초록 ▼

1. 연구개발 목표 및 내용
원전 핵심설비 해체 시 해체공정에 대한 경제성과 안전성을 증대시키고 고방사능 설비에 공통적으로 적용되는 해체 핵심기술을 개발하여 국내 해체 기반기술을 구축함
• 안전성 및 경제성을 평가하여 최적의 해체공정을 도출할 수 있는 해체공정 평가 기술 개발
• 작업자 접근이 어려운 고방사능 시설 해체작업을 원격으로 정밀하게 제어하는 기술 개발
• 고방사능 환경에서 해체 대상물을 원격절단 할 수 있는 고성능 레이저 절단 기술 개발

2. 연구결과
• 실감형 해체 시뮬레이터

1. 연구개발 목표 및 내용
원전 핵심설비 해체 시 해체공정에 대한 경제성과 안전성을 증대시키고 고방사능 설비에 공통적으로 적용되는 해체 핵심기술을 개발하여 국내 해체 기반기술을 구축함
• 안전성 및 경제성을 평가하여 최적의 해체공정을 도출할 수 있는 해체공정 평가 기술 개발
• 작업자 접근이 어려운 고방사능 시설 해체작업을 원격으로 정밀하게 제어하는 기술 개발
• 고방사능 환경에서 해체 대상물을 원격절단 할 수 있는 고성능 레이저 절단 기술 개발

2. 연구결과
• 실감형 해체 시뮬레이터 개발
- 해체공정 통합평가 방안 및 해체 시뮬레이터 핵심 단위기술
- 실감형 해체 시뮬레이터
• 원자력시설 해체 안전성 평가 기술 개발
- 해체 인적오류 안전성 평가 기술
- 해체 안전성 평가 시스템
• 고하중 해체 매니퓰레이터 요소 기술 개발
- 해체 매니퓰레이터 핵심부품
- 해체 매니퓰레이터 제어 시스템
• 해체공정 통합평가 기술 개발
- 해체공정 통합평가 단위기술 완성
- 해체공정 통합평가 시스템 확보
• 고하중 취급 고정밀 원격제어 기술 개발
- 고하중 매니퓰레이터 시작품 제작
- 고하중 매니퓰레이터 시제품 제작
• 고성능 레이저 열적절단 기술 개발
- 레이저 열적절단 기술 기반 구축
- 레이저 열적절단 시스템 개발

(출처 : 보고서 요약서 3p)

Abstract ▼

Ⅳ. Results and Proposal for Application

1. Development of the tangible decommissioning simulator

A. Conceptual design of the integrated decommissioning assessment process

○ 3D models from 2D drawings of Kori-1 were manufactured using expert knowledge over nuclear facilities, a

Ⅳ. Results and Proposal for Application

1. Development of the tangible decommissioning simulator

A. Conceptual design of the integrated decommissioning assessment process

○ 3D models from 2D drawings of Kori-1 were manufactured using expert knowledge over nuclear facilities, and 3D digital mock-up with functions of geometric and kinematic analysis was constructed to investigate geometric structures of decommissioning environment and kinematic motions of decommissioning processes, as well.
○ Database of physical and radiological characteristic evaluation over highly radioactive heavy components of the nuclear power plant (Reactor Pressure Vessel, Steam Generator, Reactor Coolant Pump, Pressurizer) was constructed, and spatial dose mapping around nuclear facilities using MCNP(Monte Carlo N-Particle) code was achieved.
○ Core technical modules of decommissioning process simulation and the integrated decommissioning assessment process were organized through the decommissioning scenario analysis of nuclear facilities, and platform software to develop the software frame of the integrated decommissioning assessment process was selected based on requirements for the software frame.

B. Development of major unit technologies for decommissioning simulator

○ The dismantling process simulation module of remarkably enhanced reliability over multiple and repetitive cutting operations using the CAD kernel, the user interface module minimizing mental transformation of the operator with the virtual fixture, and visualization module for spatial dose calculated by MCNP code were developed.
○ The software frame to satisfy requirements for the integrated decommissioning assessment process achieved by decommissioning scenario analysis of nuclear facilities was developed by CAA C extended development, and thus achieved reliability as much as commercial software and originality of developed technology, as well.

C. Completion of the tangible decommissioning simulator

○ The digital mock-up of the seamless remote dismantling system was developed by the CAD-based dismantling process simulation technology to handle the whole decommissioning process over the heavy nuclear facilities without replacement of dismantling equipment, and thus the remote dismantling system technology capable of reducing considerable time and cost for decommissioning process was achieved.
○ The tangible decommissioning simulator was developed. The simulator was able to simulate decommissioning process of heavy nuclear facilities in real time, and to train a remote operator by using the tangible remote control system capable of force reflection and immersive visualization system.

2. Development of the safety assessment technology for decommissioning of nuclear facilities

A. Conceptual design of the decommissioning safety assessment technology based on human errors

○ The methodology of safety assessment for decommissioning accident from human errors was developed. Through analyzing the state-of-the-art technologies, requirements of the safety assessment was designed and procedure of the safety assessment was established. The procedure consists of assessment step the safety of decommissioning scenarios, counter-measuring step for safety reduction and assuring step of the decommissioning safety.
○ The measurement equipment for characteristics of decommissioning worker’s behavior was manufactured. The manufacturing criteria for capable of generating the input data and linking with the integrated assessment system was designed. The measurement equipment under selection of the best hardware and software tools was developed.

B. Development of the decommissioning safety assessment technology based on human errors

○ The model of the human error assessment for decommissioning was developed. The mathematical model capable of assessing both working environments and human errors was developed.
○ The safety assessment of working environments can be quantitatively estimated based on both dose distribution and working time. The safety assessment of human errors can be quantitatively estimated based on accidents, working time, counter-measuring time.

C. Construction of the safety assessment system for decommissioning of nuclear facilities

○ The reduction technology of human errors was developed. The safety improvement technology was developed by reducing the hazards of human errors.
○ The safety assessment system for decommissioning of nuclear facilities was developed. The safety assessment system is able to measure and assess the working scenarios under virtual environments like real decommissioning situations.

3. Development of the component technologies for heavy-duty manipulator

A. Conceptual design of dismantling manipulator for NPP decommission

○ The technology requirements of remote dismantling manipulator system were established. The conceptual design of the remote dismantling manipulator system was performed by using 3D digital mock-up in terms of workability and kinematics under the given geometric condition.

B. Development of core components of dismantling manipulator

○ Original two electric actuator modules and three hydraulic actuator modules were developed for modularization design of remote dismantling manipulator system. To supply hydraulic power to hydraulic actuator modules, variable hydraulic supply device that can supply pressure and flow variably was developed. High-precision control algorithm that makes a precise control of hydraulic actuator module was also developed.

C. Construction of evaluation device for actuators of dismantling manipulator

○ To evaluate the developed hydraulic actuator modules, an assessment device was manufactured and a signal processing controller for handling various sensor signals and control inputs was developed. And also variable loading device that can supply variable load was manufactured.

D. Detail design and analysis of dismantling manipulator

○ The kinematic parameters of remote dismantling manipulator were also defined through analyzing the working space and simulating decommissioning process kinematically. Various linear and rotary actuator modules were designed for making a dismantling manipulator to have modularity. Based on the defined kinematic parameters and designed actuator modules, Detail design of a dismantling manipulator was carried out through dynamic analysis and stress analysis.

E. Development of core components for heavy-duty manipulator

○ To develop various dismantling manipulators for nuclear power plant, two hollow-type electrical actuator modules that make a possible to insert power and signal cable into the actuator modules were developed for preventing the exposure of cables. And also a small and high-torque electric-hydraulic actuator module was developed to make light-weight dismantling manipulator.

F. Design of remote control system for manipulator

○ A robust control algorithm for reducing a vibration and precise control of hydraulic system was developed using a frequency-shaped integral sliding surface and time delay control with switching action. The design of a remote control system for controlling a dismantling manipulator was carried out through the establishment of the technology requirement of the remote control system.

4. Development of the integrated assessment technology for decommissioning process

A. Development of the assessment factor for remote cutting

○ Based on the dismantling procedure of a reactor pressure vessel, the remote cut process and remote cutting test conditions were derived. The analysis of the state-of-the-art dismantling technology was performed to select the appropriate mechanical and thermal cutting method to conduct a practical cut test and produce a remote dismantling assessment factor.
○ The dismantling simulation module, user interface module, and remote dismantling assessment modules were derived based on the core module requirements which were derived in the design procedure of architecture of remote dismantling assessment system. The modules have been developed for the specialized function of remote dismantling assessment system and the compatibility with the most widely used commercial process simulation software.
○ The modules of the remote dismantling assessment system, dismantling simulation module, user interface module, and assessment module have been proven to satisfy the design requirements of system.

B. Development of the integrated assessment system for remote cutting

○ In the 3D process simulation environment which is employing a PPR(Process Product Resource) structure, on the basis of the simulation result of various dismantling scenarios for the core facilities of the nuclear power plant, the evaluation system was established to calculate the cost and safety of the decommissioning process.
○ Integrated dismantling process assessment system has the function to employ a panorama visualization studio based on curved screen to display process simulation result and assessment factor to users effectively.
○ Based on the result of process simulation and integrated assessment of the processes, the methodology for calculating optimal scenarios in view of cost and safety was developed. The dismantling process assessment system has proven that the various remote dismantling scenarios can be simulated by more than 95 %.

5. Development of heavy-duty manipulator and precise remote control technology

A. Development of the 2nd prototype heavy-duty manipulator

○ The 2nd prototype manipulator consists of completely independent modules to facilitate the configuration change and the maintenance of the manipulator. The reliability of each joint is improved by installing a integrated resolver. The frictional force was reduced by changing the mechanism structure of the translational joint. Usability was increased by adding the out put axis resolvers sensing the absolute position of the joint modules. In addition, the usability of the manipulator was improved by a adapter attaching and detaching tools and a gripper.
○ A rotary joint module using a linear actuator was developed and applied to demonstrate the usefulness of the modular manipulator by building a work area extended manipulator composed of six rotating joints.
○ A compact hydraulic power supply was designed and manufactured based on the evaluation of the maximum driving speed of the each joint of the 1st prototype manipulator. The hydraulic drive manifold consists of 6 ports for driving the six joints of the manipulator, and a port for driving the gripper and the tool adapter. And it was equipped with shutoff valves for stopping the manipulator in case of emergency such as power failure.

B. Development of the 2nd prototype manipulator control system

○ The 1st prototype manipulator control system built in the first year consists of a main controller and a remote controller. The main controller displays the each axis path generation and the status information of the manipulator through a GUI program under Windows. The remote controller that controls the hydraulic servo valve consists of a commercial HAC(Hydraulic Actuator Controller) board, a RDC(Resolver Digital Converter) board and a multi-channel RDC data collection board. Communication between main controller and remote controller adopts CAN communication method.
○ In order to overcome the limitations of 1st prototype control system, the 2nd prototype control system was constructed by newly developing a main control program, a communication method between control systems, a servo valve controller, a controller console, and a hydraulic servo control algorithm in the second year.
○ The 2nd prototype control system consists of HACs for controlling the driving modules of the manipulator and a main controller for controlling the movement of the manipulator. The main controller controls the manipulator with seven HACs through the TCP communication method, and displays the manipulator information with 3D graphic display and graphs. The HAC developed based on ARM MPU moves each joint to the position commanded by the main controller and transmits the information of the position and the pressure of each joint to the main controller. Hydraulic control algorithm and signal processing algorithm were developed and applied to the HAC.

6. Development of the laser thermal cutting technology with high performance

A. Set-up of the basis to develop the laser thermal cutting technology

○ For development of the laser thermal cutting technology, a high power fiber laser and the base equipments for safety, exhaust, electricity, and etc. were installed to the laboratory.
○ For the safety of workers, the cutting equipment and the laser control equipment were installed separately for the laser to be controlled remotely. And additional equipments such as a fume suction unit, an assist gas supply and a pressure control system for blowing the molten metal, a cable tray for protection of the fiber from the external impact were also installed.
○ In conclusion, the laser cutting system for application to the research for the cutting of the thick metal was prepared by performance verification and the operation evaluation for the installed equipments

B. Development of laser cutting head applicable for high power fiber laser

○ The basic shape and the detailed optical arrangement were designed for development of the high power fiber laser cutting head. In the design of the basic shape, the shape of the focusing optical scheme and the focal length were determined by calculation of the focused beam size. In the design of the detailed optical arrangement, the computational simulation was performed with ray tracing method. The final shape of the focusing object and the optical structure sere determined.
○ On the basis of the high power laser cutting head design, the components of the cutting head were designed and fabricated in order to be applicable to 20 kW laser power and 20 atm. assist gas pressure. The fabricated laser cutting head was evaluated by assembling test, water leak test, head temperature measurement, and gas pressurization test as well as optical performance test with the measurements of beam focusing characteristic and optical loss.
○ The physical model and the numerical calculation method were developed for analysis of the multiple physical phenomena such as gas-liquid-solid interaction, supersonic compressible flow, turbulence model, heat transfer with phase change, laser heating, and so on.

C. Development of the optimal technology for laser thermal cutting process

○ The cutting tests of the stepwise stainless steel, the thick stainless steel and the thick carbon steel were performed with 6 kW fiber laser and the developed cutting head. The cutting performance was evaluated with the cutting data such as the maximum cutting speed via thickness, kerf width, and so on.
○ By applying the stepwise cutting speed increasing technology, the cutting performance was improved in the cutting speed aspect when cutting the thick steels.
○ Supersonic nozzle and a few of sonic nozzles were fabricated to investigate the effect of a geometrical nozzle shape on cutting performance of stainless steel plate with 100 mm thickness. Cutting performance was evaluated as a function of nozzle shape.
○ In the laser cutting technology, stand-off distance refers to the distance between the nozzle exit and the specimen surface. Cutting experiment on stainless steel plate with thickness 60 mm was carried out as a function of stand-off distances. We evaluated the effect of standoff distance on laser cutting of stainless steel plate with thickness 60 mm.
○ The cutting performance for kinds of assist gas was also evaluated with the cutting test of the 60 mm thick stainless plate.
○ The laser metal cutting model in the air and the computational analysis code was developed. And the modeling and the numerical analysis technique was developed for calculating the mutual heat transfer process of fluid-solid, phase change process, and so on. The core design elements were evaluated through the computational analysis of the supersonic flow for inside the nozzle and after the nozzle exit. On the basis of this analysis, an optimum supersonic nozzle was designed which improves the amount of thrust 2.5 times larger than with the normal nozzle.

D. Development of the laser remote cutting system and assessment of its performance

○ The cutting tests of the thick stainless steel and the thick carbon steel were performed with 10 kW fiber laser which can cut 100 mm thickness with high speed. The cutting performance was evaluated with the cutting data such as the maximum cutting speed via thickness, kerf width, and so on.
○ The cutting tests of stainless pipes with maximum dimeter of 165 mm were also performed and evaluated.
○ A laser remote cutting system was constructed to remotely control the operation of each equipment required for laser cutting experiments through smaller control box. Each equipment contains laser, gas valve, and 3-axis stage providing movement of the cutting head. The constructed cutting system was evaluated through remote cutting of 60 mm thick metal plate.

(출처 : SUMMARY 23p)

목차 Contents

• 표지 ... 1
• 제 출 문 ... 2
• 보고서 요약서 ... 3
• 요 약 문 ... 4
• SUMMARY ... 18
• CONTENTS ... 35
• 목차 ... 39
• 표목차 ... 42
• 그림목차 ... 48
• 제 1 장 연구개발과제의 개요 ... 74
• 제 1 절 연구배경 ... 74
• 제 2 절 추진현황 및 연구내용 ... 78
• 제 2 장 국내외 기술 개발 현황 ... 88
• 제 1 절 해체공정 통합평가 기술 개발 ... 88
• 제 2 절 원자력시설 해체 안전성 평가 기술 개발 ... 92
• 제 3 절 고하중 취급 고정밀 원격제어 기술 개발 ... 95
• 제 4 절 고성능 레이저 열적절단 기술 개발 ... 102
• 제 3 장 연구개발수행 내용 및 결과 ... 110
• 제 1 절 실감형 해체 시뮬레이터 개발 ... 110
• 1. 개 요 ... 110
• 2. 연구내용 및 방법 ... 110
• 3. 연구 결과 ... 113
• 4. 결과 요약 ... 265
• 제 2 절 원자력시설 해체 안전성 평가 기술 개발 ... 267
• 1. 개 요 ... 267
• 2. 연구내용 및 방법 ... 267
• 3. 연구 결과 ... 269
• 4. 결과 요약 ... 314
• 제 3 절 고하중 해체 매니퓰레이터 요소 기술 개발 ... 315
• 1. 개 요 ... 315
• 2. 연구내용 및 방법 ... 315
• 3. 연구 결과 ... 318
• 4. 결과 요약 ... 463
• 제 4 절 해체공정 통합평가 기술 개발 ... 465
• 1. 개 요 ... 465
• 2. 연구내용 및 방법 ... 466
• 3. 연구 결과 ... 469
• 4. 결과 요약 ... 664
• 제 5 절 고하중 취급 고정밀 원격제어 기술 개발 ... 665
• 1. 개 요 ... 665
• 2. 연구내용 및 방법 ... 666
• 3. 연구 결과 ... 668
• 4. 결과 요약 ... 859
• 제 6 절 고성능 레이저 열적절단 기술 개발 ... 861
• 1. 개 요 ... 861
• 2. 연구내용 및 방법 ... 861
• 3. 연구 결과 ... 864
• 4. 결과 요약 ... 986
• 제 4 장 목표달성도 및 관련분야에의 기여도 ... 988
• 제 1 절 실감형 해체 시뮬레이터 개발 ... 988
• 1. 목표달성도 ... 988
• 2. 대외기여도 ... 988
• 제 2 절 원자력시설 해체 안전성 평가 기술 개발 ... 989
• 1. 목표달성도 ... 989
• 2. 대외기여도 ... 989
• 제 3 절 고하중 해체 매니퓰레이터 요소 기술 개발 ... 990
• 1. 목표달성도 ... 990
• 2. 대외기여도 ... 990
• 제 4 절 해체공정 통합평가 기술 개발 ... 991
• 1. 목표달성도 ... 991
• 2. 대외기여도 ... 991
• 제 5 절 고하중 취급 고정밀 원격제어 기술 개발 ... 992
• 1. 목표달성도 ... 992
• 2. 대외기여도 ... 993
• 제 6 절 고성능 레이저 열적절단 기술 개발 ... 994
• 1. 목표달성도 ... 994
• 2. 대외기여도 ... 994
• 제 5 장 연구개발결과의 활용계획 ... 995
• 제 1 절 실감형 해체 시뮬레이터 개발 ... 995
• 1. 기술적 측면 ... 995
• 2. 경제․사회적 측면 ... 995
• 3. 활용방안 및 용도 ... 995
• 제 2 절 원자력시설 해체 안전성 평가 기술 개발 ... 996
• 1. 기술적 측면 ... 996
• 2. 경제․사회적 측면 ... 996
• 3. 활용방안 및 용도 ... 996
• 제 3 절 고하중 해체 매니퓰레이터 요소 기술 개발 ... 997
• 1. 기술적 측면 ... 997
• 2. 경제․사회적 측면 ... 997
• 3. 활용방안 및 용도 ... 997
• 제 4 절 해체공정 통합평가 기술 개발 ... 998
• 1. 기술적 측면 ... 998
• 2. 경제․사회적 측면 ... 998
• 3. 활용방안 및 용도 ... 998
• 제 5 절 고하중 취급 고정밀 원격제어 기술 개발 ... 1000
• 1. 기술적 측면 ... 1000
• 2. 경제․사회적 측면 ... 1000
• 3. 활용방안 및 용도 ... 1000
• 제 6 절 고성능 레이저 열적절단 기술 개발 ... 1001
• 1. 기술적 측면 ... 1001
• 2. 경제․사회적 측면 ... 1001
• 3. 활용방안 및 용도 ... 1001
• 제 6 장 연구개발과정에서 수집한 해외과학기술정보 ... 1002
• 제 7 장 연구장비의 구축 및 활용 결과 ... 1003
• 제 8 장 참고문헌 ... 1005
• 끝페이지 ... 1009