ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 1 Maintenance and Building Conceptual Approach L. Waganer and R. Peipert The Boeing Company 4 October 2006 PPPL Project Meeting

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 2 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.

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 3 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 movieTool Changer movie How To Forecast Maintenance Technologies Years in Future? Consider physical laws as limiting values

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

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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 6 Removable ECH Assembly at 35º Port ECH Waveguide, 0.54 m H x 0.24 m W Opening in VV and Coil Structure, 1.54m H x 1.24 m W Opening through Bioshield, 1.6 m H x 1.6 m W Note: Removable ECH Module includes Waveguide, All Shielding, Bioshield, Mirror, and Exo-Bioshield Vacuum Vessel Permanent Transfer Chamber

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 7 Extraction of ECH Assembly Into Transfer Chamber Maintenance machine removes waveguide segment and coolant coupling Complete assembly removed into Transfer Chamber by pallet system

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 8 ECH Module Moved Into Mobile Transporter for Transit to Hot Cell for Refurbishment

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 9 ECH/Aux Port Maintenance Actions Removes blanket shielding blocks, shielding rings, and cuts coolant tubes while main port arm supports and removes blankets

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 10 View of Main Port (0º), Operational

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 11 Initial Position of Extractor Machine This is the position of Extractor after plasma shutdown and cool-down

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 12 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 13 Removal of Port Manifold/Structure The manifold/hot structure connections are disconnected and the structure is removed and set aside

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 14 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 15 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 16 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 17 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 18 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 19 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 20 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 21 Maintenance and Availability Analysis

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 22 Alternative to Cutting and Welding Blanket 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 23 Maintenance and Availability Analysis

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 24 Maintenance Slides for Engineering Summary

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 25 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.

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 26 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 27 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 Permanent Transfer 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 28 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

ARIES Review, PPPL L. M. Waganer, 4-5 Oct 2006 Page 29 Maintenance and Availability Analysis