Automated Fabrication of AHWR Fuel in Shielded Cells:

Challenges and Initiatives

S. Pandaa*, Saurabh Guptaa, A. Saraswatb, Vijay Ahireb, Sanjeev Sharmaa,

P. S. Somayajulua, K. Jayarajana
a
Bhabha Atomic Research Centre (BARC), Trombay, Mumbai–400085, India
b
Symec Engineers (I) Pvt. Ltd., Navi Mumbai-400705, India
*
Corresponding author: panda@barc.gov.in

ABSTRACT

With the growing demand of various innovative reactor design and use of Thorium as fuel, importance of
automation for fuel fabrication is realized. In order to handle the fuel remotely during its fabrication cycle,
various stages of its fabrication are required to be automated. A first of its kind full scale mock-up facility is
recently developed at BARC, to demonstrate automated fabrication, inspection and handling of (Th-233U) based
fuel pins. In order to optimise the operations and to avoid spread of contamination, equipment in the facility are
arranged in multiple inter-connected shielded cells. One of the major challenges in handling of such fuel pin is
requirement of intra-cell and inter-cell autonomous transfer of long fuel pins. This paper describes, a uniquely
designed rail guided vehicle, which automatically triggers opening and closing of heavily shielded inter-cell door
during intra cell material transfer. Further, in this paper the concept of dual robotic arms for precise handling of
pins during its fabrication is presented. All the quality inspection tests are performed remotely and
autonomously. Results of the inspection are available online at control station and operator is alerted when
monitored parameters go beyond the acceptable tolerance band. In order to avoid radiation damage to electronic
components, controllers and data acquisition system are located outside the cells. Novel methods presented in
this paper produced consistent results with considerable reliability during mock-up trials, thus ensuring their
suitability for the real system.

KEYWORDS

AHWR, U-233, THORIUM, AUTOMATED FUEL FABRICATION

1. INTRODUCTION

Advanced Heavy Water Reactor (AHWR) [1] is a unique reactor concept, designed to utilise the vast thorium
resources available in India. It will be using mixed oxides of (Th-Pu) and (Th-233U) as fuels. Fertile Thorium is
converted to fissile 233U in reactor through neutron capture and the same will be used as fuel in AHWR. 233U
produced in reactor is always contaminated with small quantities of 232U. As a few daughter products of 232U in
its decay chain are hard gamma emitters, the fuel containing 233U can only be handled behind shielded cells.
Mixed oxide (MOX) fuel for AHWR will be fabricated by powder-pellet/ceramic processes, starting from PuO2,
ThO2 and 233UO2. Although, well-established processes and techniques are available for fuel fabrication for the
operating thermal reactors and fast reactors, using UO2 and PuO2 fuel, we have limited experience of fuel
fabrication in shielded facility. Automation in fuel fabrication is also limited to equipment level, and not to the
plant level. Therefore, a first of its kind mock- up facility [2][3] is being set-up at BARC to demonstrate fully
automated fuel fabrication, including pellet fabrication, pin fabrication and assembly of fuel cluster.

The reactor core of AHWR consists of 452 fuel clusters of 4300 mm length and 118 mm diameter. The cluster
has 54 fuel pins, arranged in three rings around a central rod [4]. Each fuel pin consists of an 11.2 mm diameter
Zircalloy clad tube, welded with two end plugs and filled with MOX pellets (Fig. 1). 18 spacer pads are welded
to the clad tube.
 Fig. 1: Fuel Pin
The major operations to be performed on the clad tube or fuel pin are insertion of pellets in to the tube, end-plug
welding, buffing the welded area, various dimensional measurements, weight checking, visual inspection, X-ray
radiography, He-leak detection and gamma scanning. In addition, it involves handling material among various
equipment in various stations.

2. MOCK UP FACILITY

Large length, combined with small diameter, and presence of spacer pads makes the automated material handling
difficult. Fuel pin fabrication will be performed in a series of shielded cells (hot cells). The physical constraints
arising from hot cells are respected in the design of the mock up system. Width of the hot cells are limited to the
reach of Master Slave Manipulators (MSMs) for accessing the desired areas. In addition, no permanent structure/
equipment is placed above the automated stations, in the layout for handling the fuel pins with MSM.

We have designed a fuel pin cage (Fig. 2) with a capacity of 36 pins for transferring the clad tubes to the pin
handling plant and for transferring the fabricated pins to the cluster assembly plant. The cage doors can be
opened only in the cell using automated tools. The cage containing pins will be transferred to the cluster
assembly plant in a shielded flask. Within the plant, the pins or clad tubes will be transferred from one hot cell to
another in a pin tray. The tray and cage have features for locating them accurately at the designated stations.

Fig. 2: Dummy Pin, Tray and Cage

The mock-up plant has three simulated hot-cells [5]. A cage containing 36 empty clad tubes are brought to the
plant and another cage containing 36 fabricated pins are taken out of the facility. Automated operations begin
with pulling out clad tubes from the cage and end with inserting accepted pins into another cage. Photograph of
the set-up is shown in Fig. 3.

Fig. 3: Mock-up Facility for Pin Fabrication

3. MATERIAL TRANSFER TOOLS

In the facility, the long clad tubes and pins are transferred between cells and within a cell for feeding them to
different processing or inspection systems. Major material transfer mechanisms developed are as listed below;

3.1. Pin & Tray Handling Robot

For vertical and transverse transfer of the pins and clad tubes, they have to be lifted from the support. As the long
pin cannot be lifted by a single device, a pair of cooperative robot was developed for pin handling. The overhead
mounted robot pair is capable of lifting and transferring the long clad tubes, pins and trays in coordination.

3.2. RGV and Inter-Cell Door

Instead of transferring single pin or clad tube, six of them are loaded into a pin tray (Fig. 2) and the pin tray is
transferred between cells. A pair of Pin & Tray Handling Robot loads the pins on the pin tray and the same robot
pair loads the tray on a Rail Guided Vehicle (RGV). Rails are laid in the cells and in the common walls for
moving the RGV (Fig. 4). Contact lines laid along the rail and bus bar contactors on the RGV are used to supply
power to RGV. Inter-cell doors are embedded in the common walls for the RGV to pass through. The normally
closed door is opened only during the transfer of RGV.

3.3. Cage Transfer Tool

Pin cage weighing about 200 kg has to be transferred among different station within a Cell. A heavy-duty cage
transfer tool, which is similar to Pin & Tray Handling Tool, was developed for this.

3.4. Tools for Longitudinal Transfer of Pin

In about ten stations, the pins and clad tubes are to be moved axially to feed them to various process and
inspection systems. The axial movement ranges from few millimetres to the full length of the pin. Depending up

Fig. 4: View of the Automation System from One End of Facility

on the axial travel, accuracy and space available, different mechanisms are used for pin transfer. The pushing
force is limited to avoid damage of the pin during pushing.

3.5. NC Table for Cage Positioning

Pin cage has 36 pins or clad tubes arranged in a 6 x 6 array (Fig. 2). The cage is placed on a 2-axis NC table for
aligning the required clad tube to the clad tube-unloading tool. The same setup is used for loading the fabricated
pin into the specified location in the cage. For pushing and pulling, the clad tube (or pin) is gripped using a
pneumatic gripper and pulled (or pushed) in small increments.

3.6. Pin Clamping & Rotation Set-up

The pin has to be rotated for welding, buffing, X-ray radiography, TIR, weld bead measurement and visual
inspection. Wherever, positive rotation is required, the pins are clamped on a rotating collet; otherwise, the pins
are supported on a set of rotating rollers. The rotation is either continuous or intermittent. Wherever required, the
pins are clamped and guided to avoid vibration and wobbling of the pin.

4. INSPECTION SYSTEMS

Automated inspection techniques are developed for metrology and weight measurement. X-ray radiography,
Helium Leak Detection and Gamma Scanning are proven methods in fuel fabrication. Therefore, in place of
actual measurement, only the necessary automated motions of the pins are demonstrated.

4.1. Weight Measurement Set-Up

Weight of the fuel pin is measured by placing the pin on a frame mounted on a load cell based weighing balance.
The pin weight is measured with ±1 gm accuracy.

4.2. TIR & Weld Bead Measurement Set-Up

A LVDT based set-up is developed to measure concentricity of the top end plug with reference to the clad tube
diameter and to measure weld bead size. Three LVDTs are placed in contact with clad tube, weld bead and top
end plug. The pin is clamped and rotated to get the TIR and weld bead size.

4.3. Pin Length Measurement

After pushing the pin against a stopper, the length of pin is measured using an LVDT.

4.4. Bow Measurement

Bow of fuel pins is usually measured by placing the pin on a surface plate and visually examining the gap
between the pin and the surface plate. If a gap is visible, feeler gauges are inserted in the gap to measure the gap.
As this technique is not amenable for automation, we have developed a novel technique for bow measurement.
The set up consists of a surface plate, a set of active rollers and a set of LVDTs. The rollers can be lifted,
lowered and rotated. In the lifted condition, the rollers can rotate the pin placed on it. In the lowered condition,
the pin gets transferred on the surface plate. Readings of the LVDTs, which are mounted below the surface plate,
provide the bow. The pins are rotated to measure the bow in other planes of the pin.

4.5. Visual Inspection

A high-resolution camera, which is mounted on a moving frame, is used for visual inspection of the pin. The pin
is rotated and scanned by the moving camera across its length. Visual inspection is not automated; the operator
takes a decision, based on the image available to him at the control station.
4.6. X-Ray Radiography

X-ray radiography is done to assess the weld quality. The pin is fed into the set-up and the weld area is exposed
to X-Ray. The pin is rotated in steps to expose the weld in different angles.

4.7. He-Leak Detection

The set-up consists of a Helium Leak Test (HLT) chamber, a tray conveyor, tray pusher and a tray. The HLT
chamber has an automated leak-tight door to load or unload tray through it.

4.8. Gamma Scanning

The pin is fed through a gamma scanner to confirm the presence of fuel pellets at all locations inside the clad
tube. The system includes a passive gripper and a motorized chain drive for full-length axial travel of the pin.

5. PROCESS EQUIPMENTS

Processes required for AHWR fuel pin fabrication are similar to those in the fabrication of fuel pins of other
reactors. Therefore, we have not duplicated the process equipment in our system. However, we have
demonstrated necessary pin handling and associated equipment movements in our system. The major tools used
are listed below;

5.1. Top End Plug Welding

Material handling tools required for end plug welding are developed. The pin is fed to the welding chamber,
stopped at specified location, clamped and rotated at the required speed.

5.2. Buffing

The buffing set-up consists of two buffing wheels: one motorised and the other an idler. The welded area of the
pin is brought near the wheels; the buffing wheels are pressed against the pin; and the pin is rotated between the
pressed wheels.

6. CONTROL SYSTEM

A remote control station was developed to monitor and to control the large number of processes. Apart from the
centralized station, each cell also has separate touch screen interface for monitoring and controlling the sub-
systems. Centralized controller, referred as SCADA (Supervisor Control and Data Acquisition), monitors and
controls the activities in the three cells and the movement of RGV. Synchronization of various processes is
essential in the system. Therefore, real time feedback of the status and non-completion of an action within the
pre-defined time is reported. It helps to identification the problem, before they turn into significant failures.

Engineering Field
HMI Devices Drives

Profibus

Win CC
PLC SCADA
S7-300

Fig. 5: Overview of the Control System for AHWR Fuel Pin Fabrication
 Fig. 6: SCADA Display of one of the Cells
Centralized station periodically obtains data from remote input modules and controls various actuators through
PLC (Programmable Logic Controller). Win CC, an open architecture SCADA, is installed on an industrial PC.
It is configured for visual display of status, alarm handling, logging and report generation. Images from CCTV
cameras are also available at the control station. Fig. 5 shows overview of the control diagram for controlling
this complex system. This system aids in visualizing real time process data and facilitates configuration and
monitoring of process data.

7. CONCLUSIONS

An attempt has been made to develop a comprehensive full scale mock-up system to demonstrate all functional
and qualitative requirements of automated AHWR fuel pin fabrication. In this mock up system, many novel tools
and techniques for automated transfer of the pin and the cage have been developed. A few conventional
techniques have been modified for automated inspection. Constraints arising from the hot cell, such as space
limitations, maintainability, access and interference with remote handling tools, spread of contamination, etc. are
considered in the design. Another outcome of the mock up facility is optimised layout of hot cell and equipment,
which reduces the number of material transfers, reduces the number of equipment, optimally utilise hot cell
space and provides access for maintenance. A hybrid layout, combining the desired features of fixed-position
layout, product-oriented layout and process-oriented layout, is adopted in this mock-up demonstration. This
mock-up demonstration facility is a first step towards commercialization of automated fuel fabrication in a
shielded facility.

ACKNOWLEDGMENTS

Implementation of such large and complex system would not have been possible, if we did not have a support of
many individuals and organizations. Authors hereby duly acknowledge support and guidance from Shri Arun
Kumar, Ex-Director, Nuclear Fuels Group and Dr D. N. Badodkar, Associate Director, Design, Manufacturing
&Automation Group for development of the system. We are also thankful to Shri R C Sharma, Ex-Director,
Reactor Group for giving us permission to install the system in Reactor Group premises. We thankfully
acknowledge support from all staff members of Division of Remote Handling & Robotics, Nuclear Fuels Group
and Reactor Group.
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