MOCK-UPS IN SUPPORT OF LONGTERM REMOTE OPERATIONS IN
CHALLENGING ENVIRONMENTS
Dr Rob Buckingham FREng
Director UKAEA, Head of RACE
MOCK-UPS IN SUPPORT OF LONG TERM REMOTE

Fukushima
6 ENVIRONMENTS
August 2018
IN CHALLENGING| OPERATIONS Forum,
Fukushima Forum – August 2018

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The next few minutes…
PU RPOSE
To think a bou thow m ock -u ps ca nbe u s ed to de-ris k
rem ote opera tions forlong term fu eldebris retrieva l
TOPICS• RACE’s u s e ofm ock -u ps a tU K AEAins u pportofrem ote
opera tions a tJ ET• The m ethodolog y a nd principles tha tu nderpinu s e of
RACE m ock -u ps• Obs erva tions tha tm a y be releva ntto 1F D-D

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UKAEA’s mission“To lea d the com m ercia ldevelopm entoffu s ion
pow era nd rela ted technolog y a nd pos itionthe
U K a s a lea derins u s ta ina ble nu clea renerg y”
U K AEAhos ts J ET,the J ointEu ropea nToru s

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RACE at Culham,
Oxfordshire, UK

RACE is the U K AEA’s centre for“Rem ote Applica tions ( =Robotics ) inCha lleng ing Environm ents ”
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JET Remote Handling
SystemUKAEA has been at
the forefront of
remote handlingsystems technology
for the past two
decades, using andupgrading state-ofthe-art remotely
operated and robotic
systems, validated
using long term
mock-ups.
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MOCK-UPS IN SUPPORT OF LONG TERM REMOTE| OPERATIONS IN CHALLENGING ENVIRONMENTS
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MOCK-UPS IN SUPPORT OF LONG TERM REMOTE

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Octant 5 Boom andMASCOT

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Octant 1 BoomMOCK-UPS IN SUPPORT OF LONG TERM REMOTE

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Tools

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Control room
• 5 Opera tors
• 1 M a s cotdriver• 1 Ca m era a nd M a s cot
s u pport• 2 Boom drivers• 1 Res pons ible officer• M a s term a nipu la tor• ControlHM Is• Ca m era s u ite• VR s ys tem• Opera tions
M a na g em entSys tem

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Warning!
J ET is not1F
J ET is hig hly m a na g ed
J ET is clea n
J ET is low ra dia tion
J ET is s m a ller
J ET Rem ote Ha ndling Sys tem is s tillu niqu e
Itha s beenu s ed,m a inta ined a nd u pg ra ded for20 yea rs

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Mock-ups are important
Why?
Building trust
In-Vessel Training Facility (IVTF) that has beenused for two decades in support of remote
operations at JET.
Telescopic Articulated Remote Manipulator(TARM) is a unique hyper-redundant, slender, highpayload robotic system that is a physical mock-up forthe testing of software and control systems.
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Telescopic Articulated
Remote Manipulator• Developm entofa ctive
pos itioncontrols ys tem tom a nipu la te la rg e loa ds
w ith low rela tive s tiffnes sto ~ 10 m m precis ion• Tw o tes tend effectors• pa s s ive low frequ ency
res pons e to m otion• a ctive controlla ble
os cilla tory m otion• Tria ls ofm u ltiple,
redu nda nts ens ing• Long erterm u s e a s ag eneric tes tpla tform
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MOCK-UPS IN SUPPORT OF LONG TERM REMOTE| OPERATIONS IN CHALLENGING ENVIRONMENTS
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In-Vessel Training Facility
The IVTF ha s beena n
es s entia lcom ponentofthe J ET
rem ote ha ndling s ys tem forthe
la s t20 yea rs .
Increm enta lly developed a ndcons ta ntly a da pted
Acritica la nd inva lu a ble fa cility
indeveloping the rem ote
ha ndling s ys tem a ndproces s es :• Sa fe• Proven• Efficient( cos teffective)• Tim ely
• Field-oriented

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In-Vessel Training Facility
Equ ipm entdevelopm ent• RHS tooling developm enta nd va lida tion
• Com ponentfea s ibility s tu dies ,developm ent
verifica tiona nd va lida tion
Ta s k developm ent• Com ponentm a nipu la tiona nd ha ndling tria ls .
• Ta s k g enera tion,verifica tiona nd va lida tion
• Fa ilu re a nd recovery s cena rio verifica tion
• Boom tea ch file verifica tion.
Tra ining• Opera tors electioninterview s• Opera tortra ining• Opera tors k illretention• Opera tora s s es s m ent
Opera tions• Anom a ly u nders ta nding a nd inves tig a tion
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Validation and Verification
Requirements
guidelines andstandards

Designguidelines andstandards

Buildguidelines andstandards

Product Verification‘Did we design/build it right?’

Stakeholder
Requirements

Requirements
Specification

DesignSpecification

Built ProductRequirement Validation‘Are we building the right thing?’

Design Validation‘Do we have the right design?’
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Product Validation‘Did we build the right thing?’

Stakeholder Engagement
Invested observers. Anyone who is interested in the activity itself but who isunlikely to know the details of particular operational plans, hardware or specificoperational procedures. An invested observer is most likely to be interested in theoutcome of an activity.
Regulators. This group has been separated from invested observers andapprovers to indicate their separate regulatory function.
Approvers. We assume that there is an independent group of approvers whoshould know the details of particular hardware or specific operational procedures
so that they can make an informed independent assessment of operational plans.
Operation's management. This is the group of suitable qualified and experience
people (SQEP) who should be expected to know the details of particular hardware
and specific operational procedures with oversight of operations.
Operators. This is the group of SQEP who should be expected to know the detailsof particular hardware and specific operational procedures and be able to operate
the hardware.
Developers. This includes the original equipment design team and developers
involved in modification, upgrade and ancillary system developments.
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The Purpose of Mock-Ups
Stakeholder engagement• Approva lofcom plexhig hris k projects s u ch a s fu eldebris retrieva la t1-F
requ ire a u thoris a tiona t
hig h levels from fina ncia l,politica la nd reg u la torys ta k eholders .
• Phys ica ldem ons tra tion
com m u nica tes thecom pletenes s a nd
thorou g hnes s ofa
s olu tions u ccinctly a nd
a cces s ibly ina w a y tha t
com plexpa pers tu dies
w illfind difficu ltto m a tch.
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Mock-Up Types
Functional mock-ups seek to test thefunctionality of the system or sub-systems• U s u a lly s horterterm• Replica tes only im m edia te interfa ces• U s u a lly u s ed inea rlierprojectpha s es
• U s ed by developm enttea m forfocu s ed
technolog y a nd des ig ndevelopm ent
Environmental - operational mock-ups
seek to replicate the environment in which asystem will work•U s u a lly long erterm•

Replica tes w iderenvironm ent•

U s u a lly u s ed inla terprojectpha s es tos u pportopera tions•

U s ed by a w ide ra ng e ofs ta k eholders fordem ons tra tion,va lida tiona nd tra ining•

Allow s broa d inves tig a tioninclu dingu nintended cons equ ences a nd hu m a n
fa ctors
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The Purpose of Mock-Ups
Integrating operators• Bu ild confidence ina nu ncerta inenvironm ent• Identify w here
opera toru ncerta inty
occu rs a nd tes tm itig a tions• Identify a nd im proves pecific u s a bility
is s u es• Identify a nd prevent
opera tor‘w ork
a rou nds ’

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The Purpose of Mock-Ups
Unknown unknowns
The 1F PCVs w illpres enta la rg e
nu m berofu nk now ns a nd
u ncerta inties
M ock -u ps pla y a s ig nifica ntrole inredu cing thes e a s w ella su nders ta nding a nd im proving
collective rea ctions a nd res pons es• K now nU nk now ns••

Identify fa ilu re m odes
Pra ctice a nd develop
recovery a nd res cu es equ ences• U nk now nU nk now ns•••

Intentiona lly introdu ced
a nom a lies a llow tes ting ofopera torres pons e
Ca ptu re firs ttry ‘fa ilu re’U nk now nu nk now nproces s

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The Purpose of Mock-Ups
Recovery from failure• Extens ive tria lling ofa ll
identified fa ilu re s cena rios
occu rs w ithinIVTF• Tes ting oftools w hich ha ve
the inherentris k ofbecom ing
a tta ched to the environm ent
ors tra nded is vita l• Althou g h 1F’s rea ctors a rea lrea dy inopera ble,u nrecovera ble equ ipm ent
increa s es the w a s teinventory,incu rs cos t,a nd
potentia lly hinders fu rther
opera tions• ‘G etting ou tis m ore
im porta nttha ng etting in’
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Making Mock-Ups Work• Ha ve a nd m a inta inclea robjectives
•
•

•
•
•

As tru ctu red,ris k -ba s ed a pproa ch s hou ld be
u s ed to determ ine objectives .
U s e ofm ock -u ps s hou ld be res u lts led,flexible
a nd a g ile s ince interm edia te res u lts m a yrequ ire cha ng es .
Itis im porta ntto m a tch the rea lopera tionss chedu le a nd fa cility s chedu le.
Alow erres olu tionou tpu ta tthe rig httim e m a ybe bettertha na nexa cta ns w ertha tis too la te.
Letobjectives dicta te s tru ctu re,depth a ndm a teria ls• Loca tion•••

To bu ild s ha red confidence a cces s ibility ofa
pa rticu la rs ta k eholderm a y be im porta nt:
Fu nctiona ltes ts clos e to developerLong term opera tiona ltes ta nd developm ent
clos e to opera tor

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Clean andContaminated Systems• AtJ ET the a ctu a lequ ipm entca nu s ed fortra ining inthe IVTF m ock -u p du e tothe low levelofconta m ina tion
• AtFu k u s him a the equ ipm entis lik ely to becom e hig hly conta m ina ted•••

Equ ipm entw illneed to be m a inta ined,check ed a nd re-va lida ted a nd this m a y
m ea nm oving equ ipm entfrom the rea ctorto a s epa ra te fa cility
Ifopera tions equ ipm entis nota va ila ble fortra ining ,a dditiona ls ys tem s w illbe
neededSim u la tors m a y provide a na lterna tive fors om e elem ents ofthe tra ining• As a m inim u m ,there is a need forfou ra ctivities :••••As s em bly a nd tes tofclea nm a chines ,inclu ding s tores a nd w ork s hops
Tes ting ofclea nm a chines w ithinm ock -u ps
M a intena nce ofconta m ina ted m a chines ,inclu ding s tores a nd w ork s hops
Tes ting ofconta m ina ted m a chines• Ea ch ofthes e s pa ces w illneed to be m a na g ed a nd m a inta ined,idea lly by thes a m e tea m
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Summary
Long term phys ica lm ock -u ps ena ble efficient
res pons e to cha ng es inthrou g h-life opera tiona lrequ irem ents . M ock -u ps ena ble ha rdw a re to be
im proved a nd s k ills to be enha nced a nd m a inta ined.
Firs tinterventions into the 1F rea ctors w illbe ha rd toa pprove beca u s e the u nk now n-u nk now ns m ea ntha t
itw illnotbe pos s ible to m itig a te a llthe ris k s . Inthis
context,the principle pu rpos e ofea rly phys ica lm ock u ps is to bu ild s ha red s ta k eholderconfidence tha t
ena bles a collective decis ionto s ta rt.
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Thanks for listening!
Any questions?
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