Information Last Revised: February 17, 1993
TTP Reference Number: RL-401203
1. Technical Name of Technology: Light Duty Utility Arm System
2. Common Name of Technology: LDUA
3. PI and Telephone No: Betty A. Carteret; (509) 376-8680
4. Affiliation: Westinghouse Hanford Company
5. Technology Category: Robotics
6. Developers: DOE Underground Storage Tank Integrated Demonstration and Robotics Integrated Program
7. Application
7.1. Where (in-situ/ex-situ): In-situ characteriztion of underground storage tanks
7.2. Media: N/A
7.3. Targeted Contaminants: Underground storage tank waste
8. Scope of project (feasibility study, treatability, bench, pilot, field):
Pilot project slated for field deployment and testing of a first unit in Hanford single shell tanks. Includes system development, procurement, integration, qualification and field deployment.
9. Integrated Demonstration (ID) Need/Requirements:
Provide a remotely operated, mobile system to deploy end effectors for waste characterization and tank inspection. This technology will enhance existing capabilities which are limited to single axis deployment of instruments into tanks. The Light Duty Utility Arm provide a six degree of freedom robotic arm with a 9' multidirection reach for positioning end effectors in multiple tank locations.
10. Objective
10.1. Objective of technology (i.e., This technology will destroy VOCs in groundwater.):
The objective of this activity is to bring together technologies developed within multiple DOE laboratories into an integrated system which is qualified for field operation in Hanford tanks. The Light Duty Utility Arm System will provide the capability to gather data on chemical and physical characteristics in underground storage tanks required to support development of future retrieval, separations and processing technologies required to remediate tank wastes. In addition the system will provide capabilities to gather data to support resolution of ongoing operational and safety issues related to the Hanford tanks. The integration and testing of this system support development and qualification of technologies which will benefit the development of future, more complex robotic retrieval systems.
10.2. Baseline (baseline technology to which it is compared):
No Baseline Available (None)
11. Process Description:
A mobile deployment system, controls and operation station, and tank riser interface are staged at the tank to be examined. After installing the tank riser interface and containment enclosure, the Light Duty Utility Arm mast is deployed into the enclosure and end effector connection is accomplished. Once the appropriate end effector is installed the mast is lowered into the tank, the robotic manipulator is deployed out of the mast and the characterization or inspection campaign is initiated. After completion of data gathering the mast and arm are retracted out of the tank through a decontamination spray which removes surface contaminants from the mast, manipulator and end effectors. Data is transmitted to data acquistion stations, analyzed and archived. If follow-on operations using other characterization tools are planned the end effector changeout is accomplished and the deployment and examination operations are repeated as necessary.
11.1. Input:
11.2. Output:
12. Summary of Technology Advantages (relative to the baseline: faster, better, cheaper, safer):
This system would allow some waste characterization, in tank surveys and waste topography activities to be performed in-situ to gather data on chemical and physical properties of the waste. This will not replace laboratory analysis, however it will provide the capability to gather data in multiple locations within a tank much faster than current core sampling and laboratory analysis programs. The system is multi-functional supporting many areas requiring information on tank waste contents and the structural condition of the tanks. This multifunctional system will provide useful features for many organizations requiring data on specific areas of interest including tank surveillance and inspection programs examining existing and potential tank leaks, characterization programs providing data on waste properties, safety programs addressing issues such as status of tank environments and potentially volatile materials, and has the potential to support ongoing operations in addressing equipment problems withing the tanks. The system is designed to be adaptable to enable application of new sensing devices which may be developed in the future for specific missions. The design includes a contamination control boundary between the tank interior and the outside environment, which is not provided by the baseline technologies. This will provide a safer operating scenario and will reduce exposure to workers.
13. Limitations of Technology (relative to the baseline: faster, better, cheaper, safer):
The system will not provide sufficient capability to perform full depth profiling of waste due to limitations on the load capabilities. Current core drilling operations, although limited to providing data from a single point, have the capability to apply signficant loads to penetrate deeply through the waste to the bottom of the tank. The robotic arm system can provide multiple position samples taken within a 9' radius around the riser, but will not be able to provide full depth penetration. However, it can maneuver other equipment (up to anywhere from 50 to 100 lbs) above the waste source. These systems provide enhancing capabilities needed for waste remediation.
14. Major Technical Challenges:
The development of an arm based robotic system which can be deployed through a 12" diameter opening in a tank and reach to a depth of 48' below grade will be a technical challenge. Westinghouse Hanford Company will place a contract with a qualified vendor to design and build this system to meet required performance specifications. In addition, the rigorous Hanford operational readiness review process will impose significant requirements for review and approval of the system prior to field deployment. Stringent safety, environmental compliance, and operations requirements will be imposed on the system developers to meet the requirements for operational readiness. One of the major challenges is developing an interface between the tank and the outside environment which controls any potential releases of materials and meets all regulatory requirements (e.g. Clean Air Act). Another challenge will be the integration of multiple subsystems provided by various contributors from DOE laboratories across the country into an operating system which meets Nuclear Quality Assurance (NQA) standards.
15. Technical Effectiveness:
15.1. Performance
15.1.1. Remaining Contamination: (contamination mobility reduction, volume reduction, toxicity reduction)
Summary (20 words or less): In-situ characterization will minimize the amount of contamination removed from the tank as compared to existing characterization techniques.
Further Description (unlimited length): Additionally, mapping will aid planning for waste removal. Current waste characterization baseline technologies require removal of significant volumes of waste from the tanks. Examination of smaller samples from multiple locations within the tanks may allow development of statistical models representative of tank characterisitics. In-situ characterization can be used as a pre-screening method to identify areas where capture of samples to be removed from the tank could be most effectively applied.
15.1.2. Process Waste
15.1.2.1. Status of waste (mobility, volume, hazard, recyclability)
Summary (20 words or less): Not applicable
Further Description (unlimited length):
15.1.2.2. Treatment (needed, available)
Summary (20 words or less): Not applicable
Further Description (unlimited length):
15.1.2.3. Decontamination / Decommissioning
Summary (20 words or less): An at-tank decontamination system will be installed to remove any surface contaminants to reduce waste generated outide the tank.
Further Description (unlimited length): A pressurized spray decontamination system will be mounted just above the tank riser to remove surface contaminants as in-tank hardware is retracted from inside the tank. This system is baselined as a pelletized carbon dioxide blast which remove surface contaminants without adding additional liquids to the tank which would increase waste volume.
15.1.2.4. Disposal (needed, available)
Summary (20 words or less): Not applicable
Further Description (unlimited length):
15.1.3. Practicality
15.1.3.1. Foreclose Future Options
Summary (20 words or less): None.
Further Description (unlimited length):
15.1.3.2. Reliability
Summary (20 words or less): Detailed reliability analyses will be performed as part of the design verification process.
Further Description (unlimited length): Kinematic redundance analysis will be performed on the system using an analytical technique developed under the Cross Cutting and Advanced Technologies (CCAT) Univerity Programs. This will analyze the configuration of the vendor proposed design to determine if minor modification could result in improved performance and reliability. In addtion another University Program will provide resources to perform a failure modes reliability assessment.
15.1.3.3. Failure Control
Summary (20 words or less): The system specfication requires the vendor to provide "fail-safe" design features which would allow the arm to be retrieved in the event of failures.
Further Description (unlimited length): Failure control will be addressed in the detailed reliability analyses which will be performed on the system.
15.1.3.4. Ease of Use
Summary (20 words or less): This system will be developed with graphical user interfaces which will be capable of being operated by a specially trained tank farm operator.
Further Description (unlimited length): The man-machine interface for this system will be designed with the goal of making it's operation relatively simple for a tank farms operations technician with some special training. Graphical controls interfaces allowing supervisory control of the robotic system will ease operator fatigue.
15.1.3.5. Infrastructure
Summary (20 words or less): Not applicable
Further Description (unlimited length):
15.1.3.6. Versatility
Summary (20 words or less): The system provides a versatile instrument interface which can be adapted for future needs and the system is capable of adaptation to multiple characterization sites.
Further Description (unlimited length): The system will provide a standard Tool Interface Plate for multiple characterization and inspection end effectors. It allows the versatility to adapt future characterization tools which are designed with a compatible interface connection. The system is also versatile in that it will be capable of being used in multiple tanks, and with minimum system reconfiguration follow on systems could be developed for use at other DOE sites with underground storage tanks.
15.1.3.7. System Compatibility
Summary (20 words or less): The system is designed for use within existing tank farms operating areas. No modifications to the tanks or above ground structures should be required.
Further Description (unlimited length):
15.1.3.8. Off-the-Shelf (procurement ease)
Summary (20 words or less): The system will consist of a mix of off-the-shelf and developed hardware and software.
Further Description (unlimited length): Development of a complex robotic system will be required, however hardware for other system components can to some extent utilize available components.
15.1.3.9. Maintainability
Summary (20 words or less): The system is being designed for ease of maintenance and with reduction of worker exposure in mind.
Further Description (unlimited length): The system specification requires modularity of design to allow ease of replacement of components with limited life. In addition the system is to be designed for ease of decontamination and maintenance and repair. Detailed maintenance requirements have not yet been developed.
15.1.3.10. Safety Measures
Summary (20 words or less): Safety evaluations will be performed and protective features will be incorporated into the design to meet Hanford requirements.
Further Description (unlimited length): Safety requirements for operation in Hanford tanks are currently being identified and will be met to ensure safe operations in the tanks. Many specialized safety features will be incorporated into the design to ensure operations do not endanger workers, the public, or the environment.
15.1.4. "Works" (functions as intended):
Summary (20 words or less): Perform tank inspection and surveillance and waste characterization tasks.
Further Description (unlimited length): This system will be very effective in providing the capability to perform in-situ characterization, surveillance, and mapping of underground storage tanks. The system will provide multiple sensing capabilities which can be deployed in a larger working area in the tanks. Data gathered in these multiple locations will help to improve statistical modelling of tank characteristics. Performance of the system will be demonstrated in a cold test facility followed by operational testing in a Hanford single shell tank.
15.2. Cost
15.2.1. Start-Up Cost
Summary (20 words or less): Costs are currently being developed.
Further Description (unlimited length):
15.2.2. Operations and Maintenance Cost
Summary (20 words or less): Costs are currently being developed.
Further Description (unlimited length):
15.2.3. Life-cycle cost
Summary (20 words or less): Not available at this time.
Further Description (unlimited length):
15.3. Time
15.3.1. Years Until Available
Summary (20 words or less): The system is planned for cold testing in FY'95 and hot testing in a tank in FY'96.
Further Description (unlimited length):
15.3.2. Speed/Rate
Summary (20 words or less): Not applicable
Further Description (unlimited length):
15.3.3. Years to Finish
Summary (20 words or less): After cold and hot testing the system is slated for turnover as an operating unit in FY'96 or FY'97.
Further Description (unlimited length):
16. Environmental Safety and Health
16.1. Worker Safety
16.1.1. Exposure to Hazardous Materials/Hazards
Summary (20 words or less): Design is utilizing ALARA principles to minimize exposure of workers to hazardous environments.
Further Description (unlimited length):
16.1.2. Physical Requirements
Summary (20 words or less): Most operations will be automated and remotely controlled from an operations station outside the tank farm perimeter.
Further Description (unlimited length):
16.1.3. Number of People Required
Summary (20 words or less): A detailed operating scenario has not yet been developed.
Further Description (unlimited length):
16.2. Public Health and Safety
16.2.1. Accidents
Summary (20 words or less): Hazards and operability studies are planned for late FY'93 and will analyze accident potentials.
Further Description (unlimited length):
16.2.2. Routine Releases
Summary (20 words or less): None should occur.
Further Description (unlimited length):
16.2.3. Transportation
Summary (20 words or less): The system is planned to be mobile enabling it to be transported between Hanford tank farms. No offsite transportation is planned.
Further Description (unlimited length):
16.3. Environmental Impacts
16.3.1. Ecological Impacts
Summary (20 words or less): Regulatory analysis will be performed in late FY'93.
Further Description (unlimited length):
16.3.2. Aesthetics
Summary (20 words or less): Not applicable
Further Description (unlimited length):
16.3.3. Natural Resources
Summary (20 words or less): Not applicable
Further Description (unlimited length):
16.3.4. Energy Demands
Summary (20 words or less): A portable generator will be provided with the system to supply all power. Energy demands will not be excessive.
Further Description (unlimited length):
17. Socio-Political Interests
17.1. Public Perception
17.1.1. Proponent Reputation
Summary (20 words or less): Not applicable
Further Description (unlimited length):
17.1.2. Familiarity / Understandability
Summary (20 words or less): Public familiarity with the technologies is limited, however if required appropriate educational materials/presentations could be provided.
Further Description (unlimited length):
17.2. Tribal Rights / Future Land Use
17.2.1. Capacity for Unrestricted Use (terrestrial, aquatic)
Summary (20 words or less): Not applicable
Further Description (unlimited length):
17.3. Socio-Economic Interests
17.3.1. Economic Impacts
Summary (20 words or less): Not applicable
Further Description (unlimited length):
17.3.2. Labor Force Demands
Summary (20 words or less): Existing plant work forces and technology developers will perform operations.
Further Description (unlimited length):
18. Regulatory Objectives
18.1. Compatibility with Cleanup Milestones
Summary (20 words or less): Although not directly linked to TPA milestones this technology supports long term remediation programs which are specifically tied to these.
Further Description (unlimited length):
18.2. Regulatory Infrastructure / Track Record
Summary (20 words or less): This will be a first time effort for this technology, however experience with core sampling operations will be utilized to guide documentation processes.
Further Description (unlimited length):
18.3. Regulatory Compliance
Summary (20 words or less): To be determined following regulatory analysis later in FY'93.
Further Description (unlimited length):
19. Industrial Partnerships
19.1. Company Names:
Currently in bid evaluation process, no contracts have been placed.
19.2. Rationale:
19.3. Contract Mechanism:
19.4. Other Potential Companies:
19.5. International:
20. Intellectual Property
20.1. Patent Ownership:
20.2. Other Owners:
20.3. Patent Number:
21. Cost Sharing:
It is anticipated that costs of this activity will be shared between the DOE EM-50 Office of Technology Development and EM-30 Waste Operations organizations.
22. Background on this technology (Where did the idea come from? Who else is doing similar work? What have the results been to date? What is the most significant competitor to this technology?):
This is an outgrowth of continuing technology development activities which have been conducted at Hanford over the past several years under the Robotics Technology Demonstration Program (RTDP). The need for additional characterization system capabilities was identified in FY'92 resulting in the initiation of this work.
23. Reference Documents:
Technical Task Plan (TTP) RL-401203