R. Rinaldesi, K. Kershaw – HE Group Target Area Overhead Crane: Updated Layout Fault Analysis Recommendations for Remote Handling (ITER) Method: individual interviews with group leaders based on the April schedule -> to gather bottom-up data, EN retreat on 1st July -> the aim was to bring the MTP in line with the last schedule & saving requests from the Council in June ENMB on 26th July -> validate with group leaders the top-down arbitration R. Rinaldesi, K. Kershaw – HE Group

Target Area Overhead Crane 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) Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Hook lateral approach: Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Hook lateral approach: Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Hook longitudinal approach: Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Overall height: Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Wheel loads: Target Area Overhead Crane Aug. 1st 2013

Target Area Overhead Crane Updated layout Festoon along one walkway: Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Hoist (lifting movements) Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Hoist (lifting movements) Fault Probability Effect Intervention Duration of intervention on crane * Preventive action Price increase 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 (gearbox 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) 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) Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Hoist (lifting movements) Fault Probability Effect Intervention Duration of intervention on crane * Preventive action Price increase Breakdown position Parking zone Service brake Low 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 (brake replacement) Load laying: 4 hours Brake replacement: 4 hours - Rope drum Very low (1 case in HE history due to assembly fault) Yes (rope drum repair) Rope drum replacement: 5 days Additional inspections: non-destructive tests Rope 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 Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults example of fully redundant hoist Courtesy of Meloni Tecno-Handling srl Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Cross and Long travel (horizontal movements) Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Cross and Long travel (horizontal movements) 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 Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Mechanical Faults Cross and Long travel (horizontal movements) Fault Probability Effect Intervention Duration of intervention on crane * Preventive action Price increase 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 - Yes 4 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 1 day Incoming fault can be identified during inspections (noise measurement) *: intervention time doesn’t include lead time to have spare parts available Target Area Overhead Crane Aug. 1st 2013

Fault Analysis Electrical 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) Target Area Overhead Crane Aug. 1st 2013

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 Target Area Overhead Crane Aug. 1st 2013

Recommendations for Remote Handling (ITER) ITER Monorail Crane (Neutral beam remote handling system) Target Area Overhead Crane Aug. 1st 2013

Recommendations for Remote Handling (ITER) ITER Monorail Crane (Neutral beam remote handling system) Twist-locks Target Area Overhead Crane Aug. 1st 2013

Recommendations for Remote Handling (ITER) ITER Monorail Crane (Neutral beam remote handling system) Target Area Overhead Crane Aug. 1st 2013