Existing technologies Evolving technologies

Transcription

1 Existing technologies Evolving technologies Jean-Guy Nokhamzon CEA/DEN/DADN CEA/DEN/DADN 2010 CEA/DEN/DTEC/SDTC/LTM 1

2 Existing technologies Characterization (measurements, sampling ) Decontamination (sand blasting.) Cutting tools (reciprocating saws..) Remote handling (manipulators, carriers,..) Robotics (specific devices ) Simulation Protective suits Utilized since late 50 s, improved on projects, tested as R&D.. New evolutions due to cost and delays 2

3 Evolving technologies 3 Developing improved technologies for dismantling and demolition Continued research on technologies should be encouraged Formerly abandoned techniques should be re-examined and evaluated for applicability in a changing technological and economic environment

4 Safer, easier, smarter Evolving technologies Techniques should be: potential exposure of workers to radiation, dust emission and spread of contamination, fire hazards, easy, noise,. Quicker Cost effective (maintenance, operation, waste production) Years of experience have yield methods and lessons learned to improve performance Appropriate technology for specific applications 4

5 Research and development for decommissioning 5 3D Modelling and Simulation. Methods and Technical Developments. Appraisal & help to dismantling Site Radiological characterization Shear Laser Remote handling and cutting tools Decontamination Testing platform

6 6 Research and development for decommissioning Decontamination Liquid Decontamination New trends in Chemistry and reaction (co-précipitation, New Trends in Chemical engineering for enahnced processes Solid Decontamination Foam processes for complex volumes / shapes Gel processes for economical treatment Electrodecontamination for concrete decontamination: The Near future

7 Research and development for decommissioning 7 Numerous industrial s needs for: -Treatments of liquid effluents and solutions to decrease the chemical and radiological environmental impact The mission: propose and develop specific D processes - Dismantling and decommissioning of glove boxes and blinded cells (AREVA NC, CEA) - huge volumes and complex forms: storage tanks for fission products (CEA - AREVA NC), vapour generators (EDF - PN) - Concretes in nuclear power plants or nuclear installations (EDF, BOUYGUES TP) - Bacteriological decontamination meanings (NRBC ) - Industrial cleaning out of nuclear Phenomenological and knowledge of the processes Research R &

8 8 I liquid effluents decontamination Nowadays context : Reduce as low as possible chemical and radiological impact coming from industrial and nuclear installation objective «zero or clean reject» Abort «bitumen waste» cementation Consequences : Improvement of processes efficiency : In actual effluent treatment plants For future facilities: STE 2013 (UP1 Marcoule), STE 2015 (UP2 400 La Hague) For specific effluent coming from La Hague pond storages or decontamination workshops Integrated view for the processes Actions : Assessment and analysis of actual chemical treatment. enhancement ways proposal by simple chemical adjustment R&D on the innovative processes for effluent treatment : Microfiltration Mineral exchange Co precipitation

9 9 II decontamination of huge volume / complex form by foam processes Vapor generator cleaning (submarine, aircraft-carrier, nuclear plant) To formulate «cleaver» complex fluids (foams) that do not damage the surface of the materials (soft homogeneous corrosion or dissolution) and transfer rapidly the radiocontaminants into the complex fluid phase Products : acid phosphoric foam acid oxalic foam surfactants Foam penetration into a bundle Processes : Foam making devices Foam introduction devices decontamination/cleaning monitoring.

10 Problematic: III Gels for nuclear decontamination Extract the surfacic contamination: ground, walls, ceiling with: - reducing the exposition time for the operators - to avoid liquid effluents - producing a minimum amount of waste (mineral form), - waste compatible with standard treatment processes 1. Gel application onto the surface : by painting, by spraying 1 2. Drying and pellets formation 3. Brushing and/or vacuum cleaning to recover dry pellets including contamination 2 Type of materials : ASPIGEL FEVDI - stainless steel - iron - Aluminium - lead - concrete 3 10

11 11 Surface decontamination a real case: ISAI cells in CEA-Marcoule using ASPIGEL 100 Pulverization of a ASPIGEL 100 thin film (500 µm) Recovering of the dried pellets by brushing or vacuum cleaning

12 12 IV Concrete decontamination Industrial context : nuclear power plants decommissioning and dismantling Problematic : 2 types of contamination on the surface (~ mm) «Deep» contamination (~ cm) Specific gel formulation for concrete Improvement of an electrokinetic process with an electrolytic gel Validation on real case : Storage ponds P1 et P2 (Cadarache) STEL 146 (COGEMA Marcoule) Handford (USA) FRDD of β, γ between 2 et 2,8 FRDD of α between 2,5 et 3,8 Industrial partnership : (Bouygues TP)

13 13 Research and development for decommissioning Remote handling: MAESTRO System Hot cell 414 at APM Integration on a Brokk 90 Test of global performance cutting High thickness laser cutting

14 14 Context The need of CEA dismantling operations for the next twenty years: Insure the civil and defence clean up program (planning and financial: final cost operation) Need industrial system with: Increasing reliability Increasing productivity Improved from nuclear safety Two mains configurations of facilities at CEA Reprocessing facilities: Building 18, APM, UP1,AVM Specifications: Great cells with high density of various components (thickness 3 to 15 mm), contaminations and middle level radiations Fast reactor: Rapsodie, Phenix: main operations under water Specifications: huge, heavy components with high or multiple thickness up to 100 mm, in air or under water and high radiations level

15 15 System MAESTRO: dismantling projects under studies APM Rapsodie UP1. AVM Pétrus Bâtiment 18 Phénix

16 16 Feedback experience in remote handling Uranium storage with SAMM Arm» Hydraulic arm with position controller and joysticks ( articular mode)» Disposal < 60%» Productivity depend on the human factor» Dexterity limited in complex cell Trolley/cart Rail Cameras Tools rack Hoist/grab Telescopic shaft Arm tools Evaluation of Predator in cold area» Master / slave system» Force feedback for safety (ratio of 1/100, not enough for drive process)» Low dexterity» Open structure with linear and rotary actuators

17 Teleoperation with force feedback Teleoperation : «Maestro system» project - Industrial product - Good reliability and easy maintenance (modularity) - High capacity (around 60 dan at 2.5 m) - Dexterity (6 degrees of freedom, concurrent wrist) - no continued wrist rotation - Master Slave system with force feedback - Can be easily decontaminated and is hardened from radiation 10 kgy - Tool changer with electrical pins (no external wire) - Simple electrical wire Different tools has been tested in conditions Alternative saw Plasma torch Nibbler (up to 9 mm thin, 1m/min) Shears (up diam 55mm, 4mm thin) Rotary disk (abrasive and diamond) Laser previously in test 17

18 18 Teleoperation with force feedback Système Maestro Supervisor screen Supervisor With master arm Virtuose Camera and light on pan and tilt Hydraulic unit Slave arm MAESTRO Embedded controler

19 19 Système MAESTRO: performance of the system Slave arm: capacity 60kg at 2m30 Electromechanical changer tool waterproof, MTBF 1000 hours Force sensitivity 10kg shoulders axes, 2kg wrist unidirectional accuracy 1mm Hydraulic power unit: 150 / 210 bars, 45 litters Fire resistant fluid HFDU Temperature regulation 55 C with 40 C in cell Hardened embedded controller Hardening radiation 10 kgray 40 C ambient, waterproof umbilical 60 m, Jupiter size V multiplexer: arm, hydraulic power unit, 2 axes with lights and video cameras Graphical controller: appraisal operator Graphical model Automatic or half-automatic programming Appraisal modes: gravity compensation, clamping DOF diagnostic Force feedback master arm 6DOF + effector: Virtuose 6D 40-40: force ratio to 1/15

20 MAESTRO: Already used in industrial applications Off-shore robotics Dismantling of NPP Post-accidental Intervention Maintenance of ITER Repair of NPP Dismantling of nuclear facilities 20

21 21 Teleoperation with force feedback Teleoperation : «Maestro system» project The test field in cell 414 of APM began, The complete system for dismantling operations will be received in 2011 Size of the cell : 20m long x 5m large x 6m high With chemical process APM 414 Cell Dismantling system New carrier with 3 axes and a crane for waste removal embedded controller and hydraulic unit Maestro System Rack for 5 Tools Reduce electrical umbilical with water for cooling (low pressure)

22 22 Teleoperation with force feedback Program of Testing platform (already done ) Test of productivity in dismantling operations Define the ratio of kg/day of dismantling operations (waste in drums) Comparison with other system (without force feedback) Feed back experience of SAMM arm at UP1 (15 kg/day) Test of productivity on Building 18 of FAR mock-up Configured on a crane (head to down) Adaptation of the system to work on reverse position Test of cutting performance and accessibility Configured on a BROKK 90 Adaptation of engine for the arm (hydraulic unit) Cooling system by water to reduce dust contamination Test of cutting performance and accessibility

23 System MAESTRO: productivity test Conditions: Remote handling with indirect cameras 1 operator Grinding disk on tool changer 60 l drum for waste (material piece of 20 x20cm) Results: Start system take on grinding disk Availability 80% Productivity > 64 kg/job (5 hours) Ratio filling drum of 0.5kg/l 2% 1% 3% 3% 5% 1% 1% 4% 2% 2% 9% 10% take off grinding disk change disk positionning tool cutting tool take on gripper take off gripper handling waste to drum handling drum manual drive camera others tasks half time operator 57% break system / alarm / rescue mode Repartition tasks with MAESTRO put to park position and stop hydraulic unit 23

24 System MAESTRO: productivity test Lessons learned With force feedback, 1 operator 60% for cutting time (reduce force on the tool, no umbilical management) 10% for positioning tool (simplify by Master arm) 10% for changing disk ( reducing break disk, sensitivity force feedback and dexterity) 3% for filling drum (simplify by Master arm) 5% for positionning camera (simplify by following gripper function) Next step Test with different tools (cutting tool time) Influence of controller s mode (joystick ) Influence of the primary waste s size 24

25 25 Adaptation on a Brokk 90 for gallery of building 18 Engine adaptation Modification of the pump (3rd) and regulation of hydraulic unit to ensure the power for the arm and reduce the thermal loose (for remote handling we don t need speed, only the power) [Adaptation depending of the size of the Brokk] Removal of the basis arm and the front legs (possibility of feedback) Fire resistant fluid HFDU: Quaker chemical Quintolubric Input and output filtration 3microns Heat exchanger for water secondary refresh loop ( avoid contamination point due to the ventilation) Under integration» Umbilical of Maestro system for power and control of the engine» Regulation for two pressure (150 bars and 210 bars) to adapt the power of the arm depending of the use (join reliability and thermal looses)

26 26 Adaptation on a Brokk 90 for gallery of building 18 Adaptation of the arm for a short version: 1.96m 100 kg payload

27 27 Research and development for decommissioning Table of contents Remote handling MAESTRO System Hot cell 414 at APM Integration on a Brokk 90 Test of global performance cutting High thickness laser cutting

28 High thickness laser cutting for decommissioning Laser cutting process Advantages Less burned metal and aerosols than plasma torch (8 time) Reducing contamination on the operated cell Less communication through ventilation Positioning of the cutting head (orientation +/-15, distance 0 to 50 mm) Easier for remote handling Non homogeneous cutting components Reducing number of cutting task Source could be far away (100 m to 200m) from nuclear controlled zone Electric isolation of the cutting head, no electromagnetic field No need to have electric ground on components Drawback Cost of the generator (around 800 k for 8-12 kw) Driving of the beam to reduce the environment impact and to have the nuclear safety acceptance 28

29 High thickness laser cutting for decommissioning Plate of 12 mm after a window YAG First test Laser cutting Laser YAG continu Power 4 kw, Azote or compressed air : 4 bars Tests on representative components: Distance nozzle-component from 0 to 50 mm Head tilting +/- 15 from normal Cutting speed 30 to 210 mm/min Cutting deep 60 mm to 3 mm / min Test for CEA/UP1 dismantling project Laser head held by SAMM arm on a BROKK 150 Drive on articulated mode 29

30 30 High thickness laser cutting for decommissioning Configuration on dismantling facility Disk Laser Power with pumped diode 8kW high efficiency up 25% Good beam quality Nominal power consumption 32 kw up to 6 output Facility Fibre 400 microns 100 m long Fibre 600 microns 20 to 60 m long Water cooling unit Air pressure Coupler Hot cell Head cutting

31 31 High thickness laser cutting for decommissioning Cutting Thickness 100 mm steel (8 kw) New industrial head (CEA patent) up to 14 kw cooling by air

32 High thickness laser cutting for decommissioning Development result: new industrial head cutting (tested with a laser YAG 8kW) Maximum power working 14 kw Front cutting in air up 100mm (at 8 kw) Air cooler for the head and the fiber connector Testing under 25 hours without failure Distance from laser source to the head more than 100 m Main performance on Steel S235 : 20 mm at 400 mm/min and 80 mm at 20 mm/min Cutting 80 mm steel 50 series test: 12 m of steel 20 mm thickness cut in 30 minutes 32

33 High thickness laser cutting for decommissioning Tube double skin: speed 30 mm/min Tube diameter 150 mm thickness 8 mm 33

34 Laser cutting characteristics Drilling time - Nozzle diameter of 6 mm - Gas outflow of 400 l/min Time (s) Th 5 mm Th 10 mm Th 20mm Th 30 mm Th 40 mm Drilling time versus laser power (orthogonal position) Laser Power (kw) : V<Vl 2: Vl 3: V>Vl Performance cutting 34

35 35 High thickness laser cutting for decommissioning Laser cutting (test for UP1 operation) Cutting plate Uranus 65 double plate (12,8mm + 3,5 mm)»nozzle diameter»flow air 3mm 120 l/min (4 bars)» Dust between 0,1 and 1 micron m» main scories ties/attached to the plate Front face Back face

36 36 High thickness laser cutting for decommisioning Test facility with IRSN a whole system

37 37 High thickness laser cutting for decommisioning Test on steel plate 10 mm thick

38 38 Thanks for your attention Any question? Teleoperation Cutting tool

39 39 Research and development for decommissioning 3D modeling and simulation developments for decommissioning operations

40 40 Description of «3D modeling and simulation» activity Technical assistance to dismantling projects : 3D modeling of facilities and mechanical means involved 3D simulation : represent intervention operations Development and industrialization of a software of intervention scenarios simulation (NARVEOS) : specification, development, integration, industrial transfer add innovation in dismantling projects Teaching, training, safety assessments, project management, contracting bodies, safety authorities, engineering companies, radioprotection unit, engineering schools Facility representation (3D models, measures) Virtual visit NARVEOS Scenarios NARVEOS Interactive dosimetry Operators, robots Kinematics simulation

41 41 3D modeling Context : during the study stage of a dismantling project, intervention scenario is defined scenario describes intervention means used for dismantling studies are realized from facility drawings History : Up to 1980 : 2D drawings handmade Drawbacks : Difficulty to read and understand drawings. Drawings must be redone for every modification. From 1980 : 2D drawings made with CAD software Drawbacks : Difficulty to read and understand drawings Software used by qualified professionals Advantages : Possibility to modify and update previous drawing. Work in scale 1:1 From 1990 : 3D models made with 3D CAD software Drawbacks : Software used by qualified professionals Advantages: Ease to read and understand (perspective points of view ). One model given to every subcontractor and shared by all project actors synthesis of all building trades on a same document

42 42 3D modeling model construction 1 st method : Use of drawings Not always existing for old installations (more than 50 years) Not always up-to-date Often completed with photos or videos Precision : +/- 30 cm Difficulties: E Obtain reliable documentation (as built) Enable to go and take dimensions (radiological risk) As built????

43 43 3D modeling Model construction 2nd method : videogrammetry: The basic principle of videogrammetry is the one used in photogrammetry systems, except that videogrammetry systems use video or digital cameras instead of photo cameras and that all the processing which is needed to obtain object coordinates from the images is performed in real time, without contact and with a high level of accuracy. Cell 414 Building 214 of the APM (Marcoule pilot processing plant) 2 overall views

44 44 3D modeling Model construction 2nd method : videogrammetry 1 point of view + drawings (PYRAMIDE) Building 18 PETRUS high liquid activity tanks 1 point of view (AOMS)

45 45 3D modeling Model construction 2nd method : videogrammetry : AOMS (As built On line Modeling System) Used in APM, AVM and UP1 facilities in Marcoule Industrialized by ESIC SN, et co-developed by CEA and AREVA Only one camera 1 point of view Identification and calibration before inspection 3 points of view by object with particular points System compatible with micro station and 3D Studio Max Semi-automatic reconstruction (ESIC supply) UP1 - evaporators

46 46 3D modeling Model construction 2nd method : videogrammetry : AOMS Specific points détection

47 47 3D modeling Model construction 2nd method : videogrammetry : AOMS Specific shapes detection Update other views

48 48 3D modeling Model construction 2nd method : videogrammetry : AOMS Update other views Model generation

49 49 3D modeling Model construction 2nd method : videogrammetry : AOMS

50 3D modeling Model construction 3rd method: Laser range finder 1 or several points of view according to facilities Laser measurement based on triangulation Speed and precise according to calibration (100 points/s) Creation of points clouds Result directly compatible with 3DStudio max Points cloud Laser scanner SOISIC (MENSI) Laser scanner CALLIDUS CO2 Exchangers - EL4 50

51 3D modeling Whatever the methods : use of drawings videogrammetry laser range 3D modeling is an investment in time and money: collecting the drawings, cross-checking with pictures, videos, interviews of operators, new measurements 51

52 52 3D modeling example Example of presentation by model animation : Presentation of STEL project - Marcoule

53 Simulation in decommissioning Simulations are used to illustrate the proposed scenarios, with 3D views or animated films, for : internal and external communication, technical reviews, presentation to Safety Authorities and its technical support, Simulations can also be used to study the organization of the work: phasing of operations, workers circulation, ALARA principle application, waste stream, 200 pages = 10 minutes of simulation 53

54 54 Simulation in decommissioning Example : dismantling scenario of SILOE reactor (Grenoble)

55 Simulation in decommissioning Advantages: + increase installation knowledge + complete existing documentation + better representation and visualization of installation and means evolved + saving of time Drawbacks: - use of complicated CAD software, reserved for specialists - no interactivity Expand 3D models with information : kinematics chain radiological description path planning anti-collision interactivity Development of an interactive interventions simulation software : NARVEOS 55

56 3D Simulation NARVEOS Developed by CEA Industrialized by EURIWARE (AREVA subsidiary company) Objective : to prepare interventions missions under radiological environment constraints by simulation (conception, maintenance, dismantling) End users: Management project team Experts in radioprotection, nuclear measurements, characterization, robotics, waste management Safety and risk assessment Education institutes (INSTN, ) 2 levels of product: Field mode easy to use, possibility to replay a scenario, slight modifications, no record Engineering mode possibility to modify (and record) anything in the scenario Beginning of marketing : summer 2008 Facility representation (3D models, measures) Virtual visit Scenarios NARVEOS Interactive dosimetry Operators, robots Kinematics simulation 56

57 57 3D simulation NARVEOS Main functions : 3D models import (3DXML format) Geometric conception module (analytic shape and CSG) Radiological description (sources, screens, measure points) Interactive dose rate computation based on straight line attenuation and build-ups Virtual visit in the digital mockup Scenarios creation Dismantling simulation object by object Interactivity with animated objects (doors, tools ) Creation of communication supports (pictures, movies, videos) Robots library Robot control in articulated and Cartesian modes September 2008 Collision detection Quickly test operations feasibility Optimize scenarios Evaluate dose rate according to ALARA principle Help to decide to optimize costs and delays exchange of information between the different involved actors.

58 Simulation 3D NARVEOS Pilot fields : SILOE Study if dose rate evolution with respect to the water height within the reactor vessel Robotic scenario simulation Verification of the feasibility of a human intervention to dismantle internal structure Evaluation of hot spots AVM Evaluation of final state of the installation after rinsing UP2-400 Evaluation of different scenarios in a closed cell Check/validation of the feasibility of maintenance scenario on a distribution valve demonstration 58

59 Simulation in decommissioning Conclusion : New applications of 3D simulation : navigation, or even immersion inside 3D models of facilities to dismantle, dose uptake simulation, user-friendly access to data base of facilities and operations. Simulation is still an investment in time and money at the beginning of a decommissioning project, but: it can be exploited during the whole project life, it reduces costs later by optimizing the operations and anticipating problems. 59

60 60 Thank you for your intention Any question???