1. 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

2. Target Area Overhead Crane
Updated layout
Main characteristics:
Capacity: 40 ton
Span: increased from mm to 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

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

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

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

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

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

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

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

10. 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)
~ € (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)
~ € (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

11. 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

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

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

14. 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

15. 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)
~ € (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

16. 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

17. 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

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

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

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