DO E/ NE-0065

Dist. Category UC-79

. - ---

DOE/NE--0065
DE86 011376

Robotics and Nuclear Power

Report by the Technology Transfer
Robotics Task Team
June 1985
 DISCLAIMER

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately
owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein
do not necessarily state or reflect those of the United States
Government or any agency thereof.
 DISCLAIMER

Portions of this document may be illegible in

electronic image products. Images are produced
from the best available original document.
 ROBOTICS AND NUCLEAR POWER
T a b l e o f Contents
Page No .
I . EXECUTIVE SUMMARY ....................................... 5
F,
.A Summary ............................................. d

.B NeedeaActivities .................................... 8

11. TASK TEAM CHARTERAND MEMBERSHIP ........................ 12

A . C h a r t e r ..............................................

+
12
B . Membershi ........................................... 12
I11. TECHNOLOG EVALUATION ................................... 14
A . T e c h n i c a l Approach ................................... 14
B . C o n s t r u c t i o n ......................................... 15
'1. Elements o f C u r r e n t P r a c t i c e ..................... 16
2 . I n s p e c t i o n and Q u a l i t y Assurance ................. 17
3 . E x i s t i n g and Planned Systems ..................... 18
4 . Non-routine C o n s t r u c t i o n P r a c t i c e ................ 19
5 . P l a n t M o d i f i c a t i o n s .............................. 20
6 . Technology Needs ................................. 21
C . Reactor P l a n t Operations ............................. 22
1. Elements o f C u r r e n t P r a c t i c e ..................... 23
2 . I n s p e c t i o n and Q u a l i t y Assurance ................. 24
3 . E x i s t i n g and Planned Systems ..................... 25
4 . Non-routine Operations ........................... 25
5 . P l a n t M o d i f i c a t i o n s .............................. 26
6 . Technology Needs ................................. 26
D . Reactor P l a n t Maintenance ............................ 27
1. Elements o f C u r r e n t P r a c t i c e ..................... 27
2 . I n s p e c t i o n and Q u a l it y Assurance ................. 3 1
3 . E x i s t i n g and Planned Systems ..................... 31
4 . Non-routine Operations ........................... 33
5 . P l a n t M o d i f i c a t i o n s .............................. 34
6 . Technoloqy Needs ................................. 34
E . Fuel F a b r i c a t i o n and Maintenance ..................... 36
'1. Elements o f C u r r e n t P r a c t i c e ..................... 36
2 . E x i s t i n g and Planned Systems ..................... 36
3 . Non-rout ine Operations ........................... 37
4 . P l a n t M o d i f i c a t i o n s .............................. 38
5 . Technology Needs ................................. 38
F . Reprocessing Operations and Maintenance .............. 38
1 . Elements o f C u r r e n t P r a c t i c e ..................... 38
2 . E x i s t i n g and Planned Systems ..................... 39
3 . Non-routine Operations ........................... 39
4 . P l a n t M o d i f i c a t i o n s .............................. 39
5 . Technology Needs ................................. 40
G . Waste H a n d l i n ....................................... 40
d fC u r r e n t P r a c t i c e .....................
2 . Candidate R o b o t i c A p p l i c a t i o n s ................... 4 1
40

3 . E x i s t i n g and Planned Systems ..................... 45

4 . P l a n t M o d i f i c a t i o n s .............................. 47
 \
2

Page No .
H . Decommissionin ...................................... 47
I-TEGK~ .....................
Current P r a c t i c e 47
2 .. .................
I n s p e c t i o n and Q u a l i t y Assurance 48
3 E x i s t i n g and Planned Systems ..................... 48
4 .. Non-rout1 ne Operations ........................... 49
5
6 . Plant Modifications
Technology Needs
..............................
.................................
49
49

I . Economic Impact ...................................... 50

. .
J Safety and L i c e n s i n g Impact
'1 Safety C o n s i d e r a t i o n s
..........................
............................
51
52
2 . L i c e n s i n g C o n s i d e r a t i o n s ......................... 52

K . Technology Needs ..................................... 52

I V . DEVELOPMENTS UNDERWAY AND CONTACTS ...................... 54

References .............................................. 77

Appendices .............................................. 79
 *
:‘e .i

T ’ F
3
.--

Robotics and Nuclear Power

L i s t o f Tables

Page No.
R o b o t i c s Technology Needs 11

R o b o t i c s Technology Needs 53

P a r t i a1 Summary of R o b o t i c s Development Program and Contacts 55

 5

SUMMARY AND NEEDED ACTIVITIES

A. Summary

A t a s k team was formed a t t h e r e q u e s t o f t h e Department o f Energy t o e v a l u a t e

and assess t e c h n o l o g y development needed f o r advanced r o b o t i c s i n t h e n u c l e a r
industry. The m i s s i o n o f t h e s e t e c h n o l o g i e s i s t o p r o v i d e t h e n u c l e a r
i n d u s t r y w i t h t h e support f o r t h e a p p l i c a t i o n o f advanced r o b o t i c s t o reduce
n u c l e a r power g e n e r a t i n g c o s t s and enhance t h e s a f e t y o f t h e personnel i n t h e
industry.

The i n v e s t i g a t i o n i n c l u d e d r o b o t i c and t e l e o p e r a t e d systems. A r o b o t i c system

i s d e f i n e d as a reprogrammable, m u l t i f u n c t i o n a l m a n i p u l a t o r designed t o move
m a t e r i a l s , p a r t s , t o o l s , o r s p e c i a l i z e d devices t h r o u g h v a r i a b l e programmed
motions f o r t h e performance o f a v a r i e t y o f t a s k s . A t e l e o p e r a t e d system
i n c l u d e s an o p e r a t o r who r e m o t e l y c o n t r o l s t h e system by d i r e c t v i e w i n g o r
t h r o u g h a v i s i o n system.

Major economic b e n e f i t s w i l l be achieved t h r o u g h t h e use o f advanced r o b o t i c

systems i n maintenance o f t h e c u r r e n t g e n e r a t i o n of power r e a c t o r s r e s u l t i n g
from:

0 Reduction i n man-rem exposure ( e s t i m a t e d t o c o s t f r o m $1,000 t o

$10,000 per man-rem)
0 Reduction i n p l a n t downtime ( e s t i m a t e d t o be $500,000 t o $1,000,000
per day f o r a 1000 MWe p l a n t )

Based on a 90% r e d u c t i o n i n personnel exposure, a f a c t o r o f two r e d u c t i o n i n

p l a n t downtime, and 120 o p e r a t i n g p l a n t s b y 1995, t h e e s t i m a t e d t o t a l n a t i o n a l
annua savings w i l l range f r o m $2.88 t o $S.OB.

S i g n i i c a n t c o s t savings and r e d u c t i o n of personnel expsoure i n

decommissioning n u c l e a r f a c i l i t i e s can be achieved t h r o u g h t h e use of
robotics. E s t i m a t e d a c t u a l c o s t s have n o t been e s t i m a t e d f o r decommissioning
a c t i v i t i e s s i n c e t h e r e i s no d a t a base f o r ' t h e decommissioning o f l a r g e
n u c l e a r power p l a n t s .
 6

Safety and L i c e n s ng i s enhanced by t h e app i c a t i o n o f r o b o t i c s n the nuclear

industry. T h i s b e n e f i t i s achieved p r i m a r i l y b y r e d u c t i o n o f man-rem
exposure, hazardous m a t e r i a l c o n t r o l , i n - s e r v i c e i n s p e c t i o n s and automated
data a c q u i s i t i o n .

The t e c h n i c a l approach used b y t h e Task Team i n t h i s s t u d y i n c l u d e d t h e

e v a l u a t i o n o f t h e major s e c t o r s o f t h e n u c l e a r i n d u s t r y : construction,
r e a c t o r o p e r a t i o n s , r e a c t o r maintenance, f u e l f a b r i c a t i o n , f u e l r e p r o c e s s i n g ,
waste management, and decommissioning. For each of these, t h e f o l l o w i n g
i n f o r m a t i o n and d a t a were o b t a i n e d by personal knowledge, r e v i e w o f p u b l i c a -
t i o n s , and d i s c u s s i o n s w i t h c o g n i z a n t personnel:

0 I d e n t i f i c a t i o n of elements of c u r r e n t p r a c t ce w i t h p o t e n t i a l f o r
robotic applications

0 I d e n t i f i c a t i o n o f i n s p e c t i o n and q u a l i t y assurance a c t i v i t i e s t h a t can

be improved w i t h r o b o t i c t e c h n o l o g y

0 I d e n t i f i c a t i o n o f e x i s t i n g and planned r o b o t i c systems and development

programs t o accompl i s h these f u n c t i o n s

0 I d e n t i f i c a t i o n o f non-routine a p p l i c a t i o n s

0 Recommendations f o r p l a n t des gn changes t o accommodate r o b o t i c

systems

0 Recommendations f o r deve7opment o f advanced t e c h n o l o g i e s necessary t o

implement advanced r o b o t i c a p p l i c a t i o n s

U n i v e r s i t i e s w i t h s t r o n g r o b o t i c s programs and s t a f s i d e n t i f i e d b y t h e t a s k
team are:

o Carnegie-Mellon U n i v e r s i t y - Robot cs I n s t t u t e c o n s i s t s of a s t a f f o f
more t h a n 200 a f f i l i a t e d f a c u l t y , r e s e a r c h s c i e n t i s t s , engineers,
programmers, and graduate students.
't '*- 7
:

0 University o f Florida - Center for Intelligent Machines and Robotics

is active in robotic kinematics, control, computer graphics, and
human/machine interfaces.

0 Stanford University - Institute for Manufacturing and Automation is an

interdisciplinary organization with about 25 sponsors, including
industry and government agencies.

0 Massachusetts Institute of Technology - Many diverse robotics

programs underway in several departments. Effort is not centralized.

0 University of Texas - Center for Robotics, Manufacturing and Logistics

was established in 1985 and is developing basic science for
intelligent machines in manufacturing and military logistics.

Significant programs in robotics are in progress or planned by other

agencies. The National Aeronautics and Space Administration is planning a 10
year program for the development of robotics for space applications with
proposed funding of $100M to $ZOOM per year. The Department of Defense has
many individual robotic programs either in place or planned for automated
battlefield systems, manufacturing, and hazardous materials handling. The
Department of Energy has established programs on robotics at several national
laboratories. EPRI is also sponsoring development of robotics for reactor
operations and maintenance.

Japan has a national robotics program for all industries, including nuclear.
This program i s funded at $150M over an eight year period. The objective for
the nuclear industry is to provide a high performance robot with the
capability to use a variety o f instruments and tools in reactor maintenance.

The major near term economic benefit to the nuclear industry results from the
application of robotics to the operation and maintenance of power plants.
The mission of the development program is to support industry in the
development of an untethered, autonomous decision-making robotic system with
flexible manipulator capability for nuclear plant operation and maintenance.
 a

, E

The technology needs r e q u i r e d t o p r o v i d e t h e advanced r o b o t i c s f o r t h i s

a p p l i c a t i o n a r e summarized i n t h e f o l l o w i n g T a b l e A-1. These needs a r e ranked
i n t h r e e categories:

o Category 1: Unique t o t h e n u c l e a r i n d u s t r y ( t h e Department o f Energy

-
must l e a d these programs).
o Category 2: Common t o o t h e r a p p l i c a t i o n s , b u t c r i t i c a l f o r t h e use
n u c l e a r f a c i l i t i e s ( t h e Department o f Energy must a p p l y leverage t o
o t h e r programs 1.
o Category 3: Common t o o t h e r a p p l i c a t i o n s , b u t n o t c r i t i c a l f o r use
t h e n u c l e a r f a c l i t i e s ( t h e Department of Energy can e x p l o i t o t h e r
programs).

These t e c h n o l o g i e s w i l a l s o be a p p l i c a b l e t o r o b o t i c systems i n o t h e r major

s e c t o r s o f t h e n u c l e a r i n d u s t r y and f u t u r e n u c l e a r power p l a n t s .

S p e c i f i c needs a r e ranked i n p r i o r i t y f r o m l e f t t o r i g h t i n t h i s t a b l e . The

technology needs w i t h t h e h i g h e s t p r i o r i t y are:

o Robots w i t h v e r t i c a l access ( t o p r o v i d e m o b i l i t y and r e a c h r e q u i r e d f o r

maintenance i n t h e c u r r e n t p l a n t s ) .
o Sensors f o r s p a t i a l l o c a t i o n and o b j e c t r e c o g n i t i o n .

o Domain s p e c i f i c i n t e l l i g e n c e f o r on-board d e c i s i o n making.

o Operator/machine i n t e r f a c e

I n a d d i t i o n , a l l components f o r n u c l e a r appl i c a t i o n r e q u i r e environmental

hardening ( r a d i a t i o n , temperature, and h u m i d i t y ) and t h e c a p a b i l i t y f o r
decontamination.

B. Needed A c t i v i t i e s

A team c o n s i s t i n g of u n i v e r s i t y , n a t i o n a l l a b o r a t o r y , and i n d u s t r y
p a r t i c i p a n t s should be e s t a b l i s h e d t o c a r r y o u t t h e necessary development o f
 7

t h e i d e n t i f i e d t e c h n o l o g i e s and t o i n t e r a c t w i t h o t h e r programs sponsored b o t h

b y c o t h e r agencies and DOE t o exchange d a t a f o r t h e leveraged programs. This
development team should be c e n t e r e d a t a s i n g l e f a c i l i t y , as c o n s i s t e n t w i t h
c o s t and c o n t r a c t u a l c o n s i d e r a t i o n s . C o l l a b o r a t i o n w i t h t h e Department of
Defense, t h e N a t i o n a l A e r o n a u t i c s and Space A d m i n i s t r a t i o n , and t h e N a t i o n a l
Bureau of Standards i s recommended because o f t h e advanced s t a t u s o f r o b o t i c s
and a r t i f i c i a l i n t e l l i g e n c e programs sponsored by these agencies and t h e l a r g e
investments t h a t t h e Government i s c o m m i t t i n g t o these programs. Collabora-
t i o n w i t h f o r e i g n programs i s n o t recommended s i n c e t h e f o r e i g n programs a r e
l e s s comprehensive compared t o o t h e r U.S. programs. I n a d d i t i o n , leakage o f
s e n s i t i v e d a t a f r o m Department of Defense and N a t i o n a l A e r o n a u t i c s and Space
A d m i n i s t r a t i o n sources can be minimized by avoidance o f f o r e i g n c o l l a b o r a t i v e
programs .
A nine-year development p l a n has been prepared t o p r o v i d e t e c h n o l o g y modules
I which can be s e l e c t i v e l y assembled t o p r o v i d e a wide range o f r o b o t i c systems
f o r nuclear applications. F i e l d t e s t i n g o f these technology modules can be
performed i n Government-owned f a c i l i t i e s , such as FFTF. FFTF f o r example i s
an i d e a l t e s t f a c i l i t y t o p r o v i d e t h e i n f o r m a t i o n r e q u i r e d by u t i l i t i e s t o
a l l o w them t o use advanced t e c h n o l o g y i n commercial n u c l e a r p l a n t s .

The t a s k s and o b j e c t i v e s o f t h i s p l a n are:

Task 1.0 F l u i d Flow D e t e c t i o n System Provides an i n t e g r a t e d

sensor/expert system t o determine
f l o w o f h o t f l u i d t h r o u g h compo-
nents.

Task 2.0 Mobi 1 i t y / A c c e s s Technology Provides a nuclear-grade p o r t a b l e

power s u p p l y f o r i n - c o n t a i n m e n t
o p e r a t i o n , v e r t i c a l access
c a p a b i l i t y , and a f l e x i b l e
man ipu 1a t o r ( I' s na ke I' ) .
 10

Task 3.0 Sensors Provides thermal imaging and,

v i s i o n sensors f o r - F l u i d Flow ,

D e t e c t i o n System; s p a t i a l
l o c a t i o n sensors f o r n a v i g a t i o n
and mapping.

Task 4.0 Domain S p e c i f i c I n t e l 1 igence P r o v i d e s e x p e r t systems and s o f t -

ware f o r n a v i g a t i o n , mapping, and
maintenance o p e r a t i o n s . Also,
w i l l provide demonstration o f
radiation-resistant, on-board
computer hardware.

Key milestones f o r t h i s a c t i v i t y , assuming an October 1, 1985 s t a r t i n g date,

are :

T e s t o f i n t e g r a t e d Thermal Imaging, A p r i l 1, 1986

V i s i o n , and E x p e r t System
Complete S i m u l a t i o n o f F l e x i b l e
Man ipu 1a t o r April 1, 1987
T e s t Improved I n t e g r a t e d Thermal J u l y 1, 1987
Imaging, V i s i o n , and E x p e r t System
Demonstrate Radi a t ion-Hardened, October 1, 1985
On-Board Computer System
T e s t Advanced J o i n t f o r F l e x i b l e A p r i l 1, 1989
Manipulator
Complete T e s t i n g and Re1 ia b i 1 it y October 1, 1993
Assessment o f a1 1 Technology
Modules
 R o b o t i c s T e c h n o l o g y Needs

On- board Reliability E nv ir o n - Mec h an - Payload

Decision Human Availability mental ical Control Smart
Category Priority Mobility Sensors Making Factors Maintainability Hardening Standards Systems Systems Tools
1 DOE must vertical spatial doma i n operator modularization radiation eq u ipmen t
lead access 1oca t ion, specific control & interface decontam-
object i n t e l li- c o n s o l e standards inability
recogni; gence inter-
t ion face

2 DOE obstruction force Expert mobile i n e r t atmos- Equipment higher mu1 t fnspec-
appl i e s avoidance feedback sys t ems p 1 a t f orm- phere & facility strength arm tion
1e v e r age tactile env ir on - standards t o weight b mu t
nlent t h r u ANSI ratio, axis
interface & other multi-
organiza- inter-
t ions s e c t ing
degrees
of
freedom

3 DOE can cableless vision, adaptive maintain temperature h i gher end cutting
exploit power & viewing & learning ability humidity, specific effect- welding
data 1 iqhting system c hem ic a 1 powor ors &
t. r an s - manua 15 motors grinding
mission

D e f i n i t i o n of C a t e q o r i o s

1. Unique t o n u c l e a r f a c i l i t i e s
7. Common t o o t h e r a p p l i c a t i n n s , b u t c r i t i c a l f o r uce i n n u r l p a r f a c i l i t i e s
3. Common t o o t h e r a p p l i c a t i o n s ; i m p o r t a n t b u t not. c r i t i c a l f o r U C P i r i n u c l e a r f a c i l i t i e s
 12

11. TASK TEAM ON ROBOTICS CHARTER AND MEMBERSHIP

A. Charter

The t a s k f o r c e w i l l s t u d y t h e f o l l o w i n g s e c t o r s o f t h e n u c l e a r i n d u s t r y :

-- Construction
-- Operations
-- Maintenance
-- Decommissioning

The t a s k team w i l l p e r f o r m t h e f o l l o w i n g f o r each o f t h e above s e c t o r s :

-- I d e n t i f y elements o f c u r r e n t p r a c t i c e w i t h p o t e n t i a l f o r r o b o t i c
applications

-- I d e n t i f y i n s p e c t i o n and qua i t y assurance a c t i v i t i e s t h a t can be improved

w i t h r o b o t i c technology

-- I d e n t f y e x i s t i n g and planned r o b o t c systems t o accomplish these

f u n c t ons

-- I d e n t i f y n o n - r o u t i n e aspects/problems

-- I d e n t i f y p l a n t design changes t o accommodate r o b o t i c systems

-- I d e n t i f y advanced t e c h n o l o g i e s necessary t o perm t r o b o t c a p p l i c a t i o n s

The economic advantages o f t h e recommended t e c h n o l o g es w i l l be assessed.

B. Membership o f Robotics Task Team

Name Address

Edward E. P u r v i s , I11 U. S. Department o f Energy

Manager O f f i c e o f Breeder Demonstration
Robotics Task Team Projects
Washington, D.C. 20545
 13
P

B . Membersh i p (Cont inued 1

Address
-
Name

M a r t y Cooper, Westinghouse Advanced Energy

Coordinator Systems D i v i s i o n
R o b o t i c s Task Team P.O. Box 158
Madison, PA 15663

F l o y d Gel haus E l e c t r i c Power Research I n s t i t u t e

3412 H i l l v i e w Avenue
P.O. Box 10412
P a l o A l t o , CA 94303

Ray Gutzmann Energy Systems Group

Rockwell I n t e r n a t i o n a l Corp.
8900 DeSoto Avenue
Canoga Park, CA 91304

Dave Nyman Hanford E n g i n e e r i n g Development

Laboratory
P.O. Box 1970
Richland, WA 99352

Frank P a t t i Burns and Roe

800 Kinderkamack Road
O r a d e l l , NJ 07649

Dwight Sangrey Dept. o f C i v i l E n g i n e e r i n g

Carnegie-Mellon U n i v e r s i t y
P i t t s b u r g h , PA 15213

Mar ion Thompson General E l e c t r i c Co.

310 DeGuigne D r i v e
Sunnyvale, CA 94086
I11. TECHNOLOGY EVALUATION

A. T e c h n i c a l Approach

Each o f t h e f o l l o w i n g major s e c t o r s o f t h e n u c l e a r i n d u s t r y were e v a l u a t e d :

o Construct i o n
o Reactor Operations
o Reactor Maintenance
o Fuel F a b r i c a t i o n
o Reprocess ing
o Waste Hand1ing
o Decommissioning

F o r t h e maintenance and o p e r a t i o n s sectors, n u c l e a r r e a c t o r s i n c l u d i n g

P r e s s u r i z e d Water Reactors (PWR) , Boi 1i n g Water Reactors (BWR), Gas-Cooled
Reactors ( G C R ) , and L i q u i d Metal Reactors (LMR) f u e l reprocessing/fabrication,
decommissioning, and waste management f a c i l i t i e s were considered. Fusion
power was n o t i n c l u d e d i n t h i s i n v e s t i g a t i o n because implementation o f t h i s
power t e c h n o l o g y i s beyond t h e ten-year t i m e frame f o r deployment o f t h e
advanced r o b o t i c s systems c o n s i d e r e d i n t h i s study.

F o r each s e c t o r , t h e f o l l o w i n g i n f o r m a t i o n and d a t a were o b t a i n e d by r e v i e w o f

p u b l i s h e d documents and d i s c u s s i o n s w i t h c o g n i z a n t personnel:

o I d e n t i f i c a t i o n of elements of c u r r e n t p r a c t i c e and p o t e n t i a l f o r
r o b o t i c app 1 ic a t ion s .
o I d e n t i f i c a t i o n o f i n s p e c t i o n and q u a l i t y assurance a c t i v i t i e s t h a t
can be improved w i t h r o b o t i c technology.

o I d e n t i f i c a t i o n of e x i s t i n g and planned r o b o t i c systems and

development programs t o accomplish these f u n c t i o n s .

o I d e n t i f i c a t i o n of non-routine applications.
 15

o I d e n t i f i c a t i o n o f p l a n t design changes t o accommodate r o b o t i c

systems.

o I d e n t i f i c a t i o n o f advanced t e c h n o l o g i e s necessary t o implement

advanced r o b o t i c a p p l i c a t i o n s .

The d a t a were t h e n assessed and e v a l u a t e d t o determine t h e t e c h n o l o g y r e q u i r e d

t o permit the applications. The needs were c a t e g o r i z e d as f o l l o w s :

o Un que needs f o r n u c l e a r appl i c a t i o n s .

o Ne ds common t o o t h e r r o b o t i c systems and c r i t i c a l t o n u c l e a r

appl ic a t ions .
o Needs common t o o t h e r r o b o t i c s , b u t n o t c r i t i c a l t o n u c l e a r
applications.

Development programs were i d e n t i f i e d t o s a t i s f y t h e s e needs.

B. Construction

The d i s c u s s i o n c o n t a i n e d i n t h i s s e c t i o n assumes t h a t f u t u r e n u c l e a r i n d u s t r y
f a c i l i t y c o n s t r u c t i o n w i l l be done i n t h e f i e l d u s i n g o p e r a t i o n s o f t h e same
n a t u r e as those performed i n t o d a y ' s c o n s t r u c t i o n p r o j e c t s . However, i t w i l l
be necessary f o r f u t u r e p l a n t designs t o be c o m p a t i b l e w i t h t h e use of
robotics. T h i s w i l l r e q u i r e placement o f components so t h e y can be reached,
m a n i p u l a t e d and worked on b y r o b o t s .

I t s h o u l d be noted t h a t another t a s k team i s s t u d y i n g m o d u l a r i z a t i o n . The

degree o f m o d u l a r i z a t i o n c o u l d range f r o m p r e f a b r i c a t i o n t o l a r g e assemblies.
The recommendations o f t h a t t a s k team a r e l i k e l y t o be i n t h e d i r e c t i o n of
s h i f t i n g many s i t e a c t i v i t i e s t o a shop. Such a change i n c o n s t r u c t i o n
p r a c t i c e s would n o t e l i m i n a t e t h e use o f r o b o t i c s , b u t would be l i k e l y t o
change t h e ways i n which r o b o t i c s i s a p p l i e d .
 >

$ * ¶

16
,
1. Elements o f C u r r e n t P r a c t i c e

a. Civil

Rock and e a r t h moving - A c t i v i t i e s i n t h i s group i n c l u d e e x c a v a t i o n o f

b o t h r o c k and e a r t h , t r e n c h i n g and f i l l i n g . Most o f these a c t i v i t i e s
r e q u i r e machinery t h a t can excavate, t r a n s p o r t excavated m a t e r i a l , and
p l a c e and compact such m a t e r i a . Ifr o c k i s t o o h a r d t o be c u t by t h e
excavat ing equipment , d r i 11 ing and b l a s t i n g i s a l s o r e q u i r e d .

Steel erection - Major a c t i v i t es i n c l u d e p o s i t i o n i n g of s t e e l members

and c o n n e c t i n g them. Most connections a r e b o l t e d . However, some
connections are welded.

Concreting - Major a c t i v i t i e s i n t h i s group are forming, placement of

r e b a r , a c t u a l placement o f concrete, f i n i s h i n g and s t r i p p i n g o f
forms,

b. Mechanical

Equipment i n s t a l l a t i o n - Equipment i n s t a l l a t i o n i n n u c l e a r power

p l a n t s i n c l u d e s major components such as t h e r e a c t o r pressure vessel,
t h e t u r b i n e and t h e condenser, as w e l l as a h o s t o f equipment items o f
v a r i o u s sizes. T h i s i n c l u d e s pumps, heat exchangers and tanks. The
l a t t e r may be shop f a b r i c a t e d o r e r e c t e d i n t h e f i e l d .

Piping - I n s t a l l a t i o n o f p i p i n g i n c l u d e s i n s t a l l a t i o n o f supports, as
w e l l as p o s i t i o n i n g and c o n n e c t i n g spool p i e c e s and valves. Piping
i n c l u d e s small diameter instrument tubing, small bore p i p e (,I8

diameter and l e s s ) and l a r g e bore p i p e (over 2" diameter) which can

range up t o 30" diameter main steam p i p i n g .

Building services - The most obvious of t h e b u i d i n g s e r v i c e s work.

i n c l u d e s t h e h e a t i n g , v e n t i l a t i n g and a i r c o n d i t i o n i n g systems which
i n c l u d e blowers, r e f r i g e r a t i o n equipment, h e a t i n g b o i l e r s , h e a t i n g and
cooling coils, f i l t e r s , ductwork and duct supports. T h i s area a l s o
i n c l u d e s f i r e water d i s t r i b u t i o n and c o n v e n t i o n a l plumbing.
i
- J

17
-
c. Electrical

Equipment i n s t a l l a t i o n - Major e l e c t r i c a l equipment i n c l u d e s t h e

generator and t h e s t a t i o n switchgear. I n a d d i t i o n , t h e r e a r e motors
o f a l l s i z e s , motor c o n t r o l c e n t e r s , i n s t r u m e n t s , c o n t r o l components
and computers.
Cabling - T h i s area i n c l u d e s i n s t a l l a t i o n o f c o n d u i t s and c a b l e
t r a y s , p u l l i n g c a b l e and making t e r m i n a t i o n s .

d. Architectural

T h i s area i n v o l v e s many m i s c e l l a n e o u s a c t i v i t i e s . These i n c l u d e

i n t e r i o r w a l l s and f i n i s h e s , e x t e r i o r w a l l s and t h e i r t r e a t m e n t ,
r o o f i n g , doors, l a b o r a t o r y f u r n i s h i n g s , t i l e s e t t i n g , placement of
fire-proofing, p a i n t s and c o a t i n g s and f l o o r f i n i s h e s .

2. I n s p e c t i o n and Q u a l i t y Assurance

The t y p i c a l i n s p e c t i o n s d e s c r i b e d below do n o t i n c l u d e acceptance t e s t s

f o r equipment and system s t a r t u p t e s t s , a l t h o u g h t h e y may be performed i n
the f i e l d . These t e s t s and i n s p e c t i o n s i n c l u d e o n l y those r e q u i r e d t o
v e r i f y c o n s t r u c t i o n t h a t i s p u t in p l a c e .

a. Civil

A l l areas o f c i v i l i n v o l v e v e r i f i c a t i o n o f dimensional q u a n t i t i e s i n
some r e s p e c t . Earthwork r e q u i r e s v e r i f y i n g t h e degree of compaction
a t t a i n e d in placement o f f i l l . C o n c r e t i n g r e q u i r e s c o n d u c t i n g slump
t e s t s , t a k i n g o f c y l i n d e r s f o r compression t e s t s and t e s t s t o v e r i f y
t h e i n t e g r i t y o f c o n c r e t e t h a t has been placed. Typical inspections
f o r s t r u c t u r a l s t e e l e r e c t i o n i n c l u d e v e r i f y i n g b o l t t o r q u e s and
welding inspection.
 18

b. Mechanical

As i n t h e case w i t h c i v i l c o n s t r u c t i o n , v e r i f i c a t i o n o f dimensional
items i s r e q u i r e d f o r mechanical i n s t a l l a t i o n . Especially significant
i s t h e p i p i n g a s - b u i l t verification required by IE Bulletin 79-14.

Weld i n s p e c t i o n i s p r o b a b l y t h e most w i d e l y performed i n s p e c t i o n on

mechanical systems. I t i n c l u d e s v i s u a l , dye p e n e t r a n t and magnetic
p a r t i c l e i n s p e c t i o n s as w e l l as r a d i o g r a p h y on a r o u t i n e b a s i s .
C e r t a i n s p e c i a l welds a r e a l s o i n s p e c t e d u l t r a s o n i c a l l y . I n addition,
soap bubble, halogen and h e l i u m l e a k t e s t i n g i s performed. Most f l u i d
systems are h y d r o s t a t i c a l l y t e s t e d b e f o r e acceptance.

c. Electrical

Testing o f e l e c t r i c a l i n s t a l l a t i o n s i s p r i m a r i l y i n the nature o f

acceptance and s t a r t u p t e s t i n g , and hen‘ce i s n o t considered here.

d. Architectural

T e s t i n g o f a r c h i t e c t u r a l f e a t u r e s g e n e r a l l y does n o t have t h e same

s i g n i f i c a n c e as i n t h e c i v i l and mechanical areas. Hawever, f o r
s p e c i a l p r o t e c t i v e coatings, wet f i l m t h i c k n e s s measurements a r e
important. I n addition, b u i l d i n g leak r a t e t e s t s are required a t
times. These may i n d i c a t e d e f i c i e n c i e s i n s e a l i n g o f j o i n t s i n
e x t e r i o r walls.

3. E x i s t i n g and Planned Systems

a. E x i s t i n g Systems

C u r r e n t l y , automatic p i p e welding and tube welding systems a r e

a v a i l a b l e commercially and are used on c o n s t r u c t i o n s i t e s . These
systems are p o s i t i o n e d and c o n t r o l l e d by human operators.
 ,
F 3

19
L

Other a p p l i c a t i o n s , m o s t l y experimental i n nature, i n c l u d e :

Laser guided earthmoving and paving equipment

Laser guided t u n n e l b o r i n g machines

S h o t c r e t i n g w i t h gun mounted on an e a r t h excavator

Concrete d i s t r i b u t i o n by an arm s u p p o r t i n g a c o n c r e t e pump hose

F i r e p r o o f i n g a p p l i c a t i o n by an arm s u p p o r t i n g a spray gun

Numerically c o n t r o l l e d d r i l l i n g i n rock

Inspecting tiles on a vertical wall

Mapping c o n c r e t e r e i n f o r c e m e n t placement by a c a r r i a g e u s i n g
e l e c t r o m a g n e t i c sensors

E x c a v a t i n g r o b o t t o l o c a t e underground u t i l i t y l i n e s and uncover

them.

b. Planned Systems

Due t o t h e f a c t t h a t t h e c o n s t r u c t i o n i n d u s t r y i s so diverse, t h e r e i s
no focussed e f f o r t on a p p l i c a t i o n s o f r o b o t i c s . Many o f t h e planned
systems are those a l r e a d y l i s t e d i n t h e p r e v i o u s s e c t i o n .

4. Non-routine C o n s t r u c t i o n Operations

P l a n t m o d i f i c a t i o n s p r i m a r i l y i n v o l v e e l e c t r i c a l and mechanical systems and

equipment, a l t h o u g h t h e r e may be some s t r u c t u r a l o r a r c h i t e c t u r a l
modification. Thus, increased automation o f p i p e and tube welding would be
important. T h i s i s e s p e c i a l l y t r u e where t h e work i s done i n contaminated
o r h i g h r a d i a t i o n areas, because o f t h e p o t e n t i a l f o r r e d u c i n g personnel
r a d i a t i o n exposure.
 1

20

T y p i c a l l y , a s - b u i l t drawings e x i s t o n l y f o r s a f e t y r e l a t e d p i p i n g . Thus,
almost e v e r y p l a n t m o d i f i c a t i o n e f f o r t i n v o l v e s p r e p a r a t i o n o f a s - b u i l t ,

drawings o f t h e area i n v o l v e d j u s t p r i o r t o design o f t h e m o d i f i c a t i o n .

T h i s u s u a l l y r e q u i r e s personnel t o e n t e r t h e area t o make t h e r e q u i s i t e
measurements. I n many cases t h i s i s a r a d i a t i o n area w i t h t h e a t t e n d a n t
concern o f personnel exposure. I t would seem t h a t i t should be p o s s i b l e t o
develop a r o b o t t h a t c o u l d f i n d i t s way t o t h e area. T h i s r o b o t would t h e n
map t h e area e i t h e r by e l e c t r o n i c o r photogrammetric means, t o produce as-
b u i l t drawings. I n t h e l a t t e r case, p a i r s of s t e r e o photos c o u l d be
processed by c l o s e range photogrammetric methods t o y i e l d d i g i t i z e d data.
These d a t a c o u l d t h e n be processed b y a CAD system t o produce t h e a s - b u i l t
drawings.

5. P l a n t M o d i f i c a t i o n s

M o d i f i c a t i o n s o f p l a n t designs t h a t would f a c i l i t a t e t h e use o f r o b o t s i n

c o n s t r u c t i o n are g e n e r a l l y design f e a t u r e s t h a t would enhance
constructability. These would i n c l u d e :

o Standardizing design features

o I n c r e a s i n g u n i f o r m i t y i n c o n f i g u r a t i o n and l a y o u t

o Reducing crowding

o I n c r e a s i n g a c c e s s i b i l i t y t o items t o be i n s t a l l e d by r o b o t i c
systems
I

A d d i t i o n a l l y , f o r p l a n t s designed by CAD c o n s t r u c t a b i l i t y r e v i e w s c o u l d
i n c l u d e s i m u l a t i o n o f r o b o t i c a p p l i c a t i o n s t o c o n s t r u c t i o n on t h e CAD
system.

Other n o n - r o u t i n e c o n s t r u c t i o n o p e r a t i o n s u s u a l l y i n v o l v e a problem i n
which an o p e r a t i o n has n o t gone as planned, i n which an o b j e c t o f unusual
. s i z e o r weight i s handled, or i n which t h e r e i s some o t h e r d e v i a t i o n f r o m
t h e norm. I t i s u n l i k e l y t h a t even a system w i t h programmed l e a r n i n g c o u l d
e

be ‘ e a s i l y developed t o cope w i t h such a wide range o f s i t u a t i o n s t h a t

i cannot be a n t i c i p a t e d i n advance.

6. Technology Needs

The needs f o r technology development cover s e v e r a l areas. These a r e

discussed below i n terms o f b o t h s p e c i f i c a p p l i c a t i o n s and general areas o f
t e c h no 1ogy .
F u t u r e systems must be a b l e t o f u n c t i o n i n an u n s t r u c t u r e d work environment
t h a t i s p o o r l y c o n f i g u r e d and has minimal r e p e t i t i o n . I n o r d e r t o develop
such systems c o n s i d e r a t i o n must be g i v e n t o t h e f a c t o r s i d e n t i f i e d i n t h i s
s e c t i o n on “Technology Needs.” Systems d e s c r i b e d below assume t h a t t h e
necessary t e c h n o l o g i c a l advances w i l l t a k e place.

I n t h e c i v i l area, a d d i t i o n a l t a s k s i n which performance might be enhanced

by improvements i n r o b o t i z a t i o n i n c l u d e :

E x c a v a t i o n o f f o u n d a t i o n s f o r power p l a n t s t r u c t u r e s

Placement o f r e i n f o r c i n g s t e e l i n c o n c r e t e s l a b s

B o l t i n g and welding o f s t r u c t u r a l s t e e l j o i n t s

I n s p e c t i o n o f b o l t e d and welded j o i n t s

Use o f autonomous r o b o t s t o work under compressed a i r i n s i d e o f

caissons.

These o p e r a t i o n s are h i g h l i g h t e d , because a l l have some degree o f

r e p e t i t i v e n e s s , a l t h o u g h n o t t o t h e same e x t e n t as i n a f a c t o r y o p e r a t i o n .
I n a d d i t i o n i t should be p o s s i b l e t o u t i l i z e i n f o r m a t i o n c a p t u r e d i n a CAD
system i n t a s k s i n v o l v i n g r e b a r placement o r s t r u c t u r a l b o l t i n g .

I n t h e mechanical area, t h e most f r u i t f u l area f o r increased use of

r o b o t i c s i s i n p i p e welding. Since t h e b a s i c equipment a l r e a d y e x i s t s , t h e
changes would p r i m a r i l y be i n t h e area of r e d u c i n g t h e degree o f dependence
 I ' 1

22
*

on human o p e r a t o r s . Once t h i s i s done, t h e n e x t a p p r o p r i a t e s t e p would be

t o adapt t h e concepts developed t o weld i n s p e c t i o n .

F o r work i n a c o n s t r u c t i o n environment, t h e g r e a t e s t need i s i n t h e area of

mobility. Robots must be a b l e t o move around an uneven c o n s t r u c t i o n s i t e
and t o work i n s i d e crowded b u i l d i n g s . To, be u s e f u l i n b o l t i n g j o i n t s i n a
s t e e l frame, a r o b o t should have v e r t i c a l access c a p a b i l i t y .

Next i n importance are sensing and e x p e r t systems. For i n s t a n c e , t o p u t

t o g e t h e r b o l t e d j o i n t s o f v a r y i n g p a t t e r n s , t h e r o b o t would need t o l o c a t e
an i n i t i a l b o l t by e i t h e r t a c t i l e o r v i s u a l sensing. Once t h i s i s done,
d a t a t r a n s f e r r e d f r o m a CAD system d e s i g n of t h e j o i n t c o u l d be used t o
l o c a t e the remaining b o l t s . S e l e c t i o n of t h e proper r e b a r s f o r placement
i n a s l a b c o u l d i n v o l v e a c o m b i n a t i o n of CAD d a t a and p a t t e r n r e c o g n i t i o n .

M a n i p u l a t i o n appears t o be g e n e r a l l y w e l l developed f o r t h e needs o f

construction. However, some work on improving hand d e x t e r i t y m i g h t be
appropr iate.

F i n a l l y , a l t h o u g h n o t s p e c i f i c a l l y a m a t t e r o f r o b o t i c s , some c o n s i d e r a t i o n
should be g i v e n t o i d e n t i f y t h o s e design f e a t u r e s which make i t e a s i e r t o
use r o b o t i c s e f f e c t i v e l y i n c o n s t r u c t i o n . Once developed, t h i s i n f o r m a t i o n
should be disseminated t o designers.

C. Reactor P1 a n t Operations

Reactor p l a n t o p e r a t i o n s t h a t can be enhanced by t h e a p p l i c a t i o n o f r o b o t i c s

are i d e n t i f i e d i n t h i s s e c t i o n . I n s p e c t i o n and q u a l i t y assurance o p e r a t i o n s
s u i t a b l e f o r r o b o t i c a p p l i c a t i o n s are a l s o defined. R o b o t i c systems f o r
r e a c t o r o p e r a t i o n s b o t h c u r r e n t l y i n use o r b e i n g developed a r e described.
P l a n t m o d i f i c a t i o n s t o f a c i l i t a t e implementation of r o b o t i c systems f o r
r e a c t o r o p e r a t i o n s are suggested. There a r e some o v e r l a p p i n g areas between
r e a c t o r o p e r a t i o n s and maintenance; however , an attempt was made t o separate
these functions.
1
’

23

1. Elements o f C u r r e n t P r a c t i c e

The elements o f c u r r e n t p r a c t i c e t h a t are s u i t a b l e f o r r o b o t i c a p p l i c a t i o n

f o r t h e c u r r e n t U.S. power r e a c t o r s are l i s t e d below. These elements a r e
a p p l i c a b l e t o BWR, PWR, GCR, and LMR p l a n t s .

a. Common

o S u r v e i 11ance.
- Environment (temperature, h u m i d i t y , e t c ) .
- Safety including f i r e detection.
- Leak d e t e c t i o n (steam/water).
- Pump o i l l e v e l s / l e a k s .
- Detector inspection.
- R a d i a t i o n l e v e l s (personnel l o c a t i o n s ) .
- Detection o f loosened p a r t s .
- Noise/vibration detection.
- Instrument.
- Training.
- Security (passive/active) - personnel
1o c a t ion.
- Weld i n s p e c t i o n .
- A i r b o r n e and s u r f a c e contamination.

o Spare p a r t s storage.

o Decontamination/Cleanup.

o M a t e r i a l sample c o l l e c t i o n and t e s t i n g .

o Snubber t e s t i n g .

o Radwaste volume r e d u c t i o n h a n d l i n g , processing, c o n t a i n e r i z i n g ,

shipping.

o New f u e l r e c e i p t and i n s p e c t i o n .
 " I

24

o Spent f u e l removal, i n s p e c t i o n , and r e c o n s t i t u t i o n

b. Specific

The elements o f c u r r e n t p r a c t i c e t h a t are unique t o c u r r e n t types o f

U.S. power r e a c t o r s are summarized below.

o BWR.

- T u r b i n e generator i n s p e c t i o n .
- Off-gas system i n s p e c t i o n . .

- C o n t r o l r o d d r ve (CRD) hydrau i c c o n t r o l u n i t i n s p e c t i o n .

o PWR.

- Steam generator i n s p e c t i o n .

o GCR.

- Gas l e a k i n s p e c t on.
- Steam generator nspection.
- Maintenance o f p r i m a r y c o o l a n t blowers .
- S t a c k i n g o f g r a p h i t e moderator b l o c k s .
o LMR.

- Spent f u e l t r a n s p o r t a t on i n sodium.
- Sodium l e a k d e t e c t i o n .

2. I n s p e c t i o n and Q u a lit y Assurance

I n s p e c t i o n and qual it y assu ance a p p l i c a t i o n s t h a t can be accomplished w i t h

r o b o t i c systems are d e f i n e d below.

a. I n - s e r v i c e weld i n s p e c t on u s i n g v i s u a l , u l t r a s o n i c o r o t h e r
techniques.
 25

b. ‘ I n - s e r v i c e l e a k d e t e c t i o n u s i n g v i s u a l , u l t r a s o n i c o r o t h e r sensors.

c. I n - s e r v i c e pump o i l l e v e l s ; o i l contamination.

d. Materials testing - mechanical, chemical and r a d i o l o g i c a l sample

c o l l e c t i o n and t e s t i n g f o r aging, c o r r o s i o n , s t r e s s and r a d i o l o g i c a l
exposure.

e. Snubber t e s t i n g - h y d r a u l i c snubber t e s t i n g t o check b l e e d r a t e s ,

r e s e r v o i r l e v e l s and c o n d i t i o n s o f lock-up. Mechanical snubber t e s t i n g
v i a torque t e s t i n g .

f. S u r v e i l l a n c e i n s i d e t h e containment - remote t e l e v i s i o n t o p r o v i d e 3-D

o r h o l o g r a p h i c d i s p l a y s ; m a n i p u l a t o r d i r e c t e d carnera/laser beam.

g. Inspectionlsafety tours - useful f o r safety v e r i f i c a t i o n , training,

i n s t r u c t i o n , i d e n t i f y needed r e p a i r s , problem areas, NRC i n s p e c t i o n s ,
security, r a d i a t i o n levels, etc.

3. E x i s t i n g and Planned Systems

Although many automated, computerized, r e m o t e l y viewed and o p e r a t e d systems

a r e i n e x i s t e n c e , t h e r e are no advanced r o b o t i c s per se used i n c u r r e n t
power r e a c t o r o p e r a t i o n s . Systems planned are: (1) general purpose m o b i l e
r o b o t i c s u r v e i l l a n c e ; ( 2 ) m o b i l e weld i n s p e c t i o n r o b o t ; and ( 3 ) a
decontamination robot.

4. Non-routine O p e r a t i o n s

Nonroutine o p e r a t i o n s p r i m a r i l y r e s u l t f r o m t h e response t o unexpected

equipment f a i l u r e s . Hence, these o p e r a t i o n s a r e discussed i n S e c t i o n 4. o f
t h e Reactor Mai ntenance Section.
~

I I

26

5. P l a n t M o d i f i c a t i o n s

The major c o m p l i c a t i o n s t o r o b o t i c s u t i l i z a t i o n i n c u r r e n t p l a n t s are l a c k

o f space and t h e u n s t r u c t u r e d n a t u r e of t h e environment. P l a n t s should be
m o d i f i e d and f u t u r e p l a n t s should be designed t o i n c o r p o r a t e space f o r
' u t i l i z a t i o n o f r o b o t i c s , p a r t i c u l a r l y f o r inspections/sampling/monitoring/-
viewing during operation. S p e c i f i c areas o f p l a n t m o d i f i c a t i o n s
recommended are: (1) wider door access; (2) functional elevators; (3)
d i s t r i b u t e d power ( 4 ) improved l i g h t i n g ; and ( 5 ) e a s i e r access t o
c o n t a i nment areas.

6. Technology Needs

The technology needs t o implement t h e a p p l i c a t i o n of r o b o t i c s t o r e a c t o r

p l a n t o p e r a t i o n s are l i s t e d below:

a. Nuclear ''hardening" o f r o b o t i c components t o a l l o w more exposure t o

r o b o t i c systems d u r i n g o p e r a t i o n s .

b. Three dimensional o r h o l o g r a p h i c d i s p l a y and r a p i d scan v i s i o n systems

f o r accurate and comparative s u r v e i 11ance.

c. Robot m o b i l i t y ; c o l l i s i o n avoidance; i t e m r e c o g n i t i o n ; v e r t i c a l access,

traversing objects.

d. Mob l e power i n t e r f a c e w i t h t h e r o b o t .

e. On- i n e r e p a i r c a p a b i l t y t o reduce downtime.

f. Improved remote c o n t r o l ; r o b o t t r a c k i n g .

g. Accurate sensor feedback.

f .
. 27

D. Reactor P1a n t Maintenance

Reactor p l a n t maintenance and i n s p e c t i o n / q u a l i t y assurance o p e r a t i o n s which

a r e o r can be achieved u s i n g r o b o t i c systems are i d e n t i f i e d i n t h i s s e c t i o n .
E x i s t i n g and planned r o b o t i c systems are described. Plant modifications t o
enhance t h e a p p l i c a t i o n o f r o b o t i c s i n p e r f o r m i n g b o t h planned and unplanned
maintenance a r e suggested. Technology needs t o p e r m i t t h e design and
a p p l i c a t i o n o f advanced r o b o t i c systems f o r maintenance o p e r a t i o n s a r e
identified.

1. Elements o f C u r r e n t P r a c t i c e

Elements of c u r r e n t p r a c t i c e i n maintenance o f r e a c t o r p l a n t s s u i t a b l e f o r
r o b o t i c a p p l i c a t i o n s are summarized below:

a. Common
o Weld p r e p a r a t i o n , w e l d i n g and i n s p e c t i o n

o General a c t i v i t i e s such as d r i l l i n g , sawing, t a p p i n g holes, f a s t e n i n g

and u s i n g an assortment o f t o o l s

o Rep1 a c i n g / r e p a i r i n g d e t e c t o r s

o Control rod drives

- Removal
- Rep 1acement
- Rebuilding
- Testing
- Cleaning
- Inspection
- H y d r a u l i c c o n t r o l u n i t refurbishment

o Radwaste
- Collection/sorting/cornpaction
- Hand1 ing/mi x i ng
 I ' ' J

28

- Sampling/analysis/mass and i s o t o p i c balance

- Container capping, h a n d l i n g and c l e a n i n g

o Valves/valve seats and packing

- Rep1 ace/repai r
- Test
- Inspect

o Pumps

- Replace/repair seals, bearings & d r i v e s

- Test
- Inspect

o Piping

- Cutting
- Aligning
' - We1 d i ng
- Inspection ( i n c l u d i n g leak detection)
- Repair
- Condenser tube l o c a t i o n and c l e a n i n g

o Refueling*

- Head removal /rep1 acement

- Spent f u e l removal
- Reconstitution
- Densification
- Inspection

o Survei 11 ance

- Safety including f i r e f i g h t i n g
- Leak d e t e c t i o n (steam/water)
 29

Pump o i 1 l e v e l s / l e a k s
D e t e c t o r and i n s t r u m e n t a t i o n i n s p e c t i o n
R a d i a t i o n l e v e l s * * (personnel l o c a t i o n )
Problem areas
T r a i n ing
S e c u r i t y (personnel l o c a t i o n )
Weld i n s p e c t i o n
Damage assessment
Environment (temperature, h u m i d i t y )
Read i n s t r u m e n t s
D e t e c t loosened p a r t s
A i r b o r n e 'and s u r f a c e c o n t a m i n a t i o n

* Reference 5 i n d i c a t e s t h e mean c o n t r i b u t i o n on v a r i o u s o p e r a t i o n s t o
r e f u e l i n g outages i n BWR p l a n t s are as f o l l o w s : maintenance and r e p a i r -
21 days (31%), i n s p e c t i o n - 5 days (7%), t e s t i n g - 7 days ( l o % ) , and
refueling - 36 days (52%).

** Reference 6 p r o v i d e s t h e f o l l o w i n g r a d i a t i o n p r o f i l e f o r a PWR (none

p r o v i d e d f o r BWR): f o r c e d outage maintenance - 40%, r o u t ne ma ntenance -
30%, r e f u e l i n g - 15%, r o u t i n e o p e r a t i o n s and s u r v e i l l a n c e - 6%, i n - s e r v i c e
inspection - 5%, and waste p r o c e s s i n g - 4%.

o Spare p a r t s s t o r a g e / h a n d l i n g

o M a t e r i a l sample c o l l e c t i o n and t e s t i n g

o Snubber t e s t i n g

o Decontamination/cleanup

o F i l t e r change
 o Condenser t u b e c l e a n i n g

o Pressure r e 1 ie f Val ve removal / c a l ib r a t io n / r e p l acement

b. Specific

The elements o f maintenance which can be improved by use o f r o b o t i c s

f o r each o f t h e c u r r e n t U.S. power r e a c t o r s a r e summarized below.
These elements are c a t e g o r i z e d a c c o r d i n g t o r e a c t o r type.

o BWR

- T u r b i n e components (temporary clamping o r welding; l e a k d e t e c t i o n

and r e p a i r i n v a l v e s and m o i s t u r e s e p a r a t o r s )
- Suppression pool i n s p e c t i o n and c l e a n i n g
- Main steam i s o l a t i o n v a l v e ( M S I V ) maintenance
- Condensate f i l t e r element replacement
- N i t r o g e n - i n e r t e d containment s p e c i a l maintenance

0 PWR

- Steam g e n e r a t o r components ( l e a k d e t e c t i o n , r e p a i r , c l e a n i n g )
- Evaporator ( b o r i c a c i d )
- C a v i t y water c l e a n u p / c a v i t y c l e a n i n g
- P r e s s u r i zer h e a t e r r e p 1 acement

o GCR

- Gas storage, r e c i r c u l a t i o n systems and l e a k d e t e c t i o n and

repair

o LMR

- L i q u i d metal s p i l l d e t e c t i o n / c l e a n u p
- Fuel t r a n s f e r equipment maintenance ( l i q u i d metal h a n d l i n g )
- L i q u i d metal waste h a n d l i n g
 -.
\

-.
31

2. I n s p e c t i o n and Qual.ity Assurance

".a. P r i m a r y system weld i n s p e c t i o n u s i n g u l t r a s o n i c o r o t h e r volume r i

techniques.

b. Leak d e t e c t i o n u s i n g v i s u a l , u l t r a s o n i c o r o t h e r sensors.

c. Pump o i l l e v e l s ; o i l contamination.

d. Material testing - mechanical, chemical and r a d i o l o g i c a l sample

c o l l e c t i o n and t e s t i n g f o r aging, c o r r o s i o n , s t r e s s and r a d i o l o g i c a l
exposure.

,e. Snubber t e s t i n g - h y d r a u l i c snubber t e s t i n g t o check b l e e d r a t e s ,

r e s e r v o r l e v e l s and c o n d i t ons o f lock-up. Mechanical snubber
t e s t i n g v i a torque testing.

f. S u r v e i l l a n c e i n s i d e t h e containment - remote t e l e v i s i o n t o p r o v i d e 3-D

o r h o l o g r a p h i c d i s p l a y s ; camera/laser beam m a n i p u l a t i o n .

g. Inspection/safety tours - useful f o r safety verification, training,

i n s t r u c t i o n , i d e n t i f y needed r e p a i r s , problem areas, NRC inspections,
security, r a d i a t i o n levels, etc.

h. Steam g e n e r a t o r tube i n s p e c t i o n (except f o r BWRs).

i. General purpose i n s p e c t i o n such as holes, saw c u t s , n u t s

tightened/untightened, d e t e c t o r , c o n t r o l r o d d r i v e , v a l v e , pump and
p i p i n g inspection.

3. E x i s t i n g and Planned Systems

A r e m o t e l y o p e r a t e d s e r v i c e r o b o t has been-developed and i s i n use f o r t h e

Nuclear Steam Supply System (NSSS) maintenance. T h i s machine i s a s i x - d e g r e e -
of-freedom arm a c t u a t e d by e l e c t r i c motors and i s c o n t r o l l e d r e m o t e l y f r o m a
p o r t a b l e c o n t r o l room up t o 600 f e e t d i s t a n t . Several p a r a l l e l
 I * I
32

microprocessors provide the logic and commands to the servo-motors. The

system can be operated in a teach-and-play mode or by operator control using
television. The arm which i s waterproof. and radiation resistant can operate'
submerged in the reactor vessel or in air. It may be operated from a fixed or
mobile base or mounted upside down. The arm can reach from about 2.5 feet to
6 feet with a repeatability of -
+0.06 inches.

Remotely operated devices have been developed in the early 1970s for repair of
steam generators. One is an arm with four degrees of freedom used to place
equipment and tools remotely in the channel head of steam generators. A
Master/Slave Tubesheet Indexer uses a master mounted on a half -scale rep1 ica
of the steam generator head. These devices have been used in steam generator
tube inspection and r e p a i r .

Several in-service inspection robots for ultrasonic inspection of reactor

vessels have been developed. These computer controlled systems can operate
underwater and in a high radiation field.

A multi-axis manipulator that walks on the surface of a steam generator

tubesheet has been developed. This system uses eight pneumatically activated
fingers and electric motor drives. It has been used for inspection of steam
generator tubes.

Several industrial firms are developing versions of a pipe "walker" that will
be capable of moving through the primary coolant piping. It will be used for
inspection of welds and removal of debris in the piping.

A remotely teleoperated, multi -wheeled system has been developed for surveying
the radiation level in the cavity of TMI-2. Several national laboratories
have also supplied mobile teleoperated systems for use at TMI.
,
Remote hand1 ing devices are used for refueling, vessel head removal, vessel
inspection, control rod drive removal and rebuilding, coolant sampling,
etc., but these are primarily extensions of remote handling technology with
little or no artificial intelligence or programmability.
 33

4. Non-routine Operations
.
Non-rout ine maintenance o p e r a t i o n s , such as occur subsequent t o f a i 1 u r e o f a
component a r e summarized below. These n o n - r o u t i n e maintenance o p e r a t i o n s w i l l
p r o b a b l y be performed by a r e m o t e l y operated m a n i p u l a t o r system s i n c e these
o p e r a t i o n s a r e r e g u l a r l y encountered. The o p e r a t i o n s r e q u i r i n g many
r e p e t i t i v e o p e r a t i o n s , however, such as steam generator i n s p e c t i o n and r e p a i r
have been automated t o some degree and can be expected t o become more
automated as t h e sensor and c o n t r o l systems become more advanced.

a. S u r v e i l l a n c e / m o n i t o r i n g f o r damage.

b. Temporarylpermanent r e p a i r o f damaged item.

o Steam g e n e r a t o r t u b i n g

o Valves

o Pumps

o Core i n t e r n a l s

o Piping

o P i p e snubbers

o Pressurizer heater

c. Decontamination/water sampling and removal/waste removal.

d. Erection of shielding.

e. Recovery f r o m l i q u i d metal s p i l l (LMR o n l y ) .

 34

5 . Plant Modifications

The recommended p l a n t m o d i f i c a t i o n s o r design changes t o enhance t h e

a p p l i c a t i o n o f r o b o t i c s i n p l a n t maintenance are:

a. Accessibility.

o Space around components and p i p i n g

o Wider doors and a i s l e s

b. P r o v i d e t r a c k s o r r a i l s , b o t h v e r t i c a l l y and h o r i z o n t a l l y f o r t h e
r o b o t i c devices o r e l e v a t o r s .

c. Use modular c o n s t r u c t i o n f o r t h e p l a n t s .

d. Use c a p t u r e d b o l t s and t a p e r e d b o l t s t o f a c i l i t a t e remote operations.

e. P r o v i d e permanently i n s t a l l e d d a t a t r a n s m i s s i o n r e l a y s t a t i o n s .

f. P r o v i d e bar c o d i n g on components f o r i d e n t i f i c a t i o n ; r e l a t e coding t o

CAD system.

g. P r o v i d e index ng marks f o r abso Ute p o s i t i o n i n g conf r m a t i o n .

h, Improve l i g h t i n g .

6. Technology Needs

The f o l l o w i n g technology advancements are needed by t h e designers o f advanced

r o b o t i c systems:

a. R a d i a t i o n and o t h e r environmental hardening: Robotic systems f o r

nuclear applications w i l l r e q u i r e resistance t o r a d i a t i o n or other
hazardous environments. While t h e machines have a g r e a t e r r a d i a t i o n
 35

resistance than man, they still must have special features to assure
operation in a hostile environment. Environmental considerations
- should include temperature and humidity, and inert atmospheres.

b. Vision and other sensory capabilities: The robot must have very good
vision to be able to recognize not only the object it was sent to
repair, but also the variables caused by equipment failures. Vision
capabi 1 i ty i ncl udes such aspects as depth perception and spat i a1
relationships. The robot must be able to characterize the objects
that it picks up using a touch capability.

c. Mobility: Cableless power and data transmission are required to

provide flexible, mobile robotic systems capable of deployment in
reactor containments. Present generation systems with power cords
present serious operational concerns and limitations to their use.
Collision avoidance, object recognition and traversing, and vertical
access are also needed for mobile systems.

d. Non-Vision Sensors: The usefulness of manipulators is closely tied to

control systems that rely on sensor feedback for adaptive behavior in
an unstructured environment. Collision avoidance systems, in
particular, are necessary for nuclear applications.

e. Artificial Intelligence: Computer systems to provide expert systems

logic and adaptive controls will be necessary for advanced robotic
systems. These systems will require on-board computers with increased
capacity or wire ess data/control transmission to fixed
computer/control centers. Development of the algorithms and control
schemes for mult -arm systems and intersecting multi-axis robots are
also required.

f. Sensors: Sensors are required to measure forces accurately to permit

use of adaptive end-effectors. Tactile sensors are essential for
object identification and for adaptive control systems. Infra-red
sensors are needed for thermographic scans of operating systems to
detect defects such as leaks, insulation failures, and hot spots.
 t ' 1

36

M i n a t u r i z a t i o n of a l l of these sensors i s des r a b l e t o reduce t h e s i z e

and weight o f t h e sensing package.

g. Improved M e c h a n i c a l / E l e c t r i c a l Systems: I n o r d e r t o p r o v i d e more

compact r o b o t i c systems t o p e r m i t deployment of r o b o t i c systems i n
minimum space a p p l i c a t i o n s , h i g h e r s t r e n g t h t o weight r a t i o mechanical
\

components are r e q u i r e d . Higher s p e c i f i c power, r a d i a t i o n and

humidity/water-proof e l e c t r i c motors o r o t h e r new types o f a c t u a t o r s
are needed. M u l t i - i n t e r s e c t i n g degrees o f freedom a r e r e q u i r e d t o
p r o v i d e increased f l e x i b i 1 i t y f o r r o b o t i c systems. Improved d e x t e r i t y
i s r e q u i r e d t o p e r m i t t h e performance o f more d e l i c a t e t a s k s .

h. Smart t o o l s : Tools and end-effectors w i t h i n t e g r a t e d c i r c u i t s t h a t

p r o v i d e feedback and a d a p t i v e c o n t r o l a r e r e q u i r e d . Tools f o r
welding, c u t t i n g , g r i n d i n g , and i n s p e c t i o n are among t h e key t o o l s t o
be considered.

E. Fuel F a b r i c a t i o n and Maintenance (Reference 1)

1. Elements of C u r r e n t P r a c t i c e

a. Common

F u e l f a b r i c a t i o n r o b o t i c o p e r a t i o n s which are common t o a l l processes

i n c l u d e m a t e r i a l hand i n g and machine loading/unloading.

b. Specific

S p e c i f i c r o b o t i c a p p l i c a t i o n i n t h e L i q u i d Metal Reactor (LMR) process

i s c l e a n i n g (swabbing) c l a d tube ends p r i o r t o end cap welding.

2. E x i s t i n g and Planned Systems

a. The Department of Energy's LMR f u e l f a b r i c a t i o n l i n e , p r e s e n t l y b e i n g

i n s t a l l e d (scheduled s t a r t - u p - 1986) i n Westinghouse H a n f o r d ' s Fuel
Cycle P l a n t a t Richland, Washington, u t i l i z e s over 20 robots.
.
. '.
37
-
An e l e c t r i c r o b o t i s used i n t h e Special Nuclear M a t e r i a l v a u l t t o
l o a d / u n l o a d c o n t a i n e r s o f m a t e r i a l f r o m p a l l e t s , pass t h e c o n t a ner b y
a bar-code reader f o r i d e n t i f i c a t i o n and t o p l a c e t h e c o n t a i n e r on a
s c a l e f o r weight v e r i f i c a t i o n . The r o b o t t h e n p l a c e s t h e c o n t a ner i n
a dumbwaiter f o r t r a n s f e r t o t h e f a b r i c a t i o n l i n e . Current r o b o t i c
applications include:

o Nine custom-designed e l e c t r i c r o b o t s are used i n t h e powder

p r o c e s s i n g area f o r ' t r a n s f e r o f c a n i s t e r s o f f u e l m a t e r i a l f r o m
operation t o operation.

o A m o d i f i e d e l e c t r i c r o b o t i s used t o t r a n s f e r c o n t a i n e r s i n t o and
o u t of t h e p e l l e t i n - p r o c e s s s t o r a g e area.

o A two-armed pneumatic r o b o t i s used i n t h e p i n l o a d i n g o p e r a t i o n t o

decontaminate t h e i n s i d e o f t h e c l a d t u b e end ( b y swabbing) p r i o r
t o end cap welding.

o Nine pneumatic r o b o t s are u t i l i z e d i n t h e c l o s e - c o u p l e d c h e m i s t r y

a n a l y s i s area. The r o b o t s are used t o l o a d / u n l o a d p e l l e t samples
i n t o / o u t o f various chemistry analysis operations.

b. An LWR f a b r i c a t o r i s e v a l u a t i n g t h e use o f a r o b o t w i t h v i s i o n t o
i n s p e c t hardware dimensions d u r i n g f i n a l assembly o p e r a t i o n s .

c. GA Technologies Gas Cooled Reactor f a b r i c a t i o n l i n e i n San Diego

u t i l i z e s a r o b o t t o remove t h e green r o d s f r o m t h e p r e s s and t o s t a c k
t h e r o d s i n t o tubes f o r t r a n s f e r t o t h e r o d c a r b o n i z a t i o n o p e r a t i o n .

3. Non-routine O p e r a t i o n s

Replacement o f process equipment modules o r complete systems, e.g., pellet

press, c e n t e r l e s s g r i n d e r , r e b r i c k i n g con.tinuous s i n t e r i n g furnace, e t c . a r e
one-of - a- k i nd oper a t ions .
 ,
! ' 1

38

(1

4. Plant Modifications

The next generation LMR fuel fabrication facility will probably have to
uti 1 ize remote maintenance to meet DOE I s one rem/year whole body exposure (by
design) criteria. This is due to the recycle (high exposure) plutonium which
wi 1 1 be processed in the future. The present automated/remotely control led ,
glove box process with hands-on maintenance may have to change to a canyon-
type operation to accommodate remote maintenance. AS a minimum, the current
glove box hands-on maintenance concept wi 1 1 have to change to accommodate
robotics and this may impact the facility design.

5. Technology Needs

Advanced robotic technology will be needed in the future to accommodate remote

maintenance of LMR fuel fabrication operations to meet anticipated personnel
exposure design requirements. Smart robotic systems will be required, i.e.,
robots with artificial intelligence capability and advanced sensors (tactile,
vision). Untethered mobile robots with multiple end effectors and 50-100 lb
capacity will be needed. Homing devices, e.g., optic sensors, are needed to
be an integral part of the fabrication equipment, to allow the robot (end
effector) to ilre-calibrateiiits position in order for it to carry out its
intended maintenance operation without damaging the process equipment or
itself. The robotic system(s1 may have to be an integral part of the process
operation depending upon the fabrication concept of the future facility
(canyon vs glove box).

Demonstration o f typical remote maintenance operations is required.

F. Reprocessing Operations and Maintenance

1. Elements of Current Practice (Reference 2)

Existing nuclear fuel reprocessing plants have adopted one of two main
maintenance philosophies. The earlier plants adopted equipment duplication in
the high level (HL) radiation areas, and contact maintenance after decontamin-
ation in the medium level (M,) and low level (LL) radiation zones. Later
 39

p l a n t s moved towards remote maintenance i n t h e HL areas, b u t s t i l l r e l i e d upon

c o n t a c t maintenance i n t h e M l and LL areas. The o n l y d e p a r t u r e f r o m t h i s
arrangement i s t h e Hanford r e p r o c e s s i n g p l a n t where a l l t h e a c t i v e equipment
i s i n s t a l l e d i n a c o n c r e t e canyon w i t h overhead crane access. A l l canyon
equipment i s connected t o process and s e r v i c e l i n e s by t h e use o f r e m o t e l y
demountable jumper connections t o a1 low maintenance and r e p l acement by t h e use
o f cranes and hook-mounted impact wrenches.

Robots as t h e y are known today are n o t used i n e x i s t i n g r e p r o c e s s i n g

f ac i1 it ies .
2. E x i s t i n g and Planned Systems (References 3 and 4 )

The A l l i e d General Nuclear Services p l a n t , i n Barnwell, South C a r o l i n a ,

c o n s t r u c t e d i n 1976 and never s t a r t e d up, was designed f o r maintenance u s i n g a
combination o f cranes, power manipulators, and mechanical m a s t e r / s l a v e
m a n i p u l a t o r s i n t h e mechanical head-end o p e r a t i o n s .

Reprocessing development a c t i v i t i e s a t Oak Ridge are b u i l t around t h e f o r c e -

r e f l e c t i n g b i l a t e r a l servo-manipulator f o r use i n remote maintenance
operations. I n c o n j u n c t i o n w i t h advanced s t a t e - o f - t h e - a r t distributed digital
c o n t r o l concepts, machine-manipulator i n t e r f a c e upgrades, and remote
t e l e v i s i o n systems, i t i s expected t h a t t h i s m a n i p u l a t o r w i l l be used i n t h e
next generation reprocessing p l a n t bot f o r maintenance and t o t r a n s f e r f u e l
assemblies d u r i n g head-end operations.

3. Nonroutine Operations

Nonroutine maintenance o p e r a t i o n s cons s t o f equ pment r e p l acement , r e p a i r and

modifications.

4. P l a n t M o d i f i c a t i o n s

The design o f a r e p r o c e s s i n g f a c i l i t y i s s t r o n g l y i n f l u e n c e d by t h e r e p a i r
p h i l o s o p h y and i f r e m o t e l y maintained, by t h e remote maintenance equipment
capabilities. The f a c i l i t y and a l l i n - c e l l equipment must be arranged t o
 1 ’

40

f aci 1 itate repair for whatever maintenance phi losophy (contact or remote.) i s
used.

5. Technology Needs

Demonstration of the remotely maintainable advanced servo-manipulator in

conjunction with the advanced integrated operator station which incorporates
ergonomically designed color graphics displays and standard remote TV viewing
monitor is required.

G.

1. Elements of Current Practice

a. Common

Reactor power plants and processing facilities are constructed for

manned entry for maintenance and decommissioning. Operating
experience has shown some equipment installations have become too
radioactive for entry, especially in light of the current requirements
for keeping exposure “as low as reasonably achievable” (ALARA).

There is a need for mobile robots or automated electromechanical

manipulators to assist in equipment maintenance and decommissioning o f
process loops where remote-controlled services were not provided in
the original facility.

b. Specific

Commercial robots, modified for specific applications, can pass through

most places a man could walk and perform many tasks.

Mobile equipment with closed-circut television cameras and

manipulators could perform the following operations:
. 41

r<
o Take v i d e o and h i g h r e s o l u t i o n p i c t u r e s f o r t h e purposes o f
*
e v a l u a t i n g and p l a n n i n g maintenance t a s k s

o Perform nondestructive examination (NDE) on pipes and vessels t o

determine d e t e r i o r a t i o n

o Survey f o r f l u i d l e a k s u s i n g c l o s e d - c i r c u t t e l e v i s i o n , r a d i a t i o n
d e t e c t o r s , and leak d e t e c t o r s

o C o n t r o l / p o s i t i o n t o o l s such as wrenches, saws, c a l i p e r s , drop

c l o t h s , s h i e l d s , etc., t o e x p e d i t e t h e manned e n t r y work.

Zones t h a t are too hot f o r prolonged manned e n t r y c o u l d be s e r v i c e d by a

A r o b o t sent i n t o
m o b i l e r o b o t t o survey an u n c e r t a i n r a d i a t i o n f i e l d l e v e l .
a h o t zone would determine r a d i a t i o n f i e l d s t r e n g t h s and d i s t r i b u t i o n s t o a i d
i n d e v e l o p i n g s t r a t e g i c p l a n n i n g f o r l i m i t e d manned e n t r y and those o p e r a t i o n s
r e q u i r i n g remote o p e r a t i o n .

2, Candidate R o b o t i c A p p l i c a t i o n s

The f o l l o w i n g areas have been i d e n t i f i e d a t p l u t o n i u m process f a c i l i t i e s which

require s p e c i a l consideration i n waste handling.

a. Waste E n c a p s u l a t i o n and Storage

A t t h e Hanford Waste E n c a p s u l a t i o n and Storage F a c i l i t i e s (WESF), a

l a r g e amount of v e r y r a d i o a c t i v e m a t e r i a l , s t r o n t i u m and cesium, i s
s t o r e d i n t h e WESF pool. Scenarios have been p o s t u l a t e d (e.g., leaky
capsules, cropped cover b l o c k , d i s l o d g e d d e b r i s f r o m v e n t i l a t i o n d u c t )
i n which manned access t o WESF and t h e a p p r o p r i a t e c o n t r o l s t o c o r r e c t
t h e s i t u a t i o n would n o t be allowed. If a m o b i l e r o b o t were a v a i l a b l e ,
i t c o u l d be sent i n t o t h e pool room t o observe, a c t u a t e valves, and
p e r f o r m numerous t a s k s t o reduce r a d i a t i o n l e v e l s t o a l l o w manned
entry.
 L ' I

42

A t t h e Defense Waste Processing P l a n t , e x t r a o r d i n a r y , in-canyon I

i n c i d e n t s such as t h e damage t o t h e Pipe Trench and R a i s i n g C e l l Cover

B l o c k Out of Order have occurred. Recovering f r o m t h e s e unusual
occurrences c o u l d be s i m p l i f i e d w i t h t h e a v a i l a b i l i t y o f a
s u r v e i l l a n c e robot. The r o b o t c o u l d be used t o a s s i s t i n r i g g i n g ,
f i x t u r i n g (i.e., p i p e s d u r i n g w e l d i n g ) , and a l s o r e c o r d t h e r e c o v e r y
process on video tape. Commercially a v a i l a b l e r o b o t s , m o d i f i e d f o r
s p e c i f i c a p p l i c a t i o n s c o u l d s i m p l i f y e x i s t i n g maintenance o p e r a t i o n s
and reduce man-rem exposure l e v e l s .

b. Change Out o f Hot F i l t e r s

The changing o f HEPA f i l t e r s exposes workmen t o unnecessary r a d i a t i o n

l e v e l s because f i l t e r s a r e changed o n l y when t h e y a r e r a d i o a c t i v e .
HEPA f i l t e r s are i n t e n d e d t o be r e p l a c e d before t h e y c o l l e c t
s u f f i c i e n t r a d i o a c t i v e m a t e r i a l t o pose a risk t o personnel. As a
r e s u l t , t h e usable l i f e o f a HEPA f i l t e r may be determined by t h e
amount o f man-rem exposure d u r i n g replacement of t h e f i l t e r r a t h e r
than the actual useful l i f e o f a f i l t e r . Conversely, a p r o p e r l y
f u n c t i o n i n g f i l t e r may suddenly become v e r y hot, due t o an unusual
event, r e s u l t i n g i n an expensive changeout o p e r a t i o n due t o r a t e o f
workman burnout.

The development of a r o b o t t o change o u t r a d i o a c t i v e f i l t e r s would be

o f s i g n i f i c a n t v a l u e a t Hanford. With i t , HEPA f i l t e r s c o u l d be more
e f f i c i e n t l y u t i l i z e d , and e x c e s s i v e l y h o t u n i t s c o u l d be r e p l a c e d w i t h
minimum personnel exposure.

F o r example, a t t h e Defense Waste Processing P l a n t , i t has been

observed t h a t a s i g n i f i c a n t and undetermined amount o f r a d i o a c t i v e
m a t e r i a l has accumulated i n v e n t i l a t i o n ducts. This material i s
l o o s e l y adherent t o t h e duct w a l l s and c o u l d p r o b a b l y be d i s l o d g e d
w i t h moderate j a r r i n g o r scraping. The danger i s p o s t u l a t e d
t o occur if/when t h e m a t e r i a l were t o spontaneously d i s l o d g e and
c o l l e c t i n t h e b u i l d i n g f i l t e r system (K-3 F i l t e r ) . The f i l t e r would
be t o o h o t t o change-out b y i t s usual procedure. Radiation from the
. 43

f i l t e r p i t i s p r e d i c t e d t o be so i n t e n s e t h a t personnel would n o t be
a l l o w e d i n any b u i l d i n g i n t h e East Area. Furthermore, t i m e would be
r u n n i n g out. I n a few months, t h e r a d i a t i o n would d e s t r o y t h e f i l t e r
medium and c o n t a m i n a t i o n would be discharged f r o m t h e b u i l d i n g
v e n t i l a t o r spreading i t about t h e East Area.

Robots would be necessary f o r almost e v e r y phase o f r e c o v e r y f r o m such

an unusual occurence. A mobile, r a d i o - c o n t r o l l e d o b s e r v a t i o n r o b o t
would be sent t o t h e f i l t e r f i r s t . A heavy-duty r o b o t would be needed
t o transport shielding material t o the p i t . I t has been suggested
t h a t a r a d i o - c o n t r o l l e d f o r k t r u c k c o u l d cover t h e p i t w i t h sheets o f
l e a d o r b u i l d a w a l l of water t a n k s around t h e p i t . The t a n k s would
be f i l l e d w i t h a hose handled by another r o b o t . Also, r o b o t s c o u l d be
used t o p e r f o r m t a s k s such as s u r v e y i n g and decontaminating areas n o t
s u i t a b l e f o r manned access.

One t e c h n i q u e t h a t m i g h t be employed t o change-out a v e r y h o t f i l t e r

i s t o lower a r e m o t e l y - o p e r a t e d d e v i c e i n t o a f i l t e r p i t . A
m u l t i a r m e d t e l e m a n i p u l a t o r d e v i c e c o u l d disconnect, r i g , c u t , f i l l t h e
c a v i t y w i t h foam, and p e r f o r m o t h e r o p e r a t i o n s t o remove t h e f i l t e r .

c. Automated Laundry

An i m p o r t a n t o p e r a t i o n a t Hanford i s t h e l a u n d r y f a c i l i t y (200 West

Area). The l a u n d r y r e c e i v e s d i r t y l c o n t a m i n a t e d c o v e r a l l s , rubbers,
gloves, masks, head and f o o t covers, and t o w e l s f r o m a l l Hanford
c o n t r a c t o r s and areas. The l a u n d r y cleans/decontaminates t h i s
p r o t e c t i v e c l o t h i n g and r e t u r n s i t t o s e r v i c e on an as-needed b a s i s .
T h i s o p e r a t i o n r e q u i r e s a s t a f f o f 14 people u t i l i z e d two ( 2 ) s h i f t s
per day.

The most l a b o r - i n t e n s i v e phase o f t h e o p e r a t i o n i s s o r t i n g and

folding. If an automated d e v i c e were used and programmed i t c o u l d be
designed t o f o l d w h i t e c o v e r a l l s and handle o t h e r items. The
advantaged would be t o reduce man-rem exposure l e v e l s . Personnel
assigned t o t h e l a u n d r y are exposed t o r e s i d u a l c o n t a m i n a t i o n l e f t i n
t h e c o v e r a l l s a f t e r washing. Although, washing reduces t h e r a d i a t i o n
 l e v e l f o r each p a i r o f c o v e r a l l s t o a s a f e l e v e l , t h e r a d i a t i o n l e v e l '
a t t h e f o l d i n g s t a t i o n i s c u m u l a t i v e causing t h e sum o f t h e l e v e l s
f r o m a l l o f t h e w h i t e s i n t h e p i l e t o be h i g h e r t h a n f o r a s i n g l e
garment.

d. Alpha Caisson Storage C o n t a i n e r s

A mater a1 h a n d l i n g problem e x i s t s a t t h e Hanford f a c i l i t y i n v o l v i n g

removal of waste containers from a l p h a caissons. The Department o f
Energy, Albuquerque Operations Office, T r a n s u r a n i c Waste Lead S i t e
O r g a n i z a t i o n (TLO), r e q u i r e s t h a t technology be i d e n t i f i e d f o r
removing t h e c o n t e n t s of these caissons f o r permanent b u r i a l i n t h e
N a t i o n a l Waste Repository.

The caissons i n q u e s t i o n are 14 f e e t underground and a r e connected t o

t h e s u r f a c e w i t h an S-shaped chute. The m a t e r i a l s t o r e d i n t h e
caissons c o n t a i n s t r a n s u r a n i c m a t e r i a l and i s a s t r o n g source o f gamma
radiation.

A number o f conceptual p l a n s f o r removing t h e m a t e r i a l have been

attempted b u t none seem t o be f e a s i b l e , except one. The s o l u t i o n
having t h e g r e a t e s t p o t e n t i a l i n s o l v i n g t h e problem i s t o lower a
f l e x i b l e r o b o t arm down t h e S-shaped c h u t e w i t h a vacuum o r g r i p p e r t o
remove t h e o b j e c t s one a t a time. To remove t h e o b j e c t s , remote
viewing would be employed t o f i n d and grasp each o b j e c t and t h e n
withdraw i t through t h e S-shaped chute. Pre-programmed movement o f t h e
arm would be needed t o remove o b j e c t s a l o n g t h e c r i t i c a l S-shaped path.

There appears t o be one o r two r o b o t s commercially a v a i l a b l e t h a t

c o u l d be m o d i f i e d t o do t h i s task. But some development would be
necessary t o develop s u i t a b l e end e f f e c t o r s w i t h t h e needed arm p a t h
control.

e. Aging Waste Management and R e t r i e v a l

I ,i
45

' Waste produced f r o m f u e l r e p r o c e s s i n g i s v e r y r a d i o a c t i v e and i s

s t o r e d i n underground tanks. C u r r e n t process and waste i n v e n t o r y
c o n t r o l r e q u i r e s t h a t waste be sampled and analyzed p e r i o d i c a l l y .

Samples can be drawn f r o m r i s e r s t h a t communicate w i t h t h e tank

i n t e r i o r , b u t personnel a r e n o t a l l o w e d t o remain i n t h e neighborhood
o f t h e sample o r any equipment t h a t e n t e r e d t h e tank.

The c u r r e n t proposed approach i s t o use a s p e c i a l i z e d hand-operated

mechanism ( t h e Aging Waste Sampler). I t has s e v e r a l shortcomings,
i.e.:

o Hand o p e r a t i o n exposes tank farm o p e r a t o r s t o unnecessary r a d i a t i o n

levels .
o Hand o p e r a t i o n r e q u i r e s a complex procedure which c o u l d r e s u l t i n
human e r r o r and subsequent c o n t a m i n a t i o n spread.

o Hand o p e r a t i o n mandates a l a r g e amount o f s h i e l d i n g which makes t h e

manually operated machine cumbersome and slow.

Waste sampling would be i d e a l l y s u i t e d f o r a pre-programmed r o b o t .

The r o b o t c o u l d be programmed t o l o a d t h e sample v i a l t o t h e l a n y a r d ,
lower and r e t r i e v e t h e v i a l , d e p o s i t t h e sample i n i t s s h i e l d e d
r e c e i v e r , and decontaminate t h e used equipment. This operation could
be performed as o f t e n as needed f o r process c o n t r o l and i n v e n t o r y
w i t h o u t any r i s k o f exposing personnel and subsequent spread o f
contamination. The r o b o t i c a p p l i c a t i o n would g r e a t l y reduce t h e man-
Rem exposure and e l i m i n a t e hazards t o personnel.

3. E x i s t i n g and Planned Systems

a. Automated Bag Out Technique

A r o b o t i c system was developed and i n s t a l l e d a t Savannah R i v e r t o

r e m o t e l y remove and bag o n e - g a l l o n waste cans f r o m a g l o v e box i n a
 I ,

46

C a l i f o r n i u m source p r o c e s s i n g f a c i l i t y . Waste cans f r o m t h e f a c i l i t y

c o n t a i n sources o f r a d i a t i o n and contamination. The process was w e l l
s t r u c t u r e d f o r automation, b u t t h e area s u f f e r e d f r o m severe space
c o n s t r a i n t s which d i c t a t e d t h e s e l e c t i o n o f t h e r o b o t and i t s
p e r i p h e r a l components. The b a s i c sequence o f t h e automated bag-out
o p e r a t i o n i s t h e same as t h a t used f o r manual o p e r a t i o n . No major
s t r u c t u r a l m o d i f i c a t i o n s were made t o t h e process area. A s p e c i a l bag
p o r t , however, was i n s t a l l e d on t h e g l o v e box t o enable t h e automated
operation.

The automated system c o n s i s t s o f an i n d u s t r i a l r o b o t , a pneumatic end

e f f e c t o r and a s p e c i a l l y designed bag g a t h e r i n g - c l i p p i n g machine. The
r o b o t reaches through t h e p o r t and g r i p s a waste c o n t a i n e r , through
t h e p l a s t i c sleeve, from a h o l d i n g f i x t u r e a t t a c h e d t o an e x i s t i n g
c e l l t r a n s f e r conveyor. A s l i g h t n e g a t i v e pressure i n s i d e t h e g l o v e
box causes t h e sleeve t o expand around t h e waste can as t h e r o b o t
performs t h e g r i p p i n g o p e r a t i o n s . As t h e r o b o t arm i s withdrawn, t h e
bag t u r n s i n s i d e o u t and envelopes t h e can, forming a t i g h t p r o t e c t i v e
cover. Packaged cans are d e p o s i t e d i n a s h i e l d e d drum a c c e s s i b l e by a
remote overhead crane. The r o b o t and process components remain c l e a n
during the operation.

A c o n t r o l console i s used t o operate t h e waste removal system. Five

t e l e v i s i o n m o n i t o r s , a PA system, r a d i a t i o n monitors, and i n d i c a t o r
l i g h t s p r o v i d e feedback t o t h e o p e r a t o r . The computer program
c o n t r o l s t h e process automatica1,ly b u t stops a t v a r i o u s steps t o a l l o w
t h e o p e r a t o r t o i n s p e c t t h e process. A l t e r n a t e routines, t o stop the
o p e r a t i o n o r t o back t h e r o b o t o u t of t h e g l o v e box, are implemented
by pushing b u t t o n s on t h e c o n t r o l console. Manual motions are n o t
allowed d u r i n g normal o p e r a t i o n s due t o space c o n s t r a i n t s .

The o p e r a t o r - i n t e r a c t i v e c o n t r o l p h i l o s o p h y r e q u i r e s o p e r a t o r s t o
sequence and i n s p e c t c r i t i c a l steps i n t h e o p e r a t i o n . Operators can
r e c o g n i z e p o t e n t i a l problems, such as damaged cans o r a conveyor
misalignment, and c o r r e c t t h e problem remotely. Radiation monitors
f .
. 47

- are l o c a t e d o u t s i d e t h e g l o v e box t o determine t h e e x a c t q u a n t i t y of

m a t e r i a l i n s i d e each can. The o p e r a t o r - i n t e r a c t i v e c o n t r o l scheme
g r e a t l y reduced system i n s t a l l a t i o n time. A f u l l y automatic process
would have r e q u i r e d t h e e x i s t i n g c e l l conveyor t o be r e p l a c e d and
s e v e r a l more sensors t o be implemented t o p e r f o r m t h e necessary human
inspections. The e n t i r e process was mocked up i n a c l e a n area b e f o r e
installation. Consequently, t h e t o t a l personnel r a d i a t i o n exposure
absorbed d u r i n g i n s t a l l a t i o n was l i m i t e d t o 3 man-rems. Radiation
exposure savings d u r i n g t h e next year w i l l t o t a l over 20 man-rems.

b. R a d i o a c t i v e Waste S h i p p i n g and R e c e i v i n g

E v a l u a t i o n o f t h e use o f commercial r o b o t s i n c o n j u n c t i o n w i t h
overhead cranes f o r t r u c k l o a d i n g / u n l o a d i n g h i g h l e v e l waste s h i p p i n g
c o n t a i n e r s i s b e i n g conducted. A n t i c i p a t e d f u t u r e shipments ( h i g h
number) d i c t a t e t h a t remote o p e r a t i o n s be u t i l i z e d t o m i n i m i z e person-
n e l exposure.

4. Plant M o d i f i c a t i o n s

The use o f robots/overhead cranes w i t h remote c o n t r o l c a p a b i l i t i e s are needed

a t f a c i l i t i e s r e c e i v i n g waste. Casks should be unloaded and c a n i s t e r s removed
r e m o t e l y t o m i n i m i z e t h e man-Rem exposure. Preprogrammed o p e r a t i o n s need to
be p r o v i d e d i n o r d e r t o assure r e p e a t a b i l i t y and t h e o v e r a l l s a f e t y o f t h e
o p e r a t i o n . System waste h a n d l i n g s t u d i e s are needed t o i d e n t i f y t h e degree o f
s o p h i s t i c a t i o n r e q u i r e d f o r e x i s t i n g and new f a c i l i t y designs.

H. Decommissioning

1. Elements of C u r r e n t P r a c t i c e

Decommissioning o f n u c l e a r f u e l c y c l e , f a c i l i t i e s i n v o l v e s a broad range o f

a c t i v i t i e s r e q u i r i n g t h e a b i l i t y t o d i s m a n t l e a major f a c i l i t y i n t h e presence
o f r a d i a t i o n f i e l d s and contamination. Major elements o f t h i s e f f o r t are
discussed below.

Surveys - Components t o be removed must be surveyed t o assess t h e degree t o

which t h e y are contaminated. These surveys must a l s o e v a l u a t e r a d i a t i o n
 I . 1

48

f i e l d s i n t h e v i c i n i t y of t h e s e components as w e l l as c o n t a m i n a t i o n l e v e l s i n
t h e p o t e n t i a l work areas.

Decontamination - Components may be decontaminated t o reduce r a d i a t i o n l e v e l s

b e f o r e work proceeds.

D i smant i n g - This effort i n c l u d e s removal of components f r o m t h e f a c i l i t y as

w e l l as c u t t i n g o v e r s i z e components i n t o s m a l l e r pieces. During t h i s a c t i v i t y
aPProPr a t e s t e p s must be t a k e n t o p r e v e n t spread o f contamination.

Waste packaging - T h i s i n c l u d e s moving r a d i o a c t i v e and contaminated items t o

t h e packaging area, as w e l l as t h e a c t u a l packaging. Items i n c l u d e components
and p i e c e s removed f r o m t h e p l a n t , decontamination wastes, t o o l s , c l o t h i n g and
waste paper.

2. I n s p e c t i o n and Q u a l i t y Assurance

The p r i n c i p a i s s u e s o f i n s p e c t i o n and q u a l i t y assurance a s s o c i a t e d w i t h

decommission ng o f n u c l e a r f a c i l i t i e s i s m o n i t o r i n g o f t h e r a d i o a c t i v i t y
a s s o c i a t e d w t h waste m a t e r i a l and o f m a t e r i a l s f o r u n r e s t r i c t e d r e l e a s e .
A s c e r t a i n i n g t h e background l e v e l s o f c o n t a m i n a t i o n i n t h e f a c i l i t y t o , b e
decommissioned i s an i m p o r t a n t p a r t o f t h i s process.

The issues o f i n s p e c t i o n and q u a l i t y assurance extend beyond t h e p r i m a r y

facility. D u r i n g removal , c o n t a i n e r i z a t i o n and t r a n s p o r t o f d e b r i s and o t h e r
waste, t h e r e i s a c r i t i c a l need f o r i n s p e c t i o n and QA. This r e s p o n s i b i l i t y
c o n t i n u e s u n t i l d e p o s i t i o n i n an approved waste d i s p o s a l f a c i l i t y .

3. E x i s t i n g and Planned Systems

There a r e no e x i s t i n g t r u l y r o b o t i c systems t h a t are used i n decommissioning

a l t h o u g h t h e r e i s a moderate amount of c a p a b i l i t y w i t h r e s p e c t t o r e m o t e l y
operated equipment. Although, n o t a decommissioning o p e r a t i o n , t h e r e c e n t
removal o f a r e a c t o r thermal s h i e l d f r o m an o p e r a t i n g r e a c t o r i s t y p i c a l o f
t h e o p e r a t i o n s t h a t a r e l i k e l y t o be performed i n decommissioning. This
o p e r a t i o n was performed w i t h a plasma a r c t o r c h t h a t was r e m o t e l y p o s i t i o n e d
. 'B

49

by an o p e r a t o r . C o n t r o l o f t o r c h parameters was by a feedback c o n t r o l

;system.

A t Three M i l e I s l a n d - 2 (TMI-21, decontamination of c o n c r e t e has i n v o l v e d t h e

use o f a h y d r a u l i c l a n c e mounted on a m o b i l e base.

The S h i p p i n g p o r t decommissioning w i l l i n v o l v e t h e use o f r e m o t e l y o p e r a t e d

p i p e c u t t e r s and power hacksaws. A r e m o t e l y operated m a n i p u l a t o r i n s t a l l e d
t h r o u g h a r o o f h a t c h i s i n use a t t h e West V a l l e y Demonstration P l a n t . It i s
used f o r d i s m a n t l i n g t h e p i p i n g i n t h e chemical process c e l l s ,

4. Non-routine Operations

The e n t i r e process o f decommissioning i s n o n r o u t i n e . L i m i t e d precedent e x i s t s

f o r t h i s work and systems are j u s t b e i n g developed.

5. P l a n t M o d i f i c a t i o n s

New f a c i l i t i e s should be designed t o f a c i l i t a t e and accommodate

decommissioning. For a l l p r a c t i c a l purposes, t h e e x i s t i n g n u c l e a r f a c i l i t i e s
have n o t i n c o r p o r a t e d decommissioning as a p r i n c i p a l o b j e c t i v e d u r i n g design.
Among t h e elements t o be i n c l u d e d a r e t h e f o l l o w i n g :

0 Access f o r survey and work r o b o t s

0 U t i l i t y s u p p l y f o r decommissioning
0 Waste and scrap h a n d l i n g
0 M o n i t o r i n g systems t o e v a l u a t e r a d i o a c t i v e c o n t a m i n a t i o n l e v e l s

6. Te hnol ogy Needs

Areas i n which r o b o t i c technology can be b e n e f i c i a l t o decommissioning are i n

c o n d u c t i n g surveys, performing decontamination work, c u t t i n g , t r a n s p o r t i n g
p i e c e s t o a waste packaging area and t h e a c t u a l packaging o p e r a t i o n .

Technology needs a p p l i c a b l e t o these i n c l u d e t h e f o l l o w i n g :

o Radiation resistance of electronic materials

I
~

I . 1

50

o Radiation resistance of mechanical and hydraulic components

o Robot mobility
o Robot navigation
o Sensing systems for construction robots
o High force level manipulators
o Data transmission in radioactive and dirty environments

I. Economic Impact

The major economic benefit to the nuclear industry results from the
application of robotics to the operation and maintenance of power plants.
This is due to the multiple units for this application compared to a very
limited number of reprocessing, fuel fabrication, or waste management
facilities. If there is a resumption of construction of large numbers of
reactor plants, then there will be significant economic benefits in this
application; however, at this time, the expected new construction is limited.
When new construction is resumed, plant designs should be modified to
accomodate the use of robotics.

Substantial economic benefits through the use of robotic systems can be

achieved because of:

o Reduction in man-rem exposure

o Reduction in plant downtime

In addition, the need for rework will be reduced because of the precision and
repetitive capabilities of robotic systems. The following cost values for
these major improvements are:

o Average cost per man-rem exposure is $1,000 to $10,000.

o Average cost per day of downtime for a 1,000 MWe plant is $500,000 to
$1,000,000.
I .,
51

The c o s t s of personnel exposure have been e s t i m a t e d u s i n g t h e above c o s t s and

,the f o l l o w i n g assumptions:

o Average exposure per p l a n t s 560 man-rem per year (Reference 6 ) .

o Number o f p l a n t s i n 1995 i s 120.

o R o b o t i c s w i l l reduce personne exposure by 90%.

The c o s t s o f p l a n t downtime have e s t mated u s i n g t h e above c o s t s and t h e

f o l l o w i n g assumptions:

o Present p l a n t annual downtime i s 90 days.

o Number o f p l a n t s i n 1995 i s 120.

o R o b o t i c s w i l l reduce t h e downtime by a f a c t o r o f 2 by performing some

t a s k s d u r i n g p l a n t o p e r a t i o n and by e l i m i n a t i n g t h e need t o p e r f o r m
o t h e r t a s k s w h i l e wearing p r o t e c t i v e c l o t h i n g .

The r e s u l t s o f these c o s t e s t i m a t e s a r e summarized i n t h e t a b l e below:

Reduced Reduced Total

Out age Radiation
Exposure

Expected Annual Savings ( $ B ) $ 2.7 t o 5 4 $ 0.6 t o 0.06 $2.8 t o 6.0

J. Safety and L i c e n s i n g Impact

The a p p l i c a t i o n o f r o b o t i c s i n t h e n u c l e a r i n d u s t r y w i l l have a p o s i t i v e
impact on s a f e t y and l i c e n s i n g . Candidate a p p l i c a t i o n s would c o n s i d e r p l a n t
c o n s t r u c t i o n , r e a c t o r operation/maintenance, f u e l f a b r i c a t i o n , reprocessing,
most h a n d l i n g and decommissioning. A t t h e p r e s e n t t i m e , r o b o t i c maintenance
systems a r e n o t c o n s i d e r e d d u r i n g r e a c t o r p l a n t l i c e n s i n g . T h i s c o u l d change,
e s p e c i a l l y i f r o b o t s are used f o r maintenance d u r i n g p l a n t o p e r a t i o n .
 52

1. Safety Considerations

The s a f e t y o f c o n s t r u c t i o n workers, t e c h n i c i a n s and p l a n t o p e r a t i n g personnel

w i l l be enhanced b y t h e use of r o b o t i c systems. Examples are:

M i n i m i z i n g / e l i m i n a t i o n of personnel r a d i a t i o n exposure

Contamination c o n t r o l

Handling o f c o r r o s i v e / t o x i c m a t e r i a l

Hand1 ing/packagi ng of waste

Decontamination a c t i v i t i e s

Hazardous c o n s t r u c t i o n a c t i v i t i e s

S i z e r e d u c t i o n of contaminated equ,pmen, f a c i l t es

2. L i c e n s i n g C o n s i d e r a t i o n s

Compliance w i t h l i c e n s i n g r e q u i r e m e n t s i n v o l v i n g p l a n t o p e r a t i o n w i l l be
enhanced by use o f r o b o t i c s . Examples are:

o Enhanced s e r v i c e i n i n s p e c t i o n c a p a b i l i t i e s

o M a i n t a i n i n g personnel exposure l i m i t s

o Automated d a t a a c q u i s i t i o n and r e c o r d i n g

K. Technology Needs

The l a s t s u b s e c t i o n of each of t h e areas covered i n S e c t i o n s B thru H

i d e n t i f i e s t h e technology needs f o r each of t h e areas discussed. These needs
I .i

53

are.summarized in the accompanying table which lists these needs under major
technical categories.

Within each technical category there i s a prioritization from top to bottom.

This categorization considers that robotic technology is being developed
outside of the nuclear industry. For instance, category 3 is based on
developments in other areas of robotics discussed under Developments Underway
and Contracts. There is also a prioritization implicit in the ordering o f the
columns, with the columns on the left deemed to have higher priority than
those on the right.

Robotics Technology Needs

On-board Re1 ia b i 1it y Environ- Mechan- Payload

D e c i s i o n Human Availability mental ical Cont r o l Smart
Category Prioritj lbbilitx Sensors Making factors Maintainability Hardening Standards System Systems -
Tool s
1 DOL must vertical spatial domain operator modularization radiation equipment
lead access location, specific control & interface decontam-
object intelli- console standards i n a b i 1i t y
recogni- pence inter-
tion face

2 WE obstruction force Expert mobile i n e r t atmos- Equipment higher multi- inspeci

applies avoidance feedback systems platform- phere & facility strength arm tion
1ever age tactile environ- standards t o weight L rnulti
ment t h r u ANSI ratio, axis
interface & other multi-
o r g a n i za- inter -
tions secting
degrees
of
freedom

3 DIT CM cableless vision, adaptive maintain temperature higher end cutting

exploit power & viewing & learning ability humidity, specific effect- welding
data lighting system chemical power ors L
trans- manuals motors grinding
mission

D e f i n i t i o n o f Categories

1. Unique t o n u c l e a r f a c i l i t i e s
2. Camon t o o t h e r a p p l i c a t i o n s , b u t c r i t i c a l f o r use i n n u c l e a r f a c i l i t i e s
3. Coommn t o o t h e r a p p l i c a t l o n s ; i m p o r t a n t but n o t c r i t i c a l f o r use i n n u c l e a r f a c i l i t i e s
 54

IV. DEVELOPMENTS UNDERWAY AND CONTACTS

Today's a c t i v i t y growth f o r r o b o t i c systems p a r a l l e l s t h e expansion

experienced t e n y e a r s ago i n semiconductor m i n i a t u r i z a t i o n and computer
development. Many e d u c a t i o n a l i n s t i t u t i o n s now o f f e r courses r e l a t i n g t o
r o b o t i c technology, and s e v e r a l have e s t a b l i s h e d c e n t e r s f o r t h e i n t e g r a t i o n
o f computer science, mechanical e n g i n e e r i n g , and e l e c t r i c a l e n g i n e e r i n g i n t o
r o b o t i c and automation research.

The n u c l e a r i n d u s t r y ' s h o t c e l l e f f o r t s a t n a t i o n a l l a b o r a t o r i e s r e s u l t e d i n
an advanced s t a t e of development of master-slave systems and dexterous end
effectors. Several companies have spun o f f and a r e b e g i n n i n g t o f o c u s t h i s
background of c a p a b i l i t y on r o b o t i c systems, e s p e c i a l l y those u t i l i z i n g m o b i l e
p l a t f o r m s . A n t i c i p a t i n g a market f o r r o b o t i c systems, s e v e r a l commercial
companies a r e moving r a p i d l y t o develop systems f o r s u r v e i l l a n c e and
maintenance. S p e c i f i c problems (e.g. steam g e n e r a t o r r e p a i r / r e m o v a l , core
b a r r e l removal) have r e s u l t e d i n v e r y s p e c i a l i z e d systems, now a v a i l a b l e f r o m
t h e n u c l e a r s e r v i c e marketp ace.

The accompanying t a b l e i s a summary o f t h e c u r r e n t s t a t u s of r o b o t i c s r e s e a r c h

and development programs i n l u d i n g u n i v e r s i t y research, n a t i o n a l l a b o r a t o r i e s ,
Government agencies, p r i v a t e companies, and f o r e i g n programs. Each o f these
c a t e g o r i e s are discussed i n t h e f o l l o w i n g paragraphs.

Universities

Among t h e u n i v e r s i t i e s , Carnegie-Mellon U n i v e r s i t y has t h e most e x t e n s i v e

program t h r o u g h i t s R o b o t i c s I n s t i t u t e , which was e s t a b l i s h e d i n 1979. The
t o t a l s t a f f i n c l u d i n g f a c u l t y , r e s e a r c h engineers, and s t u d e n t s exceeds 200.
The two major areas b e i n g developed a r e automation and c o m p u t e r - i n t e g r a t e d
m a n u f a c t u r i n g and r o b o t i c s f o r hazardous environments, i n c l u d i n g underseas,
space, n u c l e a r power p l a n t s , and deep mine s h a f t s . More t h a n two dozen
c o r p o r a t i o n s and s e v e r a l Government agencies p r o v i d e f u n d i n g f o r t h e
Institute .
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Clemson U n i v e r s i t y D r . Frank W. Paul Industrial The E n g i n e e r i n g Center f o r Auto-

E n g i n e e r i n g Center 803/656-3291 DOD mated M a n u f a c t u r i n g Technology was
f o r Automated e s t a b l i s h e d i n November 1981 t o
Manufacturing s u p p o r t e d u c a t i o n and r e s e a r c h
a c t i v i t i e s a t Clemson U n i v e r s i t y
i n automated machines and robo-
t i c s , computer-aided design,
m a t e r i a l s f o r m a n u f a c t u r i n g and
systems and i n d u s t r i a l engineer-
i n g . The Center works through
i t s i n d u s t r y members and con-
t r a c t o r s on problems r e l a t e d t o
automated manufacturing. The cn
Center i s supported by a l a b o r a - cn
t o r y h a v i n g r o b o t s , microcomputer
and two VAX 11/780 computers f o r
CAD a c t i v i t i e s .

Cal i f o r n ia I n s t it u t e Dr. C a r l F. Ruoff DOD M a j o r areas o f r e s e a r c h a c t i v i t y

o f Technology, J e t NASA i n c l ude;
Propulsion Industrial --Sensor-based m a n i p u l a t o r
L abor a t o r y con t r o 1
- - M u l t i - f i n g e r e d end e f f e c t o r s
- - O p e r a t i n g systems
--Languages
--Supervisory control
--Teleoperation
--Sensing and p e r c e p t i o n system
--Human f a c t o r s
--Automatic p l a n g e n e r a t i o n
--Machine I n t e l l i g e n c e
 ,

PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Massachussetts D r . Edwin H. P o r t e r , DOD Research i n understanding manu-

Institute of Jr., 617/258-2374 NASA f a c t u r i n g , processes (assembly,
Techno1 ogy, USBM t h r e a d mating, g r i n d i n g , etc. )
Char1 es Stock Industry p r i o r t o automating them. Ex-
Draper L a b o r a t o r y , p e r t i s e i n e n g i n e e r i n g models o f
Inc. processes, design o f i n s t r u m e n t a -
t i o n f o r process m o n i t o r i n g , e x -
p e r iment a1 v e r i f i c a t i o n . P a t e n t -
ed technology includes 6 axis
f o r c e / t o r q u e sensor, remote cen-
t e r compliances, i n s t r u m e n t e d
RCC's, i n s e r t i o n s t a t i o n s f o r
p r e c i s i o n parts. Consulting
s e r v i c e s on i d e n t i f y i n g auto-
m a t i o n t a r g e t s , economic a n a l y -
s i s , system c o n f i g u r a t i o n , p r o -
duct redesign. Recently b u i l t
and d e l i v e r e d s p e c i a l t o o i - c h a n g -
i n g r o b o t w i t h 12 t o o l s , computer
and sensors f o r complete docu-
mented assemply o f p r e c i s i o n
products .
MI T Dr. David Aiken NASA Research d i r e c t e d toward
Aeronautics & 617/253-7107 s t r u c t u r a l assembly o f space
A s t r o n a u t i c s Dept. stations. Currently testing
two t e l e o p e r a t e d v e h i c l e s ,
b o t h m a s t e r - s l a v e machines.

C i v i l Engr. Dept. Dr. Gregory U.S. Army Developing a device t o detect

Baecher l e a k s i n b u r i e d water pipes.
617/253-7101

Mechanical Engr. Dr. C a r l Peterson S t u d y i n g mechanical m i n i n g o f

Dept . 617/253-5373 underground c o a l d e p o s i t s .
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Renssel aer D r . Leo H a n i f i n NASA The C e n t e r ' s e f f o r t s a r e a

Polytechnic I n s t i t u t e , 518/270-6724 Industry balance of t e c h n o l o g i c a l develop-
Manufacturing Technology ment and appl ic a t i o n s r e s e a r c h
and P r o d u c t i v i t y Center and development r a t h e r t h a n
e f f o r t s d i r e c t e d t o w a r d course o r
c u r r i c u l u m . Funded by p r i v a t e
c a p i t a l , t h e C e n t e r ' s undertak-
ings are p r o j e c t o r problem
d r i v e n i n t h e area o f manufact-
u r i n g p r o d u c t i v i t y . The Center
s o l v e s r e a l m a n u f a c t u r i n g prob-
lems on t i m e and w i t h i n a budget. w
4
F i n a l l y , t h e Center, t h r o u g h i t s
"People P r o d u c t s " and s h o r t
courses, t r a n s f e r s t e c h n o l o g y
t h a t e x i s t s and i s c o n s t a n t l y
emerging f r o m R P I and o t h e r
sources, t o i n d u s t r y . The Cen-
t e r i s c u r r e n t l y involved i n a
broad spectrum of p r o j e c t s .
These i n c l u d e : t h e use o f i n t e r -
a c t i v e computer g r a p h i c s t o
c r e a t e and s i m u l a t e numerical
c o n t r o l tapes t o e l i m i n a t e c o s t l y
N/C t a p e v e r i f i c a t i o n on t h e
machine-tool; computer g r a p h i c
simulation o f i n d u s t r i a l robot
arms; t h e a d a p t a t i o n o f m i c r o -
processors and computers as con-
t r o l 1e r s t o r e p 1 ace manual, hard-
wires, o r CAM c o n t r o l l e r s ; t h e
use o f i n t e r a c t i v e computer
g r a p h i c s t o o p t i m i z e work s t a t i o n
l a y o u t f o r r o b o t i c assembly.
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCR1PTICi.c

John Reidy Wright P a t t e r - Design and c o n s t r u c t i o n of a

son AFB r o b o t i c engine r e p a i r
f a c i l i t y f o r t h e A i r Force.

OR NL Design o f a remote-weld-
r e p a i r system concept f o r
radioactive piping.

DARPA Devel oprnent o f an a d a p t i v e

suspension system f o r a
rugged t e r r a i n v e h i c l e ,
in c l u d i n g h y d r a u l ic devices
and t h e machine i n t e l l i g e n c e
system.

Georgia I n s t . of Dr. Dickerson 25 in d u s t r ia1 Programs i n m a n u f a c t u r i n g

Tech, A t l a n t a , GA 404/894-2000 Sponsors, I B M aut omat ion, veh i c l e guidance,
i s the largest t a c t i l e sensing, and h i g h
speed/l i g h t w e i g h t motion
system.

U. o f Maryland Dr. Yang DARPA, NSF, V i s i o n systems and human

ORNL, i n d u s t r y computer in t e r a c t ion. Have
( W-Columbia) program w i t h E P R I ( t h r o u g h
GE) on i n s p e c t i o n techniques.

U. o f Rochester ME: Dr. Benson G1 eeson One f u l l t i m e graduate

Rochester, NY 716/275 -7847 Memor ia1 Fund s t u d e n t (ME Dept) i s working
on v i s i o n systems. The EE
Dept. has a P r o d u c t i o n
Automation P r o j e c t which i s
d i r e c t e d a t t h e software
devel oprnent .
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

U. o f F l o r i d a Dr. Jack Ohanian DOE, S e l f , FL Program on-going f o r s e v e r a l y e a r s

Center f o r I n t e l l i - (904) 392-0464 State, I n d u s t r y t h r o u g h 1984 under t h e d i r e c t i o n
gent Machines and D r . Joe D u f f y o f D r . Del Tesar (J. D u f f y now
Robotics (CIMAR) (904) 392-0879
S t a f f approx. 20
.
a c t in g D i r e c t o r ) Appr ox imat e
f u n d i n g l e v e l i s $3M p e r year.
grad students- S p e c i f i c - a l l programs on-going
approx. 75 w i t h emphasis t o w a r d implementa-
tion
a. Real time/man-machine systems*
1) J o y s t i c k c o n t r o l l e r s (essen-
t i a l l y complete)
2 ) 4 degrees o f freedom (DOF)
planar control l e r
3 ) 6 DOF s p a t i a l c o n t r o l l e r
4 ) 7 DOF (1 redundant DOF)
cn
c o n t r o l 1e r a
5 ) Force feedback
b. Dynamics (Robot C o n t r o l
1) Phase I - c o r r e c t f o r i n -
e r t ia1 1o a d i ng
2 ) Phase I 1 - c o r r e c t f o r de-
f l e c t i o n / f l e x i b l e loading
c. G r a p h i c s - 3D
d. M u l t i p l e r o b o t systems
e. K i n e m a t i c s
f. Mathematics

U. o f Texas Dr. Delbert A i r Force Program i n i t i a t e d i n 1985 under t h e

Center f o r Robotics , Tes a r Self d i r e c t i o n o f D r . Del Tesar ( f o r m e r -
Manufacturing, and (512) 471-3039 Texas S t a t e l y w i t h Univ. o f F l o r i d a ) . F u n d i n g
Logi s t ics S t a f f , Grad Industry i s a p p r o x i m a t e l y $lM t o $2M f o r 1985
S t u d e n t development and i s expected t o i n c r e a s e t o $5M-
un d e r w ay $7M p e r y e a r .
(Expect 200 t o t a l ) a. M o b i l e r o b o t s * s u i t a b l e f o r
b a t t l e f i e l d operations.

* T h i s work i s p a r t i c u l a r l y a p p l i c a b l e t o t h e n u c l e a r i n d u s t r y because o f t h e u n s t r u c t u r e d environment o r i e n t a t i o n .

 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGAN I ZAT ION CONTACT SPONSOR PROGRAM DESCRIPTION

(chemical, b i o l o g i c a l , nuclear
environment)
1) r a p i d runway r e p a i r
2 ) f i r e - f i g h t i n g on c a r r i e r s
3 ) ammunition h a n d l i n g
4 ) maintenance/repair
5) riveting-deriveting
6 ) j e t engine r e p a i r

b. Manufacturing robots
1) f r e e - s t a n d i n g / d a t a b a s e
controlled

c. Advanced t e c h n o l o g y development
1) new computer a r c h i t e c t u r e s
2 ) improved man-machine i n t e r -
face
3 ) mat hemat ic s
4) dynamic modeling
5 ) advanced s e n s o r s / v i s i o n
6) manipulators/end e f f e c t o r s /
materials
7 ) m i n i a t u r i z e d systems/sensor s
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Drexel Univ. Dr. A1 exander DOD Developed s o f t w a r e f o r a

Meyes t e 1 m o b i l e system ( t a n k ) w i t h
three d i s t i n c t levels of
intelligence f o r terrain
negot ia t ion.

Stevens I n s t . Dr. John Crisp U.S. Army Work i n t e l e m a t i c s . Courses

o f f e r e d i n microprocessors
and one i n r o b o t i c s .

U. o f Rhode I s l a n d Dr. M o r r i s D r i e l s Funds Others Program d i r e c t e d toward

i n d u s t r i a l applications that
involve fixed-position
r o b o t s . e.g., t o recognize cr\
and remove a p a r t f r o m a b i n w
o f parts.

Develop i n t e r d i s c i p l i n a r y
Brigham-Young Dr. Edward Red Self, Industry systems i n c l u d i n g v i s i o n ,
University (801) 378-5539 CAE, CAD, and r o b o t i c s f o r a u t o -
25 F a c u l t y , 509 mated manufacturing. Program es-
students, 100 t a b l i s h e d a few y e a r s ago and i s
grad. students on-go ing .
a. Systems devel opment/implementa-
tion
1) r o b o t s
2 ) CAE/CAD
3) Vision
4) d i g i t a l transmission
5 ) software
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

UCLA D r . Geo. A. Bekey Government Courses and R&D i n A I ,

2131743-5535 Industry m a n u f a c t u r i n g technology,
r o b o t i c s , and automat ion.

S t a n f o r d Univ. D r . E l l i o t t C. About 25 sponsors, Interdisciplinary

I n s t . f o r Manu- Lev in t ha1 i n c l u d i n g IBM, NSF organization with four major
f a c t u r ing and 4151497-9037 NASA, M e t t l e r AG, SDF, c e n t e r s whose end-products
Aut omat ion AFOSR, DARPA, DNA, a r e graduates, r e s e a r c h
E P R I , and others. r e s u l t s , and e d u c a t i o n a l
.
a c t iv i t i e s

Robotics I n s t . D r . Raj Reddy Government Large, i n t e r d i s c i p l i n a r y

Carnegie-Me1 l o n 412/578-2597 I n d u s t r y (30+) research center studying
Univ. DOE, DARPA, autonomous systems capable of
EPRI, G R I sensing, t h i n k i n g and
acting.

R o b o t i c s I n s t i t u t e was e s t a -
b l i s h e d i n . 1 9 7 9 and has more t h a n
200 s t a f f and students. A c t i v e i n
automation, c o m p u t e r - i n t e g r a t e d
m a n u f a c t u r i n g and r o b o t i c s f o r ha-
zardous environments, i n c l u d i n g
n u c l e a r and deep mine s h a f t s .
Funding i s approx. $9M p e r year.

U. o f C a l i f o r n i a David R. C r i s w e l l NASA E s t a b l i s h e d t h e Automation

L a J o l l a , CA 6191452-2047 and R o b o t i c s Panel t o p r o v i d e
CA Space I n s t . gu idance on t h e appl ic a t ion
o f advanced automation and
r o b o t i c s t o t h e I O C program. ,

U. o f Nevada-Reno Dr. N.D. P e r r e r i a DOE Evaluation o f o p t i c sensors

7021784-6094 f o r remote maintenance o f - i

reprocessing fuel f a b r i c a t i o n
equipment. ,.
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM D E S C R I P T I O N

U. of Warwick European Atomic Decommissioning s t u d i e s .
Energy Commission

Japan Advanced Ministry of Development o f h i g h

Robot Techno1 ogy International performance r o b o t w i t h
Association Trade & I n d u s t r y sufficient versatility t o
work i n n u c l e a r r e a c t o r
mai ntenance.
Kansai E l e c t r i c Mitsubishi, Fuji, Robots f o r o p e r a t i o n s i n s i d e
Power Company H i t a c h i , Medensha steam g e n e r a t o r channel head,
E l e c t r i c Mfg. Co. valve seal tensioning,
manhole c o v e r h a n d l i n g , f l o o r
d e c o n t a m i n a t i o n , and p i p e
m
elbow i n s p e c t i o n . w

Atomic Energy o f D r . C l i v e Wood Developing pressure tube

Canada, L t d . i n s p e c t i o n system.
Japan Power Demon- Four Japanese Completing r e s e a r c h and
s t r a t i o n Reactor construction development on
companies decommissioning
capabilities.
U n i t e d Kingdom C e n t r a l D.W. Perratt U.K. Development of s o p h i s t i c a t e d ,
E l e c t r i c i t y Generating heavy d u t y m a n i p u l a t o r s w i t h arm
Board-Marchwood Eng. Lab. e x t e n s i o n s and t o o l s ( b o l t i n g and
w e l d i n g ) f o r remote r e p a i r o f
Magnox s t a t i o n s .
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DE SCR IPT I O N

FRG K e r n f o r - R o b o t i c system f o r f u e l
shun gszen t r aum handlng, m o b i l e v e h i c l e
K a r l s r u h e GmbH waste p r o c e s s i n g and
decommissioning.

Westinghouse- Dr. R.E. Dah1 DOE Design , d e v e l opment ,

Hanford Co. 509/376-8724 procurement, i n s t a l l a t i o n and
o p e r a t i o n of automated,
r e m o t e l y c o n t r o l l e d LMR f u e l
f a b r i c a t i o n l i n e . Over 20
robots are u t i l i z e d .

J.D. Berger Sandia Development o f High Level

Waste S h i p p i n g C o n t a i n e r
m
handling during truck c
loading/unloading. Uses
r o b o t and overhead crane.

Oak Ridge Dr. W.D. Hamel DOE Development and d e m o n s t r a t i o n

Nat. Lab. Fuel Cycle 615/574-5961 o f f o r c e - r e f 1e c t ing b i 1 a t e r a l
Program s e r v o - m a n i p u l a t o r f o r use i n
r e p r o c e s s i n g system o p e r a t i o n &
maintenance, advanced d i g i t a l
c o n t r o l , man-machine upgrades &
r e m o t e TV system. Funded a t a
mu1t i m i 11 i o n d o l 1a r l e v e l .

Oak Ridge Nat. Lab. C. Weisbir DOE Develop and t e s t advanced

(CESAR 1 c o n t r o l systems and A I l o g i c
f o r aut onornous ve h ic l es .
Savannah R i v e r J.J. F i s h e r DOE Application of robotics i n
Nat. Lab. v a r i o u s o p e r a t i o n s such as
 ' -

PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION
"bag out" o f waste cans from
a Cf source processing
facility; radioactive sample
collection; transfer of nuclear
sources and evaluation of walking
robots .
Battelle Memorial Inst. Matt Bartilson Self Developed mobile radio-con-
trolled platform (ROCOMP)
with mani pul ator for
maintenance in nuclear power
plants. Can also be used for
.
gat her i ng smear samp 1 es
Westinghouse Hanford W. Gajewski DOE Deve 1 oped the eq u i pment , m
Company (509) 376-9586 systems and facilities for the Ln
maintenance, in-service
inspection, and surveillance
of the FFTF. Provided SISI
and LOUIE mobile robots for TMI-2.
Defense Advanced C. Kelly, I11 Supports several university,
Research Projects industry and military
Agency (DARPA) research and development
efforts encompassing most
aspects of both stationary
oil mobile systems.
National Bureau Dr. James Self Research in artificial
of Standards A1 bus intelligence applied to
(301 921-1000 interactive/autonomous
robots.
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Los Alamos DOE D e v e l o p i n g a r o b o t f o r use i n

Nat. Lab. w e i g h i n g and c a l o r i m e t r y o f
238Pu o x i d e f o r r a d i o c h e m i c a l
assay o f Pu and Am.

E 1e c t r i c Power J. T a y l o r U.S. member M o b i l e systems f o r

Research I n s t i t u t e 415/855-2030 u t i 1i t i e s s u r v e i l l a n c e and maintenance
work. Support TMI-2 c l e a n u p
w i t h s p e c i f i c remote
vehicles, i n conjunction w i t h
CMU.
m
Automated Unamned J. Canoe P r o m o t i n g t h e development o i l m
t e s t i n g o f a i r b o r n e and
t e r r i s t r i a1 v e h i c l e s ; main
f o c u s has been on m i 1 it a r y
appl ic a t ions.

Public Service E l e c t r i c H. Roman Self U t i l i t y i s assessing needs and

Gas o f NJ f o r r o b o t i c systems i n g e n e r a t i n g
s t a t i o n s working w i t h several
nearby u n i v e r s i t i e s (e.g.
NS I T 1
 "I
I.
PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGAN I ZAT ION CONTACT SPONSOR PROGRAM DESCRIPTION

GCA/PaR Systems R. Johnston O f f e r manipulators, I S 1

systems, r o b o t i c system
c o n t r o l f o r IFA.
Manufactured t h e Herman r o b o t
now a t ORNL's Y-12 f a c i l i t y .
V i k i n g Energy J. S a l u j a Developed t h e ROD r o b o t f o r
Corporation cleanup of r a d i o a c t i v e waste
a t t h e West V a l l e y
Demonstration p r o j e c t .

Remote Technology J.R. White NRC Developed t h e Surbot m o b i l e

Corp. r o b o t under SBIR f u n d i n g ;
o t h e r m a s t e r - s l ave
m a n i p u l a t i o n systems.

F o s t e r -Mi 11e r , I nc . R. Wiesman U.S. Navy Developed and p r o v i d e d t h r e e

Ramrod EOD m o b i l e systems t o
t h e sponsor.
 PARTIAL SUMMARY OF ROBOT ICs DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Oepar tment o f Defense Congress Supports numerous A I

(DOD) development e f f o r t s , and
several engineering
application projects t o
develop and t e s t s p e c i f i c
hardware systems.

SAS R&D Services, T.R. Sas Self Devel oped and commerci a1 l y
Ltd. (I) o f f e r t h e Hunter remote
c o n t r o l l e d EOD v e h i c l e .

CMS Techno1 ogies C. Stephens U.S. r e p r e s e n t a t i v e f o r

I n c . (I systems devel oped by 91 ocher
i n t h e FRG.
cn
co
T e l e Operator System C. F l a t t a u O f f e r t h e Telemac, a r a d i o
(1) c o n t r o l l e d , remote o p e r a t i n g
v e h i c l e developed i n B e l g i u m
b y ACEC and o t h e r s .
 , .-

PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION CONTACT SPONSOR PROGRAM DESCRIPTION

Spar Aerospace I.P. Stefou M a n i p u l a t o r systems f o r

Limited i n d u s t r y and h o s t i l e
environments.

Odetics, Inc. T. B a r t h o l e t Self Developed t h e s i x - l e g g e d

r o b o t p r o t o t y p e ODEX.

Automation R. Simmons EPRI, Gould Developed and o f f e r t h e I R I S

Techno1 ogy Surveyor system f o r
Corporation s u r v e i 11 ance.

Hitachi S. Kuwahara Developed and o f f e r t h e H i -

Corporation Mante remote-operated
manipulator v e h i c l e f o r
decommissioning.

Rockwell J. Schoenwald Research and development on

International a c o u s t i c r a n g i n g systems and
Science Center robot position control.
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGAN IZAT ION C 0NTACT SPONSOR PROGRAM DESCRIPTION

Babcock and W lcox I J. Kerr Self Remote i n s p e c t i o n and

C o n t r a c t Research m o n i t o r i n g systems, i n c l u d i n g
Division steam g e n e r a t o r t u b e r e p a i r
i n s p e c t i o n system.

Shimizu T. Yoshino With Kobe S t e e l , d e v e l o p e d

C o n s t r u c t i o n Co., Ltd. and o f f e r a r o b o t f o r
s p r a y i n g r o c k wool f o r t h e
fireproofing of structural
steel.

Honeywell, Inc. R. Mostrom Developed and promotes 3-D TU

Techno1 ogy S t r a t e g y v i e w i n g systems, p o w e r - l i n e
Center c a r r i e r systems, r a n g e f i n d i n g 4
systems, and v a r i o u s 0
communications systems
technologies.

SRI International D. N i t z a n NSF and o t h e r s Research and A r t i f i c i a l

I n t e l l i g e n c e and r o b o t i c
manipulators.

,
.-
\.
 PARTIAL SUMMARY OF ROBOTICS DEVELOPMENT PROGRAM AND CONTACTS

ORGANIZATION C 0NTACT SPONSOR PROGRAM DESCRIPTION

General E l e c t r i c M r . Vern Estes Self E x t e n s i v e r o b o t i c s hardware/

Company ( 305 ) 889-1401 software a p p l i c a t i o n s develop-
ment. "Factory w i t h a Future"
program i n c o r p o r a t i n g r o b o t s ,
v i s i o n , sensors and manufact-
u r i n g systems.
GE Corporate Research and Dev-
elopment Center Advanced R&D
i n areas such as computers,
languages, assembly r o b o t s ,
CAE/CAD and Laser weld t r a c k -
i n g v i a robotics.

Candi an General Barry O'Sull ivan Self M o n i t o r i n g and i n t e r v e n t i o n 4

Electric (705 ) 748-7183 systems f o r f u e l h a n d l i n g . w
Underwater r o b o t i c s system
w i t h f o r c e sensor feedback.
Westinghouse E l e c t r i c C. A. Sadlow, V.P. Self Manufacturers o f Unimate r o b o t s
Corporation Adv. Prod. Tech. s e l f -funded devel opment o f ad-
412/642-3811 vanced e l e c t r i c - d r i v e n r o b o t s ,
v i s i o n systems, laser/MIG a u t o -
mated w e l d i n g system, a r t i f i c i a l
i n t e l l i g e n c e . Supported by P r o -
d u c t i v i t y Center and R&D Center.
R o b o t i c & remote operated e q u i p -
ment developed f o r n u c l e a r a p p l i -
c a t ions.

J. G i t t Design s t u d i e s o f an autonomous
Oceancies D i v i s i on underseas v e h i c l e f o r DOD.
30 1/ 260 - 5 804

1
 72

The Center f o r I n t e l l i g e n t Machines and Robotics a t t h e U n i v e r s i t y o f F l o r i d a

has t w e n t y s t a f f members and 75 graduate students. I t s programs a r e d i r e c t e d
a t r e a l time/man-machine systems w i t h m u l t i p l e degrees o f freedom and f o r c e -
feedback. The Center i s a l s o s t r o n g i n 3D-graphics, kinematics, and
mathematical analyses.

The U n i v e r s i t y o f Texas i n i t i a t e d a Center f o r Robotics, Manufacturing, and

L o g i s t i c s i n 1985 under t h e d i r e c t i o n of D r . Del Tesar ( f o r m e r l y D i r e c t o r o f
t h e CIMAR c e n t e r a t t h e U n i v e r s i t y of F l o r i d a ) . The planned program w i l l
focus on m o b i l e r o b o t s f o r b a t t l e f i e l d o p e r a t i o n s , m a n u f a c t u r i n g r o b o t s , and
advanced techno1 ogy development.

The I n s t i t u t e f o r M a n u f a c t u r i n g and Automation a t S t a n f o r d U n i v e r s i t y i s an

i n t e r d i s c i p l i n a r y o r g a n i z a t i o n w i t h more t h a n 25 i n d u s t r i a l sponsors. This
I n s t i t u t e i s exceptionally strong i n a r t i f i c a l intelligence.

The Massachussetts I n s t i t u t e o f Technology has s e v e r a l r o b o t i c s programs

w i t h i n i t s departmental s t r u c t u r e , i.e., i n t h e Aeronautics and A s t r o n a u t i c s
Department, C i v i 1 E n g i n e e r i n g Department, and Mechanical E n g i n e e r i n g
Department. I n a d d i t i o n , t h e Charles S t a r k Draper Laboratory, Inc., is
p e r f o r m i n g r e s e a r c h i n automated manufacturing.

An E n g i n e e r i n g Center f o r Automated M a n u f a c t u r i n g Technology was e s t a b l i s h e d

a t Clemson U n i v e r s i t y i n 1981. The c e n t e r performs r e s e a r c h i n automated
machines and r o b o t i c s , computer-aided design, and m a t e r i a l s .

Government Agencies

R o b o t i c s development programs a r e b e i n g performed f o r s p e c i f i c a p p l i c a t i o n s

f o r i n d i v i d u a l branches of t h e Department o f Defense and f o r t h e o v e r a l l
M a n u f a c t u r i n g Technology Program (ManTech). Several U.S. Army programs a r e
d i r e c t e d toward hazardous m a t e r i a l s hand1 i n g and mob l e r o b o t s f o r b a t t l e f e l d
operations.
The'U.S.
-, Navy i s d e v e l o p i n g i n t e l l i g e n t r o b o t s f o r a p p l i c a t i o n s t h a t a r e
unique t o naval a p p l i c a t i o n s , such as s h i p b u i l d i n g and weapons manufacture,
r e p a i r maintenance, and o p e r a t i o n s . As p a r t o f t h e Navy Manufacturing
Technology Program, automated, a d a p t i v e r o b o t i c metal a r c w e l d i n g systems a r e
being investigated. Advanced t e c h n o l o g i e s i n c l u d e weld seam t r a c k i n g ,
c o l l i s i o n avoidance, and r e a l - t i m e weld process c o n t r o l . A passive t h r e e
dimensional v i s i o n system i s a l s o b e i n g developed f o r use w i t h t h i s welding
system. An a r t i c u l a t e d l a s e r r o b o t i c w e l d i n g system w i t h automated weld seam
t r a c k i n g i s a l s o b e i n g developed by t h e Navy.

The Naval Surface Weapons Center has been i n v e s t i g a t i n g m o b i l e r o b o t s f o r use

i n s e c u r i t y and f i r e f i g h t i n g a p p l i c a t i o n s . Sonar and i n f r a - r e d sensors
p r o v i d e t h e r e q u i r e d c o n t r o l data. The m o b i l e system i s modular so t h a t
updated components can be s u b s t i t u t e d as improvements i n technoogy a r e
ac h ieved .
The Naval Oceans Systems Center i n San Diego, C a l i f o r n i a has r e s p o n s i b i l i t y
f o r maintenance o f a R o b o t i c s and A r t i f i c i a l I n t e l l i g e n c e Database ( R A I D ) f o r
a l l Department o f Defense r e s e a r c h in these areas. T h i s on-line, computer
d a t a base can p r o v i d e summaries o f c u r r e n t programs , funding, and c o n t r a c t u a l
and o r g a n i z a t ional in f ormat ion.

The N a t i o n a l A e r o n a u t i c s and Space Agency (NASA) has sponsored t h e development

of remote systems f o r space a p p l i c a t i o n s , i n c l u d i n g remote s u r v e i l l a n c e and
sampling systems, image enhancement software, and a r e m o t e l y - o p e r a t e d
m a n i p u l a t o r system. A r e p o r t has been prepared f o r NASA a t t h e d i r e c t i o n o f
Congress by an Advanced Technology A d v i s o r y Committee.

T h i s r e p o r t , which i d e n t i f i e d advanced automation and r o b o t i c s t e c h n o l o g i e s

f o r t h e space s t a t i o n , recommended a 10 y e a r development program r e a c h i n g a
maximum annual f u n d i n g o f $lOOM t o $ZOOM. T h i s r e p o r t was o r g a n i z e d and
c o o r d i n a t e d by t h e C a l i f o r n i a Space I n s t i t u t e and i n c l u d e d p a r t i c i p a n t s f r o m
universities, industry, national laboratories, and NASA.
 I r ”, ,
74 ’.

NASA-Langley Research Center has an a c t i v e r e s e a r c h program i n t e l e -

operator/robotics. T h i s r e s e a r c h i s based on an I n t e l l i g e n t Systems Research
L a b o r a t o r y w i t h a c t i v a t o r s , sensors, computers, and g r a p h i c s d i s p l a y , a
k i n e m a t i c s i m u l a t i o n of t h e r o b o t i c systems, a d i s t r i b u t e d a r t i f i c i a l
i n t e l l i g e n c e system and a r e c o n f i g u r e a b l e o p e r a t o r c o n t r o l s t a t i o n . An
i n t e g r a t e d micro-processor c o n t r o l l e d end e f f e c t o r w i t h force, t o r q u e and
p o s i t i o n feedback i s b e i n g tested.

NASA-Ames Research L a b o r a t o r y i s t h e f o c a l p o i n t f o r a r t i f i c i a l i n t e l l i g e n c e
r e s e a r c h f o r space a p p l i c a t i o n s . Research has been c a r r i e d o u t t h e r e f o r b o t h
1anguage s e l e c t i o n and p r o c e s s i n g a r c h i t e c t u r e .

The Department o f Energy i s sponsoring a comprehensive program f o r t e l e -

operated, remote maintenance a t ORNL i n support o f t h e Fuel Recycle Program.
Developments i n c l u d e an advanced m a n i p u l a t o r , operator/machine i n t e r f a c e
systems and a r e m o t e l y operated t r a n s p o r t e r . Several m o b i l e systems have been
developed f o r use i n r a d i o a c t i v e environments, i n c l u d i n g e a r l y models a t HEDL
and ORNL, and c u r r e n t m o b i l e systems f o r TMI developed a t Carnegie-Mellon
University.

Since t h e s e o t h e r Government programs w i l l develop t e c h n o l o g i e s needed f o r use

i n r o b o t i c s used i n t h e n u c l e a r i n d u s t r y , i t i s i m p o r t a n t f o r DOE t o reach
agreements w i t h these agencies on t h e s h a r i n g of data. By l e v e r a g i n g
t e c h n o l o g i e s f r o m t h e s e Government programs, t h e investment i n development f o r
r o b o t i c s i n t h e n u c l e a r i n d u s t r y can be minimized w i t h t h e maximum b e n e f i t s t o
the industry.

F o r e i g n Programs

Japan i n i t i a t e d an e i g h t year n a t i o n a l r o b o t i c s development program i n 1984.

T h i s $150M program i n c l u d e s development of maintenance r o b o t s f o r t h e n u c l e a r
industry. Appendix A i s a p a r t i a l t r a n s l a t i o n of t h i s plan.
 75

The U n i t e d Kingdom t h r o u g h t h e Marchwood E n g i n e e r i n g L a b o r a t o r y o f t h e C e n t r a l

E l e c t r i c i t y Generating Board has developed a r o b o t i c system f o r t h e r e p a i r of
Magnox S t a t i o n s (gas-cooled power r e a c t o r s ) . These manipl u a t o r s a r e operated
over a l a r g e d i s t a n c e f r o m t h e t o p o f t h e r e a c t o r and c a r r y t o o l s f o r remote
b o l t i n g and welding operations.

I n France, E l e c t r i c i t e ' de France (EdF) has developed remote m a n i p u l a t o r s and

s p e c i a l t o o l s f o r t h e maintenance o f LWR p l a n t s . These r o b o t i c systems a r e
s i m i l a r t o those developed i n t h e U.S. f o r maintenance of LWRs. Hispano-Suiza
has p r o v i d e d an advanced r o b o t i c system named I S I S f o r EdF t o p e r f o r m
maintenance on t h e CHINON A3, a gas c o o l e d r e a c t o r . The ISIS sys'tem i s
mounted on a mast which can v a r y f r o m 16 t o 28 f e e t i n length; t h e arms have
a r e a c h o f 8 f e e t and can handle a l o a d o f 150 pounds when fu l y extended f r o m
t h e mast. The t o t a l system has e i g h t degrees o f freedom, two i n t h e mast and
s i x i n t h e arm. The system i s computer c o n t r o l l e d and uses a e l e c t r o -
h y d r a u l i c system. S p e c i f i c t o o l i n g can be a t t a c h e d f o r g r i n d ng, welding, o r
hand1 ing.

Industry

Most l a r g e U.S. c o r p o r a t i o n s have major e f f o r t s i n r o b o t i c s because of t h e

obvious need t o automate manufacturing i n order t o remain c o m p e t i t i v e . The
d e t a i l s o f these p r o j e c t s a r e n o t a v a i l a b l e because of t h e c o m p e t i t i v e n a t u r e
o f the robotics industry. However, some of these c o r p o r a t i o n s w i t h l a r g e
r o b o t i c s e f f o r t s are: General Motors, General E l e c t r i c , IBM, Westinghouse,
Rockwell, C i n c i n n a t i - M i l l i c r o n . I n a d d i t i o n , t h e r e a r e a number o f small
firms specializing i n robotics.
 , ' e .7

.' 77

P
REFERENCES

1. " A p p l i c a t i o n o f Robotics i n Remote Nuclear Fuel F a b r i c a t i o n Operations,

D. Nyman and T. Nagamoto, Canadian Nuclear S o c i e t y Meeting on Robotics
and Remote Handling i n t h e Nuclear I n d u s t r y Proceedings, Toronto, Canada,
September, 1984.

~ 2. " P o t e n t i a l Uses o f Remote Handling and R o b o t i c Techniques i n t h e Back End

of t h e Fuel Cycle", N. P. Reynolds, T. Tabe, N. Fenton and P.
Baumgartner, ibid.

3. "Analysis o f t h e O p t i o n s - R a t i o n a l e for Servomanipulator Maintenance i n

F u t u r e Reprocessing P l a n t s " , J. N. Herndon and W. R. Hamel, Proceedings
o f t h e 1984 ANS N a t i o n a l T o p i c a l Meeting i n Robotics and Remote h a n d l i n g
i n H o s t i l e Environment". G a t l i n b u r g , TN, A p r i l 1984.

4. "The Advancement of Remote Systems Technology: Past P e r s p e c t i v e and

F u t u r e PlansLL, W. R. Hamel and M. J. Feldman, i b i d .

5. " F i n a l Report, Nuclear Reactor Maintenance Technology Assessment", CIMAR

D. Tesar, D i r e c t o r , U n i v e r s i t y o f F l o r i d a , March 1980.

6. IIWorkshop t o D e l i n e a t e t h e Economic and Pol i c y Issues f o r Remote

Maintenance on Energy Systems", D. Tesar, CIMAR, University o f Florida,
March 9-10, 1981.
'.#
.
.?

79

.
Appendix A
P

T r a n s l a t i o n o f s e l e c t e d P a r t s o f " R o b o t i c s f o r Nuclear F a c i l i t i e s , " J o u r n a l of

t h e Atomic Energy S o c i e t y of Japan, Vol. 25, No. 11, p. 857-894 (1983)
c o n s i s t i n g o f T a b l e of Contents, a Summary T a b l e and Schedule.
\
 81

I.* Remote M a n i p u l a t i o n Technology i n Nuclear F a c i l i t i e s

F
11. C u r r e n t S t a t u s of Remote M a n i p u l a t i o n Technology i n Nuclear F a c i l i t i e s

1. Automation i n BWR Power P l a n t s

2. Automation i n PWR Power P l a n t s
3. Remote M a n i p u l a t i o n Technology i n Reprocessing Facilities
4. Remote M a n i p u l a t i o n Technology i n P o s t - I r r a d i a t i o n T e s t F a c i l i t i e s

111. Examples of Remote M a n i p u l a t i o n Technology Development i n Nuclear

Facilities

1. BWR Power P l a n t A p p l i c a t i o n
2. PWR Power P l a n t A p p l i c a t i o n
3. Nuclear F u e l R e c y c l i n g F a c i l i t y A p p l i c a t i o n

R&D of Robots f o r Nuclear A p p l i c a t i o n

1. BWR
2. PWR
3. Power P l a n t Decommissioning
4. General Purpose
Robots f o r Extreme C o n d i t i o n s
( N a t i o n a l P r o j e c t of t h e S t a t e - o f - t h e - A r t R o b o t i c s Technology
Development)
 82

ITEM GOAL
4

Nuclear Related Robots Deveiop r o b o t s capable o f p e r f o r m i n g

complex t a s k s such as, i n s p e c t i o n ,
maintenance and r e p a i r o f equipments
through r e m o t e ’ o p e r a t o r ’ s commands, i n
n u c l e a r r e l a t e d f a c i l i t i e s such as
n u c l e a r power p l a n t s .

O f f Shore O i l Development
Support Robots

D isaster

Systems Development Develop systems capable o f e f f i c i e n t

mobility on irregular surface such as,
s t a i r s , and s l o p e u s i n g l e g s and
wheel s.

Develop systems capab e o f p e r f o r m

f l e x i b l e and sk l l f u l m a n i p u l a t i o n
through t h e use o f m u l t i p l e
j o i n t / f i n g e r manipulator.

C o n t r o l Techno1 ogy Develop autonomous systems f o r r o b o t s .

. '.'
.
*'i
- .
.
+ '
1. 8 years s t a r t i n g a t 1983.
83

JAPANESE NATIONAL ROBOTICS PROGRATI

2. 20 B i l It z 80 M$

1984 1985 1986 1987 1988

r 1989 1990
I I T

High Re1 lab111 t y

Techno1ogy

Ridiition-Resistent
Tec_hnology

Envlromnt
Response
Techno1ogy

TOTAL SYSTEM -Design

Detail anufacture
Exoeriment
P o r i t i o n Ma intenance
While Moving Under Set

Under Sea Vision

Under Sea Manipulatiol

Technology

lOTAL system - Design

Detail Manufacture and
Exoeriment
i g h Temp. P r e s .
lamable Gas, Dust
e s i stent

iearch Technology"

erform Ne5essary
Tasks

-Deirgn
k:ail Manufacture an
Exoeriment
rstems Development

i n t r o l Technology

PPort Technology

*U.S. GOVERNMENT P R I N T I N G OFFICE: 1986-491-177:50014