Best Practices for Remote Assembly and Maintenance

1. Best Practices for Remote Assembly and Maintenance Keith Kershaw, Sources, Targets and Interactions Group Thanks to: Alessandro Tesini and Jim Palmer of ITER, Luca Dassa of EN-MME

2. Contents • Why is it important to design for remote handling? • CERN examples • ITER Remote Handling Code of Practice • Next steps • Conclusions and discussion HL LHC Remote Handling Keith Kershaw

3. Why is it important to design for remote handling ? Why use remote handling? • Maximiserunning time • Reduce exposure of personnel to hazards (radioactivity, Oxygen deficiency etc…) Why design for remote handling? • Manipulator arms cannot do everything a human can • Ensure remote maintenance is POSSIBLE • Speed up remote maintenance • Hands-on work will also be faster HL LHC Remote Handling Keith Kershaw

4. CERN examples CERN already has designed equipment to be compatible with remote handling. Examples include: • LHC collimators • SPS remote vacuum connection Luca Dassa and Keith Kershaw are preparing short course for designers HL LHC Remote Handling Keith Kershaw

5. Example : LHC collimators HL LHC Remote Handling Keith Kershaw

6. LHC collimator remote exchange… TIM for Inspection Remotely operated crane for handling and transport Telemax for inspection and disconnection HL LHC Remote Handling Keith Kershaw

7. Example : SPS Remote Vacuum connection (1978) HL LHC Remote Handling Keith Kershaw

8. The ITER Remote Handling Code of Practice Remote handling will be essential for ITER maintenance. The ITER RHCoP is part of a management process to ensure “plant” is compatible with remote maintenance and to minimisedowntime last year ITER issued CERN a Licence agreement to use the ITER RHCoP. It is not openly available. HL LHC Remote Handling Keith Kershaw

9. ITER – Fusion Tokamak After the first 7 years operation remote handling will be vital for maintenance Person for scale HL LHC Remote Handling Keith Kershaw

10. ITER use JET RH experience “Man in the loop” HL LHC Remote Handling Keith Kershaw

11. Multi-purpose deployer with twin force reflecting manipulators This is the “recovery” option for times when purpose built remote maintenance equipment needs help HL LHC Remote Handling Keith Kershaw

12. What is the ITER RHCoP? There are two main documents: “ITER RHCoP” - (Technical guidelines) “ITER Remote Maintenance Management System” IRMMS - (Managementprocesses) HL LHC Remote Handling Keith Kershaw

13. IRHCOP defines and describes ITER Remote Handling (RH) Baseline Strategy RH Design Standards for: • Location Devices • Fasteners(incl. tooling) • Welded Joints (incl. tooling) • Electrical Connectors • Fluid Connectors Key principles for: • Specification & design of RH equipment • Preparation & implementation of RH Operations HL LHC Remote Handling Keith Kershaw

14. IRHCoPExample – Location Devices Parallel Dowel Pin Arrangement Ball-End Dowel Arrangement Axial & Azimuthal Flange Location HL LHC Remote Handling Keith Kershaw

15. IRHCoPExample – Fasteners Tooling “Pop-up” captive bolts Simple bolt runner captivation captivation at thread High torque tool with dove-tail feature for local torque reaction captivation over the head HL LHC Remote Handling Keith Kershaw

16. ITER Remote Maintenance Management System (IRMMS) Includes: • Organization of ITER RH Team • Approach to RH classification • Design & procurement process for RH equipment • Method to ensure RH compatibility of ITER machine • Organization and management of RH operations HL LHC Remote Handling Keith Kershaw

17. IRMMS - RH Classification (define at start of design phase) RH Class1:Will need RH replacement / maintenance. Mock ups as part of design process RH Class 2: Only unscheduled maintenance. May involve mock ups for design process RH Class 3: failure probability < 1 in 200 years. Design for RH repair. RH equipment procured after assembly Non RH Classified: do not require remote maintenance. HL LHC Remote Handling Keith Kershaw

18. IRMMS – Management (life cycle) • Preparation and operations from concept to decommissioning • Three key teams must work together through all stages of design and operation: • ITER Plant • ITER Remote Handling Equipment • ITER Remote Handling Operations • Reviews and iterations as part of process HL LHC Remote Handling Keith Kershaw

19. ITER remote handling design compatibility checklist More than 40 points

20. Next steps We will start with short basic remote handling compatibility training courses for designers (EN MME and EN-STI) For the future we will need to develop our own code of practice and processes. This work will need to be based on realistic predictions of the capabilities of our remote handling equipment. HL LHC Remote Handling Keith Kershaw

21. Conclusions & Discussion 1 • Where appropriate, beam line equipment should be designed to be compatible with remote handling • ITER RHCoP and IRMMS provide guidelines: • management aspects (collaboration of teams) • design aspects • Even if hands-on solutions are used, the same principles can offer benefits of reduced downtime and radiation exposure HL LHC Remote Handling Keith Kershaw

22. Conclusions & Discussion 2 Thank you. Questions and discussion welcome… For every object: Analyse - from the beginning - the installation, failure and maintenance scenarios Analyse the big picture – do not rely on a magic remote handling device Luca Dassa and Keith Kershaw are preparing a short course for designers on design for remote handling compatibility – please contact us with examples or input. HL LHC Remote Handling Keith Kershaw