This information is private and confidential. © February 13, 2008 Interim Design Review of ITER...

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Interim Design Review of ITER In-Vessel Coils 26-28 Jul. 2010 Remote Handling Section

ITER_D_34J46P

Review on ELM Coil preliminary design

from view point of Remote Handling

RH Section Interim Design Review of ITER In-Vessel Coils

28Jul. 2010

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ITER_D_34J46P Input Information

Mass [tonne]: Upper ELM Coil = 2.1

EQ ELM Coil = 2.3Lower ELM Coil = 2.2In-vessel Feeder = 1.3

Outside dimension

s [m]:Upper ELM Coil = 0.9H×4.0W×0.3TEQ ELM Coil = 2.4H×3.1W×0.5TLower ELM Coil = 1.0H×4.2W×0.3TIn-vessel Feeder = 4.8H×1.0W×0.5T H=Poloidal, W=Toroidal, T= Radial

The component design information is given in the Plant Definition Form (PDF): ITER_D_25XCHP v1.0

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ITER_D_34J46P Background

Intermediate Cask

Cask Mounted Transporter (CMT)In-Vessel Transporter (IVT)

• The proposal is to utilise the baseline RH equipment as far as possible. • The MPD with a 2 tonnes capacity is now available within the baseline. However,

the coils weights are in excess of the capacity of the MPD. • The IVT will handle the coils.• The MPD will perform light duty, i.e. dexterous work as coils feeders / mechanical

connections and clamping.• An additional (non-baseline) machine to deliver the coils into the vessel is

necessary (CMT).

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ITER_D_34J46P Cask Transport System

• The new coils designs are smaller and with some in-cask manipulation can be positioned so that the front cask door can be opened without the need to withdraw the coils into the transporter cask.

• The adequacy of restricted envelope for support fixture, CMT and end-effector is yet to be assessed.

• The In-Vessel Feeder model measures 5.0m over the junction connectors (only 4.8m is stated in the PDF) and will only just fit into an intermediate cask.

• The adequacy of restricted envelope for support fixture, CMT and end-effector is yet to be assessed.

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ITER_D_34J46P End-Effector Sub-Frame

• The End-Effectors Sub-Frames have 3 principal interfaces.

• Interface to locate and secure it to the Coil Handling Features attached to the Coil

• An interface for the CMT and the IVT to carry it

• Interface to engage with the temporary supports in-vessel and with the cask support fixture.

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ITER_D_34J46P Transfer of EQ Coil into Vessel

• There is much less than 10mm clearance all around and this is not a viable working clearance. Tolerances in the port and the coil will mean potentially no clearance.

• The new design of EQ coil with mineral insulated conductors and no casing is slightly more compact and provides about 20 - 30mm of clearance through the port. This clearance is too small to rely on the precision of the CMT to avoid collision with the port.

• It will be necessary for the End-Effector Sub-Frame to have guide rollers that contact the port before the coil does.

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ITER_D_34J46P Coil Positioning and Alignment

• The present designs of locating pads do not seem to provide any positional control to the coil. There is a 5mm gap all around.

• The coil location onto its mounting pads must not be over-constrained or excessively tight. The proposed solution is to locate the coil in all degrees of freedom at one point only. It is recommended that the accurately located point is close to the feed connections.

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ITER_D_34J46P Coil Fixing

• The loose clamps that currently appear in the model are not favoured for remote handling. Each clamp needs to be presented by a delivery system, attached to a handling device and manoeuvred into position. This is potentially time consuming and has the risk that small parts may be dropped. The bolt would need to be captive in the clamp.

• Whilst the coil has 5mm of clearance all around, the clamps appear to have no clearance. This implies that each coil is located by its clamps. This is obviously impossible since if the coil is slightly misaligned from the nominal position half of the clamps cannot be fitted as there would be insufficient room.

• A solution might be to make the bolts captive on the vessel wall by swing bolts which can be hinged out of the way of the coil installation.

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ITER_D_34J46P Coil Fixing (cont’d)

• Once the coil has been clamped into position, it must be constrained from sliding on its supports.

• It is suggested that remote operable wedges located at the coil at the clamping positions are used.

• The lower loop of the Lower ELM Coil runs very close to the VS coil. The access to the fixing of the Lower Coil is impeded by the VS coil and more particularly its fixing clamps. Since the VS does not require any remote handling it should be possible to devise a more compact fixing that is less intrusive into the access space for the Lower Coil.

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ITER_D_34J46P Joint

• The reference proposal is the butt welding or brazing of the copper conductor. • There are many concerns;

• The essence of a remote handling joint is that it is reusable.• A welded joint will always be destroyed when it is cut.• A brazed joint may not be readily dismantled by simply re-melting of the braze. Cutting will probably

be required to disassemble a brazed joint.• The great amount of heat necessary to weld this copper joint will be difficult to control.• Because of the large wall thickness, it will be necessary to add filler material to a weld which is

potentially a great complication to the remote tooling.• A socket joint might be more appropriate for brazing but providing the assembly translation required

to engage the joint is not practical here.• A sliding sleeve is not generally favoured for remote operation. • A bolted design would be preferable.

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ITER_D_34J46P Joint (cont’d)

• The connection design utilising a bolted connection is a preferred solution.• The connection should be a made-to-measure bridge that conforms to the

positions of the two terminations that are to be joined. • Measurement using laser scanning or photogrammetry may be difficult in the high

radiation flux in the vessel. The measurement should be done using a jig that can be configured to the interfaces and can then be brought out of the vessel to be accurately measured in a man access area.

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ITER_D_34J46P Other Consideration

• The IVT cannot be deployed until the coil has been transferred fully inside the VV with the CMT and temporarily supported on the inner wall.

• The use of the IVT to manoeuvre and install the coil in-vessel requires the deployment of the IVT rail to the installation location. This will inhibit the use of the MPD during the IVT operations. The IVT will need to be withdrawn after each coil installation and then redeployed to remove the End-Effector Sub-Frame from the coil.

• The Equatorial Coils, water pipes and blankets impinge on the vessel port envelope. This means that an equatorial coil can only be transferred into the vessel through a port where all these items have been removed. Presumably, the transfer port would be chosen to be where the coil is to be installed. However, this would not be possible if the coil was to be installed in the region of the NB ports.

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ITER_D_34J46P General limitations from RH1. Passive alignment system with guide and flexibility

• The IVT system has position error of +-10mm. The final position exceeding this accuracy have to be achieved by structural guiding system.

• Passive and self aligning structure is necessary for precise mutual positioning especially for welding.

2. Avoiding multi-pass welding, touch start of welding

• Risk of sticking the filler wire or torch into welding bead is very high. For bore tool, it is extremely difficult to recover from this fault.

3. Avoiding seizing of bolt

1. For in-vessel materials (i.e. those which experience vacuum conditions) it is preferable that the two mating halves of the joint should be of dissimilar materials to prevent binding / galling of the threads.

2. A standard thread insert (in Al-Bronze) has been designed for JET In-vessel applications.

• Avoiding thermal cutting (and water jet)

• Dross (or abrasive water) blown behind the structure is extremely difficult to correct.

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ITER_D_34J46P Bolting interface

Avoiding dropping of bolt and achieving full disengagement: Captive Fasteners with pop-up mechanism are preferred (Reference: IRHCOP, ITER_D_2E7BC5)

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ITER_D_34J46P

36 modules for 1 toroidal ELM coil

96 modules for 3 toroidal ELM coils

278 modules for all ELM coils

X3

(worst case for probable failure)2 inlet manifolds

2 outlet manifolds

18 inlet manifolds

18 outlet manifolds

Modules required to remove for ELM coil replacement

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ITER_D_34J46P BL Modules replacement days for ELM coil replacement

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ITER_D_34J46P Consideration of Maintenance time

• The case study of only BL modules replacement time (removal / install of both SB and FW) shows following feature;

• For 3 of ELM coils not adjacent each other: minimum 179 days

• For all ELM coils : minimum 392 days

• BL manifold replacement and ELM coil replacement time are additionally required. (not yet evaluated)

• Information above must be taken into account to determine the RH class of ELM coils replacement

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ITER_D_34J46P Conclusion• The EQ coil model supplied at work kick-off (with a casing) has

insufficient clearance within the equatorial port to allow its transfer into the vessel. The revised design with MI is smaller and has around 20-30mm clearance all around relative to the port. Whilst this is less than ideal, it should be feasible to handle the coil through the port.

• The end-effector sub frame and coil fixing feature (clamping) for RH compatibility design is proposed. Implementation of those proposal to the component is expected.

• The joint connection of the coils is a complex operation. The design of the joint using copper welding or brazing is not a reversible RH process. A design which segregates a bolted conductor and a welded stainless steel water pipe is favoured.

• Non-baseline RH equipment to transport the coils into VV is necessary (CMT)

• Further progress on design of RH compatibility aspect is necessary.

• It takes more than 1 year to replace only BMs for all ELM coils replacement, and more than 0.5 year for 3 of ELM coils (not adjacent each other) replacement.

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ITER_D_34J46P Future Action for RH compatibility

RH compatibility procedure: ITER_D_2NRTWR

Template for RH Compatibility assessment Report:ITER_D_2WU3P2

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ITER_D_34J46P

Issues and Resolution PlanIssue Resolution Pre/Post

October

Adequacy of in-cask rotation of the coils and feeders considering CMT and EE usage

Design of CMT and EE, Interference check inside cask.

Pre

Clamping feature of uncertainty about positioning, risk of drop parts, space limitation around lower VS

Implementation of Captive bolt and clamp concept such as Swing bolt. Smaller design of clamp system for VS (without RH compatibility)

Pre

Sliding after positioning of coil Implementation of RH compatible shimming system such as wedges proposed by RH

Pre

Joint design for RH compatibility Design of joint with segregated bolted conductor and welded pipe

Post

No plan for hot cell work Study and create TDF for hot cell work, interface sheets as requirement for space and equipment.

Post

Compliance to RH compatibility procedure

RH class, RH assessment report, RH compatibility design, OSD, new tools identification / design, etc.

Pre / Post

This information is private and confidential. © February 13, 2008 Interim Design Review of ITER...

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