（RE-01471）ITER第一壁初期組立用機器プロトタイプの製作【掲載期間：2026-03-24～2026-05-18】

（RE-01471）ITER第一壁初期組立用機器プロトタイプの製作【掲載期間：2026-03-24～2026-05-18】 1/4入札公告次のとおり一般競争入札に付します。令和8年3月24日国立研究開発法人量子科学技術研究開発機構 那珂フュージョン科学技術研究所 管理部長 山農宏之◎調達機関番号 804 ◎所在地番号 08○第2号１調達内容(1)品目分類番号 24(2)購入等件名及び数量 ITER第一壁初期組立用機器プロトタイプの製作 一式(3)調達件名の特質等 入札説明書及び仕様書による。(4)納入期限 令和9年10月29日(5)納入場所 国立研究開発法人量子科学技術研究開発機構 那珂フュージョン科学技術研究所(詳細は仕様書による)(6)入札方法 落札決定に当たっては、入札書に記載された金額に当該金額の10パーセントに相当する額を加算した金額(当該金額に1円未満の端数があるときは、その端数金額を切り捨てるものとする。)をもって落札価格とするので、入札者は、消費税及び地方消費税に係る課税事業者であるか免税事業者であるかを問わず、見積もった契約金額の110分の100に相当する金額を入札書に記載すること。２競争参加資格(1)国立研究開発法人量子科学技術研究開発機構契約事務取扱細則第10条の規定に該当しない者であること。ただし､未成年者、被保佐人又は被補助人であって、契約締結のために必要な同意を得ている者については、この限りではない。(2)国立研究開発法人量子科学技術研究開発機構契約事務取扱細則第11条第1項の規定に該当しない者であること。(3)令和7年度に国の競争参加資格(全省庁統一資格)を有している者であること。なお、当該競争参加資格については、令和7年3月31日付け号外政府調達第57 号の官報の競争参加者の資格に関する公示の別表に掲げる申請受付窓口において随時受け付けている。(4)調達物品に関する迅速なアフターサービス・メンテナンスの体制が整備されているこ2/4とを証明した者であること。(5)当機構から取引停止の措置を受けている期間中の者でないこと。(6)当機構が要求する技術要件を満たすことを証明できる者であること。３入札書の提出場所等(1)入札書の提出場所、契約条項を示す場所、入札説明書の交付場所及び問い合わせ先〒311-0193 茨城県那珂市向山801番地1国立研究開発法人量子科学技術研究開発機構那珂フュージョン科学技術研究所 管理部契約課 電話(直通)029-277-7958E-mail: nyuusatsu_naka@qst.go.jp(2)入札説明書の交付方法 本公告の日から上記3(1)の交付場所にて交付する。また、電子メールでの交付を希望する者は必要事項(公告掲載日、件名、住所、社名、担当者所属及び氏名、電話番号)を記入し3(1)のアドレスに申し込むこと。ただし、交付は土曜、日曜、祝日及び年末年始(12月29日~1月3日)を除く平日に行う。(3)入札書の受領期限 令和8年6月15日午後1時30分(4)開札の場所及び日時 国立研究開発法人量子科学技術研究開発機構 那珂フュージョン科学技術研究所 管理研究棟１階 入札室令和8年6月15日 午後1時30分４その他(1)契約手続に用いる言語及び通貨 日本語及び日本国通貨(2)入札保証金及び契約保証金 免除(3)入札者に要求される事項 この一般競争に参加を希望する者は、封かんした入札書及び入札説明書に定める書面を本公告及び入札説明書に定める期限までに提出しなければならない。入札者は、開札日の前日までの間において、当機構から当該書類に関し説明を求められた場合は、それに応じなければならない。(4)入札の無効 本公告に示した競争参加資格のない者の提出した入札書、入札者に求められる義務を履行しなかった者の提出した入札書、その他入札説明書による。(5)契約書作成の要否 要(6)落札者の決定方法 本公告に示した物品を納入できると契約責任者が判断した入札者であって、国立研究開発法人量子科学技術研究3/4開発機構が作成した予定価格の制限の範囲内で最低価格をもって有効な入札を行った入札者を落札者とする。(7)手続における交渉の有無 無(8)その他 詳細は入札説明書による。なお、入札説明書等で当該調達に関する環境上の条件が定められている場合は、十分理解した上で応札すること。５ Summary(1)Official in charge of disbursement of theprocuring entity; Hiroyuki Yamano,Director of Department of AdministrativeServices, Naka Institute for Fusion Scienceand Technology, National Institutes forQuantum Science and Technology(2)Classification of the products to beprocured ; 24(3)Nature and quantity of the products to bepurchased ; Manufacture of Prototypes forFirst Assembly of ITER First Walls, 1set(4)Delivery period ; By 29 Oct. 2027(5)Delivery place ; Naka Institute for FusionScience and Technology, NationalInstitutes for Quantum Science andTechnology(6)Qualifications for participating in thetendering procedures ; Suppliers eligible forparticipating in the proposed tender arethose who shallA not come under Article 10 of the Regulationconcerning the Contract for NationalInstitutes for Quantum Science andTechnology, Furthermore, minors, Personunder Conservatorship or Person underAssistance that obtained the consentnecessary for concluding a contract may beapplicable under cases of special reasonswithin the said clause,B not come under Article 11(1) of theRegulation concerning the Contract forNational Institutes for Quantum Scienceand TechnologyC have qualification for participating intenders by Single qualification for everyministry and agency during fiscal 2025,D prove to have prepared a system to provide4/4rapid after-sale service and maintenancefor the procured products,E not be currently under suspension ofbusiness order as instructed by NationalInstitutes for Quantum Science andTechnology,F be able to prove that the technicalrequirements required by the NationalInstitutes for Quantum Science andTechnology are met. (7)Time limit for tender ; 1:30PM, 15 Jun.2026(8)Contact Section; Contract Section,Department of Administrative Services,Naka Institute for Fusion Science andTechnology, National Institutes forQuantum Science and Technology, 801-1Mukouyama, Naka-shi, Ibaraki-ken Japan,TEL：029-277-7958E-mail:nyuusatsu_naka@qst.go.jp(9)Please note the environmental conditionsrelating to the procurement if they are laiddown in the tender documents. ITER第一壁初期組立用機器プロトタイプの製作Manufacture of Prototypes for First Assembly of ITER First Walls仕 様 書国立研究開発法人量子科学技術研究開発機構那珂フュージョン科学技術研究所 ＩＴＥＲプロジェクト部遠隔保守機器開発グループ目次1 一般仕様.. 11.1 件名.. 11.2 目的及び概要.. 11.3 契約範囲.. 11.4 作業実施場所.. 11.5 納入物件及び納入条件.. 21.6 納期及び納入物.. 21.7 提出図書.. 51.8 検査条件.. 51.9 貸与品.. 51.10 品質保証.. 61.10.1 一般事項.. 61.10.2 本件に係る品質保証.. 61.10.3 品質保証に関する情報の提供等.. 71.10.4 品質監査について.. 71.10.5 品質計画書 (Quality Plan) について.. 71.10.6 提出図書について.. 81.11 適用法規等.. 91.12 打合せ.. 111.13 知的財産権等・技術情報の取り扱い・成果の公開.. 111.14 情報セキュリティの確保.. 111.15 コンピュータプログラム.. 121.16 CFSIの発生防止と検知及び取扱い.. 121.17 グリーン購入法の推進.. 131.18 協議.. 132 技術仕様.. 142.1 略語.. 142.2 適用図書.. 152.3 検討対象となるBM及びツールと作業プロセス.. 182.3.1 BM仕様.. 182.3.2 TFWの構造.. 222.3.3 初期組立作業時に使用されるツール.. 222.3.4 TFW保守手順.. 232.4 設計仕様.. 292.4.1 FWGの設計仕様.. 292.4.2 ESBTプロトタイプの設計仕様.. 322.4.3 CBT及びCBT制御装置の設計仕様.. 412.4.4 制御装置.. 462.4.5 プロトタイプBM保守ツール設計全般の要求事項.. 522.4.6 FW保守ツール運用に係る機器との取合い.. 532.5 FW保守ツールプロトタイプの設計.. 582.5.1 FWGプロトタイプ及び試験装置の設計.. 582.5.2 ESBTプロトタイプ及び試験装置の設計.. 612.5.3 FW保守ツールプロトタイプの制御系統合化設計.. 632.6 FW保守ツールプロトタイプの強度計算.. 642.7 FW保守ツールプロトタイプの適合性評価.. 642.8 FW保守ツールプロトタイプの製作.. 652.8.1 ESBTプロトタイプの製作.. 652.8.2 FWGプロトタイプの製作.. 652.8.3 FW保守ツールプロトタイプ制御装置の製作.. 652.9 FW保守ツールプロトタイプの工場受入試験.. 662.9.1 FWGプロトタイプの工場受入試験.. 662.9.2 ESBTプロトタイプの工場受入試験.. 712.9.3 制御系統合の機能に関わる工場受入試験.. 722.10 図書類の作成.. 73別紙1 イーター調達取決めに係る品質保証に関する特約条項別紙2 知的財産権特約条項別紙3 イーター実施協定の調達に係る情報及び知的財産に関する特約条項別紙4 本契約において遵守すべき「情報セキュリティの確保」に関する事項別紙5 コンピュータプログラム作成等業務特約条項別紙6 Technical Specification for Blanket First Assembly Tooling(ITER_D_2F6S75 v2.2)別紙7 Blanket First Assembly Tooling Requirements (ITER_D_2F6UJT v2.0)11 一般仕様1.1 件名ITER第一壁初期組立用機器プロトタイプの製作1.2 目的及び概要国立研究開発法人量子科学技術研究開発機構(以下「QST」)は、ITER 機構(以下「IO」)と締結した調達取決めに基づき、ITER ブランケット遠隔保守システム(Blanket RemoteHandling System、以下「BRHS」)及びブランケット初期組立機器の開発を進めている。BRHSは、放射線環境下となる真空容器内(Vacuum Vessel, 以下「VV」)において、遠隔操作によるブランケットモジュール(Blanket Module, 以下「BM」)の交換を行う。ブランケット初期組立用機器は、ITER建設活動の一部として非放射線下におけるBMの据付作業に用いられる。BMは、第一壁(First Wall, 以下「FW」)と遮蔽ブロック(Shield Block, 以下「SB」)から構成され、SBはVV上に、FWはSB上に固定される。BMをVV上に取り付ける際には、まず SB を VV 上に設置し、SB 電気ストラップボルト及びフレキシブルボルトを締結後に、冷却水配管構造を溶接により接続する。その後、FW を FW 把持機構で把持し SB 上に設置し、FW 電気ストラップボルト及びセントラルボルトを締結後、冷却水配管構造を溶接により接続する。BMをVVから取り外す際には上記の反対に、FW内の冷却配管構造を切断して切り離し、各種ボルトを緩めることでFWとSBの接続を解除した後にFWを移動させる。その後、SB 内の冷却配管構造を切断して切り離し、各種ボルトを緩めることで SB と VV の接続を解除した後でSBを移動させる。本契約では、IOに納入する予定のFWの初期組立に用いる各種ツールプロトタイプ及び関連装置の設計、製作及び工場受入試験を実施する。1.3 契約範囲本件では、以下の作業を実施する。(1) FW把持機構(FW Gripper, 以下「FWG」)のプロトタイプ及び試験用機器類の設計・製作・工場受入試験(2) 電気ストラップボルト締結ツール(Electrical Strap Bolt torquing Tool, 以下「ESBT」)プロトタイプ、電気ストラップボルト把持ツール(Electrical StrapBolt Handling Tool, 以下「ESBHT」)プロトタイプ及び試験用機器類の設計・製作・工場受入試験(3) 図書類の作成1.4 作業実施場所受注者事業所内21.5 納入物件及び納入条件(1) 納入物件：(a) 1.6項に示す納入物：一式(b) 1.7項に示す提出図書：一式(2) 納入場所：(a) 装置類：受注者事業所内(b) 図書類：QST 那珂フュージョン科学技術研究所 ITER研究開発棟 R134室(3) 納入条件：持込渡し・確認方法：QSTは、確認のために提出された図書(表 1、表 2、3表 2表 4及び表 6)において「確認：要」の図書)を受理したときは、期限日を記載した受領印を押印して返却する。また、当該期限までに審査を完了し、受理しない場合には修正を指示し、修正等を指示しないときは、確認したものとする。ただし、「再委託承諾願」は、QSTの確認後、書面にて回答するものとする。1.6 納期及び納入物受注者は、表 1～表 5に示す納入物を各指定の納期までに納入すること。(1) 令和9年3月23日：表 1(2) 令和9年5月31日：表 2及び表 3(3) 令和9年10月29日：表 4及び表 5提出方法は、紙媒体(各 1 部)の他、電子ファイル(正式版の PDF ファイルに加えてMicrosoft Word, Excel, Power Pointファイルなど編集可能な元ファイル)をCDなどの記録媒体に格納して持込渡しにて提出すること。 表 1 令和9年3月23日納期の納入物(ESBT図書①)納入物名言語対象ツール数量 確認ESBTStructural Integrity Report 英 〇 1部 要Compliance Matrix - DCM or VCM 英 〇 1部 要納入物に関わる電子ファイルを納めたCD - 〇 1式 不要4表 2 令和9年5月31日納期の納入物①(ESBT図書②)納入物名言語対象ツール数量 確認ESBTDesign Description 英 〇 1部 要CAD Bill of Materials 英 〇 1部 要CAD models 英 〇 1部 要Assembly Drawings 英 〇 1部 要Component Drawings 英 〇 1部 要Factory Acceptance Test Plan (FATP) 英 〇 1部 要Equipment Operation and MaintenanceManual英 〇 1部 要Factory Acceptance Test Report (FATR) 英 〇 1部 要Release Note 英 〇 1部 要納入物に関わる電子ファイルを納めたCD - 〇 1式 不要表 3 令和9年5月31日納期の納入物②(ESBTプロトタイプ)# 品名 数量1 ESBTプロトタイプ 1台2 ESBTプロトタイプ用反力受け構造(全モジュール対応分) 1式3 ESBTプロトタイプ試験装置(BM構造模擬部及び試験架台) 1台4 ESBHTプロトタイプ 1台5表 4 令和9年10月29日納期の納入物①(FWG及び制御装置図書)納入物名言語対象ツール及び関連装置*1数量 確認FWGFW保守ツールプロトタイプ制御装置Design Description 英 〇 〇*2 1部 要CAD Bill of Materials 英 〇 〇*3 1部 要CAD models 英 〇 -*3 1部 要Assembly Drawings*4 英 〇 〇 1部 要Component Drawings*4 英 〇 〇 1部 要Structural Integrity Report 英 〇 - 1部 要Cabling Diagram (CBD) 英 〇 〇 1部 要Compliance Matrix - DCM or VCM 英 〇 〇*2 1部 要Detailed Wiring Diagram (WD) 英 〇 〇 1部 要Single Line Diagram 又は One LineDiagram英 〇 〇 1部 要Factory Acceptance Test Plan(FATP)英 〇 〇 1部 要Equipment Operation andMaintenance Manual英 〇 〇 1部 要Factory Acceptance Test Report(FATR)英 〇 〇 1部 要Declaration of Incorporation 英 〇 〇 1部 要Release Note 英 〇 〇 1部 要納入物に関わる電子ファイルを納めたCD- 〇 1式 不要*1: ツール毎に○を付けた図書を作成すること。*2: 各ツールに組み込まれるローカルコントローラに関する情報についても、まとめて記載すること。*3: FW保守ツールプロトタイプ制御装置について、Bill of Materialsは提出することとするが、CAD modelの提出は不要とする。*4: 各ツールの図書には、組み込まれるローカルコントローラに関する情報も含むこと。6表 5 令和9年10月29日納期の納入物②(FWGプロトタイプ及び制御装置)# 品名 数量1 FWGプロトタイプ 1台2 FWGプロトタイプ試験用TFWモックアップ 1台3 FWGプロトタイプ試験架台 1台4 FW保守ツールプロトタイプ制御装置(Transporter mode用リモートコントローラ 1 台、制御関連ケーブル一式、その他電源装置等関連制御機器を実装したもの)1台5 FAT用C&C PC 1台6 制御関連ケーブル 1式7 FAT用C&C PCに実装するソフトウェアのソースコード 1式1.7 提出図書受注者は、表 6に示す図書を作成し提出すること。提出方法は、紙媒体(各1部を郵送)の他、電子ファイル(PDFファイルをメール送付)を提出すること。なお、使用言語は表の言語欄に従うこととする。表 6 提出図書図書名 提出時期 言語 部数 確認体制表及び詳細工程表 契約締結後速やかに 日 1部 要品質計画書(Quality Plan) 契約締結後速やかに 英 1部 要打合せ議事録 打合せ後2週間以内 日 1部 要月間報告書(Monthly Report)当月分の活動について翌月25日以前の平日に英 1部 要再委託承諾願(QST指定様式)作業開始2週間前※下請負等がある場合にQST指定書式にて提出のこと。日 1部 要1.8 検査条件1.6項に示す納入物及び1.7項に示す提出図書がそれぞれ納入又は提出され、本仕様書に定める業務が実施されたとQSTが認めたこと、及び1.9項(1)に定める貸与品が返却されたことをもって検査合格とする。1.9 貸与品(1) 貸与品(いずれも無償)(a) 1.10.5項及び2.2項に示す適用図書：1式(b) 保守ツール設計に関わる図書(JADA-23162-04DE3002)：1式(c) ツールチェンジャーの情報(可搬モーメント含む)：1式7(2) 引渡場所及び方法QST 那珂フュージョン科学技術研究所 ITER研究開発棟 R134室にて手渡し、メール送付、郵送(着払い)のいずれかによる。(3) 返却方法納期までに、1.5項(2)(b)に示した納入場所へ手渡し・メール送付・受注者負担による郵送のいずれかによる。1.10 品質保証1.10.1 一般事項(1) 受注者は、下記に示す項目を保証するよう適切な品質システムを遂行すること。(a) 契約要求事項に実施内容が合致していること。(b) 規格等に準拠していることを示す証拠が維持/保存されること。(2) 受注者の遂行する上記の品質システムは下記を満たすこと。(a) 契約に基づき実施される設計等すべての行為を網羅するものであること。(b) 作業の開始に際して、QSTに提出するQuality Planに記載されていること。(3) 受注者は、再委託先についても有効な品質システムを備えることを保証すること。 装置は永久変形又は明らかな欠陥を生じることなく、荷重試験に耐えなければならない。o 安全な取り扱い手順、点検及び試験手順、使用上の注意事項を明記した操作及び保守マニュアルを作成すること。o 製品が設計仕様に適合していることを確認するための適合宣言書又は認証書を提供すること。➢ 初期組立ツール及びエンドエフェクタは、以下の指令に準拠しなければならない。o 電磁両立性(EMC)指令 2014/30/EU11o 低電圧指令(LVD)2014/35/EUo 機械規則 2023/1230/EUo RoHS指令 2011/65/EU➢ REACH は CE マーキングの直接的な要件ではないが、IO は輸入者として REACH の義務を満たす責任を有する。そのため、納入品(包装材料を含む)にSVHC(高懸念物質)が重量比0.1％以上含まれている場合、IOに通知しなければならない。その通知は書面にて提供されなければならない。• 規格及び基準以下に、使用可能な設計規格の例を示す。ただし、機械指令への適合が確保されている限り、特定の設計規格を指定することは必須ではない。別の規格を適用する場合は、QSTに提案し、承認を得ること。➢ EN 13001-1/+A1:2009 クレーン－一般設計－第1部：一般原則及び要求事項➢ EN 13001-2:2011 クレーン－一般設計－第2部：荷重作用➢ EN 13001-3-1/+A1:2013 クレーン－一般設計－第3-1部：限界状態及び鋼構造の強度証明➢ EN 13001-3-3 クレーン－一般設計－第3-3部：限界状態及び車輪／軌道接触部の強度証明設計に適用される ITER 設計ハンドブックは以下のとおり：➢ Electrical Design Handbook(EDH)(適用図書[23]～[28])➢ Remote Handling Control System Design Handbook(適用図書[29])。ただし、以下のセクションは除外される。o 2.2 Standard partso 2.5 RH Control Roomo 2.6 Cubicle Rooms, Cabling Connectorso 2.10 Operation Viewpointso 6 Hazard identification and risk assessment• 溶接作業について溶接作業員は、該当する規格(例：ISO 9606 シリーズ又は JIS Z 3811)に基づいて資格を有していることが望ましい。溶接作業員の資格証明書、溶接手順書、及び溶接記録は提出されなければならない。溶接検査の最小範囲は以下のとおりとする：把持機器(昇降装置の一部)については、実際に検査可能な領域に対して100％の浸透探傷試験(PT)を実施すること。他の部品については、10％のPT検査を実施すること。加えて、目視検査も行うこと。 容積的非破壊検査(NDT)は不要とする。適用される規格は、設計の進行に伴って正当な理由がある場合には、見直し又は変更することができる。121.12 打合せ打合せの実施にあたっては、以下の要領に従うこと。(1) QSTとの打合せ(a) 受注者は、原則として月に1回以上の頻度でQST担当者と打合せを実施すること。 QST 那珂フュージョン科学技術研究所への来所による対面打合せ又はリモート打合せによる。(b) アクションリストを作成し管理すること。打合せ前にアクションリストの改訂版を提出すること。(c) 打合せにおいて、最新版の工程表(及びMS projectファイル)を提出すること。(d) 打合せ後2週間以内に受注者内で審査及び承認された議事録を提出し、QSTの確認を受けること。(2) ITER機構との打合せ(a) QSTはITER機構と月に1回程度進捗会合を実施している。受注者は、進捗会合にリモート参加し、必要に応じて技術情報の説明を行うこと。(b) 受注者は、打合せまでに実施した検討作業について、ITER機構との協議に使用するための各種資料(英語)の作成を行うこと。なお、作成に当たってはQST担当者と協議を行い、ヒアリング及び協議実施前に都度合意を得ること。(c) 本会議の議事録作成は不要とする。1.13 知的財産権等・技術情報の取り扱い・成果の公開(1) 知的財産権等の取扱い知的財産権の取扱いについては「知的財産権特約条項」(別紙2)及び「イーター実施協定の調達に係る情報及び知的財産に関する特約条項」(別紙3)に定められたとおりとする。(2) 技術情報の取り扱い受注者は、本契約を実施することによって得た技術情報を第三者に開示しようとするときは、あらかじめ書面によるQSTの承認を得なければならないものとする。QST が本契約に関し、その目的を達成するため受注者の保有する技術情報を了知する必要が生じた場合は、QSTと受注者協議の上、決定するものとする。(3) 成果の公開受注者は、本契約に基づく業務の内容及び成果について、発表若しくは公開し又は特定の第三者に提供しようとするときは、あらかじめ書面による QSTの承認を得なければならないものとする。1.14 情報セキュリティの確保情報セキュリティの確保については、別紙4『本契約において遵守すべき「情報セキュリティの確保」に関する事項』に示すとおりとする。131.15 コンピュータプログラム本契約におけるコンピュータプログラムの取り扱いについては、別紙5「コンピュータプログラム作成等業務特約条項」に定められたとおりとする。1.16 CFSIの発生防止と検知及び取扱い受注者は、偽造品、不正品及び疑惑品(CFSI)について管理を行うこと。 偽造品とは、法的な権利や権限を持たない複製品、代替品又はその材料や性能の特性を販売業者・供給業者・商社・製造業者によって故意に虚偽の表示をさせたもの。 不正品とは、事実と異なるものが意図的に偽って表示された物品。 疑惑品とは、外観検査、試験、又はその他の情報により、確立された業界で受け入れられている仕様又は国内/国際規格に準拠していることが確認できない可能性がある兆候があるもの。偽造品、不正品及び疑惑品(CFSI)について予防、検出、処理するための対策を講じるものとする。その際には以下の事項を考慮すること。(1) CFSI は、イータープロジェクトのために調達するすべての製品の全てのライフサイクル段階で検出できる。(2) CFSI は、イータープロジェクトに関与するすべての関係者によって検出できる。 CFSIの検出には、予定外の検査、サンプルの独立した分析、証明書の検証などの適切な手段を用いる。No 検出段階 検出場所 検出者1 受注者文書の受領・レビューQSTの施設 QST要員2 製作及び役務作業 QSTの施設、受注者の工場等 QST要員、受注者3 検査及び試験作業 QSTの施設、受注者の工場等 QST要員、受注者4 調達製品及び役務の検証QSTの施設、受注者の工場等 QST要員5 組立作業 QSTの施設、受注者の工場等 QST要員、受注者6 受注者の品質管理 受注者の工場等 QST要員7 受注者監査 QSTの施設、受注者の工場等 QST要員8 外部組織からの通知・警告QSTの施設、受注者の工場等 ASNR、その他の外部組織、メディア(3) CFSI を検出した関係者は、直ちにQSTに報告する。(4) 検出したCFSIケースが特定/評価され、ITERプロジェクトへの影響が確認された場合、CFSI発生元は、より詳細な調査(根本原因分析(RCA))を進め、さらなる是正措置及び予防措置を特定するため、重大 NCR を発行する。CFSI に関する NCR は、「Procedure for management of Nonconformities (22F53X)」に従って処理する。(5) CFSI 発生元が、進行中の QST との契約に関与しており、契約解除が ITER プロジ14ェクトに重大な影響を与える場合、CFSI 発生元が信頼性を回復するため詳細なアクションプランを作成し、QSTに提出する。1.17 グリーン購入法の推進(1) 本契約において、グリーン購入法(国等による環境物品等の調達の推進等に関する法律)に適用する環境物品(事務用品、OA機器等)が発生する場合は、これを採用するものとする。(2) 本仕様に定める提出図書(納入印刷物)については、グリーン購入法の基本方針に定める「紙類」の基準を満たしたものであること。1.18 協議本仕様書に記載されている事項及び本仕様書に記載のない事項について疑義が生じた場合は、QSTと協議の上、その決定に従うものとする。152 技術仕様受注者は、2.1～2.4項に示す内容を十分理解し2.5項以降に示す作業を実施すること。2.1 略語本件における略語を表 8に示す。表 8 略語一覧略語 正式名称 日本語訳15NDESB 15ND Electrical Strap Bolt 15ND電気ストラップボルト15NDG 15ND Gripper 15ND把持機構15NDTB 15ND Tool Base 15NDツールベースBAT Blanket Assembly Transporter ブランケット組立運搬機BM Blanket Module ブランケットモジュールBMTS Blanket Module Transfer System ブランケット運搬システムBRHS Blanket Remote Handling System ブランケット遠隔保守システムCB Central Bolt セントラルボルトCC Coaxial Connector 同軸コネクタC&C Command and Control コマンドアンドコントロールEE End Effector エンドエフェクタEP Equatorial Port 赤道面ポートESB Electrical Strap Bolt 電気ストラップボルトESBT Electrical Strap Bolt torquingTool電気ストラップボルト締結ツールESBHT Electrical Strap Bolt handlingTool電気ストラップボルト把持ツールFAT Factory Acceptance Test 工場受入試験FB Flexible Bolt フレキシブルボルトFBT Flexible Bolt torquing Tool フレキシブルボルト締結ツールFW First Wall 第一壁FWCBT First Wall Central Bolt Tool 第一壁セントラルボルトツールFWESB Fast Wall Electrical Strap Bolt 第一壁電気ストラップボルトFWG First Wall Gripper 第一壁把持機構HLCS High-Level Control System 上位制御系HMI Human Machine Interface ヒューマンマシンインターフェースIO ITER Organization ITER機構16IVTC In-Vessel Tower Crane 真空容器内搭形クレーンLLCS Low-Level Control System 下位制御系MC Monoaxial Connector 単軸コネクタNB Neutral Beam 中性粒子ビームNTS Nacelle Tool Storage ナセルツール収納部PHS Passive Holding System 受動把持機構SB Shield Block 遮蔽ブロックSBESB Shield Block Electrical StrapBolt遮蔽ブロック電気ストラップボルトSBG Shield Block Gripper 遮蔽ブロック把持機構SBTB Shield Block Tool Base 遮蔽ブロックツールベースTBD To Be Determined 未定TFU Tool Fixing Unit ツール固定部TFW Temporary First Wall 仮第一壁TPTS Through Port Transfer System 直通ポート運搬システムTSR Tool Storage Rack ツール収納ラックVV Vacuum Vessel 真空容器2.2 適用図書本件で適用すべき図書を表 9に、参考にすべき図書を表 10示す。 表 9 適用図書# 図書名 文書番号1 ITER第一壁及び遮蔽ブロックの遠隔保守ツール設計製作仕様JADA-23160TS0001-42 IS-16-23-001 Interface between First Wall(PBS 16.FW)and Blanket Remote Handling System (PBS23.01)ITER_D_33PH3Y v6.33 Technical Specification for Blanket FirstAssembly ToolingITER_D_2F6S75 v2.24 Blanket First Assembly Tooling Requirements ITER_D_2F6UJT v2.05 FW ES Tool Access built up ITER_D_X2TXST v1.36 2D model – BKT ES 14LAYERS SB (番号取得中)7 SB Electrical Strap Tool Access built-up ITER_D_X86NTS v1.28 CAD model of Temporary FW DET-03305-W179 Blanket modules dimensions and weight ITER_D_35ZJNQ v16.110 FW&SB main geometry for RH ITER_D_CANQ4W v3.111 CAD model of Tool Changer DET-03305-U12 2D: Electrical strap interface to SB ITER_D_UG4FBK 1.013 2D: Flexible interface to SB ITER_D_UGC3KZ 1.014 2D: SB insert ITER_D_UGCBHL 1.015 CAD model of SB DET-03305-X16 CAD model of SB14ND series and SB16NBseriesDET-08054-A17 CAD model of SB15ND series DET-0889018 CAD model of Storage Box shared on owncloud19 Cap system: DRW Nr: 057740 –ADRW Nr: 074421 ---20 Electrical strap:BKT_ES_14LAYERS_SB DRW Nr: 028123 --J21 FW central bolt:BKT_FW_CENTRAL_BOLT DRW Nr: 055948 --E22 List of SB GAD Drawings ITER_D_CKA4A3 1.023 Electrical Design Handbook (EDH) 以下参照24 EDH Part 1 Introduction ITER_D_2F7HD2 v1.425 EDH Part 2 Terminology & Acronyms ITER_D_2E8QVA v1.426 EDH Part 3 Codes & Standards ITER_D_2E8DLM v1.327 EDH Part 4 Electromagnetic Compatibility(EMC)ITER_D_4B523E v3.028 EDH Part 5 Earthing and LightningProtectionITER_D_4B7ZDG v3.029 Remote Handling Control System DesignHandbookITER_D_2EGPEC v3.0表 10 参考図書# 図書名 文書番号1 2D model – BLKT_ES_BOLT_M24_65_SPEC_HEAD ITER_D_2M527Y v6.02 IS-16-23-002 Interface between Shield Block (PBS16.SB) and Blanket Remote Handling System (PBS 23.01)ITER_D_33TYJV v5.13 ES to SB built-up ITER_D_U4NRQU v2.04 ITERブランケット第一壁及び遮蔽ブロックエレクトリカルストラップボルト締結ツールの概念設計 報告書TBD5 Technical proposals to facilitate BRHS Design andOperationsITER_D_37EYLB v1.2186 Heavy Duty Radiation tolerant Tool Changer and Force& Torque SensorITER_D_4KC7NJ v1.17 Design Description - PA 2.3.P1.JA.01 - Blanket RHSystemITER_D_9CQ2DW v5.28 Blanket Design Description Document (2013 FDR) ITER_D_EBUDW3 v1.19 IC-CMAF BLKT Modules FW + Shield Blocks ITER_D_PNKEV6 v3.010 FW functional tolerance drawing ITER_D_TEENH4 V1.111 FW central bolt to SB built up ITER_D_THPUWB v2.412 2D model - FW central bolt ITER_D_W263HM v1.013 Verification of the structural integrity of the RHgripping finger and of the interfacing BKT First WallcomponentITER_D_WLWB3J V 1.014 FW central bolt to FW pipes built up ITER_D_X2G8RG v1.215 Thermomechanical Analysis Preliminary Report (pads toFW fingers)ITER_D_XGUERL v1.016 Blanket FW remote Handling Compatibility Assessment ITER_D_XT87FB V 1.117 Components Technical Specification - PA 2.3.P1.JA.01- Blanket RH SystemITER_D_9CVZYE v5.118 Material Approval Request: EPDM in contact with FWITER_D_XB5662 N/AITER_D_XB5662 N/A19 Low friction/Anti-seize Coating Specification forBlanket ApplicationsITER_D_GKEM64 V 2.420 Test report – FW Central bolt tightening withreconfigurable test benchITER_D_8LZ3PM v1.021 Central Bolt Compliant Wrench assembly ITER_D_TMT6P4 v3.122 Test report of Central bolt tightening tool ITER_D_XZM8JP v1.023 2D: BKT_MODULE_15_S03 (15ND series) DRW Nr:062819 --A24 CAD model of SB15ND series DET-0889025 PA CN for PA 1.6.P1B.CN.01 for SB18 row unified waterconnector dimensionsITER_D_ATWFX4 n/a192.3 検討対象となるBM及びツールと作業プロセス2.3.1 BM仕様VVには正規ポート14個及び非正規ポート4個からなるEPが18個ある。すべての正規ポートは同寸法で、プラズマ計測、TBM、ECH 及びICH 等異なるシステムに割り当てられている(図 1 上)。非正規ポートには、中性粒子ビーム入射装置が割り当てられており、この領域のVV及びポート開口部は複雑な形状になっている。VV内に配置されるBMは図 2に示す通り、SB及びFWから構成される。SBはVV上に固定され、FWはSB上に固定される。SB 及び FW は各 18 種類の基本形状で構成されている。基本形状のうち、軌道と同じ高さに位置し、ツールへの寸法制約が厳しいBM #4を図 2に示す。これに加え、中性粒子ビームポート(NB Port,図 2内)などの各種ポート周辺は基本形状と異なる形状のSB(「SBバリアント」と呼ぶ)及び単体構造であるSB#15ND(図 4)などの特殊形状のSB(15ND系モジュール)が配置される構造となっている。各SBをVV上に固定する際は、SBGでSBを把持してVVに設置後、FB及びSBESBを締結し、VV側の同軸コネクタ(CC)又は単軸コネクタ(MC)及びSB側の配管構造を溶接することによる冷却水流路の形成が行われる。各FWをSB上に固定する際も同様に、FWGでFWを把持してSBに設置後、CB及びFWESBの締結と、冷却配管及び配管キャップの溶接が行われる。なお、ESB は FW 及び SB 間、並びに SB 及び VV 間の電気的な接続を確実にするほか、ESBT を用いてトルクを印加し締結することにより両者間を仮固定するためのボルトである。これに対して、各本固定はFW及びSB間はCBの締結、SB及びVV間はFBの締結により行われる。本契約では、FWの初期組立に用いる各種ツールの内、下記に示すFWツールプロトタイプの設計、製作及び工場受入試験を実施する。2.3.4 項に下記のツールに関係する BM 保守手順の詳細を示す。(1) FWG(2) ESBT(FWESB、SBESB、15NDESBの3種類のESBを対象とする)20図 1 VV内のBM構成21図 2 VVの断面図及びBM(SB+FW)#4の外形図 3 BM#4構造断面図22図 4 #15ND外形(上)、配管構造(中)及びESB(下)断面図(15ND系モジュール)232.3.2 TFWの構造初期組立における対象FWは、仮第一壁(Temporary First Wall：TFW)と呼ばれるモジュールとなる。TFWは図 5に示すように表面の構造が通常のFWとは異なり、冷却配管を有しない。CBや把持穴(Gripping interface, Gripping hole)の位置関係は通常のFWから変更はない。＊備考 1)TFW と同様に初期組立の対象となる SB は、TFW のような仮/簡易構造のものを用いず、最終仕様のSBを初期組立において取り付ける。図 5 TFW斜視図及び構造断面図2.3.3 初期組立作業時に使用されるツールBM保守ツールは、下記に示すように主に重量ツールと軽量ツールに大別される。BMの初期組立時には放射線環境とはならず、作業員が近づいて作業を行うことができるため、初期組立用ツールは耐放射線性と遠隔操作性を考慮する必要はない。(1) 重量ツール：BATと呼ばれる運搬機を用いて把持する。(2.4.6.1項参照)(2) 軽量ツール：ゼロGアーム(ZERO G Arm)という重量を軽減する補助装置を用いて把持し、IVTCに接続されたナセル(Nacelle)と呼ばれる作業用ゴンドラ上で作業員が作業を行う(2.4.6.4項参照)。＊上記のBATやZERO G Armの設計は本契約範囲外である。本件の検討対象となるFWGは重量ツール、ESBTは軽量ツールにそれぞれ分類され、初期組立プロセスにおいて必要となるツールである。242.3.4 TFW保守手順本項では、本件で設計・製作する保守ツールと関係するTFW保守作業手順を詳述する。2.3.4.1 FWGによるTFWの把持及び設置FWGを用いたTFWの把持及びSBへの取付け作業の概略を示す。なお、本項で述べるFWG及びTFW以外の機器に関する詳細は2.3.4.2項で後述する。 (1) BMTS収納板(2.4.6.2項)に搭載したFWGを、TPTS(2.4.6.2項)によりVV内へ搬送する。(2) BAT(2.4.6.1項)先端に具備するツールチェンジャーと、BMTS収納板上に搭載されたFWGのツールチェンジャー(図 16)との位置決めを行い、BATとFWGを勘合する。(3) BMTS収納板に搭載したTFWを、TPTSでVV内へ搬送する。(4) BATと接続したFWGと、BMTS収納板上に搭載されたTFWとの位置決めを行い、FWGの把持爪をTFWの把持穴に挿入する(図 6)。(5) FWG把持爪のフック拡張及びパッド押しつけによりTFWとFWG間を固定する(図 7)。(6) FWGが具備するCBレンチユニットにより、TFWとBMTS収納板の固定治具を締結しているCBを解除し、FWGでTFWを把持する(図 8)。(7) BAT で FWG+TFW を取付け対象の SB 位置へ移送及び SB に対する位置決めを行い、TFWをSBに設置する。(8) FWGが具備するCBレンチユニットにより、TFWのCBをSB側のCBスレッドに締結し、TFWをSBに仮固定する。(9) FWGのパッド押しつけ解除と把持爪のフック収納によりTFWとFWG間の固定を解除し、FWGをTFWから引き抜く。(10) BATによりFWGをBMTS収納板上へ受け渡す。(11) その後は、CB締結ツールによりTFWのCBに更に大きなトルクを印加することで本締めを行い、TFWをSBに本固定する。25図 6 TFWへのFWGの挿入備考)SBや固定治具(Fixture)へのFWの位置決めはFWパッドを用いて行う図 7 把持爪のフック拡張(左)とパッド押しつけ(右)による、TFWとFWG間の固定TFW26図 8 CBレンチユニットによるCB締結の解除とTFWの把持備考)図 6～図 8はBMTS収納板に固定されたTFWをFWGにより取り外して把持する工程を示した。TFWをSBに設置する手順は、図のBMTS収納板をSBとみなし、図 8から図 6の順にて実施する。)2.3.4.2 ESB締結の作業工程ESB は、各モジュール及び VV 間に電気的な接続を供給するためのボルトである。ESB はFWESB(TFWとSBを接続)、SBESB(SBとVVを接続)、15NDESB(15ND系モジュールとVVを接続)の3種類が存在する。下記にFWESBを例として、ESBを締結する際の作業手順を示す。本作業は2.3.4.1項に示す TFW設置後、CB を本締めした状態かつ FWESB が TFW側の待機用スレッドに締結された状態(図 9)を初期位置として開始する。備考)FWESBを待機用スレッドから緩め、メインスレッドに仮締めする作業は電気ストラップボルト把持ツール(ESBHT)が担当する。(1) ESBT を収納したツール収納ラック(TSR)を BMTS に搭載して VV 内に搬入する。 挿抜性を確保するために、各部にテーパー構造を有する(図 17)。・ 把持爪フック拡張駆動機構 (Gripping Finger hook expansion drivemechanism)：把持穴側の引っ掛かり構造(Gripping interface)へ勘合する爪状の構造を具備する。1 組の把持爪ユニットに対して 4 本のフックを具備する。 TFW把持穴への勘合前は把持爪フレーム内に格納され、挿入後に、駆動機構によってフックを拡張する。拡張前後の駆動概念を図 18に示す。・ 把持爪リニア駆動機構(Linear Drive for Gripping fingers)：TFWのバリアント毎の把持穴位置に対応するための駆動機構を具備する。駆動方向は、CB レンチを中心として、2つの把持爪ユニットを結ぶ方向である。・ ハードストップ(Hard stop)：図 17に示すように、把持爪はハードストップを具備する。ハードストップがFW把持穴と接触したことをBATの力・トルクセンサによって検知する。その後フックを展開し、把持爪を後退させることでフックが把持穴に着座する。(b) アクティブパッドユニット×2台 (Active Pad unit)・ 前述の把持爪とパッドの押し付けによって、TFWとFWG間を固定する構造を具備する。・ パッド及びパッド駆動機構(Pads and driving mechanisms)：把持爪の左右に位置し、TFWを把持爪方向に押し出すための駆動系を具備する。把持爪フック拡張後に押し出すことで、TFWとFWGを固定する。31・ リニアセンサ(Linear sensor)：パッドの押し付け量を監視するためのセンサを具備する。・ 圧力センサ(Compression sensor)：パッドに加わる圧力を直接測定するためのセンサを具備する。(c) CBレンチユニット(CB wrench unit)・ TFWのCBをSBのCBスレッドに締結するための機構を具備する。・ CBレンチ(CB wrench)：レンチの先端は、TFWのCBにおけるTORXソケット(図19参照、最大外径φ43)に適合するTORXビット形状を有する。・ CBレンチ昇降機構(CB wrench extension mechanism)：TFWのバリアント毎のCB深さ位置に対応するための、CBレンチ昇降方向の駆動機構を具備する。・ CBレンチ締結機構(CB wrench torquing mechanism)：CBを仮締めトルクにて締結・解除を行うための駆動機構を具備する。・ CBレンチコンプライアンス機構：CBレンチの勘合時に、位置誤差等を吸収するためのコンプライアンス機構を具備する。(d) カメラ及び照明×2台(Camera and lights)・ FWGの位置決めのためのロボットビジョン用のカメラ2台と、TFW上の位置合わせマーカー周辺の視認性を向上させるための照明を具備する。(e) ツールチェンジャーツール側(Tool changer tool side)・ BATへのFWGの固定と、電力及び制御信号を供給するためのツールチェンジャーの構造を具備する。図 16 FWG概念図(左：TFW固定面から見た側面図、右：TFW固定時)32図 17 把持爪ユニット先端概念図図 18 把持爪フックの拡張概念(左：フック収納時、右：フック拡張時)図 19 CBのTORXソケット形状332.4.2 ESBTプロトタイプの設計仕様ESBTプロトタイプの設計仕様を下記に記載する。(1) ツール構造：図 20(a) TFW、SB、及び15ND系モジュールのESB締結に対応可能な構造とする。(b) ESB締結に必要なレンチは、締結機構、反力受け構造、把持取合い等を含む複合構造とする。(2) 機能：(a) ESBに対し480 Nm±10%(MAX 800 Nm)の締結トルクが印加可能な機能を有する。(b) 導入孔(Access hole)を通じてFWESB(図 21)、SBESB(図 22)、及び15NDESBにアクセスし、各ESBを締結する機能を有する。(3) 構成機器：(a) レンチ (Wrench)・ 星形六角形(ヘクサロビュラ「TORX T80 head」)ソケットに勘合可能な形状を有する。・ 材質は時効処理を施したマルエージング鋼(maraging steel：硬度 HRC54〜56)とする。18Ni2400の使用を推奨する。・ TFW、SB、及び15ND系モジュールの各表面からESBまでの距離に応じた長さを設定する。・ 上に示したアクセス距離の違いに対応するため、複数種類のレンチを交換可能とし、人力及び一般工具による交換を可能とする。・ 以下に示す経路で各ESBへのアクセスを可能とする：- TFW：FWESB導入孔(FWESB access hole)- SB：SBESB導入孔(SBESB access hole)- 15ND系：ESB導入孔(ESB access hole、図 4参照)・ レンチは正逆方向の回転に対応すること。・ レンチ先端には受動把持機構(Passive Holding System)を具備する(図 23 参照)。(b) 締結機構・ トルク増幅器(Torque multiplier)を用いた、人力による締付け用のトルク印加システムと、それを装着するスプラインシャフト(Spline shaft)で構成する。・ 入力トルクはトルク増幅器により増幅し、レンチに伝達される。・ 使用機器例は、GEDORE社製 DREMOPLUS ALU 1300 Nm DVV-13Zとする。・ トルク増幅器への入力は、三洋機工(株)製スマートトルクレンチ(DPWシリーズ)等により人力で行う。落下防止の為のテザー等を装着すること。・ 増幅器内部のグリース漏れ防止のため、適切なシール構造を具備する。・ 時計回り及び反時計回りの両方向での締結・緩結操作が可能である。34(c) コンプライアンス機構・ 図 20 上部に示すように、トルク増幅器とレンチの接続部(Multiplier-wrenchcoupling)にクリアランスを有する。・ レンチとボルト間の組付け誤差(角度±0.5 deg、並進±2.1 mm)を吸収可能なコンプライアンス機構を具備する。・ 許容誤差を超える傾斜が発生しないよう、過傾き防止構造を具備する。(d) 反力受け構造(Key(Reaction feature))・ 各種ESB締結時に発生する反力を受け止める構造を有する。・ 使用可能なBM構造要素は以下とする。- TFW：RHインサート入口の構造(図 24)- SB(図 25)：FWESB ポケット(pocket)(共通構造(図 25内、Aの周辺))又は導入孔付近の構造(モジュール毎に異なり、配管用の溝や段差部などが使用可だが、図 27 の青色部には荷重がかからないようにすること。- #15ND系：蓋・配管導入孔(MC access hole、図 4参照)・ 反力受け構造案を図 26 ～ 図 28に示す。・ 反力受け構造の着脱及び位置調整は、人力または一般工具で実施可能である。(e) 把持用取合い(ZERO G Arm interface)・ ZERO G Armによる把持に対応した接続取合いを具備する。・ レンチはインターフェース部に対して回転可能なこと。・ 取合い付近に重心を配置し、必要に応じてカウンターウェイトの使用を許容する(ただし総重量は制限内とする)。(f) 運搬・設置用取合い・ 落下防止対策(例：テザーによる連結)及び緩み防止対策(例：Loctite、SpiraLock、NordLock、ワイヤ)を考慮する。・ ESBTはTSR及びNTS(2.4.6.6参照)との取合いを具備する。・ 作業者による把持及び位置調整を行うためのハンドル等を具備する。35図 20 ESBTの概念図図 21 FWESB構造(適用図書#5より抜粋。変更が生じた場合は別途提示する)36図 22 SBESB構造(適用図書#6より抜粋。変更が生じた場合は別途提示する)37(a) PHSコレット(b) レンチ側のPHS固定取合い図 23 PHS構造図38図 24 FWESB締結時の反力受けに利用できる構造(RHインサート側面のオレンジ色でハイライトした構造を利用する)39図 25 SBESB締結時の反力受けに利用できる構造40図 26 FWESBTの反力受け構造案図 27 SBESBTの反力受け構造案41図 28 15ND系モジュールの反力受け構造案2.4.2.1 ESBHTの設計仕様ESBHTの設計仕様を下記に記載する。 (1) ツール構造(概念図)：図 29(a) ESBT と同じ構造を持つレンチの後端に持ち手を付け、T 字レンチのような形状とする。(2) 機能(a) 各種 ESB のパーキングスレッドからの緩め及びメインスレッドへの移動と仮締め作業を行う。(b) 緩め及び締め作業は作業員の人力により行う。図 29 ESBHTの概念図422.4.3 CBT及びCBT制御装置の設計仕様CBTとCBTを動作させるための制御装置の設計仕様を本項に示す。備考)本契約ではCBT自体の設計及び製作は実施しないが、2.5.3項にてCBTを含めたFW保守ツールプロトタイプの制御系の統合を実施する。本項の内容は2.5.3項の作業を実施する上での参考情報とすること。2.4.3.1 CBTの設計仕様(1) ツール構造：図 30、図 31(概念設計。設計の進展があれば別途受注者に提示する。)(2) 機能(a) CBTはFW側のCB導入孔(CB access hole, FWに設けられたCBにアクセスするための穴)を介して、SB側のメインスレッドに仮締めされたCBにレンチを挿入し、嵌合する機能を有する。(b) レンチを介してCBに高トルクを印加し、本締めを行う機能を有する。(c) 上記本締め作業中の反力を受けるためのインターフェースを提供する。(3) CBTの機器構成CBTは以下の機構及び構造を具備する。(a) レンチユニット(Wrench unit)・ レンチ回転駆動機構とのインターフェース(本ユニットはレンチ回転駆動機構への固定と取外しが可能な構造)・ 高トルク(定格8.4 kNm±10%、最大10 kNm)に耐える高降伏強度のマルエージング鋼製レンチ(図 32)・ レンチをCBソケットに嵌合させるためのスプリング・ Zero G Arm用把持インターフェース(b) レンチ回転駆動機構(Wrench rotation drive unit)・ モータ＋ハーモニックドライブ＋平歯車によるトルク増幅機構(最大10 kNm)・ レンチへのトルク伝達ソケット・ トルク測定用のトルクメータ(c) 反力受け構造：把持爪(Gripping finger)・ FW 把持穴に挿入し、本締め時の反力を受けるためと CBT を FW に位置決めするための2本の円筒構造・ 把持穴内部の段差部に押し当てるための構造・ 把持爪の横方向位置を調整する機構(d) パッド機構(Pad mechanism)・ FW表面に押し当てるパッド構造・ パッドを昇降させるための機構(機構の動作はモータ駆動によるアクティブ方式もしくはシム方式とする)(e) ベースプレート(Base plate)43・ 上記(a)～(d)の構造を固定する構造体・ BAT用把持インターフェース：ツールチェンジャー・ツールサイド(Toolchanger_ Tool side)・ ロボットビジョン用のカメラ及び照明 ×2台・ VV内搬入装置との接続インターフェース44図 30 CBTの概念設計45図 31 CBTの概念設計(内部構造)図 32 レンチの形状・寸法462.4.3.2 CBT制御装置の設計仕様以下にCBTを動作させるために制御装置に要求される設計仕様を示す。(1) 制御対象(a) レンチ回転駆動機構(b) トルクメータ(トルク監視のみ)(c) レンチ(センサによる嵌合状態及び位置監視を行う場合のみ)(d) カメラ及び照明 ×2台(e) エアクランプ(使用する場合)(2) 装置構成(a) ローカルコントローラ・ CBTベースプレート上に実装し、固定/取外しを可能とする。(b) リモートコントローラ・ 設計対象はTransporter mode用のみ。・ CBTプロトタイプとしては、Transporter mode用リモートコントローラと、それに付随する電源装置等を1つの制御盤内に実装する。(c) 制御コンテナ内からの操作監視を想定した機能を有するPC(C&Cを実装)(3) 要求機能(a) レンチのトルク制限値・回転方向・回転角度・回転速度を制御できる。(b) レンチに印加されるトルクをトルクメータにより監視できる。(c) 上述の動作ログデータを記録し、USBメモリなどの記録媒体に保存できる。472.4.4 制御装置制御装置の構成は、大きく上位制御系(High-Level Control System, 以下HLCS)と下位制御系(Low-Level Control System, 以下LLCS)に分類される。HLCSは、主に運転員との取合いの役割を担い、操作監視に関わるヒューマンマシンインターフェース(Human MachineInterface, 以下「HMI」)及びそれに付随するアプリケーションを有する。LLCSは制御対象機器との直接の取合いを有する制御装置であり、各種ドライバやコントローラ等が実装される。図 33にその概略図を示す。各種ツールに関わる運用フェーズとして、EEがBATに接続された状態で所望の位置まで移動するTransporter modeと、EEがBMに固定された後にツール等により各種作業を行うSkid modeが挙げられる。図 33 EEに接続される制御システム構成概要Transporter modeの場合、BAT内を経由するケーブル配線に厳しい制約がある。EEには最小限のケーブルが接続されるという前提で、Transporter modeにおけるEEの設計と運用を検討する必要がある。Transporter mode時、EEの主な取合いは以下となる。・ EEのローカルコントローラ用の電源・ 通信(EtherCAT)・ カメラネットワークリンクSkid modeにおいては、EEがBMに固定された状態でEEとツールの運用を行う。Skid及び複合ケーブルは、ツールの運用(例：溶接作業)に必要なユーティリティを提供する。・ EEのローカルコントローラ用の電源・ 通信(EtherCAT)・ 圧縮空気・ 溶接ガス48・ 溶接電力Skid modeでは、コントロールコンテナ(運転室)から有線、又はモバイルコントローラにより無線での制御を可能にする。モバイルコントローラには、コントロールコンテナからの有線制御とモバイルコントローラからの無線制御の切り替えを行うキースイッチを実装する。これにより、双方の制御指令の競合を回避することができる。注意：EEには、BATによるEEの正確な位置決めのために必要なカメラが実装されている。 ただし、各要求において指定される機能を有しないツールに対しては、その要求は適用しないものとする。2.4.5.1 軽量ツール及び重量ツールに適用される要求事項軽量ツール(適用図書[4]における「All tools」)及び重量ツール(適用図書[4]における「All EEs」)に共通して適用される要求事項は適用図書[4]のNo.1～14を参照すること。2.4.5.2 重量ツールに適用される要求事項重量ツールに適用される要求事項は適用図書[4]のNo.16～37を参照すること。2.4.5.3 軽量ツールに適用される要求事項軽量ツールに適用される要求事項は適用図書[4]のNo.46～57を参照すること。2.4.5.4 FWGに適用される要求事項FWGに適用される要求事項は適用図書[4]のNo.244～253を参照すること。2.4.5.5 ESBTに適用される要求事項ESBTに適用される要求事項は適用図書[4]のNo.97～104を参照すること。542.4.6 FW保守ツール運用に係る機器との取合い本項では、BMの初期組立時に用いられる関連機器としてBAT、BMTS、IVTCナセル、NTS及びZERO G Armの概要について記載する。なお、本契約においてこれら関連機器の設計製作は対象外であり、以下は参考情報である。2.4.6.1 BATブランケット初期組立において、FWG等の重量ツールの装着先となる運搬機は、図 37に示すBATである。BATの先端にはツールチェンジャーが具備されており、重量ツール(EE機器)の装着が可能な構造となっている。図 37 BATの概略図2.4.6.2 BMTSBMTSは、BM初期組立時に必要となる機器をTPTS(直通ポート運搬システム：図 38)経由でVV内外に搬出入するための運搬システムで、運搬対象の機器はBMTS上の収納板に固定・搭載される状態となる。機器のうち、重量ツール(40kg超)はVVに搬入後、VV内でBATによって把持される設計仕様になっている。このため、重量ツールはBATに接続できるように、ツールチェンジャーを具備するものとする。BATが重量ツールをツールチェンジャー経由で把持する際は、作業者が傍にてツールの状態を確認しながら作業を実行すること。55図 38 TPTSにおけるBMTSの位置関係を示す鳥瞰図2.4.6.3 BMTS収納板の設計制約BMTSの機器収納部分は、従来の箱型から板構造(長さ：2100mm×幅：1310mm×厚さ：30mm)へと設計変更されたが、搭載面の寸法に変更はない。各種ツールはこの収納板上にクランピングモジュール(固定治具)で搭載され、ポートから VV 内に搬入される。収納板上に搭載されるツール類は、所定の外形寸法(長：2100mm×幅：1310mm×高：665mm)以内に収めるものとする。BMTS収納板の形状とツールの搭載例を図 39に示す。56図 39 BMTS 収納板の斜視図2.4.6.4 IVTC及びナセル(Nacelle)IVTCは昇降式のクレーン土台と伸縮型のアーム部からなり(図 40左)、IVTCのアーム先端部に作業用ゴンドラであるナセル(Nacelle)を接続する構造となっている(図 40右)。 ナセル上で、作業員によるVV内でのツール搬送や設置等の保守作業を行うものとする。図 40 IVTC及びナセル2.4.6.5 TSRTSRは、VV内に設置され、軽量ツールを収納・保持するためのラック(棚)である。収納部は作業時におけるツールの取り出しやすさ及び収納状態の安定性を考慮し、各ツールが確実に納まる設計となっている(図 41参照)TSRは、BM#18に設置され、BM#18との取合いを有する。また、ナセルに搭載されたZEROG Armからのアクセスが可能な配置とする。57図 41 ツール収納ラックの概念図2.4.6.6 NTSナセル上には、作業に使用する軽量ツールを収納するためのナセルツール収納部が設置するものとし、当該収納部は作業時の取り出し易さや収納の安定性を考慮し、軽量ツールが確実に納まる設計となっている(図 42参照)。図 42 IVTCナセル上のナセルツール収納部2.4.6.7 ゼロGアーム(ZERO G Arm)BATで把持しない40kg以下の軽量ツールは、ZERO G Armによりハンドリングされるものとする。ZERO G Armは、重量物や工具の取り扱いを容易にするための装置であり、バランス機構やスプリングなどを用いて把持対象の重量を軽減し、作業員の負荷を低減し操作できるよう設計される(図 43参照)。58図 43 ZERO G ArmのIVTCナセル上における使用例ZERO G Armとの取合いはGRIP GmbH Handhabungstechnik社の小型ツールチェンジャー：SHW125(図 44参照)とする。図 44 小型ツールチェンジャー：SHW125592.5 FW保守ツールプロトタイプの設計受注者は2.5.1～2.5.2項に示す作業を行い、各FW保守ツールプロトタイプ及び関連装置を設計すること。2.5.1 FWGプロトタイプ及び試験装置の設計受注者は本仕様書の 2.1～2.4 項に示した設計仕様及び設計情報を考慮し、2.5.1.1～2.5.1.4 項に示す作業を実施し、FWG プロトタイプ及び制御装置、並びに試験用装置類の設計を実施すること。2.5.1.1 FWGプロトタイプの設計受注者は、全てのTFW形状に対応できる最小台数のFWGプロトタイプを設計すること。2.5.1.2 FWGプロトタイプ試験用TFWモックアップの設計2.2項に示す適用図書[2],[8]及び、2.3.2項、2.3.4.1項、2.4.1項を基に、下記の仕様を満たす図 45の赤枠部を模擬したFWGプロトタイプ試験用TFWモックアップを設計すること。(1) 把持穴の模擬：(a) 実機と同一寸法の把持穴構造を有すること。・ 把持穴の奥にあるFWESB構造の模擬は不要。(b) 把持爪フックの拡張及び把持穴へのフックの掛かり状態を目視できる構造にすること。(2) 外形形状の模擬：(a) TFW#04において中心のスロット部からパッド押しつけ位置までの外形形状を模擬すること。(b) それ以外については、QSTの承認を得た上で省略可能とする。(3) CB及びCBスレッドの模擬：(a) CBを内蔵すること。(b) CB待機用スレッド構造(M90)を有すること。(c) CBスレッド(M64)を追加し、TFWモックアップと一体化した構造にすること。(d) 加えられるトルクを直接測定できるよう、スレッドにトルクメータを具備すること。(4) 重量の模擬：(a) 試験荷重に対する安全係数1.25×通常のFWの最大荷重1.4トンを考慮し、最大1.75 トンの重量を模擬できること。(b) 上記の重量模擬について、試験時のハンドリング性を考慮した上で、着脱式の錘またはクレーン等による荷重模擬方法を検討すること。(5) 材料：60(a) 把持穴構造及びパッド接触位置については、SUS316Lを基本とするが、機械的性質が同等のステンレス鋼も可とする。その他の箇所については、防錆処理した炭素鋼等を用いてよい。(6) 搬送治具：(a) クレーンによる搬送を考慮しアイボルトなどを具備すること。図 45 FAT用TFWモックアップで模擬すべき部位(赤枠部)2.5.1.3 FWGプロトタイプ試験架台の設計下記の仕様を満たす試験架台を設計すること。図 46に試験架台構造及び姿勢の概念図を示す。ただし、図 46の概念図とは異なる構成の代替案も可とする。(1) 床面と試験架台を固定するための取合いを設けること(備考：試験架台と床面の取合い構造は、契約後にQST担当者、IO担当者、受注者の協議により決定とする)。また、必要に応じて転倒防止錘を搭載する等、転倒しない構造にすること。(2) 試験用機器の固定及び固定姿勢の変更。(a) FWG プロトタイプを試験架台に固定するための固定構造を設けること。ただし、ツールチェンジャー構造を模擬する必要はない。(b) FWG プロトタイプ及び FWG プロトタイプ試験用 TFW モックアップの勘合作業を考慮し、作業が円滑かつ容易に行えるよう配慮した設計とすること。必要に応じて61TFWモックアップ用の架台を製作しても良い。(c) 水平姿勢及び垂直姿勢で把持試験が可能な固定構造を有すること。姿勢毎に個別の架台を適用することも可とする。把持試験の内容については2.9.1.2項を参照すること。(3) 搬送構造：(a) 試験架台下面にリフター爪が挿入可能な空間を設けるなどし、リフターで搬送するための構造を有すること。(b) クレーンによる搬送を考慮し、アイボルトなどを具備すること。(4) 備考：(a) 材質はアルミ合金、ステンレス鋼又は防錆処理した炭素鋼とし、極力軽量化すること。(b) その他、受注者側検討により提案がある場合は、適宜協議の上決定とする。図 46 試験架台構造及び姿勢の概念図(左：垂直姿勢、右：水平姿勢)2.5.1.4 FWGプロトタイプの制御装置及びソフトウェアの設計2.4.1項に示した設計仕様及び設計情報を考慮し、FWGプロトタイプを作動させるための制御装置及びソフトウェアを設計すること。(1) 制御対象：(a) 把持爪フック拡張駆動機構(b) 把持爪リニア駆動機構(c) パッド駆動機構(d) CBレンチ昇降機構(e) CBレンチ締結機構62(f) カメラ及び照明×2台(2) 装置構成：(a) 本項におけるリモートコントローラの設計対象は、Transporter mode用のみとする。(b) FWGプロトタイプとしては、Transporter mode用リモートコントローラと、それに付随する電源装置等を1つの制御盤内に実装すること。(c) Transporter mode用リモートコントローラは、全プロトタイプ制御用として1台設置することとする。(3) 要求機能：(a) 各ユニットの駆動部で、制御及び監視が必要となるパラメータについて、任意に設定及び監視可能なこと。(b) レンチ昇降機構について、レンチの位置を監視できること。(c) レンチ回転機構：レンチの回転方向及び印加したトルクを監視できること。(d) FWGプロトタイプとしては、制御盤としてキュービクルリモートコントローラ、又それに付随する電源装置等を1つの制御BOX内に実装すること。(e) 受注者による工場受入試験において単軸動作及び把持試験を実施するために必要な制御盤を設計すること。上記の(d)に示した制御盤により併用可能な場合、別機器として分ける必要はない。(f) カメラで観察した映像を監視できること。 (g) 上記のログデータを記録し、USBメモリなどの記録媒体に保存できること。2.5.2 ESBTプロトタイプ及び試験装置の設計受注者は本仕様書の 2.1～2.4 項に示した設計仕様及び設計情報を考慮し、2.5.2.1～2.5.2.3 項に示す作業を実施し、ESBT プロトタイプ及び試験用装置類の設計を実施すること。2.5.2.1 ESBTプロトタイプの設計受注者は、TFW・SB・15ND系モジュールのESBを保守可能なESBTプロトタイプを設計すること。ESBT プロトタイプは基本 1 台とし、全種類の取合いに対応可能な反力受けを具備すること。2.5.2.2 ESBHTプロトタイプの設計受注者は2.4.2.1項の設計仕様を基に、全てのTFW・SB・15ND系モジュールのESBのパーキングスレッドからの緩め及びメインスレッドへの移動と仮締めを行うための ESBHT を設計すること。2.5.2.3 ESBTプロトタイプ試験装置の設計受注者は、ESBTプロトタイプのFATを行うための試験装置を設計すること。63試験装置は、図 47に示すようにTFW、SB、15NDの構造模擬部(Structure simulate partof TFW, SB, 15ND)及び試験架台(Test stand)で構成されている。BM 構造模擬部は BM が具備する反力受け構造、ESB への導入孔、ESBヘッド部(TORXソケット含む)を模擬し、試験架台はトルク測定・固定・搬送を行うための構造及び取合いを有すること。(1) 反力受け構造模擬部(Structure simulate part of TFW, SB, 15ND)(a) 反力受けに利用できる構造として、FWESB導入孔の入口(図 24)、FWESBポケット(図 25内、Aの周辺)、15ND系モジュールの蓋・配管導入孔(図 4)を模擬した構造を具備すること。・ 模擬するTFWは、QSTと協議の上決定すること(仮：TFW#4)。・ 模擬するSBはQSTと協議の上決定すること(仮：SB#4)。・ 模擬する15ND系モジュールは #15NDとする。(b) 3種類の反力受け構造は、それぞれ簡単に交換可能な設計とすること。(2) トルクメータ(Torque meter)(a) 定格1000 Nmのトルクメータを選定すること。(3) ESBヘッド模擬構造(ESB head)(a) ESBのヘッド部(図 22のボルトヘッド、TORXソケット、PHS取合い)を模擬した構造を具備すること。ただし、M24のスレッド構造部は不要とする。材質は工場受入試験におけるトルク印加によって破損または塑性変形しない金属材料とすること。(b) 上記の構造をトルクメータに固定するための取合いを具備すること。(4) 試験架台(Test stand)(a) 上記(1)～(3)の構造及び機器を固定するための取合いを具備すること。(b) 固定方向は垂直下向きを基準とし、更に +180 degの範囲まで本設備の姿勢を変更する機能を具備すること(VV 内における TFW の各設置姿勢を模擬するため)。(c) トルクメータの固定に関しては、各反力受けに利用できる構造の中心軸を基準として、設置位置と角度を調整可能とすること。・ シムにより並進位置(最大2.1 mm)及び角度(最大0.5 deg)を調整可能であること。・ 角度調整は設定誤差量が蓄積しない構造であること。(d) 床への固定用取合いを具備すること(備考：試験架台と床面の取合い構造は、契約後にQST担当者、IO担当者、受注者の協議により決定とする)。(e) 以下の搬送構造を具備すること。・ クレーン用の吊り具としてアイボルト構造を具備すること。・ 試験架台下面にリフター爪が挿入可能な空間を設け、リフターによる搬送が可能であること。・ 本試験設備を荷台又はパレット等に固縛可能な取合いを有すること。(5) その他64(a) 上記のうち材質を指定しない構造については、各構造及び機器の固定と、ESBTによるトルク印加により組成変形や破損が発生しない強度を有する材質を選定すること。ただし、防錆処理は必須とする。(b) 受注者側検討により提案がある場合は、適宜協議の上決定すること。図 47 ESBTプロトタイプ試験設備の概念図2.5.3 FW保守ツールプロトタイプの制御系統合化設計受注者は、FW保守ツールプロトタイプの制御系を統合するため、CBT の制御装置(2.4.3項参照)と、本件で設計・製作する制御装置との間で、機能的・物理的な統合を達成するための設計を行うこと(統合した制御装置を「FW保守ツールプロトタイプ制御装置」と呼ぶ)。 制御系統合化設計にあたっては、以下を満足するよう設計を実施すること。(1) 統合の基本方針(a) 本件で設計・製作する制御装置により、CBTの操作監視を可能とすること。(b) 上位制御系について、全てのFW保守ツールプロトタイプの操作監視用としての機能を、FAT用C&C PC1台に実装するよう設計すること。FAT用C&C PCのHMIを通じて、ツールの電気的な接続の切り替えに伴い、操作監視機能の切り替えが適切に実施・機能するよう設計すること。(c) 下位制御系について、全てのFW保守ツールプロトタイプは、Transporter mode65用としてリモートコントローラ1台の制御構成にて設計すること。(d) 統合に伴い CBT の制御装置の改造が必要となる場合は、その範囲と方法を明確にし、QSTの承認を得てから改造設計に着手すること。(e) C&C機能を備えた複数の端末について、ツールへの操作指令が競合しないようにすること。(2) 具備すべき取合い(a) 電気的取合い・ 電源及び信号に関する取合い(コネクタ、ケーブル等)は、本件で設計・製作する制御システムの仕様に準拠すること。(b) ソフトウェア・データ取合い・ 本件で設計・製作する制御システムを基準として、通信プロトコル、及びデータフォーマットの互換性を確保すること。統合に伴い取合いの変換が必要となる場合は、その対応方針についてQSTと協議の上、設計方針を決定すること。(3) 備考(a) その他、受注者側検討により提案がある場合は、適宜協議の上決定とする。2.6 FW保守ツールプロトタイプの強度計算受注者は本件で設計したFW保守ツールプロトタイプに対し、強度計算を実施し、結果を「Structural Integrity Report」(表1参照)に記載すること。検討対象は、各種ツールプロトタイプを保守作業に使用した際に負荷がかかる部位とする。2.7 FW保守ツールプロトタイプの適合性評価受注者は本件で設計した FW 保守ツールプロトタイプに対し、適用図書[4]に記載された要求への対応状況を評価し、結果を「Compliance Matrix」(表1参照)に記載すること。不適合と判定した項目については、適合させるための必要な対策を検討し QST と協議すること。662.8 FW保守ツールプロトタイプの製作受注者は本件で設計したツールや装置類を 1.6 項に示す仕様にて製作すること。製作着手前に、Assembly Drawing(表1参照)を作成してQSTの確認を得ること。外部に露出する部品・筐体 (切断に用いるブレードを含む)については、試験前及び出荷前に、洗浄を実施すること。2.8.1 ESBTプロトタイプの製作表 3に示す品目、数量にて、ESBTプロトタイプ一式を製作すること。2.8.2 FWGプロトタイプの製作表 5に示す品目、数量にて、FWGプロトタイプ一式を製作すること。全てのTFW形状へ対応のために複数台数のFWGプロトタイプが必要である場合は、対応バリアントにTFW#4を含むFWGプロトタイプ、又は2.5.1.1項の設計検討結果に基づきQSTと協議の上選定した1台を製作対象とする。2.8.3 FW保守ツールプロトタイプ制御装置の製作表 5に示す品目、数量にて、FW保守ツールプロトタイプ制御装置一式を製作すること。672.9 FW保守ツールプロトタイプの工場受入試験2.8 項で製作した各種 FW 保守ツールプロトタイプ、制御装置、試験装置及び QST から貸与品(1.9項参照)を使用して、工場受入試験(FAT)を実施すること。試験実施前には、試験の実施手順、作業内容、結果(データ)の取得方法及び判定方法等に関する要領を定めたFactory Acceptance Test Plan (FATP)を作成してQSTの確認を得ること。記録/評価すべき項目は以下に示す。試験実施の際はQST及びIOメンバーの立ち合いを想定すること。また、各試験における各工程の作業時間を計測し、報告書に記録すること。また、試験実施後には、試験結果をFactory Acceptance Test Report (FATR)にとりまとめるとともに、実施中の機器の操作手順をまとめたEquipment Operation and MaintenanceManualを作成すること。各種FW保守ツールプロトタイプ一式をサイトへ運搬する準備として、別途QSTから受注者に提供する様式に従い、Release Note及びDeclaration of Incorporationを提出し、QSTの確認を得ること。2.9.1 FWGプロトタイプの工場受入試験2.8.2 項で製作した FWG プロトタイプ一式を用い、2.9.1.1 項～2.9.1.2 項に示す手順にてFWGによるFW把持に関わる試験を実施すること。2.9.1.1 単軸動作試験下記に基づいて FWG プロトタイプが具備する各駆動系の単軸動作に関する検証試験を行うこと。(1) 目的：(a) 製作したFWGプロトタイプの駆動系が正常に動作するかを確認する。(2) 使用するツール及び試験装置(a) FWGプロトタイプ(b) FW保守ツールプロトタイプ制御装置(3) 試験手順：(a) 下記ユニットの駆動部を、単軸動作させる。・ 把持爪ユニット(フック拡張機構、リニア駆動機構)・ パッド駆動機構・ CBレンチユニット(CBレンチ昇降機構、CBレンチ締結機構)(4) 計測項目：(a) 目視での動作の確認(b) 各駆動系の負荷の確認(5) 確認項目：(a) 無負荷状態での動作異常がないことを確認すること。(b) 試験結果を基に課題とその対策案を整理すること。68(6) 記録項目(a) カメラ監視映像(b) 把持爪ユニットの動作ログ(c) アクティブパッドユニットの動作ログ(d) CBレンチユニットの動作ログその他、受注者側検討により提案がある場合は、適宜協議を行うこと。2.9.1.2 把持試験下記に基づいて、FWGプロトタイプによる把持試験、CBレンチによるCB締結及び解除試験を行うこと。(1) 目的：(a) FWGプロトタイプが、TFWの荷重を模擬したFWGプロトタイプ試験用TFWモックアップ(以下、本項においては「TFW モックアップ」)を、指定した姿勢にて把持することが可能であるかを検証する。(b) FWGプロトタイプがTFWモックアップを把持した状態にて、FWGプロトタイプのCB レンチが TFW モックアップの CB に勘合でき、CB の締結及び解除が可能であるかを検証する。(2) 使用するツール及び試験装置(a) FWGプロトタイプ(b) FW保守ツールプロトタイプ制御装置(c) FWGプロトタイプ試験用TFWモックアップ(d) FWGプロトタイプ試験架台(3) 試験手順：(2.5.1.3項、図 46に描く試験架台の概念を基に、試験手順のイメージを図 48、図 49、及び図 50に示す。図中のアルファベットは下記の工程手順と対応する。)(a) FWGプロトタイプを試験架台に固定する。(b) TFWモックアップをFWGプロトタイプと勘合できる位置に持ち上げる(別架台への固定、クレーンで吊り上げる等)。(c) FWGプロトタイプとTFWモックアップを近づけ、目視で把持爪の挿入を行う。(d) 把持爪のフックを拡張し、アクティブパッドを押し出して、FWGプロトタイプとTFWモックアップを固定する。(e) TFW モックアップへの錘追加又はクレーンによる吊り上げ等により TFW の荷重を模擬する。 (f) FWGプロトタイプによりTFWモックアップを把持する姿勢へ変更する。対象姿勢は、把持爪が床面に対して水平となる姿勢及び垂直となる姿勢。(g) FWGプロトタイプのCBレンチ昇降機構を駆動し、CBレンチをTFWモックアップのCBに勘合する。(h) CBレンチ回転機構を駆動し、CBの締結及び解除動作を行う。69(4) 計測項目：(a) 把持爪の挿抜可否の確認(目視)(b) 把持爪挿入後のフック拡張及びフックの掛かり確認(目視)(c) アクティブパッドの押しつけ確認(目視)(d) 把持爪ユニットのモータ電流の計測(フック拡張、リニア駆動)(e) アクティブパッドユニットのモータ電流の計測(f) CBレンチユニットのモータ電流の計測(昇降、締結)(g) FWGプロトタイプ試験架台のCB/トルクメータに印加されるトルク値(5) 確認項目：(a) 再現性の評価(10回程度)(b) FWG プロトタイプの CB レンチによって、CB の規定トルク(図書[1]参照)での締結及び解除が可能であることを確認すること。(c) 試験後の FWG プロトタイプ各部、及び FWG プロトタイプ試験用 TFWモックアップの損傷有無を確認すること。(d) 損傷が確認された場合は、その正確な位置及び範囲を記録し、損傷の形態や影響を整理の上、試験結果としてまとめること。(e) モータへの負荷が設計計算値に対して大きく乖離が発生する場合は、設計上適切な余裕度を確保する観点から、課題として改善案を記載すること。(f) 試験結果を基に課題とその対策案を整理すること。(6) 記録項目(a) カメラ監視映像(b) 把持爪ユニットの動作ログ(c) アクティブパッドユニットの動作ログ(d) CBレンチユニットの動作ログその他、受注者側検討により提案がある場合は、適宜協議を行うこと。70図 48 (3)試験手順(a)～(e)のイメージ(左：TFWモックアップ固定前、右：後)図 49 (3)試験手順(f)の把持姿勢のイメージ71図 50 (3)試験手順(g)(h)のCBの締結(左)及び解除(右)イメージ722.9.2 ESBTプロトタイプの工場受入試験2.8.1項で製作したESBTプロトタイプ一式を用い、2.9.2.1項及び2.9.2.2項に示す手順にてESB保守に関わるFATを実施すること。2.9.2.1 設置性能試験(1) 目的(a) ESBT プロトタイプが保守対象の試験装置に対して適切に設置されることを確認し、反力受け構造との取合い精度、レンチの挿入性、及び設置再現性の評価を行うこと。(2) 使用するツール及び試験装置(a) ESBTプロトタイプ(b) ESBTプロトタイプ用反力受け構造(c) ESBTプロトタイプ試験装置(3) 試験条件(a) ESBT レンチと ESB ヘッド間に設定する位置誤差(各誤差を組み合わせた条件においてトルク印加試験を実施すること)・ 位置誤差：0 mm, +1.0 mm, +2.1 mm, -1.0 mm, -2.1 mmの5通り・ 角度誤差：0 deg, +0.5 deg, -0.5 degの3通り(b) 印加するトルク・ なし(本試験ではトルク印加をしない)(4) 試験手順(a) ESBTに反力受け構造(TFW、SB、15NDのいずれか)を設置する。(b) 試験架台に反力受け構造模擬部((a)と対応するタイプ)を設置する。(c) トルクメータ＋ESBヘッド模擬構造の固定部を調整し、(3)の試験条件(a)に示した位置誤差を設定する。(d) ESBTレンチを挿入し、レンチ先端をESBヘッド模擬構造のTORXソケットに勘合させる。併せてレンチ先端に具備されたPHSをTORXソケット奥のPHSソケットと勘合させる。(e) ESBT側の反力受け構造と試験架台側の反力受け構造模擬部を勘合させる。(f) 上記(c)～(e)を1種類の反力受け構造毎に3回繰り返す。(g) 完了後、残りの反力受け構造に交換して同様の試験を実施する。(5) 確認項目以下の項目について計測と確認を行う。(a) 試験設備の取付け可否及び勘合状態(設計図との照合)。(b) 固定状態の安定性(取付け後の剛性、ガタつきの有無)。(c) ESB導入孔に対するレンチ挿入の勘合可否(X/Y/Z方向及び角度)。(d) 繰返し設置による位置誤差の再現性。(e) 必要に応じた補正・改善案の抽出。732.9.2.2 BMトルク印加試験(1) 目的(a) ESBTプロトタイプによってESBへのトルク印加試験を行う。所定のトルクを安定的かつ、再現性をもって印加できることを確認するとともに、ツールとESB間の誤差の影響を評価すること。(2) 使用するツール及び試験装置(a) ESBTプロトタイプ(b) ESBTプロトタイプ用反力受け構造(c) ESBTプロトタイプ試験装置(3) 試験条件(a) ESBT レンチとESB ヘッド間に設定する位置誤差(各誤差を組み合わせた条件においてトルク印加試験を実施すること)・ 位置誤差：0 mm, +1.0 mm, +2.1 mm, -1.0 mm, -2.1 mmの5通り・ 角度誤差：0 deg, +0.5 deg, -0.5 degの3通り(b) 印加するトルク・ 480 Nm±10% 及び MAX 800 Nm(別途協議の上決定)(4) 試験手順(a) 2.9.2.1項の試験手順(a)～(e)に従ってトルク印加試験の準備を行う。(b) トルク印加試験を1条件につき計10回実施する。(5) 確認項目(a) 目標印加トルクに対し、10回連続で±10%以内となるかを評価すること。(b) 締結結果のトルク値、再現性、干渉の有無を確認すること。(c) 試験後のESBT プロトタイプ及び試験装置(ESB導入孔)の損傷有無を確認すること。(d) 挿入したレンチが設計仕様通りのコンプライアンス性能を有するかを確認すること。(e) 各試験結果を基に抽出された課題及び対策案は、FATR内に整理すること。※その他受注者による提案がある場合は、適宜QSTと協議の上、試験内容に反映すること。2.9.3 制御系統合の機能に関わる工場受入試験(1) 試験目的(a) 運転モードに応じた単一のリモートコントローラを介し、単一のFAT用C&C PCから、複数のFW保守ツールプロトタイプの切り替えを伴う操作監視が可能であることを試験する。(2) 使用するツール及び試験装置(a) FW保守ツールプロトタイプ制御装置(b) FAT用C&C PC74(c) 制御装置が関係するFW保守ツールプロトタイプ(試験対象のツールはQSTと受注者の協議により決定する。)(3) 確認項目(a) FAT用C&C PCによる統合操作の確認・ FAT用C&C PCにより、Transporter modeでの運用が想定される複数のFW保守ツールプロトタイプの電気的な接続を切り替えながら、その操作監視がTransporter mode 用リモートコントローラを介して実行可能であることを確認する。・ 本試験環境には、原則としてFW保守ツールプロトタイプの実機を使用する。・ 実機の使用が難しい FW 保守ツールプロトタイプについては、QST との協議の上、機器の入出力を模擬した模擬環境にて試験を実施する。(b) 操作対象切り替え機能の検証・ FAT用C&C PCのHMIを通じて、ツールの電気的な接続の切り替えに伴い、操作監視機能の切り替えが適切に実施・機能することを確認する。(c) 操作指令が競合しないことの確認及びキースイッチによる権限切り替え確認・ 初期組立機器全体の制御系としては、C&Cの機能を備えた端末として、ポータブルコントローラ及びFAT用C&C PCが存在するため、操作指令について排他制御が行われる。 FW 保守ツールプロトタイプとしてはポータブルコントローラを使用しないが、ポータブルコントローラのキースイッチによる制御権切り替えの入力信号を模擬し、キースイッチの状態に応じて、FAT用C&C PCが適切に操作を受け付けるか否かを確認する。(d) シーケンス実行能力の検証・ FAT用C&C PCのHMIを通じて、事前に準備された操作シーケンスを実行する機能を有することを確認する。(e) 共通機能の確認・ 個々のツール固有の動作確認の他、制御装置として共通の基本機能が仕様通りに動作することを確認する。例えば、非常停止ボタン押下時の動作確認や、制御装置における状態監視機能の確認等を実施する。2.10 図書類の作成受注者は、2.5～2.8項にて実施した設計・製作作業、及び2.9項の試験結果について、1.6項及び1.7項に基づく納入物及び図書一式を製作・作成し、納入すること。以上 別紙1iイーター調達取決めに係る品質保証に関する特約条項本契約については、契約一般条項によるほか、次の特約条項(以下「本特約条項」という。)による。(定義)第１条 本契約において「協定」とは、「イーター事業の共同による実施のためのイーター国際核融合エネルギー機構の設立に関する協定」をいう。２ 本契約において「イーター機構」とは、協定により設立された「イーター国際核融合エネルギー機構」をいう。３ 本契約において「加盟者」とは、協定の締約者をいう。４ 本契約において「国内機関」とは、各加盟者がイーター機構への貢献を行うに当たって、その実施機関として指定する法人をいう。５ 本契約において「フランス規制当局」とは、イーター建設地であるフランスの法令に基づき契約物品に関して規制、許認可を行う権限を有する団体をいう。(品質保証活動)第２条 乙は、本契約書及びこの契約書に附属する仕様書(以下「契約書等」という。)の要求事項に合致させるため本契約内容の品質を管理するものとする。(品質保証プログラム)第３条 乙は、本契約の履行に当たっては、乙の品質保証プログラムを適用する。このプログラムは、国の登録を受けた機関により認証されたもの(ISO9001-2015等)で、かつ、本特約条項に従って契約を履行することができるものとする。ただし、これによることができないときは、甲により承認を得た品質保証プログラムを適用することができる。(品質重要度分類)第４条 乙は、適切な製品品質を維持するため、安全性、信頼性、性能等の重要度に応じて甲が定める本契約内容の等級に従って管理を実施しなければならない。契約物品の等級及び等級に応じた要求事項は、仕様書に定める。(疑義の処置)第５条 乙は、本契約書等に定める要求事項に疑義又は困難がある場合には、作業を開始する前に甲に書面にて通知し、その指示に従わなければならない。(逸脱許可)第６条 乙は、契約物品について、契約書等に定める要求事項からの逸脱許可が必要と思わ別紙1iiれる状況が生じた場合は、当該逸脱許可の申請を速やかに甲に提出するものとする。甲は、乙からの申請に基づき、当該逸脱許可の諾否について検討し、その結果を乙に通知するものとする。(不適合の処理)第７条 乙は、契約物品が契約書等の要求事項に適合しないとき又は適合しないことが見込まれるときは、遅滞なくその内容を甲に書面にて通知し、その指示に従わなければならない。(重大不適合の処置)第８条 乙は、重大不適合が発生した場合、直ちにその内容を甲に報告するとともに、プロジェクトへの影響を最小限に抑え、要求された品質を維持するため、その処置方法を検討し、速やかに甲に提案し、その承認を得なければならない。(作業場所の通知)第９条 乙は、本契約締結後、本契約の履行に必要なすべての作業場所を特定し、本契約に係る作業の着手前に、甲に書面にて通知するものとする。当該通知には、本契約の履行のために、乙が本契約の一部を履行させる下請負人の作業場所を含む。(受注者監査)第１０条 甲は、乙に対して事前に通知することにより、乙の品質保証に係る受注者監査を実施できるものとする。(立入り権)第１１条 乙は、本契約の履行状況を確認するため、甲、イーター機構、本契約の活動に関連する日本以外の加盟者の国内機関、フランス規制当局及びそれらから委託された第三者が、第９条に基づき特定した作業場所に立ち入る権利を有することに同意する。２ 前項に定める立入り権に基づく作業場所への立入りは、契約書等に定める中間検査等への立会い及び定期レビュー会合への参加の他、乙に対して事前に通知することにより、必要に応じて実施することができるものとする。(文書へのアクセス)第１２条 乙は、甲の求めに応じ、本契約の適切な管理運営を証明するために必要な文書及びデータを提供するものとする。(作業停止の権限)第１３条 甲は、乙が本契約の履行に当たって、契約書等の要求事項を満足できないことが認められる等、必要な場合は、乙に作業の停止を命じることができる。別紙1iii２ 乙は、甲から作業停止命令が発せられた場合には、可及的速やかに当該作業を停止し、甲の指示に従い要求事項を満足するよう必要な措置を講ずるものとする。(下請負人に対する責任)第１４条 乙は、下請負人に対し、本契約の一部を履行させる場合、本特約条項に基づく乙の一切の義務を乙の責任において当該下請負人に遵守させるものとする。(情報のイーター機構等への提供)第１５条 乙は、本契約の履行過程で甲に伝達された情報が、必要に応じてイーター機構及びフランス規制当局に提供される場合があることにあらかじめ同意するものとする。以上知的財産権特約条項(知的財産権等の定義)第１条 この特約条項において「知的財産権」とは、次の各号に掲げるものをいう。一 特許法(昭和34年法律第121号)に規定する特許権、実用新案法(昭和34年法律第123号)に規定する実用新案権、意匠法(昭和34年法律第125号)に規定する意匠権、半導体集積回路の回路配置に関する法律(昭和60年法律第43号)に規定する回路配置利用権、種苗法(平成10年法律第83号)に規定する育成者権及び外国における上記各権利に相当する権利(以下総称して「産業財産権等」という。)二 特許法に規定する特許を受ける権利、実用新案法に規定する実用新案登録を受ける権利、意匠法に規定する意匠登録を受ける権利、半導体集積回路の回路配置に関する法律に規定する回路配置利用権の設定の登録を受ける権利、種苗法に規定する品種登録を受ける地位及び外国における上記各権利に相当する権利三 著作権法(昭和45年法律第48号)に規定する著作権(著作権法第21条から第28条までに規定する全ての権利を含む。)及び外国における著作権に相当する権利(以下総称して「著作権」という。)四 前各号に掲げる権利の対象とならない技術情報のうち、秘匿することが可能なものであって、かつ、財産的価値のあるものの中から、甲乙協議の上、特に指定するもの(以下「ノウハウ」という。)を使用する権利２ この特約条項において「発明等」とは、次の各号に掲げるものをいう。 一 特許権の対象となるものについてはその発明二 実用新案権の対象となるものについてはその考案三 意匠権、回路配置利用権及び著作権の対象となるものについてはその創作、育成者権の対象となるものについてはその育成並びにノウハウを使用する権利の対象となるものについてはその案出３ この契約書において知的財産権の「実施」とは、特許法第２条第３項に定める行為、実用新案法第２条第３項に定める行為、意匠法第２条第２項に定める行為、半導体集積回路の回路配置に関する法律第２条第３項に定める行為、種苗法第２条第５項に定める行為、著作権法第21条から第28条までに規定する全ての権利に基づき著作物を利用する行為、種苗法第２条第５項に定める行為及びノウハウを使用する行為をいう。(乙が単独で行った発明等の知的財産権の帰属)第２条 甲は、本契約に関して、乙が単独で発明等行ったときは、乙が次の各号のいずれの規定も遵守することを書面にて甲に届け出た場合、当該発明等に係る知的財産権を乙から譲り受けないものとする。 Doljac G. Hery R. Murakami S. Noguchi Y. Palmer J. Reich J. Torralba pinedo A. 25 Jul 2025:recommended v2.124 Jul 2025:recommended v2.122 Jul 2025:recommended v2.124 Jul 2025:recommended v2.123 Jul 2025:recommended v2.122 Jul 2025:recommended v2.125 Jul 2025:recommended v2.124 Jul 2025:recommended v2.1IO/DG/ESD/ACSDIO/DG/ESD/PPEDIO/DG/ESD/ACSDIO/DG/ESD/ACSDNational Institutes for Quantum SciIO/DG/CP/MAP/RHPIO/DG/CP/MAPIO/DG/SID/CID/CMSApprover Orlandi S. 31 Jul 2025:approved Head of ITER Construction ProjectInformation Protection Level: Non-Public - UnclassifiedRO: Hery RaphaelRead Access LG: Annex B reviewers, LG: Annex B reviewers 2, LG: IO TRO 2.3.P1.JA.01, LG: IO PA PT 2.3.P1.JA.01,LG: DA PA PT 2.3.P1.JA.01, AD: ITER, AD: IO_Director-General, AD: External Management AdvisoryBoard, AD: IDM_Controller, AD: Nuclear Safety Inspectors, AD: Auditors, AD: ITER ManagementAssessor, pro#drn#IDM UID2F6S75VERSION CREATED ON / VERSION / STATUS30 Jul 2025 / 2.2 / ApprovedEXTERNAL REFERENCE / VERSION別紙6PDF generated on 31 Jul 2025DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogTechnical Specification for Blanket First Assembly Tooling (2F6S75)Version Latest Status Issue Date Description of Changev1.0 Signed 20 Feb 2025v1.1 Signed 07 Mar 2025 The updates aim to better reflect the recent discussions between IO andJADAv2.0 Approved 25 Apr 2025 First consolidated version with many updatesv2.1 Signed 22 Jul 2025 List of Sign-Off Authorities changedNo change of content compared to v2.0v2.2 Approved 30 Jul 2025 Updates in sections 8.1 and 9.1 according to QARO's suggestionsSUPPLYPage 1 of 106Table of Contents 1 PURPOSE.32 ACRONYMS & DEFINITIONS.32.1 Acronyms.32.2 Definitions.53 APPLICABLE DOCUMENTS & CODES AND STANDARDS.63.1 Applicable Documents.63.2 Reference documents.73.3 Applicable Codes and Standards.84 SCOPE OF WORK.94.1 Overview of Blanket Modules Assembly.94.2 Final design of End Effectors and Tools.164.2.1 Shield Block Gripper.174.2.1.1 Interfaces with the Shield Block.214.2.2 Flexible Cartridge Bolt Torquing Tool Base.224.2.3 Electrical Strap Bolt Torquing Tool.244.2.4 Viewing Tool.314.2.5 Shield Block Pulling and Welding Tool Base.324.2.6 Coaxial Connector Welding Tool.394.2.7 Coaxial Connector Cutting Tool.424.2.8 Monoaxial Connector Pulling Tool.444.2.9 Monoaxial Connector Alignment Measurement Tool.494.2.10 Monoaxial Connector Welding Tool.504.2.11 Monoaxial Connector Cutting Tool.524.2.12 End Cap Handling Tool.544.2.13 End Cap Welding Tool.564.2.14 End Cap Cutting Tool.574.2.15 15ND Gripper.584.2.16 15ND Tool Base.624.2.17 First Wall Gripper.644.2.18 First Wall Central Bolt Torquing End Effector.664.2.19 Blanket Tooling Supporting Equipment.714.2.20 In-Vessel Tool Storage.774.2.20.1 Tool Storage Rack.77SUPPLYPage 2 of 1064.2.20.2 Nacelle Tool Storage.794.2.21 End Effector design constraints.804.2.21.1 Enveloping dimensions.804.2.21.2 Pre-SRO transfer context.834.2.22 Tool design constraints.874.3 Control System for Blanket Tooling.894.3.1 Control System Architecture Requirements.894.3.2 Control System Detailed Requirements.944.3.3 Control System Scope and Indicative Bill of Materials.974.4 Production of final End Effectors, Tools and I&C systems.1004.5 Factory Acceptance Tests.1004.6 Site Acceptance Tests.1005 LOCATION FOR SCOPE OF WORK EXECUTION.1016 IO DOCUMENTS & IO FREE ISSUE ITEMS.1017 DELIVERABLES AND SCHEDULE MILESTONES.1017.1.1 Schedule for delivery.1017.1.2 List of deliverable documentation.1038 OVERARCHING REQUIREMENTS.1048.1 Quality Assurance requirements.1048.2 Nuclear class Safety.1058.3 Seismic class.1059 SPECIAL MANAGEMENT REQUIREMENTS.1059.1 Review meetings.1059.2 CAD design requirements.10610 APPENDICES.106SUPPLYPage 3 of 1061 PurposeThis Technical Specification describes the scope of work and deliverables to develop the toolingnecessary for the first assembly of all Shield Blocks and Temporary First Walls2 Acronyms & Definitions2.1 AcronymsThe following acronyms are the main ones relevant to this document. Abbreviation Description15NDG 15ND Gripper15NDTB 15ND Tool BaseAD Applicable DocumentsALARA As Low As Reasonably AchievableAVC Arc Voltage Control (for TIG welding tool)BAT Blanket Assembly TransporterBM Blanket Module (FW + SB)BMTS Blanket Module Transfer SystemBRHS Blanket Remote Handling SystemBT Bolting ToolBTSE Blanket Tooling Supporting EquipmentCB Central BoltCBT Central bolt Bolting ToolCC Coaxial ConnectorCCCT Coaxial Connector Cutting ToolCCPT Coaxial Connector Pulling ToolCCT / ECCT Cap Cutting Tool / End -CCWT Coaxial Connector Welding ToolCHT / ECHT Cap Handling Tool / End -CMAF CAD Model Approval FormCMM Configuration Management ModelCOG Centre Of GravityCRO Contract Responsible OfficerCWT /ECWT Cap Welding Tool / End -DCM Design Compliance MatrixDDP Design Development PlanDM Detailed ModelDMNP Dexterous ManipulatorDOF Degrees of FreedomECHT End Cap Holding ToolECWT End Cap Welding ToolECCT End Cap Cutting ToolEDH Electrical Design HandbookEDR Equipment and Documentation ReviewSUPPLYPage 4 of 106EE End EffectorES Electrical StrapESB Electrical Strap BoltESBT Electrical Stap Bolt Torquing toolFAT Factory Acceptance TestFBT FCB Torquing Tool BaseFCB Flexible Cartridge BoltFDR Final Design ReviewFEM Finite Element MethodFS Flow SeparatorFSCT Flow Separator Cutting ToolFSHT Flow Separator Handling ToolFSWT Flow Separator Welding ToolFW First WallFWCBT FW Central Bolt Torquing End EffectorFWESBT FW ES bolt Bolting ToolFWG FW GripperFWTB First Wall Tool BaseGM3S General Management Specification for Service and SupplyHLCS High-Level Control SystemHLT Helium Leak testing ToolHMI Human-Machine InterfaceICD Interface Control DocumentICSR In-Cask Storage RackIMK Inter Modular KeypadsIO ITER OrganizationIPT In Port TransporterIS Interface SheetIVDT In-Vessel Deployment TrolleyIVT In-Vessel TransporterJADA Japan Domestic AgencyLLCS Low-Level Control SystemMC Monoaxial ConnectorMCAMT Monoaxial Connector Alignment Measurement ToolMCCT Monoaxial Connector Cutting ToolMCPT Monoaxial Connector Pulling ToolMCWT Monoaxial Connector Welding ToolMTO Material Take OffMTPP Module Tool Pallet PlateNBDL Neutral Beam Duct LinerNBI Neutral Beam InjectionNDE Non-Destructive ExaminationNTS Nacelle Tool StorageOD Outer DiameterPAT Pipe alignment ToolSUPPLYPage 5 of 106PBS Plant Breakdown StructurePCR Project Change RequestPCT Pipe Cutting ToolPHS Passive Holding SystemPR Project RequirementsPRO Procurement Responsible OfficerPWT Pipe Welding ToolQAP Quality Assurance ProgramRD Reference DocumentsRFA Rail Fixing ArmRH Remote HandlingRoX Return on ExperienceSAT Site Acceptance TestSB Shield BlockSBESBT SB ES bolt Bolting ToolSBG SB GripperSBTB Shield Block Tool BaseSDP System Design ProcessSL Seismic LoadSR Safety Relevant for nuclear safetySRD System Requirements DocumentSRO Start of Research OperationTB Tool BaseTBD To Be DecidedTFU Tool Fixing UnitTMNP Tool ManipulatorTSR Tool Storage RackTSS Tooling Services SkidUHS Umbilical Handling SystemUTC Umbilical Temporary ClampVC Vacuum CleanerVFA Vehicle Fixing ArmVM / VMNP Vehicle ManipulatorVT Viewing ToolVV Vacuum VesselWPQR Welding Procedure Qualification RecordWPS Welding Procedure Specification2.2 DefinitionsSite or ITER Site or IO Site: the construction site and areas under operation. This includes anyplace IO staff operates on a regular basis if specified by the IO. SUPPLYPage 6 of 1063 Applicable Documents & Codes and standards3.1 Applicable DocumentsIn the event of inconsistencies between the specification and the applicable documents, theinformation in this Technical Specification takes precedenceRef Title IDM Doc ID Version[1] Blanket First Assembly Tooling Requirements 2F6UJT 2.0[2] FW & SB main geometry for RH CANQ4W 3.1[3] Blanket modules dimensions and weight 35ZJNQ TBC[4] CAD model of Temporary FW DET-03305-W[5] CAD model of SB DET-03305-X[6] CAD model of SB15ND series DET-08890[7] CAD model of SB14ND series and SB16NB series DET-08054-A[8] CAD model of Tool Changer DET-03305-U[9] CAD model of Storage Box shared onowncloud[10] 2D: Gripping hole and ESB wrench torque reactioninterface of TFWTBD[11] List of SB GAD Drawings CKA4A3 1.0[12] PA CN for PA 1.6.P1B.CN.01 for SB18 rowunified water connector dimensionsATWFX4 n/a[13] 2D: Electrical strap interface to SB UG4FBK 1.0[14] Electrical strap:BKT_ES_14LAYERS_SBDRW Nr: 028123 --J[15] 2D: Flexible interface to SB UGC3KZ 1.0[16] FCB Inboard:BKT_FC_IB_BEFORE_CUSTO DRW Nr: 023426 --E[17] FCB Outboard:BKT_FC_IB_BEFORE_CUSTO DRW Nr: 037672 --B[18] 2D: SB insert UGCBHL 1.0[19] Coaxial and monoaxial:BKT_MABA_HYDRAULIC_CONNECTION DRW Nr: 025795 --E[20] 22D: Temporary FW TBD[21] FW central bolt:BKT_FW_CENTRAL_BOLT DRW Nr: 055948 --E[22] Cap system: DRW Nr: 057740DRW Nr: 074421--A---[23] 2D: Passive Holding System (PHS) TBD[24] SSelection and locational specification of cameras. TBD[25] Interface information of Zero G Arm TBDSUPPLYPage 7 of 106[26] Interface information of Nacelle TBD[27] 2D: BKT_MODULE_15_S03 (15ND series) DRW Nr:062819 --ANotes:[21] – Drawing version –E under review, but applicable[22] - Drawing 074421 is under review, but applicable[27] – Drawing version –A under review but applicable3.2 Reference documentsReference documents are not required to be compliant with but can be referenced for informationRef Title Doc ID Version[R1] Interface Sheet of SB 33TYJV 5.1[R2] Interface Sheet of FW 33PH3Y 6.3[R3] FE analysis of SB#09 during flexible cartridge bolttightening for first assemblyCDTHED 1.0[R4] Test report – FW Central bolt tightening withreconfigurable test bench8LZ3PM 1.0[R5] Test report –The reaction force measurement of FWhydraulic pipe cap cuttingYQB5Q7 1.0[R6] Study on design options of FW tool base 2D6VG6 1.0[R7] Recommendation on the 15NDL handling interfacemodification7SQ4Z8 1.0[R8] Test report – Welding Trials of TIG welding toolprototype for FW hydraulic pipes and caps5ZVHWD 1.0[R9] 11_-_Tooling_Description (presentation at PTWorkshop)4T8QNV 1.0[R10] TKM COMPLEX : LEVEL_L1, EQUIPMENTARRANGEMENT DRAWINGSTU482P 1.5[R11] Maintenance needs for permanently installed socketsin B11, B14 and B7466V9NP 2.1[R12] D2-2: Central Bolt Compliant Wrench assembly TMT6P4 3.1[R13] RH Controller Interface Protocol THQSYN 1.1[R14] RHSL Definition using XText PAW2QX 1.1[R15] Structural analysis report of the 15NDL handlinginterface7T3MAH 1.0[R16] IO Tool Changer Preliminary ConnectorConfiguration assessment94QMP6 1.0[R17] Test report of Central bolt tightening tool XZM8JP 1.0SUPPLYPage 8 of 1063.3 Applicable Codes and StandardsLaws and Regulations Grippers (FW, SB, 15ND) are subject to French Machinery Regulation 2023/1230/EUor “Lifting devices” as exchangeable equipment for the Blanket Assembly Transporter. Manufacturer of the grippers are required to comply with below requirements A safety factor of 1.25 shall be applied on the payload for the structural analysis as partof the design justification A static load test shall be conducted by applying a load of 1.1 times the payload to thegripper as part of the FAT in two positions: a horizontal orientation and a downwarddirection and then submit the test records. Note that, if the weight is simulated, there isno necessity to mimic the FW shape in the load test. Equipment shall withstand the loadtest without permanent deformation or patent defect Develop operation and maintenance manuals specifying safe handling procedures,inspection and testing procedure, and precautions for use Provide a conformity declaration or certification to confirm that the product adheres tothe design specifications Initial assembly tools and end effectors shall comply with following directives, as“interchangeable equipment” Electromagnetic Compatibility (EMC) Directive 2014/30/EU Low voltage Directive (LVD) 2014/35/EU Machinery Regulation 2023/1230/EU RoHS Directive 2011/65/EU Although REACH is not a direct requirement for CE marking, IO is responsible for meetingREACH obligations as the importer. Therefore, if the delivered items (including packagingmaterials) contain any SVHC at or above 0.1 wt%, IO must be notified. Such notificationshall be provided in written formCodes and StandardsExamples of permissible design standards are listed below. However, specifying a designstandard is not mandatory as long as compliance with the Machinery Directive is ensured. If adifferent standard is to be applied, it must be proposed to IO for approval.  EN 13001-1/+A1:2009 Cranes - General design - Part 1: General Principles andRequirements EN 13001-2:2011 Cranes - General design - Part 2: Load actions EN 13001-3-1/+A1:2013 Cranes - General design - Part 3-1: limit states and proof ofcompetence of steel structures EN 13001-3-3 Cranes - General design - Part 3-3: Limit states and proof of competenceof wheel/rail contactsThe ITER design handbooks that shall be applied to the design are as follows (The specific partsto which it will be applied are described in Section 4.2.): Electrical Design Handbook (EDH) [CA09], [CA11], [CA10], [CA36], [CA37] Remote Handling Control System Design Handbook [CA20]. Note that, the followingsection is excludedo 2.2 Standard partso 2.5 RH Control Roomo 2.6 Cubicle Rooms, Cabling Connectorso 2.10 Operation Viewpointso 6 Hazard identification and risk assessmentSUPPLYPage 9 of 106The welder should be qualified to the relevant standards (e.g., ISO 9606 series or JIS Z 3811). The welder's certificate, welding procedure, and welding records shall be submitted. If the welderis certified independently of the standards, the decision shall be made in consultation with IOThe minimum extent of weld inspection shall be as follows: For the Grippers (part of liftingdevice), 100% PT inspection on practically inspectable areas shall be the performed, while forother components, 10% PT inspection shall be applied. Additionally, visual inspections shall alsobe conducted. Volumetric NDT is not requiredApplicable standards can be refined or changed as the design progresses with proper justificationfor the change4 Scope of WorkThis section defines the specific scope of work, in addition to the requirement list as defined in[1]. First, an overview of the Blanket Module assembly is provided, followed by the necessarytasks to be performed and the preliminary designs of the Tools & End Effectors that serve astheir basisThe scope of supply shall consist of the following steps for all End Effectors and Tools identifiedby IO in this document:1. Final Design based on the Preliminary Designs supplied by IO2. Develop control system for Blanket Assembly Tooling3. Production of SRO End Effectors and Tools prototypes (First Batch of Tooling)a. Note that skipping the prototype is an option4. Production of pre-SRO End Effectors and Tools (Tooling Production Units for pre-SRO)5. Factory Acceptance Tests6. Site Acceptance TestsJADA will manufacture the tools and end effectors for Blanket assembly, provide manuals, andperform functional testing, but the actual Blanket assembly operations and preparation, includingcreation of WPSs for real blanket piping welding, are not within JADA’s scope4.1 Overview of Blanket Modules AssemblyBlanket Modules (BM) consist of Shield Blocks (SB) and First Wall (FW) units (see Figure 1). For pre-SRO operations, Temporary First Wall (TFW) units will be used, which will not haveactive cooling, meaning there will be no pipe joint to be made between SBs and TFWs. ShieldBlocks are connected to the VV via Flexible Cartridges (for positioning) and captive FlexibleCartridge Bolts (for fixing) (see Figure 2). TFWs are connected to the SB via a Central Bolt (CB)(see Figure 3) and pads for positioningSUPPLYPage 10 of 106Figure 1 Blanket Module attached to the VVFigure 2 Flexible Cartridge interface between VV and SB (yellow outline is the border between SB and VV components)Figure 3 Central Bolt interface between SB and TFW (yellow line is the border between TFW and SB)SUPPLYPage 11 of 106SBs and TFWs will be transferred to their position in the vessel by the Blanket AssemblyTransporter (BAT), using dedicated End Effectors called Shield Block Gripper (SBG) and FirstWall Gripper (FWG). After the SBs are temporarily fixed in position by the BAT, FCBs and Electrical Strap Bolts(ESB) must be tightened to predefined torque levels. FCB torquing will be performed by aspecific FCB Tightening Tool Base (FBT), which is an End Effector to be handled and fixed tothe front of the SB by the BAT. ESB tightening will be done by a the Electrical Strap BoltTorquing Tool (ESBT) using the front pockets of the SB to react the torque applied. Pictures ofthe concept for these EEs and Tools will be shown later in dedicated sectionsBlanket manifolds, supplying cooling water to BMs, are routed in the space between VV andSB. Two ways have been developed to connect manifolds to BMsThe first solution is where the inlet and outlet manifolds meet in a Coaxial Connector (CC) (seeFigure 5), which is welded to the SB pipe stub at the bottom of the SB. CC is used for most ofthe SBs. The tools used at this joint are: CCWT: Coaxial Connector Welding Tool CCCT: Coaxial Connector Cutting ToolBoth should weigh less than 40 kg (similar to all Tools), handled by the zero G arm on the IVTCNacelle and to be fixed to the Tool Fixing Unit (TFU) of a Shield Block Pulling & Welding ToolBase (SBTB). When the Tool axis is horizontal, the zero G arm should, ideally, be aligned so that there is nomoment load that the operator has to compensate. However, there are situations, when this isimpossible, due to ergonomic reasons or space constraints. Tools and their gripping features (forthe zero G arm and for handling) should be designed so that an operator can compensate themoment load generated from the CoG being at an offset from the last swivel joint of the zero Garm. Figure 4 Explanatory figure of moment load on operator (video from https://www.cyborg-arms.com/ (accessed on 24/01/2025). Moment load to compensate is equal to (tool weight x CoG offset)SUPPLYPage 12 of 106Figure 5 Coaxial Connector as interface between SB cooling channels and Blanket ManifoldsThe second solution consists of 2 Monoaxial Connectors (MC) (see Figure 6) to be welded to thebottom of the SB, instead of a single CC. In this case, one of the two SB access holes must becapped off. MCs have to be welded to SB pipe stubs, whereas a butt weld should join the EC toa lip on the SB. All SBs in rows 8 and 18 and three 15ND blocks (15ND, 15NDA, 15NDB) haveMC connectors. The tools used for this are: MCPT: Monoaxial Connector Pulling Tool MCAMT: Monoaxial Connector Alignment Measurement Tool MCWT: Monoaxial Connector Welding Tool MCCT: Monoaxial Connector Cutting Tool ECHT: End Cap Handling Tool ECWT: End Cap Welding Tool ECCT: End Cap Cutting ToolAll of these are light tools and should weigh less than 40kg. They are to be handled with the useof a load compensation device. Except for ECHT, all are to be fixed to the TFU of SBTB. ECHTis a very simple tool for picking and positioning the EC. Figure 6 Monoaxial Connector as interface between SB cooling channels and Blanket ManifoldsThe remaining parts of the BM cooling system are out of scope for this work, because neitherthe SB nor the TFW will have active cooling at the pre-SRO phase. Regardless of no cooling,CC and MC connections must be welded during First Assembly because correcting a failed weldat this phase bears a lot less risk than at later assembly phases15ND modules are irregular Shield Block units at the entry of the 3 NB ports (see Figure 7). Toinstall them, a specific Gripper (15NDG) will have to be developed and a Tool Base (15NDTB)to fix and align the abovementioned tools for welding MCs and ECs. SUPPLYPage 13 of 106Figure 7 15ND Shield Block in Sector 3When all SB welding processes are done and FCB and ES bolts are torqued, the FWG (via BAT)installs the TFW modules, applying a temporary torque on the CB. After this, a First Wall CentralBolt Tightening End Effector (FWCBT) will torque the CB to the predefined level. As a last step,the ESBT tool is to be used again, to tighten the ESBs of the TFW to the same torque level asfor the SBsA Viewing Tool (VT) should be used by an operator before and after each cutting or weldingoperation to inspect the pipe joints visually. When a Tool is being used, it is important to assess, which other Tools will be needed insubsequent operations. Also, there are cases, where the Tools are used in combination tocomplete an operation. For example, MCAMT and MCWT are always used together MCWTfollowing MCAMT. These Tools, which are not being used, but will be needed soon, should be stored in-vessel forquicker and easier tool replacement. For this, a Tool Storage Rack (TSR) and a Nacelle ToolStorage (NTS) shall be developed. TSR is an End Effector, connected to one of the SBs or TFWs in row#18 and it should be ableto hold at least 4 ToolsNTS is a structure that should be fixed to the IVTC Nacelle basket frame, and it should be ableto hold 2 Tools. The Tools stored in the NTS are directly accessible to the Operator, who can usethe zero G arm (also fixed to the Nacelle basket) to pull out or depose a ToolSee Table 1 for a complete list of End Effectors, Tools and Supporting Equipment to bedeveloped in the context of Shield Block and Temporary First Wall First AssemblyIn Table 5, the EEs and Tools are listed in the order of usage. It is also shown, which tools areused together with which End Effectors. All End Effectors have Tool Changer interfaces, but notall of them remain connected to the BAT. Tool Bases, such as SBTB and 15NDTB are placedinto position on the target SB (or 15ND) by the BAT, after which they are fixed automatically tothe target Component. Then, the Tool Changer Master Side disconnects from the Tool Side andthe BAT leaves the Tool Base. After the disconnection from the BAT, services shall be fed viathe TSS to the Tool Bases via separate cables, connected manually by an operator from one ofthe nearby NacellesSUPPLYPage 14 of 106End Effectors Tools AuxiliaryShield Block Gripper (SBG)Electrical Strap Bolt TorquingTool (ESBT)Blanket Tooling SupportingEquipmentFlexible Cartridge Bolt TorquingTool Base (FBT)Viewing Tool (VT) Tooling Services Skid (TSS)Shield Block Pulling and WeldingTool Base (SBTB)Coaxial Connector Welding Tool(CCWT)Umbilical Handling System(UHS)15ND Gripper (15NDG)Coaxial Connector Cutting Tool(CCCT)Umbilical Temporary Clamp(UTC)15ND Tool Base (15NDTB)Monoaxial Connector AlignmentMeasurement Tool (MCAMT)In-vessel Tool StorageFirst Wall Gripper (FWG)Monoaxial Connector PullingTool (MCPT)Tool Storage Rack (TSR)First Wall Central Bolt TorquingEnd Effector (FWCBT)Monoaxial Connector WeldingTool (MCWT)Nacelle Tool Storage (NTS)Monoaxial Connector CuttingTool (MCCT)End Cap Handling Tool (ECHT)End Cap Welding Tool (ECWT)End Cap Cutting Tool (ECCT)Table 1 End Effectors and Tools included in the scope of First Assembly of SB and TFW modulesEnd EffectorsAnticipated numberof variantsShield Block Gripper (SBG) 3Flexible Cartridge Bolt Torquing Tool Base (FBT) 1Shield Block Pulling and Welding Tool Base (SBTB) 5-10 (modular design)15ND Gripper (15NDG) 115ND Tool Base (15NDTB) 1First Wall Gripper (FWG) 1First Wall Central Bolt Torquing End Effector (FWCBT) 1Total number of End Effectors to develop 13-18Table 2 Anticipated total number of End Effectors to develop (number of production units will differ)SUPPLYPage 15 of 106ToolsAnticipatednumber of variantsElectrical Strap Bolt Torquing Tool (ESBT) 1Viewing Tool (VT) 1Coaxial Connector Welding Tool (CCWT) 1Coaxial Connector Cutting Tool (CCCT) 1Monoaxial Connector Alignment Measurement Tool(MCAMT)1Monoaxial Connector Pulling Tool (MCPT) 1Monoaxial Connector Welding Tool (MCWT) 1Monoaxial Connector Cutting Tool (MCCT) 1End Cap Handling Tool (ECHT) 1End Cap Welding Tool (ECWT) 1End Cap Cutting Tool (ECCT) 1Total number of Tools to develop 11Table 3 Anticipated total number of Tools to develop (number of production units will differ)End EffectorsAnticipated numberof variantsBlanket Tooling Supporting EquipmentTooling Services Skid (TSS) 1Umbilical Handling System (UHS) 1Umbilical Temporary Clamp (UTC) 1In-vessel Tool StorageTool Storage Rack (TSR) 2Nacelle Tool Storage (NTS) 1Total number of Auxiliary Components to develop 6Table 4 Anticipated total number of Auxiliary Components to develop (number of production units will differ)SUPPLYPage 16 of 106Initial Assembly EEs and Toolsin the order of usageEnd Effector ToolSupportingequipmentSBG - BATFBT - BTSE- ESBT n/a - manualCCWTCCCTMCPTMCAMTMCWTMCCTECHTECWTSBTBECCTBTSE15NDG - BATMCPTMCAMTMCWTMCCTECHTECWT15NDTBECCTBTSEFWG - BATFWCBT - BATTable 5 EEs and Tools in the order of usage during First AssemblyIn addition to the End Effectors and Tools, a Blanket Tooling Supporting Equipment (BTSE)system shall be developed, composed of a Tooling Services Skid (TSS) located in the Port Cell,an Umbilical Handling System (UHS) located in the Equatorial Port and several in-vesselUmbilical Temporary Clamps (UTC) to provide services to said EEs and Tools (see section4.2.19)The development of End Effectors shall include the design and supply of custom mounts (seesection 4.2.21) that can be used to connect the EEs to the Storage Box in transfer configuration4.2 Final design of End Effectors and ToolsJADA and their Contractors shall conduct the final design for all the EEs and Tools in Table 5for IO approval. This scope of work shall include: Final design based on the preliminary designs provided by IO in this document and therequirements listed in Ref. [1]SUPPLYPage 17 of 106 Identification of number of variants for each EE and Tool to accommodate BM variants.  Identification of number of production units for each EE and Tool variant in closecollaboration with IO Identification of number of spare units for each EE and Tool variant in close collaborationwith IO Confirmation of compliance with the requirements specified in Ref. [1], with the creationof the Design Compliance Matrix (DCM) as an example of verification means. The DCMneeds to be completed during/after the completion of design validation tests, FAT andSAT Creation of document deliverables for design approval (Design description, CAD modelsand drawings, detailed list of document deliverables is specified in 7.1.2)First Batch items shall be used as Final Production Units if they performed well at FAT/SAT andare not damaged. The following sections present preliminary designs of EEs and Tools (and the auxiliaryequipment) to be used for Blanket First Assembly. They give an overview of the design, and theyshould be read together with Ref. [1], which lists the detailed general and functionalrequirements4.2.1 Shield Block GripperThe SBG is an End Effector to grasp and transport the SB. Design descriptionThe main functions and corresponding sub-systems of the SBG are as follows: Central Clamping Mechanism to securely grasp the M64 thread of the SB ESB Wrench Units to tighten ESB consisting of:o A motorized extension mechanism to insert the wrench into the ESB socket afterthe SB is placed on the Flexible Cartridgeso A motorized translation mechanism to reach different ESB positionso A motorized wrench rotation mechanism to apply torque to the ESBo Maraging steel wrenches with high yield strength to apply torque Base Plate (or Gripper Frame) as structural housing of the device and equipped witho Tool Changer Tool Side for connection to the BAT General EEo Interface feature for connection the SBG to SBo Two cameras for robot vision for positioning the SBGo Embedded controllerThe main function of the SBG is to be able to carry Shield Blocks to their destination inside thetokamak and tighten the ES Bolts to temporary torque level. The SBG performs temporary fixingoperation of the ESB to the parking thread (M72) on the SB side (so-called ‘re-parking’) in orderto prevent the ESB from becoming free while SB handling. The concept of compliancemechanism on the wrench to achieve this is provided by the IO [R12]The SBG may have multiple variations, but all the variants should have the functionality to:move the ES wrenches towards and away from the Central Barrel; and to raise and lower themSUPPLYPage 18 of 106in order to reach the ESB socket through the access hole of the SB. This second function isnecessary, because the wrenches need to be retracted whilst the SB is picked up and being movedinside the vessel. The wrenches should only be extended when the SB is positioned safely on theFlexible CartridgesFigure 8 Overview of the main functions of the Shield Block GripperSB installation using the SBG (and the BAT arm) is show in Figure 9 belowFigure 9 Shield Block installation concept using the SBGProcess and Interface DescriptionThe interfaces of the SBG are similar to the interfaces between TFW and SB. After deliveringthe SB into position within the VV, the SBG should tighten the ESBs to a temporary torque level. SUPPLYPage 19 of 106Figure 10 Overview of the front access holes of the SBFrom the access holes shown in Figure 10, the SBG will make use of the Central Bolt interface(blue) and ESB access holes (yellow). After the SB is positioned properly on the FlexibleCartridges (see Figure 2), the SBG should extend its wrenches through the SB access hole toreach the ESB sockets. As can be seen in Figure 12, the SB access hole is a M24 female thread(with a minor diameter of 20.75 mm), which is the thread used for connecting the TFW ElectricalStrap to the SB, using a similar Electrical Strap Bolt. Thus, it is important that the SBG wrenchshould not damage these threads. Wrench body should be cylindrical. Figure 11 Cross-section of the SB at the ES positionFigure 12 SB ESB access holeThe wrenches of the SBG need to move to and away from the central barrel, to be able to graband fix as many Shield Blocks as possibleSUPPLYPage 20 of 106A list is provided in Table 6 for the position of all Electrical Staps for all SBs. This table is not acomplete list of all ESB depths. There are cases, where the two ESBs are at two different depthswith respect to the SB front face. So, the models of all SB variants should be checked to acquirethe full list of ESB depths. In the table below, the 15ND Shield Blocks are also listed, but they will have separate 15NDGrippers. It is clear from the table that the vertical movement range of the SBG wrenches is quitelarge. Also, the ES depth with respect to the front SB surface varies a lot (e.g. difference in depthbetween row 8 and row 15 is 203.3 mm). Due to these large variations, it is not expected that oneSBG design will be sufficient to cover all SB rows. However, the number of SBG variants shouldbe kept reasonably low. Also, SBGs should be able to operate in an upside-down configuration(rotated by 180 degrees around the central barrel by the joints movement of BAT) in order tohave more flexibility (e.g. row 14 and 15 should be handled by the same SBG design, only in aflipped orientation)8 9 10 111 493 342 151 164.92 493 342 151 164.93 493 342 151 164.94 493 342 151 164.95 493 342 151 164.96 493.3 329.4 163.9 173.97 578 428 150 88.78 560 410 150 519 440 290 150 135.510 572 377 195 13811C 444 150 294 211.211ECH 444 150 294 211.211S 579 205 374 218.712 449 153 296 219.913 456 163 293 212.614 535 150 385 25115 546 396 150 254.316 575 320 255 195.617 492 339 153 208.618 519.5 179.5 340 122.714 NB 535 150 385 183.414 NC(V) 570 190 380 253.314 ND(V) 460.6 310.6 150 233.114 NDL 460.6 310.6 150 177.1414 NE X X X 214.715 NB 530 360 170 189.615 NC(V) X X X 257.915 ND 36715 NDL 36715 NDV 36715 NE X X X 230.715 ST 546 396 150 196.316 ST 575 320 255 136.618 ANU 430 280 150 122.718 E 430 280 150 122.7Distance centralbolt ES UPDistance centralbolt ES DOWNDistance from SB surfaceto ES bolt headSB Distance between ESTable 6 ES bolt positions with respect to CB insert [2]For most of the SBs (incl. all regular ones), the ES and CB positions fall within one straight line. However, there are a few special SB types, for which the ES bolts are at an offset. The SBG forthese SBs will need to have offset mounting positions for the wrenches or they will have to benew variants altogetherSUPPLYPage 21 of 106Table 7 Shield Blocks with ES bolt position offset [2]In the following paragraphs the IO proposal is presented for the concept of the SBG. It shall benoted that the concept follows the technical requirements presented in Ref. [1], but it only showsthe main functions and interfaces, which shall be elaborated furtherFigure 13 SBG main components and interfaces with SB4.2.1.1 Interfaces with the Shield BlockInterfaces with the SB (similar for all EEs connected to SB) (colours according to Figure 13):1. Keys for alignment and to constrain rotation. These interface with the FW pipe grooves ofthe SB2. Pressing pads to provide rigid connection3. Central Barrel interface. 4. Captive Clamping Mechanism with clamping and pulling mechanismSUPPLYPage 22 of 106The figure below further explains the interfaces between SBG (and all SB Tool Bases) and ShieldBlock front featuresFigure 14 Interfaces of SB End Effectors (interface directions: w: Central Barrel axis; u,v: coordinate system in the blue planeof the SB above, with v parallel to the FW cooling channel groovesConstraints (colours according to Figure 13 and Figure 14): Keys are preventing rotation (around “w” axis) Pressing pads and Captive Central Clamping Mechanism are blocking vertical motion(translation in “w” direction and rotation around “u” and “v) Central Barrel blocks translation in “u” and “v” direction4.2.2 Flexible Cartridge Bolt Torquing Tool BaseThe FCB Tool Base is an End Effector used to tighten the FCB to a high torque levelDesign descriptionThe main functions and corresponding sub-systems the FBT are as follows: Wrench positioning arm to align the wrench with the access hole of the target SB usingzero-backlash screw drives with manual operation Torque application system integrated to the arm to apply torque on the FB consists ofo Motor + harmonic drive + torque multipliero Maraging steel wrench with high yield strength to withstand high torques Base Plate equipped witho Tool Changer Tool Side for connection to the BAT General EEo Interface feature for connection the FBT to SBo Two cameras for robot vision for positioning the FBTo Embedded controller Accessory: FCB bolting tool for an operator to perform bolting of the FCBo Wrench with handling feature by operatoro PHS at the tip of the wrenchAt the joints of the FBT Wrench positioning arm, zero backlash screw drives are used to alignthe wrench with the access hole. The torquing should be done by the combination of a compact motor and a torque multiplier. The wrench used for applying the high torque is made from maraging steel, with very high yieldSUPPLYPage 23 of 106strength. The wrench head takes the form of the Straight type shown in [R17] Figure 2-4 (1),with a small clearance to permit minor misalignment with the socket. The connection betweenthe torque multiplier and the wrench should be made via a torque transducer, to measure theapplied torque directly on the wrench sideJust like all the other EEs, the FBT should also be equipped with two cameras in the verticalplaneA GEDORE DVV-100ZRS (gear ratio 1:28.5) torque multiplier (or similar) should be used toproduce the required torque:https://www.gedore.com/en-at/products/torque-tools/torque-multipliers-accessories/torque-multipliers/dvv-60zrs---dvv-130zrs-torque-multiplier-dremoplus-alu-6000-13000-nm---4400-9530-lbfft/dvv-100zrs---2653133 (accessed on 18/10/2024)This type of multiplier has grease inside without sealing at the input and output shafts. Thus, theGEDORE multipliers should always be contained in a housing with one seal at each opening(input shaft + output shaft)Figure 15 FBT concept designFigure 16 Simplified scheme of the links and joints of the FBT conceptThe concept design presented in Figure 15 has a few major points, where it does not meet therequirements yet. The missing points are: Develop the concept to show all functions. For example, the rotation DoF around thecentral holeSUPPLYPage 24 of 106 It should be assessed if the joint screws can be motorized. If not, a cover should be addedto the full FBT, with access only to the screw keys, to prevent accidents and preservecleanliness Tool Changer Tool Side interface to be added, positioned so that the arm can rotate toreach holes on the opposite side Interface with SB to be added. SBG, SBTB and FBT should share the SB interfaces (seesection 4.2.1.1). Process DescriptionAfter the SB is installed on the VV wall and the ESBs are temporary tightened, the next operationis to tighten the FCBs, which are, in their default position, embedded in the Flexible Cartridgesand secured by a parking thread (Figure 17). The first step is for an operator to engage the FCBwith the threaded insert of the SB. This is a fully manual bolting operation with a long wrench;hand tightness is sufficient (around 50 Nm); no prescribed torque is to be applied. JADA and their contractor shall develop this simple wrench as an accessory to bolt the FCBs. This wrench should have the proper engagement and PHS at one end and a manual handle at theother end. Its length should be sufficient to reach the deepest FCBs, including the FCB to bebolted during 15ND attachment (see section 4.2.15 and Figure 77 in particular)Figure 17 Flexible Cartridge Bolt initial engagement – done manuallyThe FCBs must be torqued to a high torque level, which cannot be done manually. For this, adedicated Tool Base (the FBT) shall be used. The FBT shall be transferred into the VV via theIVDT Storage Box and picked up by the BAT for positioning inside the vessel. The FBT shouldhave the interfaces as the SBG to connect to the BAT General EE via the Tool Changer on oneside and then to connect to the target SB via the same interfaces presented in 4.2.1.1 on the otherside. The sequence to align with an SB access hole is the following:1. Theoretical position is set using the screw drives and resolvers. Joint angles arepredetermined based on CAD data (using the as-built SB information if necessary)2. Misalignment is checked with e.g. by a sensor attached to the shaft3. Correction of joint angles4.2.3 Electrical Strap Bolt Torquing ToolThe Electrical Strap Bolt Torquing Tool is used for tightening the SB ESBs, 15ND ESBs andTFW ESBs (see Figure 18). Therefore, it should have one generic design with possibilities forreconfiguration for the SB or the TFWSUPPLYPage 25 of 106Design descriptionThe main functions and corresponding sub-systems of the ESBT are as follows: Manual torque application mechanism consisting of ao Torque multiplier provides the required torque for ESB tighteningo Maraging steel wrench with PHS at the wrench tipo Torque input with 1/2 inch socketo Zero G arm interface COTS Torque wrench to apply torque to the input socket Torque reaction feature which has the following configurationso Interface with SB pocket (multiple variants)o Interface with TFW RH interface side wallso Interface with 15ND monoaxial access holesFor the ESB wrench, the same requirements apply as for the SBG wrenches, they should fitthrough the M24 insert of the SB (see Figure 12) without damaging the threadAs the ESBT should be designed to be a manual tool, there is no need to make several versionsof it, the wrench could simply be replaced to reach ES Bolts at different depths (see Table 6)Figure 18 Electrical Strap Bolts of the Shield Blocks and Temporary First WallsThe ESBT should be a fully manual tool without any automatization. It should comprise acalibrated torque wrench attached to a torque multiplier to produce the required torque fortightening the ESBs, and a reaction feature (key) to interface with the pocket of the SB and theRH insert of the TFW. The shape of the TFW ESB access hole and the reaction feature iscommon across all variantsSUPPLYPage 26 of 106Figure 19 Features (highlighted in orange) to be used for reacting the torque applied on the ESB (left: SB pocket side walls;right: TFW RH interface side walls, and it is possible to use the other RH interface insert, or gripping hole)The concept design for Electrical Strap Bolt Torquing Tool is shown in the figure below. Figure 20 ESBT concept designThe ESBT shown above is a concept design, some of the areas will have to be refined, such asthe coupling between the wrench and the interface between the zero G arm and the multiplierhousing. The latter interface is highly customizable, so the exact geometry is TBD consideringaccessibility and ergonomics. Also, the multiplier housing geometry in the figure above issimplified, it will probably have to be welded together from two partsThe exemplary torque multiplier in Figure 20 is a DREMOPLUS ALU 1300 Nm DVV-13Z fromGEDORE:https://www.gedore.com/en-at/products/torque-tools/torque-multipliers-accessories/torque-multipliers/dvv-13z-torque-multiplier-dremoplus-alu-1300-n-m---950-lbf-ft/dvv-13z---2653370 (accessed on 09/12/2024)This type of multiplier has grease inside without sealing at the input and output shafts. Thus, theGEDORE multipliers should always be contained in a housing with one seal at each opening(input shaft + output shaft)SUPPLYPage 27 of 106The torque multiplier above has a gear ratio of 1:5, which means that for a target final torque of480 Nm, 96 Nm will have to be applied to the top input socket. Even though the ESBT is a lightweight (below 10 kg) manual tool with the PHS system at thewrench tip, it cannot be expected that an operator can hold it and apply torque at the same time,without damaging the insert, sometimes doing this upside-down in the tokamak. Thus, the ESBTshould be designed to be held continuously by a load compensation device (e.g. zero gravityarm), which is connected to the Nacelle and positioned and operated by an operatorThe number of key and wrench variants to be expected (to be confirmed via comprehensivestudy): Wrench: ~4 variants, including 1 variant dedicated to 15ND Key: ~8 variants, including ~2 variants for regular SBs and TFWs, ~5 for the SBspresented in Figure 23, Figure 24 and Figure 25, and 1 variant dedicated to 15NDThe total number of variants depends on the final design of the TFWProcess and Interface DescriptionMost of the Shield Blocks (e.g. rows 1-6, 9-11 and row 18) share the same SB pocket geometry(SB#4 is one example), which means that the key can be common for all these Shield Blocks. The spline shaft connection with the key allows flexibility for axial alignment, and the ESBT ingeneral will be less sensitive to geometric tolerances of the SB pocket and to the ESB positionwith respect to the ES pocket positionFigure 21 ESBT in the context of SB#4Shield Block rows 12-17 have narrower pockets, but other dimensions are the same (taper angle,depth), so there will have to be a second version of the key, which is easy to replace. Only thesnap ring has to be taken off and the key can be slid off the spline shaftSUPPLYPage 28 of 106Figure 22 ESBT in the context of SB#15Also, as can be seen in Table 6, the ESB depth varies a lot from row to row. The configurationshown in Figure 22 shows an example (row 15) where the ES pocket is narrow and the ESBdepth is one of the largest. The difference between row 4 and 15 in ESB depth is too much forthe spline shaft to cope with, so the wrench should be replaced with a longer oneFigure 19 above shows reaction features to be used on regular SBs. However, there are a few SBinstances, where the SB ES position is not aligned with the FW ES position. This means that theSB ESB access hole is not in the pocket of the FW ES. In these cases, the ESBT will not be ableto make use of the pocket side walls in the same way. Instead, the ESBT should have custom keyvariants interacting in another way with the FW ES pocket or use other features of the SB. TheESBT will be reconfigured with the custom key before targeting one of these special SBsFigure 23 ESB access hole positions on 15NC (left) and 15NCA (right) type Shield Blocks and the features (highlighted inorange) that could be used for reacting the tightening torque applied to ES BoltsSUPPLYPage 29 of 106Figure 24 ESB access hole positions on 15NE (left) and 14NE (right) type Shield Blocks and the features (highlighted inorange) that could be used for reacting the tightening torque applied to ES BoltsAs highlighted in Figure 23 and Figure 24, the ESBT keys for these irregular SBs will need tobe custom made for this purpose. Figure 25 ESB access hole positions on Shield Blocks in row 7 and 8Figure 26 Key design proposal for 15NCSUPPLYPage 30 of 106Figure 27 Key design proposal for SB row 8It is also foreseen that the same ESBT tool will be used on 15ND Shield Blocks for applying thefinal torque on the one ESB the 15ND has (see Figure 73). For this, another key design will haveto be developedFigure 28 ESBT design for 15ND blocksFigure 29 Explanation of ESBT design for 15NDSUPPLYPage 31 of 106In order to avoid lateral movement of the wrench due to the applied force on the wrench handle,either the top part of the ESB access hole (as shown above) can be used as force reaction or else,both MC access holes can be usedThe figure below shows how the ESBT should be used to tighten TFW ES bolts, using the sameESBT design. In fact, the components shown in Figure 30 are the same as the ones in Figure 21. Figure 30 ESBT used on TFW in row #4It must be noted that TFWs are at CDR phase and if there will be any changes to the interfacestructure during the TFW design development, IO will assess the impact and then contact JADAto request impact assessment. 4.2.4 Viewing ToolIt is necessary to visually inspect all joints (CC, MC, EC) before and after the welding or cuttingoperation. This is the first, quick step of the inspection, to check that everything is where it shouldbe and there is no obstruction. Alignment will be measured precisely later by dedicated tools(CCWT and MCAMT) that do not provide footage of the joint, only distance measurement data. Thus, a Viewing Tool (VT) is to be prepared, which is a unit integrating a portable screen andcontrol system that can easily be handled by an operator on the Nacelle. As a provisionalselection, the OLYMPUS IPLEX GX/GT videoscope system or an equivalent product shall bepurchased and supplied. Since this is a COTS (Commercial Off-The-Shelf) purchase, FAT / SATare not required. Figure 31 Example for an endoscopic visual inspection unit with screen and control system integrated (this example is anOLYMPUS IPLEX GX/GT videoscope system)SUPPLYPage 32 of 106There are only a few specific requirements related to the VT, which all have to do with providinga clear, well-lit, high-definition footage of the joints. The above provisional selection isconsidered to meet these requirements. The endoscope will reach the joints via the SB accessholes, similarly to the Tools used for creating or disconnecting the welds. In the CC and MC case the pipe joint is perpendicular to the pipe axis, so the endoscope headeither must be small enough to be bent at 90 degree or it must have a right-angle mirror at theend. Remotely driven insertion tube can also be used:https://static3.olympus-ims.com/data/VideoLibrary/Videos/Precisemovements_360.mp4?rev=FB06(accessed on 19/11/2024)Figure 32 Remotely driven insertion tube4.2.5 Shield Block Pulling and Welding Tool BaseThe purpose of the Shield Block Pulling and Welding Tool Base (SBTB) is to provide a rigidinterface between the SB and the Tools used for pipe welding and cutting operations. Not onlydoes it have to be stiff enough to align and fix Tools with respect to the target SB, but it mustprovide necessary services to the Tools, including current and shielding gas, and its EmbeddedController box should accommodate motor controllers to control the motors integrated into theTools. The Tools themselves will have control cables and other service cables that should all beconnected to the connectors located on the SBTBDesign descriptionThe main functions and corresponding sub-systems of the SBTB are as follows: Tool Fixing Unit (TFU) Provides alignment functionality for Toolso XY table for radial alignmento Z linear guide for axial positioning can be implemented either in the TFU or Toolo Shim block to adjust Tool positions for different SBs Base Plate equipped witho Central Clamping Mechanism locks the SBTB to the SBo Tool Changer interface to allow modular tool exchangeo Two cameras for robotic visiono Embedded controllerThe SBTB will comprise a Tool Fixing Unit (TFU), which should provide alignmentfunctionality for the Tools (XY table for radial alignment). Z linear guide for axial positioningcan be implemented either in the TFU or Tool side. The same interfaces are to be used for connecting to the SB as for the SBG (see section 4.2.1.1)An overview of the SBTB concept is given in the following figuresSUPPLYPage 33 of 106Figure 33 Overview of the SBTB concept (with CCWT mounted) (Z linear guide might be integrated into the Tools eventually)A more detailed overview of the SBTB concept is given in the figure belowFigure 34 SBTB concept descriptionThe functions described in the figure above are common to all SBTB variants, irrespective of thetarget SB. As mentioned above, the functions are gathered into modules, which can bereconfigured rather quickly. However, this reconfiguration is to be done ex-vesselSimilarly, the Tools, which are to be attached to the SBTB, should have a modular design, thusreducing the number of variants. For example, instead of having a large number of CCWT andCCCT variants for different CC depths, they should have one generic design and coarse verticaladjustment should be made by a shim, the thickness of which should correspond to the target SBand which is to be placed between the Tool and the TFU of the SBTB (see Figure 34 and Figure35). Please note that for a few Shield Blocks, the CC can be tilted in two directions. These shouldbe identified by checking the GAD drawings in [11] or the 3D modelsSUPPLYPage 34 of 106Figure 35 Modules of the SBTB and CCWTThe modules of the SBTB are connected by bolts, thus can be separated easily. Some of themodules will be common for all SBTB configurations (such as the load bearing arm, XY tablemodule and tool holder module (see Figure 36)), whilst some will have smaller or larger numberof variants. For example, if the taper angle of the shim is large due to the large inclination of theCC, the Tool Changer will have to move in order not to clash with the tool holder module (anexample of this will be shown later for SB #7). Only one shim variant will be required for eachSB variant, and the same shim variant might be compatible with multiple SB variants having thesame CC angle. Different sizes of Central Barrel modules will probably be necessary to becompatible with all SB geometries. It is also expected that the Tool Base plate will need smallmodifications (in length, camera placement, pocket dimensions) in order to fit all SBs, CCs andMCsFigure 36 SBTB modules shown separatelyOne of the key features of the SBTB is the alignment of the Tools with respect to the SB accessholes to the Coaxial and Monoaxial Connectors. Radial misalignment should be taken care of bythe XY table module, whereas angular misalignment should be avoided by preciselymanufactured shim modules. For this, the shims will have to be specific for all CC and MCangles. The residual angular misalignment between the Tool and SB hole is expected to beSUPPLYPage 35 of 106negligible compared to the allowed gap and step between the CC (or MC) and the SB pipe stub. There is no need to produce multiple shim blocks or shims to account for manufacturing errorsbetween multiple SBs of the same variant. Figure 37 SBTB and CCWT degrees of freedom (Central Barrel module is to be updated) (Z linear guide might be integratedinto the Tools eventually)The total number of DoFs, when assembled with CCWT, can be seen in Figure 37. As discussedearlier, the XY table is needed to correct radial misalignment, precise shimming will preventangular misalignment and another custom shim between the Tool and the TFU will align thetorch (or cutting blade) with the pipe joint axially. The purpose of Z linear guide, shown in Figure 38 and Figure 37, is to lower and raise the tip ofthe Tool with respect to the nominal position. The CCWT design will include an embeddeddistance sensor, which is mounted with an axial offset with regards to the position of the weldingtorch. After applying the pulling force, the residual gap and step between the CC/MC and the SBstub should be measured by the distance sensor and if it is acceptable, the Tool can be raisedback to perform the weldProcess and Interface DescriptionThe SBTB will be transferred into the VV by the IVDT and picked up by the BAT for in-vesselpositioning. For this, two cameras are needed at the SBTB plate ends, facing the target SB. Afterthe SBTB is positioned on the target SB, the embedded Central Clamping Mechanism of theTool Base is engaged with the SB insertGiven the large number of CC and MC angles (with respect to the CB angle) and positions (withrespect to the CB axis position), multiple SBTB variations will be needed. However, the SBTBconcept presented in Figure 33 has a modular design, which can be easily reconfigured fordifferent SBTB variants. SUPPLYPage 36 of 106Figure 38 Shield Block Pulling and Welding Tool Base in the context of Shield Block #15 (Z linear guide might be integratedinto the Tools eventually)When the SBTB is configured ex-vessel for a given target SB, neither the Tool nor the loadbearing arm (see figure above) is connected to the Tool Base. Figure 39 Retrieval of the SBTB from the IVDT (the rest of the BAT arm is not shown)The in-vessel assembly of the SBTB includes a few quick and simple steps that can be carriedout by an operator. For the Tool handling, the operator should use a zero G arm, until it is securedfirmly to the TFU of the SBTBSUPPLYPage 37 of 106Figure 40 In-vessel assembly steps of the SBTBIn Figure 40, the assembly steps are shown for CCWT in the context of SB#15. For all the othertools (CCCT, MCAMT, MCPT, MCWT, ECWT, ECCT), there are even fewer steps, and theassembly is reduced to fixing the tool to the TFU or using the load bearing arm only (probablyin the case of MCPT)Welding operations will be performed after FCB and ESB tightening. The sequence of thecomplete welding scenario for CC welding is the following:Assembly(0.) Configure SBTB modules ex-vessel, send into the vessel via the IVDT to be picked upby the BAT arm1. Place the Tool Base onto the target Shield Block. Automatic locking of the Tool Base tothe SB via Central Clamping Mechanism2. Select welding tool shim to compensate CC depth with respect to nominal. Fix shim toWelding Tool3. Insert Welding Tool with the use of the zero G arm. Fix to Tool holding structure4. Do rough alignment with the XY tableFine alignment7. Set Welding Tool height so that the displacement sensor is facing the pipe joint. 8. Measure radial misalignment (eccentricity) with respect to the SB stub. For this, the Zlinear guide and the built-in rotation of the welding tool should be used. 9. Adjust on XY table until an acceptable radial misalignment is achievedPulling10. Lower CCWT until the displacement sensor is in line with the joint to be welded11. Apply 2-ton pulling force (20 kN)12. Measure misalignment between the joint sides. If the misalignment is not acceptable, trywith a higher pulling force (up to 30 kN)Welding13. Raise CCWT so that the welding torch is at the joint position. SUPPLYPage 38 of 10614. Approach the joint with the welding torch15. Produce weld. Use built-in AVC system to enhance weld properties16. Release pulling forceInspection17. Lower Welding Tool until the displacement sensor is in line with the joint18. Scan the weld beadAfter the last step the CCWT can be removed from the SBTB to make space for NDT equipment. So far, the SBTB has been presented in the context of SB#15. However, as can be seen in thetable below, the angle between the CC and the CB axes varies significantly from one SB toanother, meaning that the shim angles will have to vary with themdeg mm1 0 79.82 0 79.83 0 79.84 0 79.85 0 79.86 1.1 93.57 26.8 77.28 16.3 MONOAX9 4.4 86.110 5.8 69.311C 1.8 148.211ECH 1.8 148.211S 1.8 155.812 5.0 145.513 5.2 137.614 6.7 181.515 4.8 189.416 5.9 117.817 4.2 12418 0 MONOAX14 NB 6.7 128.914 NC(V) 6.7 19014 ND(V) 6.8 172.214 NDL 6.7 172.214 NE 6.7 164.815 NB 4.8 13615 NC(V) 5.6 191.115 ND MONOAX15 NDL MONOAX15 NDV MONOAX15 NE 5.6 18315 ST 4.7 159.316 ST 5.9 87.718 ANU 0 MONOAX18 E 0 MONOAXAngle between CB& CC (or MC)Distance between CCand SB hole opening SBTable 8 CC position and alignment variants [2]The most extreme case is SB#7, where the tilt of the CC is 26.8 degrees. In order to cope withthis large angle, the SBTB will have to be reconfigured with a new Tool Changer holder moduleas wellSUPPLYPage 39 of 106Figure 41 SBTB for SB#7When it comes to cutting, saw cutters produce swarf that needs to be removed from the SB tothe best possible extent. A vacuum channel should be included in the cutting tool design, and asocket to connect the suction hose to. On the SBTB, a compact vacuum cleaner should be locatedsomewhere, with current feed from the Embedded Controller. From the vacuum cleaner, asuction hose should be connected to the cutting tool socket on its stationary part. The vacuumcleaner should be detachable from the SBTB by hand, because it is only needed for cutting toolsFigure 42 Proposal for vacuum cleaner location on the SBTB4.2.6 Coaxial Connector Welding ToolThe purpose of the Coaxial Connector Welding Tool is to make the welded connection betweenthe SB stub and the CC. The CCWT has CC pulling function to position it for welding with theSB stub, measurement function for checking the groove fit-up, and the welding function for CCand SB stubDesign descriptionThe main functions and corresponding sub-systems of the CCWT are as follows:SUPPLYPage 40 of 106 Tool heado Enclosure for rotation and translation (Z drive) mechanismso Interface with SBTB TFUo Cable managemento Zero G arm interface Pulling mechanismo 2 ton (extendable to 3 ton) pulling force on CC to engage with SB stub Displacement sensoro Measurement of misalignment between the axes of the SB hole and the CC Welding torch mechanismo Full penetration weld between SB pipe stub and Coaxial Connector (ID ø101 mm,thickness 2.5 mm)o AVC mechanismo Extendable welding torch (ø70 mm → ø101 mm)o Feed of inert gas to welding areaThe previous section already provided some insight to the Coaxial Connector Welding Tool(CCWT) concept, as it was used as an example for the SBTBThe CCWT will have multiple functionalities to achieve a successful weld between the CC andSB pipe stub. The CCWT has CC pulling function to position it for welding with the SB stub,measurement function for checking the groove fit-up, and the welding function for CC and SBstubFigure 43 Cross-section of the SB at the CC positionWhen the SB is installed to the VV, the CC will not be in its final position showed in Figure 43,but it will be pushed down towards the VV by the SB. Pulling force will need to be applied inorder to engage the CC with the SB tapered hole and then with the Helicoflex seals (see Figure5). This force is to be exerted by a pulling mechanism integrated into the CCWT design. Due to theexpected spring-back effects, the pulling force should be applied during the whole weldingprocess, which means that when the welding tool rotates, it must rotate around the stationaryinner pulling mechanismThe CCWT should also comprise a displacement sensor as pipe alignment measurement system. This sensor should be axially offset with respect to the welding torch, which means that for thedistance measurements the CCWT will have to be moved axially. The purpose of thedisplacement sensor is to provide radial misalignment measurement before pulling to setcoaxiality with the SBTB XY table and to make a full 360-degree scan of the pipe joint beforeSUPPLYPage 41 of 106and after welding. Before welding, the aim is to check the residual gap and step between the CCand the SB stub. If the misalignment is out of range, the pulling force should be raised, andmeasurement should be repeated. After welding, another measurement must be made, but nowthe aim is to do a quick scan to see that the weld bead has been formed properly, before properNDT testingFigure 44 Overview of the CCWT main componentsAs the CCWT has to pass the SB hole opening (diam. 70 mm), the outside diameter of the CCWTis limited. When the welding torch is in position and aligned with the pipe joint, it will be 15-20mm away from the pipe wall. To cross this gap, the welding torch must be moved radially by anextension mechanism to set the required stand-off distance (see bottom right corner of Figure44). In addition to this extension mechanism, an Arc Voltage Control system should be integratedinto the CCWT head design, which can move the torch in-out radially in a controller mannerduring the welding processAs the welding torch and displacement sensor will move relative to the TFU, cabling will haveto follow. Cable management for these should be taken care of within the enclosed volume ofthe CCWTThe pulling rod of the CCWT should connect to the internal bottom slot of the CC. It should benoted that these internal slots, are not aligned angularly with the SB, meaning that it should bechecked first by the operator how they are aligned and then the pulling rod tip will have topositioned accordingly. The pulling rod should be threaded (see Figure 45), and preload should be applied by simplytorquing a nut, thus converting rotational torque into a pulling force. The rod end, however,should have bolt head feature to prevent rotation after aligned with the MC bottom slotsA load cell should provide force feedback from the pulling rod preload. This is to be placedbelow the nut, as shown in Figure 45SUPPLYPage 42 of 106Figure 45 Pulling rod head componentsProcess and interface descriptionThe CCWT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operatoron the IVTC Nacelle will use the zero G arm to pick the CCWT from the TSR and move it to theSBTB already mounted on the target SB. The CCWT will be locked to the TFU of the SBTB viaclamps. 4.2.7 Coaxial Connector Cutting ToolThe purpose of the Coaxial Connector Cutting Tool is to cut to connection between the SB stuband the CCDesign descriptionThe main functions and corresponding sub-systems of the CCCT are as follows: Tool heado Enclosure for rotation and swage cutter feed mechanismso Interface with SBTB TFUo Cable managemento Zero G arm interface Tool alignment mechanismo Fix and align the Tool axis to the CC Cuttero Double swage cuttero Radial feed mechanism Accessory: Pipe Facing ToolThe context is the same for the Coaxial Connector Cutting Tool (CCCT) as for the CCWT (seeFigure 43). The pipes are to be cut with a double swage cutter cutting head with radial feed. Apipe alignment mechanism should provide stabilization and fixing at the head of the tool, makinguse of the inner pipe of the CCThe CCCT must pass the diam. 70 mm opening of the SB, so the swage blades will have to bemounted on a mechanism that can extend and retract them radiallyA conceptual design has already been developed for the CCCT, which covers some of thefunctions mentioned aboveSUPPLYPage 43 of 106Figure 46 CCCT concept designFigure 47 Cutting head of the CCCT concept designThe concept design presented in the figures above and has a few points, where it does not meetthe requirements listed in Ref. [1] yet. The missing points are: The CCCT should be made compatible with as many SB designs as possible. For this,the smaller diameter end part of the tool must be longer, to be able to cover the varyingdistances between the SB-CC joint and the SB opening presented in Table 8 and Figure43 One requirement in [1] is to constantly monitor the cutting force/torque required toachieve the preset feed rate. It is preferable that the radial feed of swage blades be motor-driven. This is intended to detect when the cutting is complete Greased parts, such as bearings and gears, should be enclosed in sealed volumes. Theconcept design must be modified accordinglySUPPLYPage 44 of 106As an accessory to the CCCT a handheld Pipe Facing Tool is to be developed to provide a surfacethat is good enough for rewelding procedures. The exact required surface quality should bedefined by testingFigure 48 Example of a Pipe Facing ToolProcess and interface descriptionThe CCCT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operator onthe IVTC Nacelle will use the zero G arm to pick the CCCT from the TSR and move it to theSBTB already mounted on the target SB. The CCCT will be locked to the TFU of the SBTB viaclamps. When the cutting operation is complete, the tool and then the Tool Base are taken away. TheShield Block is then removed from the vessel via the BMTS. After this, when the area around the CC is free, an operator can come with the Nacelle to use thePipe Facing Tool to produce a proper cut surface for rewelding operations. The operator will settemporary protections beforehand, to avoid spreading swarf and will vacuum out everythingafterwards4.2.8 Monoaxial Connector Pulling ToolThe purpose of the Monoaxial Connector Pulling Tool is to pull the MC into place to engagewith the SBDesign descriptionThe main functions and corresponding sub-systems of the MCPT are as follows: Tool heado Enclosure for pulling mechanismo Interface with SBTB and 15NDTB TFUo Cable managemento Zero G arm interface Shell designo To accommodate MCAMT and MCWT Pulling lock endo Interacting with the MC slot to apply the pulling forceo 2 ton (extendable to 3 ton) pulling force on MC to engage with SB stubSUPPLYPage 45 of 106When it comes to welding/cutting the Monoaxial Connectors, the environment is different fromthat of the CC. The pipes are smaller in diameter, which calls for more compact designsFigure 49 MC positions on SB#8 (left) and #18 (right)In addition to having 2 MC connections instead of one CC, SB#8 has a large tilt angle betweenthe MC and the CB axes (see Table 8). Therefore, the SBTB concept design has been adapted tothis SB, to show that with an appropriate shim design the same equipment can be used (see Figure54)Just like the CC, the MC needs to be pulled continuously during welding. The force needed isthe same as in the case of the CCWT, 30 kN at the maximum. Due to the confined space relatedto the MC configuration (see Figure 59), the structure of the MCPT should be the inverse of theCCWT, in the sense that instead of the stationary central pulling rod the MCPT should have ahollow cylinder that can apply the pulling load on the locking mechanism at the tip and at thesame time it should accommodate the MCAMT and MCWT tools. Figure 50 MCPT concept designAs the MCAMT and MCWT needs a window through the cylinder of the MCPT for sensor lightand welding torch respectively, the MCPT cylinder will have to rotate with the tools so that thewindow is always aligned with the sensor or torch. However, the locking tip has to be stationary,which means that the MCPT cylinder should be able to rotate freely with respect to the lockingmechanism. SUPPLYPage 46 of 106Figure 51 Locking mechanism tip of the MCPTIn the concept design presented above the locking mechanism is engaged with the MC slot viaa lock engagement key, which is reaching down the MCPT cylinder to be inserted into the slotof the lock. Stoppers machined into the lock will provide a solid hard stop for the operator toknow when the lock is fully engaged. The lock engagement key is manually operated and shouldbe removed when the lock is engaged to make space for toolsThe lock concept presented in Figure 51 is only one possible solution. Another solution is shownbelow, where instead of the 3 M6 bolts, one central thread transfers the pulling load to the lockingfeature at the bottomFigure 52 Alternative concept for the locking mechanism of the MCPTAs discussed above, the MCPT will have to rotate with the MCAMT and MCWT. This meansthat the rotation drive can be integrated into the Tool or the MCPT as well. In the former casethe MCPT mechanism should only exert the pulling force, and the top flange (see Figure 50 andFigure 53) of the cylinder should be mounted on bearings to be able to rotate with respect to thepulling mechanism. In the latter case, the MCPT mechanism should pull and rotate the cylinderflange at the same time. The allocated space for the MCPT mechanism is shown in the figure below. This is only andapproximation, the occupied space will naturally depend on if the drive mechanism will beSUPPLYPage 47 of 106needed or not. If it will be part of the MCPT, it can claim more space at the expense of theMCWT and MCAMT, which will then be simplerFigure 53 MCPT shown in the context of SB #8 with the SBTB structureThe advantage of using the MCPT as a carrier for the MCAMT and MCWT is that only theMCPT will have to have shims, the tools attached to it do not. Since the axial alignment of theMCAMT and MCWT with the MC joint will have to be done via their internal longitudinal drive,the Z linear guide of the Tool Base TFU will be redundant in this case. However, it can help tocompensate for the different MC depths, thus reducing the number of MCPT shim variantsProcess and interface descriptionThe MCPT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operator onthe IVTC Nacelle will use the zero G arm to pick the MCPT from the TSR and move it to theSBTB/15NDTB already mounted on the target SB. The MCPT will be locked to the TFU of theTool Base via clampsThe SBTB, already presented in section 4.2.5 should be used in this case as well. It can be seenin Table 8 that only the 8th and 18th Shield Block rows have Monoaxial Connectors (and 15NDSBs, but they have so special shape that they need a dedicated Tool Base (discussed later))SUPPLYPage 48 of 106Figure 54 SBTB configured for SB#8In the figure above it is shown how the SBTB needs to be reconfigured to be compatible withMC welding. In the case of SB#8, one of the two MC access holes does not coincide with the SBfront face symmetry plane (left MC in Figure 49). For the MC with an offset, another TFUconnection position must be used on the top of the shim (bottom right textbox in Figure 54)Figure 55 TFU placed in an offset position on the shim to align with the out-of-line MC position on SB#8Due to the need for reconfiguration between the two MCs, the welding of these SB rows (andthe 3 irregular 15ND blocks) must be done in two turns, welding one of the MCs in one turn forall SBs in the target row, reconfigure and then weld the second MC in another turnThe 15NDTB does not have a concept design yet, but it should have a TFU mechanism similarto that of the SBTB and the functions should be the same. On the 15ND the MC joint positionsare located much deeper (see Figure 78) from the surface of the Shield Block and the 15NDTBdesign will have to take this into account. Nonetheless, it is possible to make the MCPT (andMCAMT, MCWT) even longer, if neededSUPPLYPage 49 of 106Figure 56 MCPT shown in the context of SB #8 with the SBTB structure4.2.9 Monoaxial Connector Alignment Measurement ToolThe aim of the Monoaxial Connector Alignment Measurement Tool (MCAMT) is to align theTFU of the SBTB (and 15NTB) to be coaxial with the SB hole for the pipe welding to beperformed correctly. Design descriptionThe main functions and corresponding sub-systems of the MCAMT are as follows: Tool heado Enclosure for axial drive mechanismo Interface with MCPTo Cable managemento Zero G arm interface Displacement measuremento Measurement of misalignment between SB hole and MCThe MCAMT concept design can be seen in the figures belowFigure 57 MACMT concept designSUPPLYPage 50 of 106It can be seen in the figure above that the MCAMT does not need a shim, because it is mountedon the MCPT, which is already aligned axially with the MC joint before pulling. The MCAMTshould be able move axially with respect to the MCPT to perform scans and to axially align itselfwith the pipe joint. MCAMT should be equipped with a mechanism to centre itself relative tothe inner cylinder of MCPTFigure 58 MCAMT head unit conceptProcess and interface descriptionThe MCAMT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operatoron the IVTC Nacelle will use the zero G arm to pick the MCAMT from the TSR and move it tothe SBTB/15NDTB already mounted on the target SB. The MCAMT will be locked to the MCPTtangentially but will be able to move axially with respect to itThe alignment of the TFU should be done in the following order:1. Coarse alignment of the TFU with respect to the SB access hole by operator visual check. Note: The SBTB TFU could have engravings for the expected X and Y positions of theMC axis to be aligned with indicators fixed to the TFU XY table2. Assembly of MCPT onto the Tool Base TFU (select appropriate shim between the two)3. Engagement of the MCPT locking mechanism with the MC bottom slot with the use ofthe lock engagement key. Remove lock engagement key. (see Figure 50)4. Insertion and fixing of MCAMT into the MCPT. 5. Scan SB hole to check radial misalignment6. Fine alignment of the TFU to match MCAMT axis with SB hole axis7. Lower MCAMT head via its internal axial drive to be aligned with the MC pipe joint8. Apply pulling force with the MCPT to pull the MC into position9. Scan MC-SB pipe joint area to check residual gap and step10. If the misalignment is acceptable, remove MCAMT and continue with MCWT to performthe welding. If the misalignment is not acceptable, repeat from step 9 with a larger pullingforce4.2.10Monoaxial Connector Welding ToolThe Monoaxial Connector Welding Tool (MCWT) will be used to connect MCs to the SB pipestub. The environment can be seen in the figure below for SB#8SUPPLYPage 51 of 106Design descriptionThe main functions and corresponding sub-systems of the MCWT are as follows: Tool heado Enclosure for axial drive mechanismo Interface with MCPTo Cable managemento Zero G arm interface Welding torch mechanismo Full penetration weld between SB pipe stub and Monoaxial Connector (ID ø43.72mm, thickness 2.5 mm)o AVC mechanismo Feed of inert gas to welding areaFigure 59 The joint to be connected is an ID 43.72 pipe with 2.5 mm thicknessThe TFUs might be different for the FW and SB Tool Bases but the welding tool tip design andthe functions of the tool should be the same, except for the pipe alignment mechanism, which isneeded to align the FW pipe with the Flow Separator, but not needed for the MCThus, the MCWT should be a welding torch that has the AVC system integrated into either thewelding head or the rear mechanism. In the latter case the full length of the MCWT will bemoved by the AVC. After the tool is inserted into the MCPT cylinder this AVC system or aseparate mechanism should be used to approach the joint with the welding torch. Since alignment is done by the MCAMT, the MCWT will not have a displacement sensorThe concept design for the MCWT is shown in the figure below. SUPPLYPage 52 of 106Figure 60 MCWT conceptThe MCWT design should allow welding to be performed in 3 different depths, due to possiblerewelding operations (see Figure 61). However, the MCWT does not necessarily need an axialdrive, because no active axial adjustment is foreseen during the welding operations. So, there are2 options to cope with the 3 different welding positions:1. The MCWT has axial drive, and axial position is adjusted for the 1st, 2nd or 3rdweld2. There is a shim between the MCWT and MCPT. The shim variations are:1. 14 mm for 1st weld2. 7 mm for 2nd weld3. No shim for 3rd weldProcess and interface descriptionThe MCWT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operatoron the IVTC Nacelle will use the zero G arm to pick the MCWT from the TSR and move it tothe SBTB/15NDTB already mounted on the target SB. The MCWT will be locked to the MCPTtangentially but will be able to move axially with respect to it4.2.11Monoaxial Connector Cutting ToolThe aim of the Monoaxial Connector Cutting Tool (MCCT) is to cut the welded joint betweenthe MC and the SB pipe (see Figure 59). For this, a double swage cutter should be used. Design descriptionThe main functions and corresponding sub-systems of the MCCT are as follows: Tool heado Enclosure for rotation and swage cutter feed mechanismso Interface with SBTB and 15NDTB TFUo Cable managemento Zero G arm interface Tool alignment mechanismo Align the Tool axis with the SB hole Cuttero Double swage cuttero Radial feed mechanism Accessory: Pipe Facing ToolSUPPLYPage 53 of 106In case of a failed weld, the MC-SB connection is to be cut on the MC side, which means thatthe MC pipe stub will become shorter with each cutFigure 61 Monoaxial Connector cutting positionsThe MC shortening must be compensated on the SB side. For a repair, the pipe section with thefailed weld will be cut off and a new pipe section will be welded in its place. This new pipe willhave to be longer by the cut off length. It is very important that the cut surface of the MC should be appropriate for rewelding operations. As the swage cutters do not provide a clean-cut profile, a Pipe Facing Tool should be used afterthe Shield Block is removed (see Figure 48). The Pipe Facing Tool used for CC and MC can bethe same tool if its adjustment range allowsFigure 62 Proposal for FW pipe cutting that should be adopted for MC cuttingThe proposal shown in the figure above must be modified to match the MC case, but the functionsshould be similar: Cutters actuated by a central shaft.  Rollers providing centralization and rigidity during cutting. However, in the MC case,this roller mechanism should use the SB pipe for centralization, so the size of the structureneeds to be reducedSUPPLYPage 54 of 106Due to the fact that the alignment is done by the MCAMT, the MCCT will not have adisplacement sensor. Axial positioning of the swage blades should rely on precisionmanufacturing and dimensional inspection of the Tools, meaning that because of the accuratelyknown distances between the TFU and cutters (for MCCT) and also the TFU and displacementsensor (for MCAMT), the cutters will already be in position when installed after the MCAMTProcess and interface descriptionThe MCCT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operatoron the IVTC Nacelle will use the zero G arm to pick the MCCT from the TSR and move it to theSBTB already mounted on the target SB. The MCCT will be locked to the TFU of the SBTB viaclamps. When the cutting operation is complete, the tool and then the Tool Base are taken away. TheShield Block is then removed from the vessel via the BMTS. After this, when the area around the MC is free, an operator can come with the Nacelle to usethe Pipe Facing Tool to produce a proper cut surface for rewelding operations. The operator willset temporary protections beforehand, to avoid spreading swarf and will vacuum out everythingafterwards4.2.12End Cap Handling ToolThe purpose of the End Cap Handling Tool is to handle ECsDesign descriptionThe main functions and corresponding sub-systems of the ECHT are as follows: Handle Keyo 17 mm hexagon keyo Passive Holding SystemOn each Shield Block with Monoaxial Connectors, there is one (row #8 and row #18) or two(15ND, 15NDA and 15NDB) SB access hole(s) that must be cappedThe sole purpose of the End Cap Handling Tool (ECHT) is to pick an End Cap and engage itwith the thread in the SB access hole for one of the MCsFigure 63 MC access holes with End Caps on SB #8 and #18SUPPLYPage 55 of 106Figure 64 MC access holes with End Caps on SB #15ND (15NDA and 15NDB are similar)Figure 65 End Cap and joint geometryThe relevant dimensions of the End Cap can be seen in the figure above. The thickness to bewelded is, again, 2.5 mm, but the other dimensions of the joint are unique to the End CapThe ECHT should be a fully manual tool, a holding stick, with the 17 mm hexagon socket andPHS on one end and a handling feature on the other end. Process and interface descriptionAn operator should be able to insert the PHS male side at the tip of the ECHT into the PHS socketon an End Cap, thus grabbing one from a tray or box to be located on the Nacelle. Using theECHT the operator will then position the EC into the access hole on the target SB and screw itinto the SB hole thread until the visible surface of the EC is completely flush with the SBshoulder. After reaching the final position and feeling resistance, the EC should by tightened byhand (around 15Nm), to temporarily secure it to the SB before welding operationsIn order not to lose alignment with the MC hole, the SBTB (or 15NDTB) has to stay in place forEC welding (and cutting possibly), which means that the ECHT will have to reach down the TFUto reach positionSUPPLYPage 56 of 106Figure 66 ECHT reaching down through the SBTB TFU (already aligned with the MC of SB#8) to engage with the End CapBy keeping alignment, time and effort can be saved between MC and EC welding. This meansthat MC and EC welding (and all related activities (pulling, EC placement, cutting)) are linkedby alignment and should be done sequentially. 4.2.13End Cap Welding ToolThe End Cap Welding Tool (ECWT) will be used to connect ECs to the SB lips. Design descriptionThe main functions and corresponding sub-systems of the ECWT are as follows: Tool heado Enclosure for rotation mechanismo Interface with SBTB and 15NDTB TFUo Cable managemento Zero G arm interface Welding torch mechanismo Full penetration weld between SB lip and End Cap (thickness 2.5 mm)o AVC mechanismo Feed of inert gas to welding areaGiven that after welding the MC, the SBTB (or 15NDTB) TFU is already aligned with the SBhole, there is no alignment to be done before the End Cap Welding Tool (ECWT) is attached. The counterbore of the SB is 55 mm in diameter, the outer diameter of the EC is ~51.7 mm. Thisposes relatively tight space constraints to the design of the ECWT. The torch cannot beperpendicular to the EC face, it must be tilted at an angle, to provide space for the fixation of thetungsten electrode and sufficient volume around the tungsten to be filled with shielding gas, etc. A cross-section of this area of the SB is given in the figure below with relevant dimensionsSUPPLYPage 57 of 106Figure 67 Cross-section of the SB at the End Cap position [12]To determine the maximum outer diameter of the tool, the followings must be considered: The diam. 55 mm section between the lips of subsequent ECs Using the MCAMT, a coaxiality of 0.1 mm can be set between the TFU and the SB holeTo provide additional centring for the tool, the PHS socket may be used, by having a centringrod at the tip. However, this is not expected to be needed, because the tool alignment providedby the MCAMT beforehand is expected to be fine enough for the built-in AVC system of theECWT to cope with slight residual misalignmentsFigure 68 Overview of the ECWT concept (showing an old SB design, where the hole diameter is the same between the lips andat the opening)For axial positioning, either the centring shaft or the front face of the End Cap can be used, whichmeans that the TFU should gently be lowered until a hard stop and then fixed. This will result ina precisely aligned welding torchProcess and interface descriptionThe ECWT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operatoron the IVTC Nacelle will use the zero G arm to pick the ECWT from the TSR and move it to theSBTB already mounted on the target SB. The ECWT will be locked to the TFU of the SBTB viaclamps. 4.2.14End Cap Cutting ToolThe aim of the End Cap Cutting Tool (ECCT) is to cut the welded joint between the EC and theSB lip. For this, a hole saw cutter should be used. Design descriptionSUPPLYPage 58 of 106The main functions and corresponding sub-systems of the ECCT are as follows: Tool heado Enclosure for rotation and hole saw feed mechanismso Interface with SBTB and 15NDTB TFUo Cable managemento Zero G arm interface Tool alignment mechanismo Align the Tool axis with the EC Cuttero Hole sawo Axial feed mechanismIn the case of a failed weld, the End Cap must be removed by cutting. The End Cap Cutting Tool(ECCT) should use a hole saw to make the cut. In this case, this seems to be the only possibility,due to the tight space between the weld and the SB openingThe hole saw will inherently generate swarf, which needs to be removed by a vacuum suctionhose integrated into the ECCT designRegarding the hole saw, its outer diameter should be at least 52 mm, to be able to pass throughthe created hole with a new EC easily. It should be as big in diameter as possible but should keepa small stand-off distance from the inside the diameter of the counterbore. Figure 69 Concept design of the ECCTThe hole saw outside diameter has a lower and an upper limitation. The lower is that the createdhole should be big enough for a second EC to pass through. The upper limitation has to do withthe fact that the hole diameter between subsequent EC lips is smaller than that of the frontcounterbore (see Figure 67). So, the hole saw of the ECCT will need to be smaller than thisdiameter, taking into account the runout of the saw with respect to the SB hole axisProcess and interface descriptionThe ECCT will be brought into the vessel via the TSR (see section 4.2.20). Then, an operator onthe IVTC Nacelle will use the zero G arm to pick the ECCT from the TSR and move it to theSBTB already mounted on the target SB. The ECCT will be locked to the TFU of the SBTB viaclamps. 4.2.1515ND GripperThe 15NDG is an End Effector to grasp and transport the 15NDSUPPLYPage 59 of 106Design DescriptionThe main functions and corresponding sub-systems of the 15NDG are as follows: Two Gripping Cones to securely grasp the 15ND consists ofo One gripping cone with rigid connection to the Gripper Frame and the other conehaving floating featureo M24 bolts and bolt drive mechanism to tighten bolts to the 15ND threads Static Pressing pads to contact the surface of 15ND to support moment load ESB Wrench Unit to tighten ESB consisting of:o A motorized extension mechanism to insert the wrench into the ESB socket afterthe 15ND is placed on the Flexible Cartridgeso A motorized wrench rotation mechanism to apply torque to the ESBo Maraging steel wrenches with high yield strength to apply torque having PHS Gripper Frame as the structural housing of the device and equipped witho Two cameras for robot visiono Tool Changer interfaceo Embedded controllerFigure 70 15NDG conceptHaving two fixed conical fits with the Shield Block would overconstrain the interface and perfectconnection at both cones would be impossible to achieve. Thus, one of the cones should havefloating features that allow slight axial and radial play in order to have perfect connection at bothcone positionsThe 15NDG interface requires a measurement to accommodate slight misalignment. Althoughthe nominal hole positions of the 15ND series modules are identical, the three 15ND modulesmay have slight variations of hole position/surface profile within the design tolerances. If bothcones are rigidly fixed, the interface would become over-constrained, making perfect alignmentdifficult to achieve due to these slight variations. Such misalignment could lead to slightindentation and increased friction, obstructing the cones from being engaged/disengagedTo mitigate this risk, at least one of (A) or (B) needs to be implemented. Also, (C) should beimplemented for recovery. The primary option is (A) Floating Cone, and others are back-upoption in case that the option (A) does not work wellSUPPLYPage 60 of 106(A) Floating Cone (Making one of the cones adjustable to the slight hole variation):A floating cone has slight axial and radial play with respect to the 15NDG frame, as illustratedbelow. It remains floating prior to engagement with the 15ND module but becomes fixedbetween the frame and the 15ND body after bolt tightening, thereby functioning as a moment-supporting element. Figure 71 One of the 15NDG cones that allows slight axial and radial self-alignment(B) Pre-adjusted Cone (Making one of the cones adjustable to the slight hole variation):Based on dimensional measurements of the actual fabricated 15ND modules, adjustments can bemade either by applying shim plates or by fabricating individually fitted cone blocks to preciselymatch the measured geometry. In this option, the cone is fixed prior to 15NDG deployment into the VV(C) Threaded hole feature + pressing bolt (Adding alternative recovery function):By implementing threaded hole feature + pressing bolt, the 15NDG can push against the 15NDsurface if the cone becomes stuck in the hole. The hole and bolt need to be accessible for theoperator and activated manually during a recovery scenarioThe 15NDG should also comprise an embedded wrench mechanism to apply temporary torqueon the one ESB (see Figure 73). If technically feasible, the 15NDG should apply final torque onthe ESBSince the 15ND series has the deepest ESB access hole (over 400mm), a long wrench would beneeded. To satisfy the Storage box size and general EE capacity constraints, it is allowed to useextension wrench for 15ND/15NDG caseThe 15NDG design should take into account the manual bolting of the side FCB (as explainedlater), because it must be performed whilst it is still attached to the 15ND block via the BAT,meaning that: 15NDG parts should not obstruct the bolting wrench access to the side FCB (see Figure76) The Tool Changer Tool Side on the 15NDG should be positioned so that when the BATis attached, it leaves sufficient space for the Nacelle to come from the left side (see Figure72). The 15NDG only needs an embedded ESB wrench mechanism and does not need to have aembedded temporary fixation function for the FCB(s), but it is necessary to consider that theoperator can accessed from the left side by Nacelle for manually bolting the FCBSUPPLYPage 61 of 106Process and Interface DescriptionDue to the irregular shape of the 15ND Shield Blocks (3 in total), they cannot be handled by theSBG. The gripping features of the 15ND Gripper (15NDG) are not the same as those of the SBG. There is still an ESB to be torqued but on the 15ND blocks there is no Central Bolt InsertFigure 72 15ND Shield Blocks in Sectors #2 and #3Figure 73 Interfaces of the 15ND Shield Blocks; 15NDG space reservation shown in transparent blueThe interfaces on 15ND Shield Blocks for RH operations can be seen in the figure above. The15NDG should make use of the conical RH interfaces located on the front surfaceFigure 74 Cross-section of the RH interface concept of the 15ND blockSUPPLYPage 62 of 106The worst-case posture for the 15ND handling is when it is held in a horizontal position (seeFigure 75) and the moment load on the General End Effector roller axis is the highest. Thisposture should be avoided, if possible, but the loads resulting from this should be taken intoaccount when designing the 15NDG. Figure 75 15NDG worst-case handling posture of the 15NDGAs can be seen in Figure 76, the ESB is slightly outside the triangle of the 3 FCBs, which meansthat the temporary fixation (ESB torquing) can potentially result in an instable state of the SB. Because of this, it is necessary to bolt the FCB that is farthest from the gripping cones(highlighted with red circle in Figure 76). This is a simple bolting operation with a preliminarytorque applied on the bolt (~50 Nm) performed by an operator on the Nacelle. For this, the boltingtool accessory of the FBT might be used (see section 4.2.2)Figure 76 15ND ES position and alignment with respect to the 3 FCBs; red circle shows the FCB to be bolted by hand4.2.1615ND Tool BaseThe 15ND Tool Base (15ND TB) is an End Effector, which provides a rigid interface betweenthe 15ND and the Tools used for pipe welding and cutting operationsDesign DescriptionThe main functions and corresponding sub-systems of the 15ND TB are as follows: Tool Fixing Unit (TFU) Provides alignment functionality for Toolso XY table for radial alignmento Z linear guide for axial positioning can be implemented either in the TFU or Tool Base Plate equipped witho Two Gripping cones lock the 15ND TB to the 15NDo Static Pads similar to 15NDGo Tool Changer interface to allow modular tool exchangeSUPPLYPage 63 of 106o Two cameras for robot visiono Embedded controllerProcess and Interface DescriptionAfter the 15ND block is placed and necessary bolts are temporary torqued, the followingoperations need to be performed on the 15NDs:1. Final torquing of the 3 FCB bolts2. Welding of MC joints3. Welding of End CapsAll these operations should be performed on the same 15ND Tool Base (15NDTB). In the 15NDcase, using the same Tool Base is possible because the number of repetitions is very low, and theaccess hole alignments are always the same. For connection to the 15ND, the 15 NDTB should replicate the features of the 15NDG (coneswith embedded bolts and motors, passive pads) shown in Figure 70 and Figure 71To torque the FCBs of the 15ND blocks, no alignment function is needed because the orientationof the FCB axes is known and there is only 3. For torquing, the same torque multiplier + motorcombination can be used as in the case of the FBT (see section 4.2.2), only with different wrenchlengths (possibly). On the 15NDTB baseplate 3 mounting positions (aligned with the axis of theFCBs) for this torquing mechanism should be created, with the same locking and reactionfeatures as at the tip of the FBT arm. Figure 77 Height difference between FCB and ESB at 15NDAs can be seen in Figure 77 above, there is a considerable height difference between the twoFCBs accessed from the front 15ND face (see Figure 73) and the one on the slanted face on theside. This height difference must be taken into account when planning the FCB torquing process. A wrench extension may need to be fixed to the FBT wrench to reach the side FCB socket. Like the SBTB, the 15NDTB should have a Tool Fixing Unit, which could be the same that isused on the SBTB. A precisely manufactured shim module should provide angular alignmentbetween the target SB hole and TFU axes. As the 2 MCs of this SB are parallel to each other,one shim design should be sufficient for all 15ND MCs. TFU XY table should be able to alignwith both MC holes without reconfiguration e.g. by extending the linear guides. SUPPLYPage 64 of 106The tools to be used, and to be made compatible with the 15NDTB TFU are: MCAMT, MCPT,MCWT, MCCT, ECWT, ECCTThe operations are the same as for regular SBs, but it must be noted that in the 15ND case, theMC joint position is quite deep down the access hole, compared to row #8 or #18. Thus, dedicatedextensions may be needed for some of the tools listed above. This is to be assessed after the15NDTB (with TFU) has been designed and it is clear what is the difference in the distancebetween the TFU mounting position and MC joint in the 15NDTB and SBTB case. Figure 78 MC joint depth in the context of 15ND Shield BlocksLike in the SBTB case, a compact vacuum cleaner should be located somewhere on the 15NDTB,with current feed from the Embedded Controller. From the vacuum cleaner, a suction hose shouldbe connected to the cutting tool socket on its stationary part. The vacuum cleaner should bedetachable from the 15NDTB by hand, because it is only needed for cutting tools4.2.17First Wall GripperThe aim of the First Wall Gripper (FWG) is to pick First Wall or Temporary First Wall unitsfrom the BMTS and transfer them to their target location in-vessel. The FWG should also applytemporary torque to the Central Bolt of the FWFrom all the tools in the list of Table 1, the First Wall Gripper design has the highest maturity atthe time of writing of this document. This section is mostly a presentation of the already definedFWG features. However, some aspects of the FWG still need to be refined, these aspects are alsodefined hereDesign descriptionThe main functions of the FWG: Gripping finger interfaces to lock the FWG to the gripping holes of the TFW Active pad units on the sides of the gripping fingers to apply a preload on the grippinghooks, a preload that is large enough to secure the TFW firmly in any orientation withinthe vessel Linear sensor to monitor pad spring deflection Linear drive units to move the gripping fingers towards and away from the central wrenchin order to adjust the finger positions to the target TFWSUPPLYPage 65 of 106 Central wrench mechanism with embeddedo automatic extension mechanism to engage with the socket of the TFW Central Boltafter the TFW has been placed onto the target SB by the BATo torquing mechanism that can screw the Central Bolt into the insert of the SB until itis fully engaged and apply temporary torque Two cameras for robot vision Tool Changer Tool Side at the back of the FWG for connection to the BAT Embedded controllerFigure 79 First Wall Gripper main functionsProcess and interface descriptionAs shown in the figure above, the wrench goes through the FWG structure, and the Tool ChangerTool side. In order to determine what is the length of the wrench section that sticks out, theinternal structure of the FWG needs to be looked atFigure 80 SB#15 will require the longest extension of the FWG wrench [2]The longest wrench stroke is needed for FW15, where the distance between the gripping interfaceand the Central Bolt socket is the biggest (213 mm) in the fully bolted position. The CB wrenchlength needs to be less than the available height of 665 mm when FWG is placed in the StorageBox with tips of the gripping fingers and the CB wrench alignedSUPPLYPage 66 of 106Figure 81 FWG engaged with SB#15;defining the wrench extension strokeThe stroke of the wrench extension should be over 184 mm. If we look into the internal structureof the FWG, we can see how much of the wrench length will actually stick out of the FWG bodyFigure 82 Defining the FWG wrench rear extension lengthWith 190 mm wrench extension length, the Tool Changer master side completely covers theextension even in the full retracted position4.2.18First Wall Central Bolt Torquing End EffectorThe aim of the First Wall Central Bolt Torquing End Effector (FWCBT) is to apply the finaltorque to the CB of the TFW. The FWCBT is an End Effector, because it should not have a fix connection to the TFW butshould remain connected to the BAT during operationDesign descriptionThe main functions and corresponding sub-systems the FWCBT are as follows: Wrench unit consists ofo Maraging steel wrench with high yield strength to withstand high torqueo Spherical seat to allow tilting wrencho Spring for engaging the wrench to the Central Bolt socketSUPPLYPage 67 of 106o Interface feature for Rotation drive unit Rotation drive mechanism to apply torque on the wrench unito Motor + harmonic drive + Gears for torque amplificationo Wrench compliance mechanism to accommodate the bolt misalignmento Torque meter to measure the torque applied to the wrench Base Plate equipped witho Two pins to engage FW gripping holes for receiving the reaction torqueo Adjusting feature for pins lateral positiono Passive pads to contact with the surface of the TFWo Tool Changer Tool Side for connection to the BAT General EEo Interface feature for connection the FWCBT to FWo Two cameras for robot visiono Embedded controllero Interface features to connect to BMTS mountsThere is an existing FWCBT concept design, which will have to be modified and the requiredmodifications to match the requirements in ([1]) are listed in this section. Figure 83 Overview of the existing FWCBT concept (1/2)Figure 84 Overview of the existing FWCBT concept (2/2)SUPPLYPage 68 of 106The modules of the existing FWCBT concept and the required modifications are listed belowWrench mechanism:Due to the space constraints of the IVDT Storage Box (max. 665 mm height), the wrench itselfhas to be inserted into the wrench mechanism manually, when the FWCBT is already in positionon the target TFW, and the BAT is in a frozen position. This means that the wrench mechanismmust be open from the top for the wrench insertionPassive pad mechanism:This should be replaced with a passive spring-loaded pressing padGripping hook drive unit:This can be removed altogether. Since the BAT will carry the FWCBT all the time, no activegripping hook interface is requiredTool Changer interface:This interface should be placed in line with the two gripping interfaces. When positioned ontothe target TFW, the Tool Changer and BAT should not block the lateral sides of the FWCBT foreasy access with the wrenchPad:Spring loaded passive pads are to be included in the FWCBT to provide a softer interface withthe TFW front wall. The interfacing surface could remain the sameGripping finger:To be replaced with 2 pins. The pins should have a guiding feature (e.g. chamfer) at the end foreasy engagement with the gripping hole. The basic function of the 2 pins is to transfer the reactiontorque to the TFW. When the torque is applied, it is expected that the BAT will rotate slightly,because the torsional load coming from the torque exceeds the brakes’ performance. When thepins touch the gripping hole side walls, the reaction torque will be led to the TFW rather than theBAT armBaseplate:The baseplate should have oblong holes for mounting the static pins to be able to reconfigure theFWCBT for different TFW geometries manually outside the vesselWrench:Maraging steel wrench, long enough to cover all TFW geometries. The wrench head takes theform of the Straight type shown in [R17] Figure 2-4 (1), with a small clearance to permit minormisalignment with the socketIn addition to the list above, the FWCBT should include two cameras, one on each end (verticalwhen aligned with TFW), for robot visionWhilst the CBT Tool Base is held by the BAT, the TFW should remain accessible from one sidefor an operator to install the wrench with the zero G armEspecially on the inboard side and for BMs that are farther from the BAT deployment port it isvery difficult for the BAT to reach over the Tool Base to the “far side” to the Tool Changer butat the same time leave the “near side” free enough for the operator to approach. SUPPLYPage 69 of 106Figure 85 Explanation of “far side” and “near side”. Near side: that side of the Tool Base, which is closer to the BATdeployment port; far side of the Tool Base: opposite from the BAT deployment portFigure 86 Accessibility of the CBT (replaced with FWG in this kinematic simulation) in row 2 from the side by an operator. Inthe case of row 2 it is not possible to approach the CBT from the left sideSUPPLYPage 70 of 106Figure 87 Accessibility of the CBT (replaced with FWG in this kinematic simulation) in row 18 from the side by an operator. Inthe case of row 18 it is not possible to approach the CBT from the left sideThe CBT was designed so that the Tool Changer is always approachable from the “near side”,no matter if the target TFW is left or right from the BAT deployment port. For this, there are 2possible solutions:1. The embedded controller and Tool Changer (handled as one unit) can be mounted onboth sides of the Tool Base during ex-vessel reconfiguration phase2. The CBT can be flipped around the CB axis by 180 degrees, meaning that the 2 pins willchange sides and the lower will become the upper and vice versa. a) b)Figure 88 CBT design options to leave one side of the Tool Base free for the operator: a) Tool Changer can be mounted onboth sides; b) CBT can be flippedThe FWCBT is not going to be fixed to the Temporary First Wall during operation. So, in contrastwith other End Effectors, it does not inherently have the necessary interfaces on the opposite sidefrom the Tool Changer Tool Side to be fixed to BMTS mounts connecting it to the Storage Plate. Thus, new interfaces will have to be developed for the transfer configuration on the BMTS. Process and Interface DescriptionFrom Table 9, it can be calculated that the wrench will have to protrude into the FW by amaximum length of ~345 mm. Even though these numbers are applicable to final FWs, notnecessarily to TFWs (to be checked), so there could be a variation in the exact values, but thistable shows well the magnitude of the wrench extension. With a wrench protrusion of 345 mm,it is hardly possible to fit within the 665 mm high Storage Box if there is a heavy-duty wrenchSUPPLYPage 71 of 106mechanism on the top of the wrench. Thus, the FWCBT should be designed so that the wrenchcan be inserted into the mechanism manually by an operator on the Nacelle. 2 151 136 133 2692 136 133 2693 136 138.5 274.54 136 138.5 274.55 136 138.5 274.56 136 133 2697 136 133 2698 109 133 2429 136 133 26910 136 133 26911C 169 98 26711ECH 169 98 26711S 169 98 26712 169 98 26713 169 98 26714 213 93 30615 213 98 31116 169 98 26717 169 98 26718 102 98 20014 NB 169 93 26214 NC(V) 213 84.7 297.714 ND(V) 213 94 30714 NDL 213 93.9 306.914 NE 213 96.6 309.615 NB 169 93 26215 NC(V) 213 103.7 316.715 ND15 NDL15 NDV15 NE 213 103 31615 ST 213 131.4 344.416 ST 152.4 131.4 283.818 ANU 102 98 20018 E 102 98 200SBDistance between GH &Central Bolt HeadDistance between T-RidgePlane and first surface ofGripping HoleSumTable 9 Final First Wall Central Bolt and gripping interface depth [2]4.2.19Blanket Tooling Supporting EquipmentThe aim of the Blanket Tooling Supporting Equipment (BTSE) is to provide services to EndEffectors and Tools inside the VV. The services to be provided are:Power to the embedded controller Power to the Embedded Controller of the End Effector Power to the TIG welding torch Communications (feedback and control) Compressed air Shielding gasBTSE consists of following equipment: TSS (Tooling Services Skid): A system that provides necessary utilities such as TIGwelding power, shielding gas, and compressed air for tooling operations inside thevacuum vessel.  UHS (Umbilical Handling System): A mechanism that manages and guides theumbilical from the TSS to the tools, ensuring proper routing and support inside thevacuum vessel. SUPPLYPage 72 of 106 UTC (Umbilical Temporary Clamp): A clamp used to secure the umbilical at multiplepoints inside the vacuum vessel to prevent sagging and ensure proper positioningThe further detailed design of the UHS and UTC, including component selection, will beprovided by IO. The procedure for applying backing gas to the welding points and its technicalrequirements are subjects of current discussion and are intended to be included in the nextrevisionA Tooling Services Skid (TSS) should include TIG welding equipment (power supply andshielding gas) outside the vessel. Only power and communication should be fed to the TSS fromthe power distribution box on the Port Cell wall of level L1, to which the TSS should be close. Figure 89 Arrangement of junction boxes for maintenance operations at level L1 [R10]The junction boxes marked with blue circles have 2 sockets [R11]: 1 x 400V 3 Phase Socket 63 A 1 x 230V Single Phase Sockets 16/32 ATSS should be plugged directly into the sockets mentioned aboveThe TSS should comprise the following equipment: TIG welding power generator Shielding gas cylinders Gas mixerSUPPLYPage 73 of 106 Air compressor Remote controller (see section 4.3)All supplies should be joined into either a bundle or an umbilical. Henceforth in this section theoutput of the TSS will be referred to as umbilical. The umbilical is to be led from the TSS to the Umbilical Handling System (UHS) located insidethe Equatorial Port. The UHS is going to be transferred into the EP by the TPTS (and when inposition, it will be locked to the pockets on the Port side walls via keys (manually operated)Figure 90 Overview of the Blanket Tooling Supporting Equipment system conceptFigure 91 UHS installation by the TPTS: 1. UHS is carried by the TPTS via the Equatorial Port; 2. UHS is lowered into finalposition; 3. Side keys are engaged, UHS is lockedSUPPLYPage 74 of 106The UHS should comprise a coil with 30 m of umbilical/bundle on it. This comes from anestimation, considering a “worst-case” scenario, where the umbilical is led from the EP entranceto the farthest BM position on the inboard side (see Figure 92 below). Based on this estimation,the needed length is ~20 m, but a safety margin of 1.5 is appliedFigure 92 Estimated maximum needed length of umbilicalThe coil is to be manually operated and should not have slip rings but a fixed connector whichrotates with the coil. When the needed amount of umbilical is uncoiled and the coil is fixed withbrakes, it should be possible to connect the welding skid umbilical to the connector of the coil inany random angular position it is in. Figure 93 Tooling Services Skid in the Equatorial Port CellSUPPLYPage 75 of 106Figure 94 Connection between Tooling Services Skid and Umbilical Handling SystemFigure 95 UHS in Equatorial PortInside the VV, the umbilical should be clamped at multiple positions to avoid hanging in thetorus. The Umbilical Temporary Clamp (UTC) should be able to connect to the VV, a SB or aTFW. Using the ESB threads seems straightforward, because they are the same M24 thread inall 3 cases. The M24 thread does not exist in the TFW design at the moment, but it will be addedas a feature to its baseplate designThe end of the umbilical should connect to one of the Tool Changer connectors, to which itshould be fixed firmly. The connector and fixing mechanism of the umbilical should be manualSUPPLYPage 76 of 106Figure 96 Installation of in-vessel umbilicalFigure 97 In-vessel umbilical clampingFigure 98 End Effector cablingSUPPLYPage 77 of 106Figure 99 Operation configurationWhen the End Effector is operating, an operator on a nearby Nacelle (see Figure 99) shouldcontrol processes from an HMI unit. The connection between the Embedded Controller and theHMI should be made via a cordless connection (e.g. Wi-Fi). The Embedded Controller shouldalso have connection to the RH control room via the umbilical4.2.20In-Vessel Tool StorageIn-Vessel tool storage options are necessary to enhance productivity by skipping the need totransport Tools from outside the vessel each time they are needed. When a Tool is being used, it is important to assess, which other Tools will be needed insubsequent operations. Also, there are cases, where the Tools are used in combination tocomplete an operation. For example, MCAMT and MCWT are always used together, MCWTfollowing MCAMT. Two options should be developed for in-vessel storage of the Blanket Assembly Tools. Firstly,a Tool Storage Rack (TSR) that is for a longer-term solution aimed at storing Tools on BM18independently from the BAT or the IVTC Nacelle (after having been fixed to one of the SBs orTFWs in row #18). Secondly, a Nacelle Tool Storage (NTS) should provide quick access to 2Tools for the operator in the NacelleThere can be multiple TSRs inside the vessel, for the operator to have the complete selection ofTools for the operations being performed (MC welding, CC welding, etc.). However, the Toolsthat are momentarily being used should be stored on the NTS, to have quick interchangeabilityThus, the TSR and NTS on the Nacelle will have to work in symbiosis, because the TSR willtransfer Tools into the VV via the IVDT and BAT, but the required ones will be placed via thezero G arm into the NTS for quick access. After a Tool is not needed anymore, it can be deposedback into the TSR and when a TSR is full of unused Tools, it can transfer them back to ex-vessel,where they can be taken away to long-term storage4.2.20.1 Tool Storage RackTSR is an End Effector, connected to one of the SBs or TFWs in row #18 and it should be ableto hold at least 4 Tools. The TSR should be made compatible with SBs and TFWs in row #18. SUPPLYPage 78 of 106Since the target is always row #18, the TSR should only have 2 versions, one that is compatiblewith SB#18 and one that is compatible with TFW#18When the TSR connects to SB#18, it should have the same interfaces as the other EEs connectingto SBs. This is presented in section 4.2.1.1Figure 100 Concept design for Tool Storage Rack showing main functionsThe Tool example shown in the figure above is the CCWT concept design, which will probablybe the biggest and heaviest of all Tools. However, the TSR should be made compatible with allTools, either by adapting all Tools to a common TSR interface or by having different mountingplates or extensions to mount different Tools. Figure 101 TSR concept design inside the Storage Box volume (2100x1310x665), Tool Changer Tool Side positioned in themidplane of the Storage Box, as prescribed in section 4.2.21In the case, where the TSR is attached to TFW#18, the gripping functions of the FWG should becopied, namely the active pads and gripping fingers (see section 4.2.17). For the TSR thepositioning function of the gripping fingers is not needed, they should be at a fixed positioncorresponding to the gripping hole positions on TFW#18SUPPLYPage 79 of 106Figure 102 TSR mounted on Shield Block 18, with 4 CCWTs4.2.20.2 Nacelle Tool StorageNTS is a structure that should be fixed to the IVTC Nacelle basket frame, and it should be ableto hold 2 Tools. The Tools stored in the NTS are directly accessible to the Operator, who can usethe zero G arm (also fixed to the Nacelle basket) to pull out or depose a ToolFigure 103 NTS concept designThe maximum payload of the Nacelle is 250 kg, which can be distributed as such: 1 operator in protective gear = 90 kg 2 Tools = 80 kg Zero G arm including elevating mechanism = 65 kg NTS system including fixations = 15 kgThus, the upper limit for the NTS, with all fittings and fixtures, is 15 kg. On the other hand, theupper limit for the zero G arm, with the elevator mechanism and fittings included is 65 kg. SUPPLYPage 80 of 106Figure 104 TSR and NTS operating in combination; a Tool is being retrieved from TSR to be placed into the empty slot on theNTS4.2.21End Effector design constraints4.2.21.1 Enveloping dimensionsAll End Effectors should be equipped with the Tool Side of the Tool Changer to be able toconnect to the BAT General EE. Not only does the EE have to fit within the Storage Box of theIVDT (LxWxH: 2100x1310x665), but the Tool Side of the Tool Changer must be in such aposition on the EE that the BAT can approach it with the Master Side of the Tool Changer,engage, lock and lift the EE vertically, away from the EE mountsFor context, the dimensions of the IVDT Storage Box are shown belowFigure 105 Dimensions of the IVDT Storage Box (bigger)SUPPLYPage 81 of 106Figure 106 Side view of the IVDT Storage BoxFigure 107 Top view of the IVDT Storage BoxEach End Effector should have a custom designed mount, which is also in the scope of the currentTechnical Specification. The mounts should mimic the in-vessel features that the EE will connectto eventually. For example, the SBG mount should comprise a central hole with a M64 insertand it should also have side grooves for the keys of the SBG. This is further explained in section4.2.21.2. The component fixing method to the Storage Box will be the same as it is to the StoragePlate described in section 4.2.21.2The End Effectors to be designed cannot occupy the full volume of the Storage Box, becausethey have to be grabbed by the BAT and elevated to take them off of their custom mounts, whichare fixed to the bottom plate of the Storage Box. SUPPLYPage 82 of 106The enveloping dimensions of the EE (with mount included): LxWxH: 1780x1300x665 mm (seeFigure 108The Tool Changer Tool Side must be installed to every End Effector. In transfer configurationinside the Storage Box, the Tool Changer Tool Side must face upwards, but its axis can be tiltedtowards the central solenoid axis by a maximum of 29 degrees. The Tool Changer should be positioned in the symmetry plane of the Storage Box. Its angularorientation should coincide with the 0-degree configuration of the General End Effector ToolRoll Axis, meaning that if we look at the Tool Changer Tool Side as a triangular shape, one ofits sides should face the port and the point of the triangular shape should face the inboard side ofthe tokamak (all Tool Changers are oriented so in the pictures below)Figure 108 Available volume for placement of the Tool Changer Tool Side (yellow) with respect to the space reservation of theEEs (transparent orange (includes yellow))Figure 109 Side view of the Tool Changer Tool Side placement volume (yellow) with respect to the space reservation of theEEs (transparent orange (includes yellow))SUPPLYPage 83 of 106Figure 110 Horizontal Tool Changer positioning option extreme configurations (red triangle highlights the angularorientation that coincides with the GEE Tool Roll Axis 0-degree configuration (explained before))Figure 111 Tool Changer Tool Side possible tilted configurationsTool Changer placement must be confirmed with IO for each EE, once the EE design is maturedenough, in order to perform a kinematic analysis with BAT VR tools4.2.21.2 Pre-SRO transfer contextDuring pre-SRO assembly all the Shield Blocks, Temporary First Walls and End Effectorsrelated to Blanket Assembly will be transferred into the vessel via the Blanket Module TransferSystem (BMTS)Functions of the BMTS:• All equipment will be mounted on a Storage Plate• Storage Plates are mounted on the BMTS carriage by the Through Port Transfer System(TPTS) in the Port Interspace• BMTS carriage delivers equipment from Interspace to In-Vessel via rails• At the end of the rails in the VV, the Storage Plate is tipped at 90 degrees to show thedelivered component to the Blanket Assembly Transporter (BAT)SUPPLYPage 84 of 106Figure 112 Overview of the BMTS conceptFigure 113 BMTS carriageThe Storage Plate concept will be shown through the example of SB9 and the SBG EEThe Storage Plate inherits the length and width of the baseplate Storage Box of the IVDT(presented in the previous section), 2100x1310 mm. The height restriction for the equipmentbeing transferred is the same as in the IVDT Storage Box context (see Figure 106), namely 665mm measured from the Storage Plate top surface. Also, the same restrictions apply to the spaceoccupied by the End Effector on the Storage Plate, as described in Figure 108. The thickness ofthe plate is 30 mm, and it is made out of stainless steel. SUPPLYPage 85 of 106Figure 114 Overview of Storage Plate (in SB9 transfer config)As can be seen in the figure above, there will be Clamping Modules connected to the StoragePlate that facilitate quick connection of mounting modulesFigure 115 Presentation of clamping modules and interfacing features on the Storage PlateThese clamping modules are manufactured by Imao in Japan:https://www.imao.com/catalog/en/categoryviews/?categorycode=&category=$102107&page=1Two different sizes will be needed, and the bigger ones will only be needed for SB transfer, dueto their higher load capacity. The two selected modules are CP150-12063 and CP150-20100,with 15 and 35 kN clamping force respectivelySUPPLYPage 86 of 106Figure 116 Clamps and modules used for the attachment of SB9Figure 117 SB9 mounted on the Storage Plate via the modulesClamping module should always be oriented so on the Storage Plate that their sockets areperpendicular to the side of the Storage Plate (it does not matter which side), to be directlyaccessible for the operator to activate the clamping mechanism with a key. An electric drill willbe used for this with an extension wrench, to speed up the process. It is also important that themodules should not obstruct the access to any of the clamps in useSUPPLYPage 87 of 106Figure 118 Unobstructed direct access to clamping module sockets from the side of the Storage PlateOther Shield Block mounting modules should follow the same concept, using the bigger clampsfor the central ES pedestal and Central Key module, because in the vertical (tipped by BMTS)configuration, these are expected to carry the bulk of the SB weight. Apart from the Shield Blocks, all the other equipment (EEs, TFWs) should be mounted on thesmaller type clamps. An example for SBG is shown belowFigure 119 SBG mounted on the Storage PlateIn order to reduce the number of clamp reconfigurations and to make the exchange of equipmentfaster, the clamp positions should follow a pattern (defined by JADA and subcontractors) on theStorage Plate, and the module designs should be adapted to these existing, patterned clampingpositions4.2.22Tool design constraintsThe Tools will be transferred into the VV and installed to a temporary tool storage on the IVTCNacelle. It will be possible to store 2 Tools at the same time on the Nacelle. SUPPLYPage 88 of 106Figure 120 Temporary tool storage on the Nacelle. Normally, one Tool is stored, and one is in operation (left), but the NTSshould be able to store 2 Tools at the same time (right)Tools should be designed to be compatible with the NTS. Also, their design should allow beinglifted out of the storage vertically by the zero G arm. The zero G arm will be able to reach abovethe temporary storage for a Tool to be fixed to its tool interface. Figure 121 Operator installing a Tool to the SBTB located on a SB in row 18; another Tool is stored in NTSFigure 122 Operator installing a Tool to the SBTB located on a SB in row 9; another Tool is stored in NTSSUPPLYPage 89 of 106Figure 123 Theoretical reach of the zero G arm. TBC with supplierThe zero G arm connection will be realized with the use of a COTS Tool Changer interface. Between the tool side of the COTS Tool Changer and the Tool itself, a roll joint is to be added. This is to be further explained by IO when the model for this concept is consolidated, followingdiscussions on the feasibility with potential suppliers. 4.3 Control System for Blanket ToolingJADA and their contractors shall develop the control system for Blanket Assembly ToolingThe scope is composed of the following activities: Design of control system for Blanket Assembly Tooling Design of I&C hardware design and softwareo Controller design (cubicle layout in Skid and wiring diagrams)o Data acquisition and signal monitoring system designo Command and Control software for FATo Command and Control software for implementing to a mobile device Development of the FATP/SATP Manufacturing of I&C hardwareo Remote Controller for Transporter mode and Skid modeo Local Controller for Blanket Assembly Toolingo A cubicle for Skido Mobile device including Command and Control software for Skid mode Providing Command and Control software which is used for FAT Testing in FAT/SAT Design justification by completing the DCMJADA will support integration with Command and Control for the control container4.3.1 Control System Architecture RequirementsThe Blanket Tooling (23.01) is part of the integrated PBS23 system that needs to be remotelycontrolled from outside the Vacuum Vessel. The overall PBS 23 Control System architecture isshown in the figure below, with PBS 23.01 highlightedSUPPLYPage 90 of 106File NetworkRH NetworksLow-LevelControl SystemCODAC NetworksCINCSNCODACHigh-LevelControl SystemCIS CSSDevice I&CPBS 23.01Low-LevelControl SystemHigh-LevelControl SystemDevice I&CPBS 23.02Low-LevelControl SystemHigh-LevelControl SystemDevice I&CPBS 23.03Low-LevelControl SystemHigh-LevelControl SystemDevice I&CPBS 23.05Low-LevelControl SystemHigh-LevelControl SystemDevice I&CPBS 23.06Low-LevelControl SystemHigh-LevelControl SystemDevice I&CPBS 23.11EquipmentManagementSystemRH SupervisorSystemPlantSystemHostPlantInterlockSystemPlant SafetySystemRH PlantControllerPBS 23.07 PONRHDatabaseFigure 124. Integrated PBS23 Control System (PBS23.01 highlighted)The Blanket Tooling control system shall have 3 tiers: High-Level Control System (HLCS): Operator interfaces in the control room or viamobile device, Low-Level Control System (LLCS): Embedded equipment controllers, Device I&C: Actuators and sensors on the devicesFor the Blanket Tooling, the low-level control system shall be divided into two parts: Remote controller: Common control module located outside of vacuum vessel, Local controller: Tool specific axis drivers on-board the end-effectorsAs previously described, there are two modes of operation of the Blanket Tooling System: Operation of the Tooling when mounted on the BAT (Transporter mode), Operation of the Tooling when installed on the vessel walls (Skid mode)The deployment and routing of the connections for the two modes of operations is indicated inthe figure belowSUPPLYPage 91 of 106RemoteController(LLCS-R)LocalController(LLCS-L)ControlContainer(HLCS)(HLCS)EthernetEtherCAT, ServicesTransporter modeSkid modeSkidUmbilicalMobile C&CFixed C&CBATBAT CubiclesEnd-EffectorFigure 125. Distribution of the Blanket Tooling Control SystemThe operation mode through the Transporter has tight constraints for cable routing. The designand operation of the end-effectors in this mode shall be based on the transporter routing aminimal set of cables to the end-effectors:- Power for end-effector local controller- Communication (EtherCAT),- Camera network linkThe operation mode through the Blanket Tool Supporting Equipment (BTSE) shall support theoperation of the End-Effector and Tools in the installed positions. The Skid and umbilical cablingshall provide the required services for the Tool operations (e.g. welding operations):- Power for end-effector local controller- Communication (EtherCAT),- Pressurized air,- Welding gases,- Welding powerIn the Skid Mode, the architecture (figure 111) allows control from either the wired remotecontrol container or from the wireless local handheld control deviceA key switch shall be implemented in the Skid remote controller to switch between the wiredC&C control and the wireless C&C control to avoid any conflict between the twoNote: The Blanket End-Effectors have cameras fitted that are required for the accuratepositioning of the end-effectors by the Transporter. These cameras shall be interfaced directlywith the BAT Vision System rather than the Blanket Tooling Control SystemHigh-Level Control SystemThe Blanket Tooling shall provide the following HLCS HMI’s: Command & Control (C&C): HMI to operate the end-effector/toolingSUPPLYPage 92 of 106o Fixed HMI in control container with wired ethernet connection,o Mobile HMI on Nacelle with wireless ethernet connectionThe Blanket Tooling System shall interface with the Virtual Reality HMI (not part of thisprocurement contract). The procedures for operating the Blanket Tooling System shall beintegrated into the overall in-vessel assembly procedures that shall be managed by the OperationsManagement System (not part of this procurement contract)Low-Level Control SystemThe Blanket Tooling system shall have remote controllers for the two operation modes: Cubicle based remote controller: This provides the control module for remote control ofthe end-effectors when mounted on the BAT (Transporter Mode), BTSE Skid based remote controller: Provides the control module and process servicesfor the remote control of the end-effectors and tools when fitted to VV (Skid Mode)The Blanket Tooling end-effectors listed below shall each have on-board local controllers: SBG: Transporter Mode only FBT: Transporter Mode and Skid Mode SBTB: Transporter Mode and Skid Mode 15NDG: Transporter Mode only 15NDTB: Transporter Mode and Skid Mode FWG: Transporter Mode only FWCBT: Transporter Mode onlyThe specific control system elements that shall be provided as part of the Blanket Tooling ControlSystem are shown in the figure below (not greyed out items)SUPPLYPage 93 of 106CommandandControlOperationsManagementSystemFile NetworkRH InputDevicesRH Operator Interfaces (High-Level Control System)VirtualRealityVisualizationCubicle RemoteControllerSkid RemoteControllerSBG LocalControllerFBT LocalControllerSBG EEI&CFBT EEI&CSBTB EEI&CRH Control NetworkTool ChangerconnectorSBTB LocalController15NDG LocalController15NDTB LocalControllerTools I&C15NDTB EEI&CTools I&CFWG LocalControllerFWCBT LocalController15NDG EEI&CFWG EEI&CFWCBT EEI&CLocal Wiring Local WiringCommandandControlRH InputDevicesMobileCamera networkTo BAT VisionSystemFixedServices ServicesIVTC NacelleControl ContainerFigure 126. Blanket Tooling Control System elementsTransporter Mode OperationIn Transporter Mode, the Blanket Tooling End-Effector is mounted on the end of the BAT viathe Tool Changer. The service lines to the End-Effector are connected, and the cameras on theEnd-Effector are connected back to the BAT vision systemThe operations require sequential operations of the BAT and the End-Effector. For example:- BAT is positioned to stand-off position to Blanket module,- Using the vision system feedback, the BAT aligns and engages the End-Effector with theBlanket Module,- The Tooling End-Effector is then operated to grip the Blanket Module,- The Tooling End-Effector releases the Blanket Module fixation,- The BAT is operated to transfer the Blanket Module load onto the BAT,Low-Level Control System TransporterModeSkidModeSUPPLYPage 94 of 106- The BAT moves the Blanket Module away from the VV wallThe operation sequences must be carried out in the precise validated order. This shall be ensuredby implementing the sequences of the BAT and the Tooling in a common play-back fileSkid Mode OperationIn the Skid Mode, the Blanket Tooling End-Effector is installed on the Vacuum Vessel andcontrolled from the BTSE Skid. It shall be possible to operate the tool either remotely from the Control Container or locally byan operator on an IVTC Nacelle. To enable this, the Skid remote controller shall support wirelesscommunication. This arrangement shall allow the Command & Control HMI to be run on amobile computer that is carried on the IVTC Nacelle inside the vesselNote: These two operating methods are essentially the same. The only difference is the C&Cusing wireless communication with the Skid instead of wired communicationFigure 127. Wireless operation of the Blanket Tooling from in-vessel Nacelle4.3.2 Control System Detailed RequirementsCommand & Control HMIThe C&C HMI shall consist of a GUI, a joystick, and an emergency stop buttonThe C&C application shall provide the operator with the functionality to operate the BlanketTooling System:- Display of status data,- Interface to build and send operating commands,- Running pre-recorded operation sequences,- Display of messages (events, warnings, alarms)The C&C shall communicate with the EE controller using the Low-Level CIP API (provided byIO [R13])The design of the C&C layout shall involve review iterations with the ITER operation team atan appropriate time in the development lifecycleThe EE controller communication data (status data, commands, alarms, events) shall be providedto the IOA version of the C&C shall be provided for operation of the EE in the Transporter mode remotelyfrom the control room – ‘fixed’ C&CSUPPLYPage 95 of 106A version of the C&C shall be provided for operation of the EE in the Skid mode locally fromthe Nacelle – ‘mobile’ C&CIntegrated C&CBATDisplayToolingDisplayAutomatic SequenceBATControllerToolingControllerRH networkFigure 128. Concept of Integrated C&C for safe execution of Blanket Assembly operationsFixed C&CThe fixed C&C shall be designed to run on a standard control room computerThe fixed C&C shall be implemented to run on the Red Hat Enterprise Linux (latest versionused by CODAC)The fixed C&C source code shall be provided to the ITER operation team and JADA shallsupport the integration of the Blanket Tooling fixed C&C with the BAT C&CThe integrated C&C shall have the capability to run pre-programmed sequences (written usingStructured Language format [R14]) involving sequential operation of the BAT and BlanketTooling controllers (see figure above)Mobile C&CFor the Skid Mode, a C&C is required to run on a robust mobile handheld device to allow alocal operator to operate the Blanket Tooling that is installed on the VV wallThe handheld device shall have wireless communication with the Skid remote controller. Thehandheld device shall include an emergency stop button to trip the system into the safe stateThe mobile C&C shall run on the handheld device and provided the functionality required tooperate the Blanket Tooling System (End-Effector and Tools)The mobile C&C HMI shall be designed taking into account human factors engineeringThe mobile C&C shall take into account that the operators will be wearing light gloves in theVacuum VesselFigure 129. Example of a robust mobile robot control deviceSUPPLYPage 96 of 106Cubicle Remote ControllerThe Blanket Tooling System shall include a Cubicle Remote Controller for controlling the end-effectors when they are attached to the BAT (Transporter Mode)The function of the Cubicle Remote Controller shall be:- Provide interfacing with the C&C HMI,o Periodic sending of status data to HMI,o Processing of HMI commands- Run a Tooling State Machine,o Manage the overall tool functionality (motions and tool process)- Provide interfacing with the actuator drivers (embedded in End-Effectors)o Sending motion commands and monitoring sensor data via EtherCAT- Implementing an Emergency Stop circuito Trip and reset from the controllero I/O for tripping by external protection systems. The Cubicle Remote Controller shall be built for installation in a standard CODAC cubicleIt is expected that the Cubicle Remote Controller will be fitted into a BAT cubicle and will getconnections to AC power and RH networks from the BAT cubiclesSkid Remote ControllerThe Blanket Tooling System shall include a Skid Remote Controller for controlling the end-effectors and tooling when installed on the VV wall (Skid Mode)The function of the Skid Remote Controller shall be:- Provide interfacing with the C&C HMI,o Periodic sending of status data to HMI,o Processing of HMI commands- Run a Tooling State Machine,o Manage the overall tool functionality (motions and tool process)- Provide interfacing with the actuator drivers (embedded in End-Effectors)o Sending motion commands and monitoring sensor data- Implementing an Emergency Stop circuito Trip and reset from the controllero I/O for tripping by external protection systems- Provide interfacing with Tooling process controllers (e.g. welding controllers)The Skid Remote Controller shall support both hardwired Ethernet communication and wirelessEthernet communication with the C&CThe Skid Remote Controller shall utilize the same hardware as the Cubicle Remote ControllerThe Skid Remote Controller shall be installed in the Blanket Tooling Skid moduleThe Blanket Tooling Skid module shall include Tooling Controllers specific to the toolingprocesses being deployed. It is assumed that these will be COTS products. In some cases, suchas with welding tools, power and signals might be directly connected to the tool instead of routingthrough the tool changer and the embedded controller on end effectorEnd-Effector Local ControllersLocal Controllers shall be developed for each of the Blanket Tooling End-EffectorsThe End-Effector Local Controllers shall control the motions of the specific End-Effector andTooling (where applicable)SUPPLYPage 97 of 106The End-Effector Local Controllers shall support the interfacing of VoIP cameras. The Ethernetuplink shall connect to the BAT Vision SystemCommunication with the End-Effector actuator drivers shall be using EtherCATThe Local Controller components will depend on the specifics of each end-effector. Anindicative local controller based on Beckhoff products is indicated in the schematic belowEtherCATCoupler1 ChannelController2 ChannelControllerMulti-functionalI/ORelay RelayNetworkHubEthernet UplinkEtherCAT LinkOn-boardcamerasOn-boardactuatorsOn-boardactuatorsOn-boardrelays/switches48V DCPSAC PowerFigure 130. Sample End-Effector Local Controller4.3.3 Control System Scope and Indicative Bill of MaterialsThe following tables are to provide clarity over the scope of the control system componentsTransporter Mode Skid ModeControl Container Control Container Mobile DeviceHigh-Level Control SystemC&C IO (JADA providefor FAT)IO (JADA providefor FAT)JADAOMS IO IO -Viewing IO IO -Virtual Reality IO IO -Low-Level Control SystemCubicle BAT JADA (in Skid)Remote Controller JADA JADALocal Controller JADA provides local controller in each EETable 10. Scope of the supply of different control system elements for operating EESUPPLYPage 98 of 106Indicative Bill of MaterialsCommand & Control HMIPersonal Computer plus Emergency Stop buttonRugged Mobile Computer with built-in EmergencyStop buttonCommand & Control Software applicationCubicle Remote ControllerDC power supply 24V DC TBD 1Processor board Beckhoff CX8110* 1Emergency Stop circuitController Software applicationSkid Remote ControllerDC power supply 24V DC TBD 1Processor board Beckhoff CX8110* 1Wireless access point TBDEmergency Stop circuitController Software applicationTooling Process Controller(s)SBG Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 1FBT Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 1SBTB Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 115NDG Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDSUPPLYPage 99 of 106Multifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 115NDTB Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 1FWG Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port GigaConcept TSW304 1FWCBT Local Controller (embedded in EE)DC power supply 48V DC TBD 1EtherCAT coupler Beckhoff EK1100 1Axes Drivers Beckhoff EL7xxx series TBDMultifunctional I/O Beckhoff Elxxxx series 1Ethernet switch port (DIN rail) GigaConcept TSW304 1CablingCabling from Cubicle Remote Controller to BATTool Changer connectorCabling from Skid Remote Controller to ToolChanger connector (umbilical)End-Effector on-board cabling from localcontrollers to I&C componentsEnd-Effector on-board cabling for Tool I&Ccomponents (SBTB & 15NDBT EE’s)Power cable to connect Skid to power outletNetwork cable to connect Skid to RH networks (viaCODAC Network Panel)SparesSpares shall be provided to cover 2 years ofoperationMeasurement and test equipmentMeasurements and test equipment needed for themaintenance of the system shall be defined by thesupplier and provided as part of the procurementTable 11. Indicative Bill of Materials for Blanket Tooling Control System* The Beckhoff processor and hardware have been identified as indicative components. However, the IO would like to have a standard approach between the Blanket Tooling and theSUPPLYPage 100 of 106BAT (not defined yet). The Contractor shall work with the IO to agree the final selection of theprocessor board. The operating system will be determined by the hardware chosen4.4 Production of final End Effectors, Tools and I&C systemsThis task shall comprise the following points: Execution of the manufacturing design Procurement of materials, parts and components Manufacture of the parts and components Identification, inspection and dimensional control of parts and components Assembly and inspection/dimensional control of assembled sub-systems and equipment Formal inspection, dimensional control and functional testing of the “stand-alone”subsystems Interface compliance checking with the Tool Changer and its electrical connector Producing manufacturing reports Producing FAT procedure Producing SAT procedure4.5 Factory Acceptance Tests Factory Acceptance Testing (FAT)o Tests based on FAT plan established in section 4.4 Labelling, cleaning, packaging, handling, shipment and storage Shipping to IO siteGiven the FOAK nature of the project, while JADA and their contractor will make reasonableefforts to achieve the expected performance of the delivered products, specific outcomes (e.g.,weld quality) in the actual execution cannot be guaranteed. If the implementation based on thistechnical specification and IO-approved drawings does not meet the expected performance, IOand JADA will discuss potential revisions to the technical specification, including anyadditional time & cost required4.6 Site Acceptance TestsThe Site Acceptance Tests (SAT) are a subset of the FAT tests, described in section 4.5, usingthe same test equipment as practically possibleSince the SAT tests are performed on IO site, JADA shall send test equipment used during FATtesting. This provision requires the jigs manufactured for FAT to be sent to IO, but those thatform part of the supplier’s infrastructure and cannot be easily removed are not subject toshipmentOut of scope for JADA, shared for information only:After the formal SAT, additional tests will be performed on IO site to test the Blanket AssemblyTooling components with testing equipment that will have been manufactured and/or set up inthe basement of Building 22 (TAP building), such as the Heavy-Duty Robot or Shield Blockmock-up, etcNext, the Blanket Assembly Tooling equipment will be transferred to the main assemblycontractor for them to use with BAT at their premises. This stem is part of the BAT FAT testsSUPPLYPage 101 of 1065 Location for Scope of Work ExecutionUntil finishing the FAT tests, JADA can perform the work at their own locationSAT tests are to be performed on IO site6 IO Documents & IO Free issue itemsOn demand, IO will share all 3D data of the concept designs created by IO in-house, related toBlanket Assembly ToolingNo free issue item is expected from IO7 Deliverables and Schedule Milestones7.1.1 Schedule for deliveryThe following list specifies the indicative quantity of final production units to be manufacturedand delivered to IO. The final quantity shall be determined on an actual cost basis, ensuring thatthe portion converted from the existing BRHS PA scope aligns with the initial assemblyequipmentSUPPLYPage 102 of 106Indicative number of items to be shipped as final production units:Description Quantity* CommentEnd EffectorsSBG 2 Including 1 spare from each variant, number of variants TBCFBT 2 Including 1 spareSBTBSeecommentThe SBTB has modular design, with multiple module variants insome cases (e.g. shim). In general, every module variant musthave at least 1 spare. When an SBTB is in operation inside thevessel, another SBTB is in reconfiguration outside the vessel forthe next target SB15NDG 215NDTB 2FWG 2Including 1 spareFWCBT 3 1 in operation, 1 in reconfiguration, 1 spareToolsESBT3 Including 1 spare. 2 could be used at the same time by 2 NacelleoperatorsVT3 Including 1 spare. 2 could be used at the same time by 2 NacelleoperatorsCCWT 2CCCT 2MCAMT 2MCPT 2MCWT 2MCCT 2Including 1 spareECHT3 Including 1 spare. 2 could be used at the same time by 2 NacelleoperatorsECWT 2ECCT 2Including 1 spareAuxiliary systemsTSS 2UHS 2Including 1 spareUTC20 Including spares. These are relatively cheap items and many willbe used at the same time to fix the umbilical to the BMs. TSR 4 Including 1 spare. 3 used at the same time in-vesselNTS 2 Including 1 spare*Quantity to be supplied from each variant (if there are variants)SUPPLYPage 103 of 106Please find hereafter the expected high-level schedule:JADA will provide their own detailed schedule separately from this documentScheduleMilestonesDescription ExpectedTime#1 Blanket Assembly Tooling First Batch Q1 2028#2 Blanket Assembly Tooling Final Production Units Q1 20307.1.2 List of deliverable documentationJADA shall provide IO with the documents and data required in the list belowTechnical DesignFamilyDocument Title Further Description ExpectedTimeDesign DescriptionDocumentDesign DescriptionDocumentDescription of tools and endeffectorsFor DesignApprovalQuality Assurance Quality Plan - After contractsignatureBill Of Material-BOMCAD BOM BoM of all assemblies,including list of COTS items,with suppliers indicatedFor DesignApprovalAssembly orComponentDefinition DrawingAssembly Drawing Assembly drawings of eachEnd Effector, Tool andAuxiliary SystemFor DesignApprovalAssembly orComponentDefinition DrawingComponentDrawingFinal manufacturing drawings For DesignApprovalEngineeringAnalysis andCalculation ReportAnalysis Model FEM model of all analyses thathave been performed if FEManalysis is performedFor DesignApprovalEngineeringAnalysis andCalculation ReportStructural IntegrityReportAll analysis reports that havebeen createdFor DesignApprovalElectrical Diagram Cabling Diagram-CBD- For DesignApprovalElectrical Diagram Detailed WiringDiagram-WD-Electrical Diagram Single LineDiagram or OneLine Diagram-SUPPLYPage 104 of 106Verification Report Compliance Matrix- DCM or VCMThe DCM needs to becompleted during/after thecompletion of FAT and SATFor DesignApprovalAcceptance Plan Factory AcceptanceTest Plan-FATP- Before startof FATAcceptance Plan Site AcceptanceTest Plan-SATP- Before startof SATAcceptance Recordor ReportFactory AcceptanceTest Report-FATR- BeforeshippingAcceptance Recordor ReportSite AcceptanceTest Report-SATR- ForacceptanceOperation andMaintenance ManualEquipmentOperation andMaintenanceManualIncluding assembly manual insub-assembly level componentBefore startof FATOperation andMaintenance ManualSoftware UserManual-SUM- Before startof FATRelease Note Release NoteSuggested templates forRelease Note (QVEKNQ_v3.1)Beforeshipping8 Overarching requirements8.1 Quality Assurance requirementsThe Quality class for Blanket Assembly End Effectors and Tooling is QC3 for both First Batchof Tooling and Tooling Production Units for pre-SRO. Specific QA requirements are definedbased on Appendix 2 of Quality Classification Determination (ITER_D_24VQES v6.0) asfollows Design Control Simplified design reviews will be conducted as specified in 9.1 in regular meetings andin IDM review process. Independent verifications are not required.  Software Control & Models Development IO acceptance of software and models for design and operation is not required Procurement / Documents and Records Suppliers’ Quality plans are required from JADA’s direct contractors. Exemptionrequests shall be submitted to the QARO regarding the subcontractors’ QP on a case-by-case basis Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) plans shall besubmitted to IO. Inspection and Test Plan are not required The Release Note is required to be submitted to IO before shipping.  Declaration of compliance to directives specified in 3.3 is required. Static load testresults in FAT for grippers shall be submitted. Material certificates are required for keymaterials (e.g. wrench made of maraging steel) Manufacturing Assembly & Installation / Inspection & Testing Simplified Manufacturing Readiness Review (MRR) will be conducted in the regulartechnical meetings as needed as specified in 9.1SUPPLYPage 105 of 106 The application and grade approach of quality control levels are described in IO specificprocedure (ITER_D_TVL3Y5 v2.0). Supplier Reliability is to be evaluated by JADAand submitted to IO. In case of QSL 4, there is no specific intervention point or holdpoint to be applied Quality Audits The application of quality control level is described in IO specific procedures(ITER_D_TVL3Y5 v2.0) IO’s quality audits to the suppliers / contractor site are not required if the supplier iscertified under ISO 9001 or equivalent Handling, Storage, & Transportation The products delivery shall start only after contractor’s release note and shippingnotification are accepted by IO Products shall be properly packaged. Desiccants and accelerometers shall be includedin the packages as needed.  There is no specific transportation and storage requirement to be applied. Storage andpreservation activities in IO’s site are not required by JADA Inspections and verifications to the products (sampling methods) are not required atreception time NCR & DR Control All major NCR’s related to ITER project issued by JADA and its suppliers shall besubmitted to IO for review and acceptance in accordance with IO procedure For all major NCR’s related to ITER project, a root cause analysis shall be issued bythe DA’s / suppliers / contractors and approved by IO Any minor NCR’s related to ITER project by JADA and its suppliers do not requiresubmission to and review of IO All the Deviation Request (DR) will be submitted to IO / JADA for review and approvalbefore implementation.  Risk and Opportunity Management IO regular risk and opportunity management process including training activitiesrelated to the process is not required. However, risks shall be registered in the ProjectRisk and Opportunity Register (PRR)8.2 Nuclear class SafetyNot applicable. Radiation hardness nor decontamination is not required for initial assembly toolsand end effectors8.3 Seismic classNo specific safety requirement related to PIC and/or PIA and/or PE/NPE components apply. Seismic assessment is not required for initial assembly tools and end effectors9 Special Management requirements9.1 Review meetingsSimplified FDR and MRR will be performed on the submitted documents via the IDM system,and discussions will take place during regular meetings as needed. Manufacturing activities maycommence upon the approval of the documents according to the simplified MRR procedure, suchas the following documents: Design Description DocumentSUPPLYPage 106 of 106 Drawings CAD model / Bill of Materials9.2 CAD design requirementsThe CAD models, 2D drawings and electrical diagrams and etc. shall be provided in STEP orCATIA and in their native format. Pdf of the 2D drawings shall also be provided. Along with theCAD model, a Bill of Materials (BOM) for all assemblies, including a list of COTS items, shallbe submitted. Change management for CAD model is not required10 AppendicesNo appendicesRequirements document for End Effectors and Tools tobe used for the First Assembly of Shield Blocks andTemporary First Walls1. In order to find the requirements for a specific EE or Tool, column "Scope" on theRequirements tab shall be filtered2. If the component is an EE, the name of the specific EE, "All EEs" and "All EEs & Tools" shallall be selected from the list when filtering3. If the component is a Tool, the name of the specific Tool "All Tools" and "All EEs & Tools"shall all be selected from the list when filteringHow to use this document:The requirements listed in this document are specifically targeting First Assembly, which meansthat there are no requirements related to nuclear environment. Also, it is taken into account thatat this stage, light duty operations can be performed manually by an operator, which reduces theeffort and cost. During the creation of this list, the document in RD1 has been checked, but it containsrequirements related to the nuclear stage and ones related to obsolete designs. Thus, in case ofconflict, the current requirements document supersedes the content of RD1RD1: ITER_D_872ZLZ v1.0 - WG05 BRHS Tooling Requirements Master SpreadsheetBackground:Explanation for requirement "Importance" collumnExpected: A requirement that should be present in the proposed solution, but its absence wouldnot disqualify the solutionMandatory: The solution must comply with the requirement別紙7Nr. Scope Requirement Target value Tolerance Importance Comments1 All EEs & ToolsThe state and/or position of each function shall be monitored by sensors incase of automated processesn/a n/a Mandatory2 All EEs & ToolsVisual indicators shall be used for hands-on operated motions(engravements,marks, flags, etc.)n/a n/a Mandatory3 All EEs & ToolsTools & EEs shall be designed in such a way that there will be no risk oflosing or dropping of any object during handling or operation inside thevesselEnd Effectors are secured by Tool Changer interfaceTools are secured by zero G arm Tool Changer. Additional hand tools shall be secured by a tetherExposed bolts shall have a design that prevents bolt loosening (e.g. Loctite,SpiraLock, NordLock, wires,.)n/a n/a Mandatory4 All EEs & ToolsThe used materials shall comply with the following specifications:- For structures and bolts: Stainless steel, Aluminium Bronze or Aluminiumshall be preferred. Maraging steel is authorized for the wrenches of thetorquing tools. Carbon steel is authorized only with corrosion preventioncoating or painting and in locations where the carbon steel parts are notexposed to direct friction contact with the in-vessel component- FKM (Viton) or EPDM sealsn/a n/a Mandatory5 All EEs & ToolsLubrication shall be done in an enclosed volume, protected with sealing,taking into account the followings:- The use of oil is not permitted. Any potential use case shall be agreedby IO, if its use cannot be avoided. - One seal for grease can be allowed only if the possibility of greaseleakage is very low, otherwise double containment is mandatory. If grease isinjected into the part , double containment shall be done. If vacuum greaseis applied as a thin layer, single containment is acceptableIn case the lubrication cannot be done in an enclosed volume, surfacecoating such as Diamond Like Coating (DLC) or dry lubrication solutionsuch as S-compound film shall be usedn/a n/a Mandatory6 All EEs & ToolsThe enveloping dimensions of the EEs and Tools shall be limited in order tofit within the bigger storage boxes that transfer items to in-vesselLxWxH:2100x1310x665maximum Mandatory7 All EEs & ToolsIf technically feasible, the enveloping dimensions of the EEs and Tools shallbe limited in order to fit within the smaller storage boxes that transfer itemsto in-vesselLxWxH:2100x1310x460maximum Expected8 All EEs & ToolsAll locking functions of EEs and Tools shall remain locked in case of apower/service failuren/a n/a Mandatory9 All EEs & ToolsTorquing tools (ESBT), EEs with torquing functions (FBT, FWCBT) andcutting tools (CCCT, MCCT, ECCT) shall be able to move in both directionsfor recovery in case the tool jamsn/a n/a Mandatory10 All EEs & ToolsTorquing tools (ESBT) and EEs with torquing functions (FBT, FWCBT) shallbe able to release the torque applied to the wrenchn/a n/a Mandatory11 All EEs & ToolsTorquing tools (ESBT) and , EEs with torquing functions (FBT, FWCBT)shall be designed to allow no less than 10 cycles before tool requires a re-calibration. Torque deviation outside the tolerance values (±10%) requiresrecalibrationn/a n/a Mandatory12 All EEs & ToolsEEs that have automatically engaged wrenches (SBG, 15NDG, FWCBT)shall have a position feedback function to confirm that the wrench tip isfully engaged with the bolt socket before torquing operation startsn/a n/a Mandatory13 All EEs & ToolsWelding processes for Blanket modules and tooling shall be qualifiedaccording to:- EN ISO 15609-1, Specification and qualification of welding procedures formetallic materials: Welding procedure specification Part 1: Arc welding- EN ISO 15614-1, Specification and qualification of welding procedures formetallic materials - Welding procedure test - Part 1: Arc and gas welding ofsteels and arc welding of nickel and nickel alloys (ISO 15614-1:2003)Preparation and qualification of the WPS for in-VV welding are outside thescope of JADA. JADA will conduct welding trials using test samples andweld quality assessment as part of the verification of the manufacturedequipmentn/a n/a Mandatory14 All EEs & ToolsAll local heat sources or any sources of electrical arcs and sparks generatedby the Blanket Tooling that may cause fire risk shall be identified. As aconsequence of identification of possible local heat sources sufficient tocause fire, the measures to mitigate such risk shall be definedn/a n/a Mandatory15 All EEs Shield Block EEs shall mimic the interfaces of the First Wall, if possible. n/a n/a Expected16 All EEsEEs should use pressing pads to provide a more rigid connection to theComponent. Pads can be active or passive (spring loaded or static) but theyshall be the primary support point for the EEn/a n/a Expected17 All EEsEE interfaces with the Shield Block shall be generic for all EEs, withminimum number of variantsn/a n/a Mandatory18 All EEsThe mechanical locking state of the EE (except for FWCBT, which is notlocked to the FW) to the in-vessel component (SB, FW, etc.) shall bemonitoredn/a n/a Mandatory19 All EEsIn the case of grippers (FWG, SBG), the mechanical locking between thegripped Component (SB or FW) and the in-vessel component to which it isinstalled (VV or SB) shall be monitoredn/a n/a Mandatory20 All EEsIn the case of grippers (FWG, SBG), functions related to gripping the targetin-vessel component (wrench/gripper engagement), functions related tofixing the component in-vessel (CB or ES bolt torquing) and functionsrelated to reconfiguring the gripper for a new target component(wrench/gripper shifting) shall be automatized and controlled from the RHcontrol roomn/a n/a Mandatory21 All EEsEvery function of the EE, that may lead to the impossibility to safely removethe EE in case of failure (should the control system or the mechanicalsystem fail) shall be equipped with manually actuated recovery means, sothat it can be removed by the BATn/a n/a Mandatory22 All EEsEE shall have an interface enabling to connect to the Tool Side of the ToolChangern/a n/a Mandatory23 All EEsThe Tool Changer tool side shall be fixed to the symmetry plane of the EEwhen feasible, concentrically with the Central Barrel. When not feasible, theTool Changer tool side shall be on the lateral side (lateral when aligned withthe target component (SB or TFW))n/a n/a Expected24 All EEsIf technically feasible, the EE design shall include the possibility of beinggrabbed by the BAT from both lateral sides (lateral when aligned with thetarget component (SB or TFW)). There are two options for this: 1. The EE issymmetrical and it can be flipped. 2. The EE has two Tool Changers or atleast Tool Changer fixing brackets on both sidesn/a n/a Expected25 All EEsEE functions shall be modular, so that the EE can be reconfigured forspecific targets. As much as possible, the EE shall be standardizedn/a n/a Expected26 All EEsThe connection between the EE and the Tool Changer tool side shall be asstiff as possible (e.g. without the introduction of spring mechanisms) inorder to have precise control over the position of the EE tipn/a n/a Mandatory27 All EEsWhen the EE is fixed to a vessel component (SB, FW) the following shallapply: 1. Those functions, that need to be set once (e.g. TFU positioning)shall be hands-on operations, without automatization. 2. Periodic motionsand recurring functions (such as tool rotation) shall be motorized. Theseautomated functions shall be controlled by an operator nearby (on theNacelle) via a screen or keypad interface with sensory feedbackn/a n/a Expected28 All EEsThose EE functions that are needed for positioning and fixing the EE to itsworking position on the SB/FW shall be controlled from RH control roomwhilst being connected to the General EEn/a n/a Mandatory29 All EEsAll EEs shall be designed so that they only have one connector for eachservice type (control, sensing, air, gas, etc.) at the Tool Changer connectorn/a n/a Mandatory30 All EEsLocal distribution of services towards the embedded drive units of the EEshall be made within the EE itself, using an embedded controller boxn/a n/a Mandatory31 All EEsTo avoid any cable entanglement risk, dynamic cables shall be either routedthrough cable chains or covered by protective covers. Non-mobile cablesshall be attached to the Tool Base along their routingn/a n/a Mandatory32 All EEsThe grouped main services line shall connect to the automatic connector ofthe Tool Changer tool side. Then, the services shall be routed to theembedded controller within the EE. This embedded controller shall have asufficient number of sockets to provide services to Toolsn/a n/a Mandatory33 All EEsWelding current shall be fed to the Tool directly either from the automaticconnector of the Tool Changer Tool side, or the welding power cable shallbe branched off of the bundle coming from the UHS to bypass the automaticconnector and connect to the Tool directlyRouting through the Embedded Controller shall be avoidedn/a n/a Mandatory34 All EEsTwo robot vision cameras including lights shall be installed on every EE,with relative configuration specific to each EE. Detailed referencedocument: TBDn/a n/a Mandatory35 All EEs The weight of all EEs shall be limited. 1 ton maximum Mandatory36 All EEsThe weight of all EEs, whose purpose is to carry in-vessel components (i.e. Grippers) shall be further limited500 kg maximum Mandatory37 All EEsThe torsional moment applied by the EE to the General EE tool roll axis shallbe limited7.5 kNm maximum Mandatory38 All EEsTool Bases (SBTB, 15NDTB) shall not obstruct backgas channel openingsnear CC or MC access holes for any SB. All SB designs shall beinvestigated, backgas holes shall be located and the Tool Base designsshall be adapted to provide clear accessn/a n/a Mandatory39 All EEsThe following EEs shall share the same connecting interfaces with the SBs:SBG, SBTB, FBT, TSR. This shall consist of static keys and a CentralClamping Mechanism interface to fix the EE to the SBn/a n/a Mandatory40 All EEsThe EEs defined in RQ38 shall fit with the SB central hole for centralization,via a Central Barrel interface, with a reasonable gap between the barrel andthe SB hole. Attention shall be paid to the fact that Shield Block rows 3-5,7-9,14-17 have a diam. 180 mm central hole, whereas Shield Block rows1,2,6,10-13,18 have a diam. 190 mm central holeproposed gap: 1.0mm0/+0.5 mm Mandatory41 All EEsThe EEs defined in RQ38 shall connect to the Central Bolt insert of the SB,via a Central Clamping Mechanism embedded in the Central BarrelassemblyM64x4 n/a Mandatory42 All EEsThe Central Clamping Mechanism of the EEs defined in RQ38 shall engagewith the CB insert thread by clamping and a pulling load (preload) shall beapplied to the clamping head. All of this shall be done by a mechanismintegrated into the SBGpulling force TBD tolerance TBD Mandatory43 All EEsThe Central Clamping Mechanism of the EEs defined in RQ38 shall be fullyretractable to the Central Barrel interfacen/a n/a Mandatory44 All EEsThe locking interface of the EEs defined in RQ38 shall aim to avoid orminimize any damage to the SB M64x4 threaded insert. There are severaloptions for this, including but not limited to: reduced engagement length(with respect to final FW CB connection); Central Clamping Mechanismmade of softer material; smart choice of Central Clamping Mechanismthread tolerance to provide more clearance; DLC coating of CentralClamping Mechanism thread to provide lubricationn/a n/a Mandatory45 All EEsFor positioning the EEs defined in RQ38 onto the SB, the EE shall havestatic keys interfacing with the FW pipe grooves of the SBn/a n/a Mandatory46 All ToolsThe mechanical locking state of the Tool to the EE and to the in-vesselcomponent (VV, SB, FW, etc.) shall be monitoredn/a n/a Mandatory47 All ToolsEvery function of the Tool, that may lead to the impossibility to safelyremove the Tool in case of failure (should the control system or themechanical system fail) shall be equipped with manually actuated recoverymeans, so that it can be removed by the BATn/a n/a Mandatory48 All ToolsThe connection between the Tools and Tool Fixing Units (TFU) shall bestandardized as much as technically feasible. Also, it shall be isostatic andrepeatable for tools exchange accuracyn/a n/a Expected49 All ToolsCentre of gravity of the tool shall be as close to the zero G arm tool changeraxis as practically achievable, so that when the operator is handling the toolthe moment is minimizedn/a n/a Expected50 All ToolsTools and their gripping features (for the zero G arm and for handling) shallbe designed so that an operator can compensate the moment loadgenerated from the CoG being at an offset from the tool changer of the zeroG armn/a n/a Mandatory51 All ToolsLight tools shall have guiding structure for insertion into the TB(e.g. The tool tip tapered. The welding tool’s electrode shall not contact TB.)n/a n/a Mandatory52 All ToolsTools shall be designed with fixation features/interfaces to store on theTool Storage Rack (TSR) and Nacelle Tool Storage (NTS) interfacen/a n/a Mandatory53 All ToolsTools shall be equipped with ergonomic handling features to be safelygrabbed and carried by an operator and/or attached to a zero G armn/a n/a Mandatory54 All Tools Weight of the tool shall be limited, so that it can be operated manually. 40 kg maximum Mandatory55 All ToolsVery light tools shall not be designed to be compatible with loadcompensation devices. These tools shall be handled manuallyapprox. 3 kg maximum Mandatory56 All ToolsTools shall be designed so that they have one connector for each servicetype. The design of the Tool shall include the distribution of these services,if necessaryn/a n/a Mandatory57 All ToolsService connections between the Tool & EE shall be grouped for minimumnumber of automated or hands-on connectorsn/a n/a Mandatory58 All ToolsWelding Tools (CCWT, MCWT, ECWT) shall include Arc Voltage Control(AVC) and Touch-Start systemn/a n/a Mandatory59 All ToolsWelding Tools (CCWT, MCWT, ECWT) shall provide shielding gas to thewelding torchn/a n/a Mandatory60 All ToolsBackgas channels of the SB shall be used to provide backgas to the CC andMC jointsn/a n/a Expected61 All ToolsThe welding tools (CCWT, MCWT, ECWT) shall have necessary insulation toprevent unwanted arcingn/a n/a Mandatory62 All ToolsThe welding tools (CCWT, MCWT, ECWT) shall have the ability to tack weldand to start from any tangential positionn/a n/a Mandatory63 All ToolsThe welding tools (CCWT, MCWT, ECWT) shall be passively cooled byambient airn/a n/a Mandatory64 All ToolsFor cutting tools related to CC and MC cutting (CCCT, MCCT), cut facesthat are to be used for re-welding shall be suitable in terms of sufaceroughness and accuracy for re-welding directly or following a mechanicaltreatmenttotal runout: 0.05roughness inradial dir.: Ry 2.5TBC Expected65 All ToolsCutting tools (CCCT, MCCT, ECCT) shall be equipped with hard limits toavoid damage from the contact of the tool head against the pipe end. Afterthe cutters have cut through, the operation will be stopped by control, but incase it was not, hard stops shall prevent further motion of the cutter inorder not to damage the Tool or SB or etcn/a n/a Mandatory66 All ToolsCutting tools (CCCT, MCCT, ECCT) shall be equipped with feedback fromthe required cutting force (e.g. by measuring output motor torque orcurrent) and the cutting tool shall automatically stop if there is anunexpected rise in resistance as a result of stuck or broken tooln/a n/a Mandatory67 All ToolsCutting tools with saw or lathe-type cutters shall have the means to extractswarf from the cutting area. An internal vacuum channel shall lead from thecutter to the stationary Tool parts connected to the TFU, where a socketshall be included for connecting the suction hose of the Tool Basen/a n/a Mandatory68 All ToolsMaximum quantity and nature of swarf shall be determined quantitativelyand shared with IOn/a n/a Mandatory69 All ToolsAlignment, welding and cutting tools (CCWT, CCCT, MCAMT, MCWT,MCCT, ECWT) shall be manufactured and assembled so that the distancebetween the TFU interface and the- displacement sensor for CCWT and MCAMT- swages for CCCT and MCCT- welding torch for MCWT and ECWThas a precise positional tolerance. This is important for alignment repeatability when an alignmentmeasurement tool (CCWT or MCAMT) is replaced with another toolaxial positionalaccuracy: 0.1 mmn/a Mandatory70 Shield Block GripperThe Shield Block Gripper is an EE. Thus, all generic EE requirements shallbe applied to itn/a n/a Mandatory71 Shield Block GripperThe SBG shall have the same interfaces with the SB as other EEsconnecting to regular SBs, as defined in RQ38n/a n/a Mandatory72 Shield Block Gripper The SBG shall be able to carry the heaviest SB. 4 tons n/a Mandatory73 Shield Block GripperThe SBG shall be equipped with one wrench on either side (2 in total) of theCentral Barrel, to tighten the ES bolts. These wrenches shall be extendableand retractable to reach SB ES bolt sockets when the SB is in positionn/a n/a Mandatory74 Shield Block GripperThe SBG shall be capable of torqueing both ESBs by wrench mechanismsintegrated into the SBG240 Nm ±10 % Mandatory75 Shield Block GripperIf technically feasible, the SBG shall be capable of applying final torque tothe ESBs480 Nm ±10 % Expected76 Shield Block GripperThe thread engagement length and tightening torque of the ESBs shall bemonitored through the attachment processn/a n/a Mandatory77 Shield Block GripperThe ESB wrenches of the SBG shall be capable of moving towards and awayfrom the Central Barrel to be able to handle more SB configurations withone SBG type. Naturally, if there is a SBG type that is dedicated to onespecific SB type due to its irregular shape, the wrenches cna be at fixedpositionsn/a n/a Mandatory78 Shield Block GripperThe ESB wrench tip shall be designed so that it can pass through the SBM24 insert (minor diameter 20.75 mm) to access the SB ESB, withoutdamaging the thread either by keeping a clearance during the engagementand torquing process and/or by having a layer of soft coating on the wrenchshank (e.g. EPDM, aluminium)tip diameter: 20mmmaximum Mandatory79 Shield Block GripperThe SBG variants shall be able to operate in an upside-down configuration,where the SBG is rotated by 180 degrees around the Central Barrel. This isto minimize the number of variants, to be able to handle SBs with close tosymmetrical ESB positions (e.g. rows 14 and 15)n/a n/a Mandatory80 Shield Block GripperOne SBG type shall be compatible with as many Shield Blocks as possible,without overcomplicating the designn/a n/a Expected81 Shield Block GripperThe Tool Changer tool side shall be installed onto the SBG so that its axiscoincides with the axis of the Central Barrel but it is on the opposite side ofthe SBG structuren/a n/a Mandatory82 Shield Block GripperThe distance from the SBG Tool Changer Tool Side interface plane to the SBinterface plane shall be limited, in order to keep the moment load on theGeneral EE roll axis at accetable level400 mm maximum Mandatory83 FCB Torquing Tool BaseThe Flexible Cartridge Bolt Torquing Tool Base (FBT) is an EE. Thus, allgeneric EE requirements shall be applied to itn/a n/a Mandatory84 FCB Torquing Tool BaseThe FBT shall have the same interfaces with the SB as other EEsconnecting to regular SBs, as defined in RQ38n/a n/a Mandatory85 FCB Torquing Tool BaseOne FBT type shall be compatible with as many Shield Blocks as possible,without overcomplicating the designn/a n/a Expected86 FCB Torquing Tool BaseThe FBT shall use a wrench, made of maraging steel grade 18Ni1900, totorque the FCBs to the required level8.4 kNm ±10% Mandatory87 FCB Torquing Tool BaseThe FBT wrench shank (the part between the wrench tip and the torquetransducer) shall be a cylindrical rodn/a n/a Mandatory88 FCB Torquing Tool Base The Passive Holding System (PHS) shall be fixed to the FBT wrench tip. n/a n/a Mandatory89 FCB Torquing Tool BaseThe FBT shall comprise a torque multiplier unit (e.g. GEDORE DVV-100ZRS)coupled with a motor (e.g. SHA-32A (gear ratio 101) harmonic drive) toapply torque on the wrenchn/a n/a Mandatory90 FCB Torquing Tool BaseA torque transducer shall be integrated between the torque multiplier andthe wrench in order to measure the output torque directly. In case thetransducers, that are available on the market, are deemed too big becausethey would clash with the arm, a smaller transducer can be used insteadbetween the motor and torque multiplieraccuracy: TBD n/a Mandatory91 FCB Torquing Tool BaseThe connection between the torque multiplier and its factory reaction arm ismade via a cylidrical serrated feature. The factory reaction arm of the torquemultiplier shall be removed and the FBT arm parts interfacing with themultiplier shall have a serrated hole to fit the serrated male feature of thetorque multipliern/a n/a Mandatory92 FCB Torquing Tool BaseThe arm of the FBT shall be capable of transfering the reaction torque tothe Tool Base baseplate and eventually to the SB via the static keysinterfacing with the SB front grooves8.4 kNm ±10% Mandatory93 FCB Torquing Tool BaseIn case the full FBT assembly does not fit inside the Storage Box, thewrench, torque multiplier and motor shall be manually detachable from theend of the load bearing armn/a n/a Expected94 FCB Torquing Tool BaseThe individually handled components to be installed to the FBT in-vessel(e.g. the unit comprising the wrench, motor and torque multiplier) shall havelimited weight40 kg maximum Mandatory95 FCB Torquing Tool BaseThe individually handled components to be installed to the FBT in-vessel(e.g. the unit comprising the wrench, motor and torque multiplier) shallinclude interfacing features with the load compensation device (zero Garm)n/a n/a Mandatory96 FCB Torquing Tool BaseThe FBT shall have one accessory, which is a simple handheld wrench. Thiswrench shall be used by an operator on a Nacelle as a bolting tool to engagethe FCBs before the FBT is attached to the SB. FCBs shall be bolted tohand tightness (no prescribed torque). The wrench shall have engagementfeatures with the FCB socket and the PHS on one end and a handle at theother endn/a n/a Mandatory97 ES Bolt Torquing ToolThe Electrical Strap Bolt Torquing Tool (ESBT) is a Tool. Thus, all genericTool requirements shall be applied to itn/a n/a Mandatory98 ES Bolt Torquing ToolThe ESBT shall be compatible with the SB pocket side walls (the pocket forthe TFW Electrical Strap) at the ES bolt access hole and with the TFW RHinterface features (side wall of the RH interface insert or side wall of theopposite RH interface insert) to provide reaction torque. For the few SBs, where there is an offset between the SB ESB axis and TFWESB axis, the ESBT can also make use of the SB grooves (for FW coolingpipes) as reaction featureIn the case of the 15 ND blocks, the ESBT key shall make use of the MCaccess holes as reaction features. Only the upper part of the MC accesshole, aboce the EC lips shall be used for thisn/a n/a Mandatory99 ES Bolt Torquing ToolThe ESBT shall have a standard T80 torx end to engage with FW and SBESBsn/a n/a Mandatory100 ES Bolt Torquing ToolThe ESBT wrench tip shall be designed so that it can pass through the M24insert (minor diameter 20.75 mm) to access the SB ESBn/a n/a Mandatory101 ES Bolt Torquing Tool The PHS shall be added to the ESBT wrench tip. n/a n/a Mandatory102 ES Bolt Torquing ToolThe ESBT shall be able to provide the final torque to fix the ES by wrenchmechanisms integrated into the ESBT480 Nm ±10% Mandatory103 ES Bolt Torquing ToolThe ESBT shall include a torque wrench and a torque multiplier (e.g. GEDORE DVV-13Z) with reaction features to interface with the SB andTFW. All of this shall be integrated into one assemblyn/a n/a Mandatory104 ES Bolt Torquing ToolDuring positioning, after engagement with the ESB socket and during thetorquing operation, the ESBT shall be held by a load compensation device(zero G arm). Thus, the ESBT design shall be optimized for constantly beingheld by the load compensation system (regardless of its weight) butoperated manuallyn/a n/a Mandatory105 Viewing ToolThe Viewing Tool (VT) shall be a handheld endoscope capable of performingvisual inspection of CC, MC and EC joint areas before and after welding andcutting operationsn/a n/a Mandatory106 Viewing ToolThe endoscope camera head size shall be small enough to be able to accessall the joints (CC, MC, EC) and inspect them from multiple anglesn/a n/a Mandatory107 Viewing ToolThe VT endoscope head shall have a demountable side viewing tip (e.g.:flexible/remotely driven insertion tube or right angle mirror) to look at CCand MC pipe jointsn/a n/a Mandatory108 Viewing ToolThe VT shall be capable of providing live HD (1080p or better) footage of thejoints from the distance of a few millimetresn/a n/a Mandatory109 Viewing ToolThe VT shall have manual focus fuction for the operator to set arbitrary viewangles and inspect the joint thoroughlyn/a n/a Mandatory110 Viewing ToolThe cable of the camera shall be stiff enough to keep its shape after it isbent by the operator to provide better viewing anglen/a n/a Mandatory111 Viewing Tool The VT shall have its own light source with adjustable light intensity. n/a n/a Mandatory112 Viewing ToolThe VT shall be able to work continuously in an ambient temperature of upto 50 Celsius degreesn/a n/a Mandatory113Shield BlockPulling&Welding Tool BaseThe Shield Block Pulling & WeldingTool Base (SBTB) is an EE. Thus, allgeneric EE requirements shall be applied to itn/a n/a Mandatory114Shield BlockPulling&Welding Tool BaseThe SBTB shall have the same interfaces with the SB as other EEsconnecting to regular SBs, as defined in RQ38n/a n/a Mandatory115Shield BlockPulling&Welding Tool BaseWith the manual reconfiguration of the SBTB, SBTB should be designed tobe compatible with as many Shield Blocks as possible, without making thedesign overly complexn/a n/a Expected116Shield BlockPulling&Welding Tool BaseThe SBTB shall comprise one Tool Fixing Unit (TFU) that is compatible withthe CCWT, CCCT, MCAMT, MCPT, MCWT, MCCT, ECWT, ECCTn/a n/a Mandatory117Shield BlockPulling&Welding Tool BaseThe TFU of the SBTB shall be designed so that it can take up the loadcoming from the pulling mechanism of the CCWT or MCPTNominal: 20 kNMaximum: 30 kNn/a Mandatory118Shield BlockPulling&Welding Tool BaseThe TFU shall have a position adjustment mechanism in two directionswithin the plane perpendicular to the axis of the Coaxial Connector, allowingthe TFU's tool mounting point to be aligned with the axis of the Shield Blockholecoaxiality: 0.1 mm maximum Mandatory119Shield BlockPulling&Welding Tool BaseTBC: In case the Z vertical drive is not integrated into the Tools, the ToolFixing Unit of the SBTB shall be capable of lowering and raising the Toolsafter the alignment has been set. This is to allow the distance measurementsensor to reach and scan the joint and then to switch from measurement towelding torch and align the torch with the jointvertical motionrange:±30 mmminimum Mandatory120Shield BlockPulling&Welding Tool BaseThe SBTB TFU fixing features shall be designed so that they providecentralization for the Tools. This is needed when one Tool is replaced withanother, but the target pipe joint remains the same (e.g. MCAMT replacedwith MCWT). The coaxiality of two Tools fixed to the TFU in successionshall stay within limitsrepeatablecoaxiality: 0.1 mmn/a Mandatory121Shield BlockPulling&Welding Tool BaseThe SBTB design shall comprise a shim, placed between the SBTB plateand the SBTB TFU to align the TFU with the target pipe joint. Shimdimensions shall correspond to the CB-CC and CB-MC nominal angles. Before the SBTB is transferred into the vessel, it shall be reconfigured withthe shim corresponding to the target SB13 shim anglevariationsn/a Mandatory122Shield BlockPulling&Welding Tool BaseThe SBTB plate shall have multiple mounting poistions for the shims (andTFUs on top of them). The positions shall correspond to CC and MCpositions on the SBs and shall enable the TFU to be used for fine positionalignment onlyat least 5positions:1 for CC2 for MCs of SB82 for MCs of SB18n/a Mandatory123Shield BlockPulling&Welding Tool BaseThe SBTB shall be capable of providing services to the tools (current, shieldgas, pressurized air (if needed)). For this, it shall have hand operatedconnectors, that are compatible with the Tools. Welding current and shieldgas may be supplied directly to the tool without routing through the TBn/a n/a Mandatory124Shield BlockPulling&Welding Tool BaseOn the SBTB, a small-size vacuum cleaner with dust container shall beintegrated to be able to remove and store temporarily the swarf generatedby cutting. The vacuum suction hose shall be able to connect to theappropriate Tool socketn/a n/a Mandatory125 Coax. Conn. Welding ToolThe Coaxial Connector Welding Tool (CCWT) is a Tool. Thus, all genericTool requirements shall be applied to itn/a n/a Mandatory126 Coax. Conn. Welding ToolThe CCWT shall include a pipe alignment measurement system in order tomeasure the coaxiality of the welding head with respect to the SB hole withtarget accuracy. Alignment shall be performed by the SBTB TFU butcontrolled by the alignment measurement system of the CCWTcoaxiality: 0.1 mm maximum Mandatory127 Coax. Conn. Welding ToolThe CCWT shall have connecting features to the SBTB TFU, to which itmust be locked rigidly after installation and before operationn/a n/a Mandatory128 Coax. Conn. Welding ToolThe CCWT shall include a pipe pulling mechanism, with the purpose ofremoving the gap (and step) between the CC and the SB lipgap&step: 0 mm 0/+0.2 mm Expected129 Coax. Conn. Welding ToolThe pulling mechanism of the CCWT shall pull the CC by their dedicatedinternal slots, below the water inletNominal: 20 kNMaximum: 30 kNn/a Mandatory130 Coax. Conn. Welding ToolThe pulling mechanism of the CCWT shall apply pulling force during thewhole welding process to keep the gap and step between the CC and SB atan acceptable levelgap&step: 0 mm 0/+0.2 mm Expected131 Coax. Conn. Welding ToolThe CCWT shall be able to cope with any angular CC slot (the feature at thebottom of the CC, which is used by the pulling head of the CCWT to applythe pulling force) alignment, because there is no guarantee that the slot willbe vertical or horizontal, it will be aligned randomlyn/a n/a Mandatory132 Coax. Conn. Welding ToolThe CCWT shall include an optical measurement system to measure thegap and step between the CC and the SB lipresolution: 10 µm maximum Mandatory133 Coax. Conn. Welding ToolThe welding head and distance measurement sensor of the CCWT shall becapable of rotation motion with respect to the stationary pulling mechanism400 degrees inboth directionsminimum Mandatory134 Coax. Conn. Welding ToolThe cabling of the welding head and distance sensor shall allow the relativemotion between the welding head and the stationary core. Cablemanagement shall be taken care of within the encased volume of the CCWTn/a n/a Mandatory135 Coax. Conn. Welding ToolThe CCWT shall get its services from the SBTB. Welding current and shieldgas may be supplied directly to the tool without routing through the TBn/a n/a Mandatory136 Coax. Conn. Welding ToolThe CCWT head shall fit through the diam. 70 mm opening of the SB. Thus,the diameter of the tool shall be limitedø 69 mm maximum Mandatory137 Coax. Conn. Welding ToolThe CCWT welding torch shall be movable in the radial direction withrespect to the Tool body to approach the CC pipestroke: 17.5 mm minimum Mandatory138 Coax. Conn. Welding ToolThe CCWT shall be capable of producing an autogenous full-penetrationweld between the CC pipe and the SB lip using TIG weldingID: ø 101 mmthickness: 2.5 mmn/a Mandatory139 Coax. Conn. Welding ToolThe CCWT welding head shall be designed so that welding can be perfomedin 3 depths. The 3 depths are: nominal joint position (as shown in assemblydrawing), two subsequent positions after rewelding, with 7 mm offset foreach towards the CC bottom side3 positions with 7mm offset inbetweenn/a Mandatory140 Coax. Conn. Cutting ToolThe Coaxial Connector Cutting Tool (CCCT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory141 Coax. Conn. Cutting ToolThe CCCT shall use swage cutter(s) to cut the CC outer pipe, in order togenerate a cut profile that is compatible with reweldingn/a n/a Mandatory142 Coax. Conn. Cutting ToolThe CCCT shall have connecting features to the SBTB TFU, to which it mustbe locked rigidly after installation and before operationn/a n/a Mandatory143 Coax. Conn. Cutting ToolThe CCCT shall fit through the diam. 70 mm opening of the SB. Thus, thediameter of the tool shall be limitedø 65 mm maximum Mandatory144 Coax. Conn. Cutting ToolThe CCCT shall be able to extend its swages in the radial direction to reachthe CC piperadial stroke:21 mmminimum Mandatory145 Coax. Conn. Cutting ToolThe CCCT shall be capable of doing cuts after welding and reweldingoperations in 3 positions along the CC axis. The 3 positions are: nominaljoint position (as shown in assembly drawing), two subsequent positionsafter rewelding, with 7 mm offset for each towards the CC bottom siden/a n/a Mandatory146 Coax. Conn. Cutting Tool The cutter feed rate shall be controlled during the whole cutting procedurefeed rate TBD bytestingn/a Mandatory147 Coax. Conn. Cutting ToolThe CCCT shall be able to cut through the CC outer cylinder from inside thepipeID 101 mm /thickness: 2.5 mmn/a Mandatory148 Coax. Conn. Cutting ToolThe position of the cutter blade(s) and motor input current shall bemonitoredn/a n/a Mandatory149 Coax. Conn. Cutting ToolThe CCCT shall have a Pipe Facing Tool as accessory, to be used after theSB is removed, to provide a surface that is appropriate for reweldingoperationsn/a n/a Mandatory150 Monoax. Conn. Pulling ToolThe Monoax. Conn. Pulling Tool (MCPT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory151 Monoax. Conn. Pulling ToolThe MCPT shall have connecting features to the SBTB and 15 NDTB TFU,to which it must be locked rigidly after installation and before operationn/a n/a Mandatory152 Monoax. Conn. Pulling ToolThe MCPT shall include a pipe pulling mechanism, with the purpose ofremoving the gap (and step) betweenMC and the SB lipgap&step: 0 mm 0/+0.2 mm Expected153 Monoax. Conn. Pulling ToolThe pulling mechanism of the MCPT shall pull the MC by their dedicatedinternal slots, below the water inlet/outletNominal: 20 kNMaximum: 30 kNn/a Mandatory154 Monoax. Conn. Pulling ToolThe MCPT shall be able to cope with any angular MC slot alignment,because there is no guarantee that the slot will be vertical or horizontal, itwill be aligned randomlyn/a n/a Mandatory155 Monoax. Conn. Pulling ToolThe MCPT shall consist of a locking feature at the tip to engage with theinternal slot of the MC and a shell structure that connects the lockingmechanism with the tool head connecting to the TFU of the SBTB (or15NDTB)n/a n/a Mandatory156 Monoax. Conn. Pulling ToolThe shell structure of the MCPT shall be free to rotate with respect to thelocking mechanism, when the pulling force is appliedn/a n/a Mandatory157 Monoax. Conn. Pulling ToolThe MCPT shell shall be hollow to accommodate the MCAMT and MCWTtools. The MCPT shell shall rotate with the MCAMT and MCWT tools, butthe interface between the MCPT and the tools shall allow the tool's relativeaxial movement (e.g. a spline shaft connection is recommended)n/a n/a Mandatory158 Monoax. Conn. Pulling ToolThe MCPT shell shall have appropriately positioned and sized openings toallow the MCAMT to scan the SB hole and the MC-SB joint and also toallow the MCWT welding torch to approach the joint without the possibilityof a short-circuit between the torch and the MCPT cylindern/a n/a Mandatory159 Monoax. Conn. Pulling ToolThe MCPT opening shall be sized so that welding can be perfomed in 3depths. The 3 depths are: nominal joint position (as shown in assemblydrawing), two subsequent positions after rewelding, with 7 mm offset foreach towards the MC bottom side3 positions with 7mm offset inbetweenn/a Mandatory160 Monoax. Conn. Pulling Tool The MCPT shell outer diameter shall be smaller than the SB hole diameter. diam. 41 mm maximum Mandatory161 Monoax. Conn. Pulling ToolA mechanism shall connect the MCPT cylinder to the TFU, which shall beable to apply a puling force on the cylindern/a n/a Mandatory162 Monoax. Conn. Pulling ToolEither the MCPT or the MCAMT and MCWT shall include a rotationmechanism with respect to the TFU. MCPT shall rotate together with theMCAMT and MCWT400 degrees inboth directionsminimum Mandatory163Monoax. Conn. AlignmentMeasurement ToolThe Monoax. Conn. Alignment Measurement Tool (MCAMT) is a Tool. Thus,all generic Tool requirements shall be applied to itn/a n/a Mandatory164Monoax. Conn. AlignmentMeasurement ToolThe MCAMT shall have connecting features to the MCPT, to which it mustbe locked rigidly after installation and before operationn/a n/a Mandatory165Monoax. Conn. AlignmentMeasurement ToolThe MCAMT shall fit within the cylinder of the MCPT. n/a n/a Mandatory166Monoax. Conn. AlignmentMeasurement ToolThe MCAMT shall have an embedded axial drive meachansim, which allowsaxial movement of the MCAMT head with respect to the MCPTn/a n/a Mandatory167Monoax. Conn. AlignmentMeasurement ToolThe MCAMT shall include an optical measurement system to measure thegap and step between the Monoaxial Connector and the SB lipresolution: 10 µm maximum Mandatory168Monoax. Conn. AlignmentMeasurement ToolEither the MCPT or the MCAMT shall include a rotation mechanism withrespect to the TFU400 degrees inboth directionsminimum Mandatory169Monoax. Conn. AlignmentMeasurement ToolThe cabling of the distance sensor shall allow the relative motion betweenthe TFU and the MCAMT. Cable management shall be taken care of withinthe encased volume of the MCAMTn/a n/a Mandatory170 Monoax. Conn. Welding ToolThe Monoax. Conn. Welding Tool (MCWT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory171 Monoax. Conn. Welding ToolThe MCWT shall be capable of producing an autogenous full-penetrationweld between the MC pipe and the SB lip using TIG weldingID: ø 43.72 mmthickness: 2.5 mmn/a Mandatory172 Monoax. Conn. Welding ToolEither the MCPT or the MCWT shall include a rotation mechanism withrespect to the TFU400 degrees inboth directionsminimum Mandatory173 Monoax. Conn. Welding ToolThe cabling of the welding head shall allow the relative motion between thewelding head and the TFU. Cable management shall be taken care of withinthe encased volume of the MCWTn/a n/a Mandatory174 Monoax. Conn. Welding ToolThe MCWT shall get its services from the SBTB. Welding current and shieldgas may be supplied directly to the tool without routing through the TBn/a n/a Mandatory175 Monoax. Conn. Welding ToolThe MCWT shall have connecting features with the MCPT, to which it mustbe locked rigidly after installation and before operationn/a n/a Mandatory176 Monoax. Conn. Welding Tool The MCWT shall fit within the cylinder of the MCPT. n/a n/a Mandatory177 Monoax. Conn. Welding ToolThe MCWT shall include the AVC system which shall be used to approachthe pipe with the welding torch, when the tool is in positionn/a n/a Mandatory178 Monoax. Conn. Welding ToolThe MCWT shall have an embedded axial drive meachansim, which allowsaxial movement of the MCWT head with respect to the MCPTn/a n/a Mandatory179 Monoax. Conn. Welding ToolThe MCWT axial drive shall allow welding to be performed in 3 depths. The3 depths are: nominal joint position (as shown in assembly drawing), twosubsequent positions after rewelding, with 7 mm offset for each towards theMC bottom side3 positions with 7mm offset inbetweenn/a Mandatory180 Monoax. Conn. Welding ToolThe MCWT welding torch shall be extendable radially to be able to passthrough the window of the MCPT to approach the welding areastroke ~10 mm n/a Mandatory181 Monoax. Conn. Cutting ToolThe Monoaxial Connector Cutting Tool (MCCT) is a Tool. Thus, all genericTool requirements shall be applied to itn/a n/a Mandatory182 Monoax. Conn. Cutting Tool The MCCT shall use swage blade(s) to cut the MC pipe. n/a n/a Expected183 Monoax. Conn. Cutting ToolThe MCCT shall only be used after coaxiality of the TFU with respect to theSB hole has been set on the TFU, using the MCAMTcoaxiality: 0.1 mm maximum Mandatory184 Monoax. Conn. Cutting ToolThe MCCT shall have connecting features to the MCPT, to which the MCCTmust be locked rigidly after installation and before operationn/a n/a Mandatory185 Monoax. Conn. Cutting Tool The MCCT shall fit within the cylinder of the MCPT. n/a n/a Mandatory186 Monoax. Conn. Cutting ToolThe MCCT cutter feed rate shall be controlled during the whole cuttingprocedurefeed rate TBD bytestingn/a Mandatory187 Monoax. Conn. Cutting Tool The MCCT shall be able to cut through the MC cylinder from inside the pipeID: ø 43.72 mmthickness: 2.5 mmn/a Mandatory188 Monoax. Conn. Cutting ToolThe position of the cutter blade(s) and motor input current shall bemonitoredn/a n/a Mandatory189 Monoax. Conn. Cutting ToolThe distance between the MCCT cutting blade(s) and the tip of the toolshall be limited54 mm maximum Mandatory190 Monoax. Conn. Cutting ToolThe MCCT head shall be designed so that cutting can be performed in 3depths. The 3 depths are: nominal joint position (as shown in assemblydrawing), two subsequent positions after rewelding, with 7 mm offset foreach towards the MC bottom side3 positions with 7mm offset inbetweenn/a Mandatory191 Monoax. Conn. Cutting ToolThe MCCT shall have a Pipe Facing Tool as accessory, to be used after theSB is removed, to provide a surface that is appropriate for reweldingoperations. This Pipe Facing Tool can be the same as the one used for CC,only adapted to the smaller diametern/a n/a Mandatory192 End Cap Handling ToolThe End Cap Handling Tool (ECHT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory193 End Cap Handling ToolThe ECHT shall be a simple rod with the 17 mm hexagon socket and thePassive Holding System on one end and a handling feature on the other end. The reason for this is that the TSR might be left in place for multiple workshifts or days during which other assembly operations will continue,possibly above the TSRn/a n/a Expected274 Nacelle Tool StorageThe Nacelle Tool Storage (NTS) shall be fixed to the Nacelle basket frameThe NTS is neither an EE nor a Tool, so generic requirements do not applyn/a n/a Mandatory275 Nacelle Tool Storage The NTS shall be made from either stainless steel or aluminium. n/a n/a Mandatory276 Nacelle Tool Storage The NTS weight, including all fittings and fixtures, shall be below limit. 15 kg maximum Mandatory277 Nacelle Tool Storage The NTS shall be able to store Tools (all types). 2 Tools stored n/a Mandatory278 Nacelle Tool StorageThe Tools in the NTS shall be accessible from above, to be grabbed by thezero G arm and pulled out of the NTS verticallyn/a n/a Mandatory279 Nacelle Tool Storage Tools shall be locked when mounted on the NTS. The lock shall be manual. n/a n/a Mandatory280Blanket Tooling SupportingEquipmentThe Blanket Tooling Supporting Equipment (BTSE) shall provide services toEnd Effectors and Tools inside the VV:- Power to the Embedded Controller of the EE- Power to the TIG welding torch- Communications (feedback and control)- Compressed air- Shielding gasThe BTSE is neither an EE nor a Tool, so generic requirements do not applyn/a n/a Mandatory281Blanket Tooling SupportingEquipmentThe TSS frame in the Port Cell shall comprise the following equipment:- TIG welding power generator- Shielding gas cylinders and gas mixer- Air compressorn/a n/a Mandatory282Blanket Tooling SupportingEquipmentThe umbilical (or bundle) shall be led from the TSS to the UmbilicalHandling System (UHS) located inside the Equatorial Port, where the UHSshall be locked to the Port side walls via a manually operated or automatickey mechanismn/a n/a Mandatory283Blanket Tooling SupportingEquipmentThe UHS shall comprise a coil with 30 m of umbilical on it. The coil shall bemanually operated and shall not have slip rings but a fixed connector whichrotates with the coil. When the needed amount of umbilical is uncoiled andthe coil is fixed with brakes, it shall be possible to connect the welding skidumbilical to the connector of the coil in any random angular position it is inn/a n/a Mandatory284Blanket Tooling SupportingEquipmentInside the VV, the umbilical shall be clamped at multiple positions to avoidhanging in the torus. The clamp shall be able to connect to the VV, a SB or aTFW. Using the ESB threads seems straightforward, because they are thesame M24 thread in all 3 casesn/a n/a Mandatory285Blanket Tooling SupportingEquipmentThe end of the umbilical shall connect to one of the Tool Changerconnectors, to which it shall be fixed firmly. The connector and fixingmechanism of the umbilical shall be manualn/a n/a Mandatory286287288289290291292293294295296297 Flow Sep. Welding ToolThe Flow Separator Welding Tool (FSWT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory Not in the scope of Initial Assembly298 Flow Sep. Welding ToolThe FSWT shall include a pipe alignment mechanism in order to setperpendicularity and coaxiality of the welding head with respect to the FSholecoaxiality: 0.1 mm maximum Mandatory Not in the scope of Initial Assembly299 Flow Sep. Welding ToolThe FSWT shall have connecting features to the SBTB TFU, to which itmust be locked rigidly after installation and before operationn/a n/a Mandatory Not in the scope of Initial Assembly300 Flow Sep. Welding ToolThe FSWT shall include an optical distance measurement sensor to scanthe joint before weldinggap&step: 0 mmresolution: 10 µm0/+0.2 mm Mandatory Not in the scope of Initial Assembly301 Flow Sep. Welding ToolThe welding head and distance measurement sensor of the FSWT shall becapable of rotation motion with respect to the stationary pipe alignmentmechanism400 degrees inboth directionsminimum Mandatory Not in the scope of Initial Assembly302 Flow Sep. Welding ToolThe cabling of the welding head and distance sensor shall allow the relativemotion between the welding head and the stationary core. Cablemanagement shall be taken care of within the covered volume of the FSWTn/a n/a Mandatory Not in the scope of Initial Assembly303 Flow Sep. Welding Tool The FSWT shall get its services from the SBTB. n/a n/a Mandatory Not in the scope of Initial Assembly304 Flow Sep. Welding ToolThe FSWT shall fit though the diam. 104 mm opening of the SB. Thus, thediameter of the tool shall be limitedø 95 mm maximum Mandatory Not in the scope of Initial Assembly305 Flow Sep. Welding ToolThe FSWT shall be capable of producing an autogenous full-penetrationsquare butt weld between the FS pipe and the SB using TIG weldingø 70 mmthickness: 2.5 mmn/a Mandatory Not in the scope of Initial Assembly306 Flow Sep. Welding ToolThe FSWT shall be reconfigurable (not in-vessel) to produce the samewelds at different diameters, for when the joint is cut and needs to berewelded with an oversized FSDiameters:ø 70 mmø 73 mmø 76 mmn/a Mandatory Not in the scope of Initial Assembly307 Flow Sep. Cutting ToolThe Flow Separator Cutting Tool (FSCT) is a Tool. Thus, all generic Toolrequirements shall be applied to itn/a n/a Mandatory Not in the scope of Initial Assembly308 Flow Sep. Cutting ToolThe FSCT shall include a pipe alignment mechanism in order to setperpendicularity and coaxiality of the cutter with respect to the SB holen/a n/a Mandatory Not in the scope of Initial Assembly309 Flow Sep. Cutting ToolThe FSCT shall have connecting features to the SBTB TFU, to which it mustbe locked rigidly after installation and before operationn/a n/a Mandatory Not in the scope of Initial Assembly310 Flow Sep. Cutting ToolThe FSCT shall be able to cut the welded joint between the FS and the SBusing a hole sawø 70 mmthickness: 2.5 mmn/a Mandatory Not in the scope of Initial Assembly311 Flow Sep. Cutting ToolThe hole saw of the FSCT shall be capable of spinning motion with respectto the stationary pipe alignment mechanismn/a n/a Mandatory Not in the scope of Initial Assembly312 Flow Sep. Cutting ToolThe FSCT shall be able to move the hole saw linearly along the tool, while itis spinning, with respect to the stationary pipe alignment mechanism core ofthe toolstroke: 10 mm minimum Mandatory Not in the scope of Initial Assembly313 Flow Sep. Cutting Tool The FSCT shall get its services from the SBTB. n/a n/a Mandatory Not in the scope of Initial Assembly314 Flow Sep. Cutting ToolThe FSCT shall fit though the diam. 104 mm opening of the SB. Thus, thediameter of the tool shall be limitedø 95 mm maximum Mandatory Not in the scope of Initial Assembly315 Flow Sep. Cutting ToolThe FSCT shall be reconfigurable (not in-vessel) to replace the hole saw forcutting different FS diameters, to be able to cut oversized FS as wellDiameters:ø 70 mmø 73 mmø 76 mmn/a Mandatory Not in the scope of Initial Assembly316 Flow Sep. Cutting ToolThe FSCT design shall comprise a suction device to remove the chipsgenerated during the cutting operationn/a n/a Mandatory Not in the scope of Initial Assembly317 First Wall Tool BaseThe First Wall Tool Base (FWTB) is an EE. Thus, all generic EErequirements shall be applied to itn/a n/a Mandatory Not in the scope of Initial Assembly318 First Wall Tool BaseThe FWTB shall connect to the FW by making use of the gripping fingerholes. For this, standardized gripping fingers shall be usedn/a n/a Mandatory Not in the scope of Initial Assembly319 First Wall Tool BaseThe locking function of the gripping finger units of the FWTB shall beautomatizedn/a n/a Mandatory Not in the scope of Initial Assembly320 First Wall Tool BaseThe gripping finger unit of the FWTB shall have a built in force sensor, to beused during insertion into the FW gripping holen/a n/a Mandatory Not in the scope of Initial Assembly321 First Wall Tool BaseFWTB shall use pressing pads to press onto the FW units after the grippingfingers have been lockedforce TDB n/a Mandatory Not in the scope of Initial Assembly322 First Wall Tool BaseThe pressing pads of the FWTB shall be retractable and extendable byautomatic meansn/a n/a Mandatory Not in the scope of Initial Assembly323 First Wall Tool BaseThe FWTB shall be reconfigurable to be compatible with the FW ESBT, theCBTn/a n/a Mandatory Not in the scope of Initial Assembly324 First Wall Tool Base The FWTB shall have rigid interfaces for TFUs, in the case of PCT and PWT. n/a n/a Mandatory Not in the scope of Initial Assembly325 First Wall Tool BaseThe FWTB TFUs shall provide a drive shaft for raising/lowering, rotation andmaking fine adjustments to the tooln/a n/a Mandatory Not in the scope of Initial Assembly326 First Wall Tool BaseThere shall be an automatic fixing interface between the TFUs and theFWTB on the TFU siden/a n/a Mandatory Not in the scope of Initial Assembly327 First Wall Tool BaseAfter being fixed to the FWTB, the TFU shall receive services from theFWBT, though a connector between the two, which shall be connectedmanually by the operatorn/a n/a Mandatory Not in the scope of Initial Assembly328 First Wall Tool BaseOne FWTB design shall be compatible with as much FW designs aspossible. For this, the gripping finger units shall be moveable vertically. Thissetting shall be a hands-on operation to simplify and save space for otherfunctionsn/a n/a Expected Not in the scope of Initial Assembly329 First Wall Tool BaseThe TFU planar position with respect to the FWTB shall be adjustable on anautomatized cross-roller tablen/a n/a Expected Not in the scope of Initial Assembly330 First Wall Tool BaseThe FWBT frame shall be capable of transmitting the reaction torque fromthe CBT to the FW8.4 kNm ±10% Mandatory Not in the scope of Initial Assembly331332333334335336337338339340341342343344345346347348349350351352353354355356357358359360361362363364365366367368369370371372373374375376377378379380381382383384385386387388389390391392393394395396397398399400401402403404405406407408409410411412413414415416417418419420421422423424425426427428429430431432433434435436437438439440441442443444445446447448449450451452453454455456457458459460461462463464465466467468469470471472473474475476477478479480481482483484485486487488489490491492493494495496497498499500501502503504505506507508509510511512513514515516517518519520521522523524525526527528529530531532533534535536537538539540541542543544545546547548549550551552553554555556557558559560561562563564565566567568Scope Importance might not be needed for First Assembly (TBC)All EEs & Tools Mandatory not in the current scope of First AssemblyAll EEs ExpectedAll ToolsShield Block GripperFCB Torquing Tool BaseES Bolt Torquing ToolViewing ToolShield Block Pulling&Welding Tool BaseCoax. Conn. Welding ToolCoax. Conn. Cutting ToolMonoax. Conn. Pulling ToolMonoax. Conn. Alignment Measurement ToolMonoax. Conn. Welding ToolMonoax. Conn. Cutting ToolEnd Cap Handling ToolEnd Cap Welding ToolEnd Cap Cutting Tool15ND Gripper15ND Tool BaseFirst Wall GripperFW Cent. Bolt Torq. End EffectorTool Storage RackNacelle Tool StorageBlanket Tooling Supporting EquipmentFirst Wall Tool BaseFlow Sep. Cutting ToolFlow Sep. Welding ToolEnd Effectors ToolsSBGFBTESBTCCWTCCCTMCPTMCAMTMCWTMCCTECHTECWTECCT15NDGMCPTMCAMTMCWTMCCTECHTECWTECCTFWGFWCBTFirst Assembly EEs and Tools in theorder of usageSBTB15NDTBAbbreviations Description15NDG 15ND Gripper15NDTB 15ND Tool BaseAD Applicable DocumentsALARA As Low As Reasonably AchievableAVC Arc Voltage Control (for TIG welding tool)BAT Blanket Assembly TransporterBM Blanket Module (FW + SB)BMTS Blanket Module Transfer SystemBRHS Blanket Remote Handling SystemBT Bolting ToolCB Central BoltCBT Central bolt Bolting ToolCC Coaxial ConnectorCCW CounterclockwiseCCCT Coaxial Connector Cutting ToolCCPT Coaxial Connector Pulling ToolCCT / ECCT Cap Cutting Tool / End -CCWT Coaxial Connector Welding ToolCHT / ECHT Cap Handling Tool / End -CMAF CAD Model Approval FormCMM Configuration Management ModelCOG Centre Of GravityCW ClockwiseCWT /ECWT Cap Welding Tool / End -DDP Design Development PlanDM Detailed ModelDMNP Dexterous ManipulatorDOF Degrees of FreedomEC End CapECHT End Cap Holding ToolECWT End Cap Welding ToolECCT End Cap Cutting ToolEDH Electrical Design HandbookEDR Equipment and Documentation ReviewEE End EffectorES Electrical StrapESB Electrical Strap BoltESBT Electrical Stap Bolt Torquing toolFAT Factory Acceptance TestFBT FCB Torquing Tool BaseFCB Flexible Cartridge BoltFDR Final Design ReviewFS Flow SeparatorFSCT Flow Separator Cutting ToolFSHT Flow Separator Handling ToolFSWT Flow Separator Welding ToolFW First WallFWCBT FW Central Bolt Torquing End EffectorFWESBT FW ES bolt Bolting ToolFWG FW GripperFWTB First Wall Tool BaseHLT Helium Leak testing ToolICD Interface Control DocumentICSR In-Cask Storage RackIMK Inter Modular KeypadsIO ITER OrganizationIPT In Port TransporterIS Interface SheetIVT In-Vessel TransporterJADA Japan Domestic AgencyMC Monoaxial ConnectorMCAMT Monoaxial Connector Alignment Measurement ToolMCCT Monoaxial Connector Cutting ToolMCPT Monoaxial Connector Pulling ToolMCWT Monoaxial Connector Welding ToolMTPP Module Tool Pallet PlateNBDL Neutral Beam Duct LinerNBI Neutral Beam InjectionNDE Non-Destructive ExaminationOD Outer DiameterPAT Pipe alignment ToolPBS Plant Breakdown StructurePCR Project Change RequestPCT Pipe Cutting ToolPFPO-I Pre Fusion Plasma Operation IPHS Passive Holding SystemPR Project RequirementsPWT Pipe Welding ToolQAP Quality Assurance ProgramRD Reference DocumentsRFA Rail Fixing ArmRH Remote HandlingSAT Site Acceptance TestSB Shield BlockSBESBT SB ES bolt Bolting ToolSBG SB GripperSBTB Shield Block Tool BaseSDP System Design ProcessSL Seismic LoadSR Safety Relevant for nuclear safetySRD System Requirements DocumentTB Tool BaseTBD To Be DecidedTFU Tool Fixing UnitTMNP Tool ManipulatorTR Tool RackVC Vacuum CleanerVFA Vehicle Fixing ArmVM / VMNP Vehicle ManipulatorVT Viewing ToolVV Vacuum VesselWPQR Welding Procedure Qualification RecordWPS Welding Procedure Specification