medium

Emergency motor is switched on and operations can continue at a lower speed (20% of nominal speed)

- - -

Incoming fault can be identified during inspections (temperature measurement)

~20.000 € (2nd motor

with diff. Unit)

Gearbox – fracture of shaft, gear or key

Very low (1 case at CERN due to intensive use at a load exceeding capacity)

Drop of load is avoided by emergency brake; load slips ~40 cm before being stopped with a deceleration of 1 m/s2. Intervention of personnel is required to manually lay the load on the ground

Yes (load

laying)

Yes (gearb

ox repair)

- Load laying: 4 hours

- Gearbox repair: 4 days

- Additional inspections: noise measurement and oil analysis

- Oversizing: gearbox designed as if it would be used in a heavy-duty crane (continuous use at full load)

~15.000 €

(heavy-duty

gearbox)

Gearbox/ Rope drum– seized bearing

Very low (never happened at CERN)

No hoist movement is possible (load stuck)

Yes (gearbo

x repair)

- 4 days

- Additional inspections: noise measurement

- Oversizing: gearbox is designed as if it would be used in a heavy-duty crane (continuous use at full load)

-

11




Fault Probability

Effect

Intervention



Price increas

e

Breakdown

position

Parking

zone

Service brake

Low


Yes (load

laying)

Yes (brake replacemen

t)


- Brake replacement: 4 hours

- -

Rope drum

Very low (1 case in HE history due to assembly fault)


Yes (load

laying)

Yes (rope drum repair

)


- Rope drum replacement: 5 days

- Additional inspections: non-destructive tests

-

Rope Low

The entire load is sustained by the second rope (swaying); the load can be safely laid on the ground

- Yes 1 day (no exposure to radiation)

Incoming fault can be identified during visual inspections

-

*: intervention time doesn’t include lead time to have spare parts available

12


example of fully redundant hoist


Courtesy of Meloni Tecno-Handling srl

13


Cross and Long travel (horizontal movements)


14



- All the 4 wheels are motorized with self-braking motor+gearbox

- Motors and brakes are independently controlled

- In normal conditions only 2 motors are working; the other 2 motors are not

used and their brakes are left open


15




Fault Probability

Effect

Intervention



Price increas

e

Breakdown

position

Parking

zone

Motor -short-circuit between phases

Medium

One wheel is blocked; both emergency motors are switched on and able to push the crane and complete the operation

- Yes4 hours (no exposure to radiation)

Incoming fault can be identified during inspections (temperature measurement)

~15.000 € (2

additional

motors and

gearboxes;

oversize of

motors)

Gearbox/Wheel – fracture of shaft, gear or key

Very low

The wheel becomes loose; one emergency motor is switched on and operations can continue

- - -Additional inspections: noise measurement and oil analysis

-

Gearbox/ Wheel - seized bearing

Very low

One wheel is blocked; both emergency motors are switched on and able to push the crane and complete the operation

- Yes 1 dayIncoming fault can be identified during inspections (noise measurement)

-*: intervention time doesn’t include lead time to have spare parts available

16

Fault AnalysisElectrical Faults

- Cubicles (both power and control) are located in a separate room

- The following equipment is on-board of the crane:

Junction boxes

Encoders / Laser (position detectors)

Weighing system

Cameras

- The only fault that will need access of personnel is a defect on wiring:

intervention time is about 1 hour (with spare wires already installed)


17

Recommendations for Remote Handling (ITER)

Consider RH compatibility from earliest stage of development cycle Prefer vertical load transfer during installation and removal Use of a crane provides compliance in 5 d.o.f. (helps self alignment) Provide for self alignment (into position and with handling equipment) –

typically use of cones Keep operations simple Recovery techniques vital

Provide space for handling trajectories and for vision Provide visual clues for gross alignment motions Protect sensitive equipment


18


ITER Monorail Crane (Neutral beam remote handling system)


19




Twist-locks

20




Target Area Overhead Crane: -Updated Layout -Fault Analysis -Recommendations for Remote Handling...

Documents

Transcript of Target Area Overhead Crane: -Updated Layout -Fault Analysis -Recommendations for Remote Handling...