maintenance and building conceptual approach

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006

Maintenance and BuildingConceptual Approach

L. Waganer and R. PeipertThe Boeing Company

4 October 2006PPPL Project Meeting


Maintenance Design Approach• Port maintenance adopted, replacing large blanket and divertor modules

• Replace all first wall/blanket and diverter modules ECH launchers every 3.0 FPY. Remainder is life-of-plant.

– Blanket and divertor modules removable inside core

– ECH launcher designed as a removable assembly

• All power core maintenance fully robotic and automated based on prototypes and production plants

• Work simultaneously on all three field periods

• Employ maintenance machines inside fixed port transfer chambers just outside bio-shield

• Pass all used and new modules via airlocks to mobile transporters

• If conventional tube welding is used, auxiliary maintenance machines ports are needed. Remote disconnects would cut maintenance time by a factor of 4.


Compare similar 1950’s and 2000’s technologies and Project into the Future!

•Automobile Assembly

• Surgery (knee, hernia, heart, lung )

• Vision Correction (glasses vs. laser)

• Electronics (transistor vs. LSIC)

• Data Storage (tape drive » floppy drive

» hard drive » solid state) (20 yr time span)

Deburring movie Tool Changer movie

How To Forecast Maintenance Technologies 40-50 Years in Future?

Consider physical laws as limiting values


Mid-Plane View Shows Maintenance At Main and ECH/Aux Maintenance Ports

• Simultaneous maintenance in 3 FP

• Fixed Transfer Chambers control contamination and enhance times

• Mobile Transporters transfer used and new components to/from Hot Cell

• Main Port is used for removing blanket and divertor modules

• ECH launcher/waveguide removed as an assembly

• ECH port can then be used as Auxiliary maintenance port

• Manipulators inside Bioshield at center of power core remove divertor inner tubes and shielding and cut outer divertor tube/support


Example of Pallet Transfer Technology for ECH Module Assembly

We may want to adapt a conveyor approach similar to the efficient pallet handling transfer system used in freighter aircraft, C5, C17, C141, et. al.


Removable ECH Assembly at 35º PortECH Waveguide, 0.54 m H x 0.24 m WOpening in VV and Coil Structure, 1.54m H x 1.24 m WOpening through Bioshield, 1.6 m H x 1.6 m W

Note: Removable ECH Module includesWaveguide, All Shielding, Bioshield, Mirror, and Exo-Bioshield Vacuum Vessel

PermanentTransfer Chamber


Extraction of ECH Assembly Into Transfer Chamber • Maintenance machine removes

waveguide segment and coolant coupling

• Complete assembly removed into Transfer Chamber by pallet system


ECH Module Moved Into Mobile Transporter for Transit to Hot Cell for Refurbishment


ECH/Aux Port Maintenance ActionsRemoves blanket shielding blocks, shielding rings, and cuts coolant tubes

while main port arm supports and removes blankets


View of Main Port (0º), Operational


Initial Position of Extractor Machine

• This is the position of Extractor after plasma shutdown and cool-down


First Action Is To Remove Bioshield Door

• After the door is positioned inside Transfer Chamber, bridging structure is positioned

• Vacuum vessel door and port shielding is removed and set aside inside Transfer Chamber


Removal of Port Manifold/Structure

• The manifold/hot structure connections are disconnected and the structure is removed and set aside


Removal of Port Blanket and Shield

• This port blanket and shield module is the largest component to be removed

• It is also the only module that has an integral shield

• It is sized to clear port opening and provide maximum access to interior of power core


Design Approach to Extract Inner Coolant Tube and Shielding to Access Welded Joint

• If welded joints are to be used to secure outer divertor coolant tubes, joint must be shielded

• Entire inner tube and shielding assembly is removed allowing access to outer tube weld region

• Access is from outside of coil structure near center of machine


Removal of Divertor Tubes and Shielding

• The inner tubes and shielding for the Divertor plates are removed by floor and ceiling mounted manipulators (24 places at ± 12.5°)

• This is done simultaneously with ECH assembly removal and main port opening procedures


Preparation for Divertor Plate Removal

• This depicts the main port Extractor holding the Divertor Plates (24 pl) while the cutting bore tool on the central manipulator severs the outer coolant tube, which is the Divertor structural support

• The Diverter plates span two blanket modules but they fit through the main port opening


Divertor Plate Removal

• This view shows the removal of the Divertor plates

• After removal, they are moved to the Hot Cell via the Mobile Transporter

• During this step, the inner manipulator can be removing other coolant tube assemblies


Removal of Blanket Modules

• This is a typical procedure for removal of the blanket modules

• The Blanket modules are attached to the Hot Shield with four fasteners deep within the blanket close to the Hot Shield

• Tools disengage the fasteners while gripping the walls of the access holes, thus providing holding force for fastener removal and blanket handling


Removal of Blanket Module (Cont’d)

• Blanket module is being removed from Power Core and placed in Mobile Transporter

• As soon as this module is moved from its position on the Hot Shield, the Auxiliary Manipulators can begin to remove the shield blocks and shield rings for access to and severing the Blanket coolant tubes


Maintenance and Availability Analysis

Availability AnalysisSummary of Maintenance Actions Maint Days, Total Maint Days/FPY Availability

Scheduled Power Core, Major 50.27 16.76 95.6%Scheduled Power Core, Minor (ref ARIES-AT) 6.05 98.4%

Unscheduled Power Core (ref ARIES-AT) 20.56 94.7%Reactor Plant Equipment, Sched + UnSched (ref ARIES-AT) 9.27 97.5%

Balance of Plant, Sched + UnSched (ref ARIES-AT) 9.37 97.5%Total 84.7%

Main Port Shutdown Port OpeningDivertor Plates

Shielding Blocks

&Blanket Modules

Shielding Rings & Coolant Tubes

Shield & Support System

Insp.


Shielding Blocks

&Blanket Modules

Divertor Plates

Chamber Inspection

Port Installation

Start-Up

TaskShutdown &

Prep for Maint.

Open Three Main Maint.

Ports

Twenty-four Divertor

Plates (8 x 3 Sectors)

Blanket Modules (65 x 3 Sectors)

Shielding Rings & Inner Coolant Tube

(65 x 2 x 3 Sectors)

Inspect, Clean &

Vacuum - Inspect Repairs






Inspect Chamber

After Build-Up

Close Three Main Maint.

Ports

Inspect, Diagnostics &

Prep for Operation

Time (Hrs) 30.00 10.20 20.40 240.50 139.75 26.00 230.75 429.00 26.40 2.00 13.40 38.00

ECH/Aux Port ShutdownECH

Assembly

Shielding Blocks

&Blanket Modules



Insp.


Shielding Blocks

&Blanket Modules

Chamber Inspection

ECH Installation

Start-Up

TaskShutdown &

Prep for Maint.

Remove Three ECH

Assemblies

Shielding Blocks & Cut Weld (65x 6 x 3 Sectors)



Make Any Needed Repairs



Shielding Blocks &

Welds (65x 6 x 3 Sectors)

Inspect Chamber

After Build-Up

Install Three ECH

Assemblies

Time (Hrs) 30.00 8.40 240.50 139.75 24.00 230.75 429.00 2.00 9.60 38.00

BIO-Chamber ShutdownDivertor Coolant Tubes

Divertor Plates


Insp.

Divertor Plates

NDI WeldsCoolant Tubes

InstallationStart-Up

TaskShutdown &

Prep for Maint.

Twenty-four Coolant Tubes (8 x 3 Sectors)

Cut Plates Coolant Tube Weld (8 x 3

Sectors)

Inspect Outside for Damage &

Repair

Weld Plates Coolant Tube

(8 x 3 Sectors)

Complete Coolant Tube Weld Inspect.

Twenty-four Coolant

Tubes (8 x 3 Sectors)

Time (Hrs) 30.00 9.40 20.40 12.00 26.40 0.55 13.10 38.00

Total Time (Hrs)

Total Time (Hrs)

KEYSOperational Tasks

Parallel/Simultaneous Tasks

ARIES MAINTENANCE TASKS

Disassembly 466.85 Hrs. Replacement 739.55 Hrs.

Total Maintenance Time 1,206.40 Hrs. Inherent Availability 95.6%

Removal Tasks Replacement Tasks


Alternative to Cutting and WeldingBlanket Coolant Tubes

Current Technology

• Embed shielding blocks and rings to protect weld region

• Time-consuming procedure that generates contamination

Proposed Future Technology

• Remotely operated coolant clamp, Marmon type?

• Clamp and actuating mechanism can be replaced during refurbishment period

• Eliminates need for auxiliary port and equipment

• Reduces core maintenance time by factor of 4



Blanket Modules



Insp.


Blanket Modules

Divertor Plates

Chamber Inspection

Port Installation

Start-Up

TaskShutdown &

Prep for Maint.


Ports




N/A

Inspect, Clean &


N/ABlanket

Modules (65 x 3 Sectors)



Inspect Chamber

After Build-Up


Ports


Prep for Operation

Time (Hrs) 30.00 10.20 20.40 72.80 26.00 53.40 26.40 2.00 13.40 38.00


Assembly



Insp.


Chamber Inspection

ECH Installation

Start-Up

TaskShutdown &

Prep for Maint.

Remove Three ECH

AssembliesN/A


N/A

Inspect Chamber

After Build-Up

Install Three ECH

Assemblies

Time (Hrs) 30.00 8.40 24.00 2.00 9.60 38.00


Divertor Plates


Insp.

Divertor Plates



TaskShutdown &

Prep for Maint.



Sectors)


Repair


(8 x 3 Sectors)


Twenty-four Coolant


Time (Hrs) 30.00 9.40 20.40 12.00 26.40 0.55 13.10 38.00

Total Time (Hrs)

Total Time (Hrs) Total Maintenance Time 292.6 Hrs. Inherent Availability 98.9%



Aries Estimated Maintenance Times = Using Couplings ConnectionsRemoval Tasks Replacement Tasks



Advanced Remote Coolant DisconnectsSummary of Maintenance Actions Maint Days, Total Maint Days/FPY Availability




Yearly Electricity Capacity 8,766,000,000 kwhrPrice of Electricity $0.065 $/kwhr

Availability Revenue 100.00% $569,790,000

87.60% $499,136,04084.70% $482,612,130 $16.5 M Lost Revenue


Maintenance Slides for Engineering Summary


Maintenance Design Approach• Port maintenance adopted, replacing large blanket and divertor modules

• Replace all first wall/blanket and diverter modules ECH launchers every 3.0 FPY. Remainder is life-of-plant.

– Blanket and divertor modules removable inside core

– ECH launcher designed as a removable assembly

• All power core maintenance fully robotic and automated based on prototypes and production plants

• Work simultaneously on all three field periods

• Employ maintenance machines inside fixed port transfer chambers just outside bio-shield

• Pass all used and new modules via airlocks to mobile transporters

• If conventional tube welding is used, auxiliary maintenance machines ports are needed. Remote disconnects would cut maintenance time by a factor of 4.


Mid-Plane View Shows Maintenance At Main and ECH/Aux Maintenance Ports

• Simultaneous maintenance in 3 FP

• Fixed Transfer Chambers control contamination and enhance times

• Mobile Transporters transfer used and new components to/from Hot Cell

• Main Port is used for removing blanket and divertor modules

• ECH launcher/waveguide removed as an assembly

• ECH port can then be used as Auxiliary maintenance port

• Manipulators inside Bioshield at center of power core remove divertor inner tubes and shielding and cut outer divertor tube/support


Removable ECH Assembly/ Auxiliary Maintenance Port

• Removable ECH Module includes Waveguide, All Shielding, Bioshield, Mirror, and Exo-Bioshield Vacuum Vessel

• Entire module assembly can be withdrawn into Transfer Chamber

PermanentTransfer Chamber

Aux Manipulator removes blanket shielding blocks, shielding rings, and cuts coolant tubes while main port arm supports and removes blankets

ECH Module Moved Into Mobile Transporter for Transit to Hot Cell for Refurbishment


Preparation for Divertor Plate Removal

• This depicts the main port Extractor holding the Divertor Plates (24 pl) while the cutting bore tool on the central manipulator severs the outer coolant tube, which is the Divertor structural support

• The Diverter plates span two blanket modules but they fit through the main port opening



Availability AnalysisSummary of Maintenance Actions Maint Days, Total Maint Days/FPY Availability





Shielding Blocks

&Blanket Modules



Insp.


Shielding Blocks

&Blanket Modules

Divertor Plates

Chamber Inspection

Port Installation

Start-Up

TaskShutdown &

Prep for Maint.


Ports






Inspect, Clean &







Inspect Chamber

After Build-Up


Ports


Prep for Operation

Time (Hrs) 30.00 10.20 20.40 240.50 139.75 26.00 230.75 429.00 26.40 2.00 13.40 38.00


Assembly

Shielding Blocks

&Blanket Modules



Insp.


Shielding Blocks

&Blanket Modules

Chamber Inspection

ECH Installation

Start-Up

TaskShutdown &

Prep for Maint.

Remove Three ECH

Assemblies

Shielding Blocks & Cut Weld (65x 6 x 3 Sectors)






Shielding Blocks &

Welds (65x 6 x 3 Sectors)

Inspect Chamber

After Build-Up

Install Three ECH

Assemblies

Time (Hrs) 30.00 8.40 240.50 139.75 24.00 230.75 429.00 2.00 9.60 38.00


Divertor Plates


Insp.

Divertor Plates



TaskShutdown &

Prep for Maint.



Sectors)


Repair


(8 x 3 Sectors)


Twenty-four Coolant


Time (Hrs) 30.00 9.40 20.40 12.00 26.40 0.55 13.10 38.00

Total Time (Hrs)

Total Time (Hrs)



ARIES MAINTENANCE TASKS


Total Maintenance Time 1,206.40 Hrs. Inherent Availability 95.6%

Removal Tasks Replacement Tasks

maintenance and building conceptual approach

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