Currently, with the development of
information technology, virtual reality is rapidly gaining popularity - an
amazing technology that promises to radically change the interaction of people
with information.
Virtual reality is understood as the
modeling of a 3-dimensional environment, when interacting with which a person
perceives it as real, which causes a feeling of presence in it. This
effect is achieved with the help of special equipment: glasses or a virtual
reality helmet, due to their design, provide a stereoscopic 3D image of the
simulated world, motion sensors calculate movements in the real world and
transform them into the virtual world. In addition, the equipment set may
include controllers that track the movement of a person's hands and transfer
them to the virtual world, which allows you to pick up virtual
objects, throw them, or perform other actions involving the use of hands [1].
In the early stages of its
development, virtual reality was used mostly in the gaming industry, but at the
moment its use is rapidly growing in other areas. Currently, virtual reality
technologies are actively used in design, construction, various training
machines and simulators, medicine and other areas of human activity [2,3].
There is also a process of
introducing VR technologies into the nuclear industry, which will reduce errors
in design, improve the quality of training specialists, and facilitate the
verification of various scenarios of the technological process.
In the virtual world, emergency situations
can be simulated that cannot be reproduced in real life, and thanks to this, a
specialist previously familiar with theoretical material gains experience close
to real life [4].
An important role in the process of
training specialists in the field of nuclear energy is played by training,
which involves immersion in a professional environment in order to obtain the
necessary skills. For this, various training systems are used, which are aimed
at creating working conditions similar to real ones in order to consolidate
theoretical knowledge. The simulators visualize ongoing
technological operations, allow you to consider various situations, thanks to
which skills are developed in choosing the best actions in each case. The
introduction of virtual reality technologies in such simulators will improve
the quality of training specialists.
In this work, the integration of VR
technologies into a training simulator for controlling the technological
process of a FA line
was carried out.
Currently, various training systems
in the form of full-scale or analytical simulators are used to train
specialists in the nuclear industry.
A full-scale simulator is usually a
digital twin of a nuclear power plant. It provides modeling of all operating
modes on a real scale: normal operating modes, design emergency modes and
beyond design basis accidents.
An analytical simulator is a
simulator whose information and motor fields are presented on display screens,
and the equipment is controlled using a "mouse" or screen sensors.
During training on the above
simulators, the output of certain dynamic parameters is carried out in graphic
form, usually on the screen or a file for printing.
A simulator using virtual reality
technologies differs from the above-mentioned ones in that employees are
immersed in a full-fledged copy of the workplace during training and practice
all routine actions until they become automatic, which allows them to increase
their level of awareness when working on real equipment and reduce the risks of
incidents and emergency situations. Such simulators allow simulating
situations that may arise in practice, without exposing students to any risks
or restrictions [5].
Thus, the implementation of virtual
simulators is relevant at the present time. This can become a useful tool in
the educational process and will significantly improve its quality and
efficiency, as well as save time and resources in a rapidly changing world. Currently,
various training systems in the form of full-scale or analytical simulators are
used in the training of specialists in the nuclear industry [6].
The simulator for assembly and
control of the RU BREST-OD-300 FA using virtual reality technologies
is designed as shown in Figure 1. When the trainee puts on virtual reality
glasses, the application in Unity is launched on the graphics server to form a
virtual space.
Fig. 1. Concept of the simulator operation
using virtual reality
The graphic server provides
information on the formation of 3D space from the first person for virtual
reality glasses, and also sends data for monitoring, displaying the location
and behavior of the character in the virtual environment. Thanks to this, the
engineer-instructor can monitor the actions performed by the operator and set
the necessary scenarios.
FA (fuel assemblies) are structural
elements of a nuclear reactor that contain nuclear fuel and serve to control
nuclear reactions and heat release. The FA assembly and control process
includes several stages:
Component
manufacturing.
FA manufacturing
typically involves the production of fuel rods, which contain the nuclear fuel
(e.g., uranium-235) and a cladding to prevent leakage of radioactive materials.
This process also includes the production of structural components of the
FA, such
as rod holders, containment cladding, and other necessary components.
FA
assembly.
Fuel rods
are placed in a certain order inside the frame. Structural elements are secured
in such a way as to ensure the reliability and integrity of the FA.
Quality and safety
control.
This process includes visual inspections for defects, cracks or other damage to
FA components. Measuring dimensions and geometric parameters to ensure that the
FA meets
design requirements. Conducting material tests and analysis to standardize and
ensure safety standards. Checking radiation levels and ensuring that there are
no leaks from the FA.
Pre-operation
testing.
Testing the strength and stability of FA
under
loads and vibrations. Simulating heat generation conditions in the reactor to
test the efficiency of cooling and heat generation control.
Packaging and transportation.
Protecting
FA
from
damage during transportation and storage. Preparation of all necessary
documents and quality certificates to accompany fuel assemblies.
The entire process of FA
and
control is carefully regulated and subject to numerous checks to ensure the
safety and efficiency of the nuclear reactor.
Unity is one of the most popular
game engines used to create various game applications on various platforms. A
free version is provided for beginner developers. Unity can be used to develop
both 2D and 3D projects [7].
Unity has relatively low system
requirements, which is an obvious advantage, since many novice developers do
not have excellent system parameters. In addition, the engine itself and
projects on it do not take up much disk space, which makes you pay attention,
especially when the computer memory is occupied by other important applications
[8].
The C# language is used for writing
scripts, which gives a winning position, since it is much easier for a beginner
to write in this language [9].
In terms of the number of game
resources, called assets, Unity takes the leading position, in the Unity store
you can find a huge variety of ready-made animations, 3D models, textures,
audio and much more.
There are over 50,000 such resources
available in the built-in store, many of which are free [11].
The equipment used in this work is
represented by virtual reality glasses Oculus Rift S and two Oculus touch
controllers (one for each hand) (see fig. 2). These
glasses have excellent light insulation, a good viewing angle and are quite
convenient to use due to the comfortable weight distribution.
The
controllers track the movement of hands and fingers, transmitting all gestures
to the virtual world with good accuracy, which allows you to take objects
inside this world, throw them, press buttons and much more [12].
An important advantage of the
Oculus Rift S equipment, which distinguishes it from other models, is the
presence of the Oculus Passthroug+ functionality, which is responsible for the
user's safety [13].
It works like this: when the user leaves
the previously configured play area, the picture displayed on the glasses'
display switches to the real world in black and white so that the user can see
the surrounding world and avoid hitting obstacles. The user will not be able to
continue playing until he or she returns to the play area.
So, the Oculus
Rift S hardware has an excellent price-quality ratio and is the optimal choice
that meets the requirements and conditions of this work.
Fig. 2. Oculus Rift S equipment
The
operation of the unit is as follows. The FA head, the lock drive head, nuts and
flaring are fed on the sluice installation plate with a conveyor to the
operating area of the unit robot. The tilter moves the FA frame,
fixed in the witness cradle, into a vertical position (see fig. 3). The robot
determines the coordinates of the location of the pipes on the frame with the
probe of the tightening and gripping mechanism. The head
of the FA is fixed on the installation plate of the lock with the conveyor by
the gripper of the twisting and gripping mechanism, it is lifted vertically,
and the force-torque sensor installed on the twisting and gripping mechanism
weighs the head of the FA, thereby determining the presence of the head of the FA
in the twisting and gripping mechanism. The FA head is
installed on the FA frame pipes, pressed and fixed with a grip. After that, the
grip of the tightening and gripping mechanism is released and moved behind the
nut to the installation plate of the sluice with a conveyor. The clamp of the
tightening and gripping mechanism grips the nut on the sluice plate with a
conveyor and moves the robot, to determine the presence of the nut, to the
bracket with the sensor. The presence of the nut is determined. The nut is
moved to the FA frame and screwed onto the pipe. The nut is considered to be
screwed if the number of nut turns is between 10 and 12 turns and the
tightening torque exceeds 1 N/m. If the number of turns is less than 10 and the
torque on the nut tightening mechanism exceeds 1 N/m, the nut is considered to
be loose. In this case, the nut is unscrewed by the nut tightening mechanism. Then the
operator decides whether to tighten it again or send the FA for disassembly.
The remaining nuts are tightened. After tightening the nuts, the installation
robot, with its tightening and gripping mechanism, grabs the flare from the
installation plate of the gateway with the conveyor and checks for the flare on
the bracket with the sensor. After determining the presence of
flaring, the robot of the installation flares the FA frame pipes, rolling the
edges of the pipes. The operator controls the flaring of the pipes using three
video surveillance devices located around the head of the FA. The robot of the
installation fixes the head of the lock drive with a twisting and gripping
mechanism and determines the presence of the head of the lock drive with a
force-torque sensor. The lock drive head is fed oriented inside
the FA head, rotates inside the FA head by 30° and is held. The tilter, using a
pneumatic cylinder, moves the lock drive rods. The rods enter the holes of the
lock drive head and fix it. The operator, using video cameras, controls the
fixation of the lock drive head. After fixing the lock drive head, the robot
returns to its original position. The coordinate non-copying
manipulator grasps the FA by the head, the grippers of the
cradle are released, the FA is moved by the CM to the next technological
position. The tilter moves the cradle to a horizontal position for transporting
it to the next technological position [1].
Fig. 3. Mnemonic diagram and 3D
visualization of the FA section
The retort is designed to
accommodate the FA during washing and drying. The installation includes: a
retort, a water supply device, an air preparation device, a bubbler, a drain
device, a drying device, and biological protection (see fig. 4). The water
supply device is designed to fill with distilled water. The air preparation
device is designed to prepare and supply air to the bubbler. The drain
device is designed to drain water from the retort into a special container. The
drying device is designed to heat the air and blow off the FA. Biological protection
is designed to protect repair personnel from exposure to FA during repair work
in the event of a FA hanging inside the installation.
From the FA tilter, the CM is
transported to the retort of the FA washing and drying unit. The FA is washed
with distilled water (at a temperature of 20 to 30 °C) in two cycles, including
filling the retort with water, washing the FA with bubbling, and draining the
water. The washing time in one cycle is at least 30 minutes.
The wash water is collected in
receiving tanks. From the receiving tanks, the wash water is pumped for
processing in another building.
Drying of the fuel assemblies is
carried out in a retort by blowing hot air over the fuel assemblies (at a
temperature of 100 to 120 °C). The drying time is at least 40 minutes [16].
Fig. 4. Mnemonic diagram and 3D
visualization of the FA washing and drying unit
After switching on the LCS, the leak
detector will automatically start and perform a check and adjustment of the
sensitivity threshold for the internal calibrated leak (determination of the
sensitivity threshold of the leak detector, LDST), and the
leak detector will be calibrated (see fig. 5). The value
of the LDST is
determined automatically and displayed on the leak detector control panel (to
continue operations, the LDST should not
exceed 7·10-11m3Pa/s). If the LDST exceeds
the permissible value, it is necessary to re-check and adjust the leak detector
sensitivity threshold, as well as re-calibrate the leak detector). If the
permissible value of the LDST is exceeded after 2 cycles of
testing and adjustment of the sensitivity threshold for the internal control
leak, suspend work until the causes of the negative test result are eliminated.
Open the retort pneumatic actuator
and purge the retort with nitrogen for at least 5 minutes. After the purge time
has expired, close the actuator.
Check the system sensitivity
threshold (SST) of the
system using an external calibrated leak. SST should be no more than 2.5·10-10m3Pa/s.
If the obtained value of the SST exceeds
the permissible value (the plant control system will issue a message about an
unsatisfactory result of the SST), repeat the SST determination using an
external calibrated leak. Repeat the vacuuming of the system.
The
permissible number of repetitions of the SST test for the external control leak
is two. If the SST exceeds the permissible value after repeated tests, suspend
the work until the causes of the negative result of the SST test are
eliminated.
The FA is delivered to the CM unit,
which moves it and stops above the retort. Upon reaching the specified CM
positioning coordinates, the retort pneumatic actuator is opened, and the
nitrogen supply is switched on. The CM carriage drive is switched to lowering.
When the
marking of the FA is aligned with the reading device, the FA is stopped to read
its number. Then the lowering of the FA continues until it is completely
inserted into the retort.
The
CM carriage drive stops, the CM gripper is disengaged from the FA head and
moved away from the retort. A necessary condition for disengaging the CM
gripper from the FA head is the operation of the product presence sensor,
confirming the full entry of the FA into the retort. The actuator closes.
The
nitrogen supply is stopped using a fore vacuum pump and the retort is pumped
down to a pressure of less than 6 Pa. The pressure in the retort is controlled
by a vacuum sensor. After reaching the specified vacuum value, the leak
detector switches to leak control mode and is connected to the retort.
The
operation of checking the tightness of the FA is performed. If the obtained
leak value is less than the permissible helium leak flow (the FA is tight),
then a calibrated helium leak (helit) is connected to the retort to check the
operability of the installation. The leak detector should show the corresponding
leak value. After disconnecting the helit from the retort, the leak value
should return to the background flow from the tight (good) FA.
If the
leak value obtained during FA inspection is greater than or equal to the
permissible helium leak threshold, the FA is considered leaky and is rejected.
Before extracting the FA, nitrogen is released into the retort. The release is
performed through a pipeline connected to the lower part of the retort. The CM
gripper is oriented along the retort axis. Upon reaching the specified CM
positioning coordinates, the vacuum valve is opened.
The CM
gripper is lowered and mated with the FA head. With the help of the CM, the FA
is unloaded from the retort and fed to the subsequent position of the FA assembly
and inspection section. The vacuum valve is closed. The nitrogen supply is
stopped [17].
|
|
|
Fig. 5. Mnemonic diagram and 3D
visualization of the FA leakage control unit
The installation for monitoring the
surface contamination of fuel assemblies is designed to monitor the
contamination of the FA surface using the smear method (see fig. 6). The
installation includes: a retort, a sampling unit, a device for reading FA
markings, and biological protection of the retort.
The FA is lowered
into the retort using the CM through the sampling unit, where the smear is
collected. The samples are collected from the surface of the peripheral fuel
elements when the FA is lowered at a reduced speed. The replacement cartridge
is removed from the sampling unit after the FA is
removed from the retort. The cartridge removed from the clip
is packed in a plastic bag, after which it is sent to the laboratory for
preparation of counting samples and subsequent measurements.
The numerical values
of the dosimetric characteristics of the FA contamination surface
are entered into the FA passport.
Fig. 6.
Mnemonic diagram and 3D visualization of the installation for monitoring the
surface contamination of FA
The FA is delivered to the CM unit,
which moves it from the surface contamination control unit and stops above the
slipway (see fig. 7).
Upon reaching the specified CM positioning coordinates, the weighing device
measures the mass of the FA.
If the mass of the FA is within the
permissible mass values for this type of FA, then the CM carriage
drive is switched on for lowering, which is performed by aligning the FA
marking with the reading device. The CM carriage drive stops, the reading and
transmission of the received FA number to the upper level of the APCS is
performed, after which the FA continues to lower until it is completely
inserted into the slipway. Before lowering, the CM grip opens the tailpiece
lock, moving the lock drive to the lower position. The cycle of checking the FA
entry into the stack includes sequentially performed operations: lifting the CM
carriage until the FA is completely extracted from the stack, turning the CM
grip by 60°, lowering and then lifting the FA, turning the CM grip by 60° and
repeating the lowering/lifting of the FA;
return (rotation)
of the CM grip to the initial position, lowering the CM carriage until the FA
is fully inserted into the pile. The CM carriage drive is stopped and switched
from lowering to lifting after the weighing device readings are reset, while
the full insertion of the FA into the pile is confirmed by the operation of the
FA presence sensor in the pile.
During the movement of the FA in
the slipway, the value of the change in the actual weight of the FA is
constantly monitored (according to the current readings of the weighing device)
with the transfer of the monitoring results to the upper level of the APCS. At
the line control AWS, the monitoring results can be displayed both as current
readings of the weighing device and as maximum values of the
change in the weight of the FA during each lowering/lifting.
If all the
obtained values of the FA weight deviation do not exceed the permissible
values, the operability of the tailstock lock is checked. The CM gripper closes
the tailstock lock, moving the lock drive to the upper position. The result of
the check is determined by the joint operation of the drive movement control
sensor and at least one of the lock collet control sensors.
For FA with
the
RCPS, it is
envisaged to perform operations to control the patency of the FA channel. To
perform this control, the CM gripping device is disconnected from the FA head
and moved from the stock, while a necessary condition for disconnecting the CM
gripping device from the FA head is the activation of the FA presence sensor.
The cycle of
monitoring the patency of the FA channel includes the following sequentially
performed operations: switching on the drive and moving the crossbar of the
control unit of the RCPS to the slipway, switching on the drive of the gripping
device of the RCPS to lower it to the stop in the head the head of the RCPS, which is
confirmed by the sensor of the gripper approach to the RCPS, switching on the
gripper drive and turning it 90° clockwise (gripping the gripper with the head
of the RCPS),
switching
on the drive of the gripping device of the RCPS to raise the upper position
with subsequent switching it to lower the RCPS of the control system to the
lower position. During the movement of the RCPS of the control system in the FA
channel, the value of the change in the weight of the control system. Next, the
following is performed on the installation: turning on the gripper drive and
turning it 90° counterclockwise (disconnecting the RCPS
gripper
from the RCPS
head),
turning on the RCPS
gripper drive to lift to the initial
position, turning on the drive and returning the crossbar to the initial
position (from the slipway), positioning the CM above the slipway and coupling
the CM gripper with the FA.
If the obtained values of
the FA mass and the deviations in the FA weight and the
RCPS
are
within the permissible values and the operability of the
tailstock lock is confirmed, then the FA is considered suitable, and the
control results are entered into the APCS database in the form of a report.
Upon completion of all inspection cycles provided for a given type of FA, the CM
opens the shank lock, removes the FA from the stock and moves it to the
geometry and appearance inspection unit.
If the obtained values
of the FA mass, FA weight deviation or the RCPS go beyond the
permissible values, the monitoring will be continued until the completion of
the current operations of the corresponding cycle (until the FA is removed from
the slipway), after which the monitoring cycle is interrupted and the
monitoring results are entered into the APCS database with the corresponding
defect indicator.
If,
during the inspection of the tailpiece lock, the drive movement control sensor
or none of the lock collet control sensors are triggered, then the CM gripping
device opens the tailpiece lock and the CM carriage is switched on to lift
until the FA is completely removed from the stack, and the inspection results
are entered into the APCS database with the corresponding defect indicator.
All the
above operations with the FA, recognized as defective by any parameter, are
performed without exiting the "Automated" mode. In case of
interruption of control, the CM opens the tailstock lock, extracts the FA from
the stack and moves it to the foaming section [19].
Fig. 7. Mnemonic diagram and 3D
visualization of the installation for monitoring the mass of FA, monitoring the
entry of FA into the slipway
When the CM performs the specified
coordinates, the gripping device of the CM platform opens the tailstock lock,
moving the lock drive to the lower position, after which the CM carriage drive
is switched on for lowering, which is the result of combining the FA card with
the reading device (see fig. 8).
The CM
carriage drive stops, the marking is read and the FA number is transmitted to
the upper level of the APCS of the FA
line. Then the FA
continues to be lowered until it is fully inserted into the retort (until it
lands on the support surface of the centralizer), at which point the FA final
position sensor is triggered.
After the end position sensor of the FA
is triggered, the CM closes the tailpiece lock, disconnects the gripping device
and removes it from the FA head and from the area of action of
the upper sensor of the length measurement device (upper optical micrometer).
After this, the FA length is measured by two optical micrometers located at a
known distance from each other (determined in advance by the FA simulator). The
upper optical micrometer records the position of the upper edge of the FA head,
the lower micrometer is used to determine the position of the lower edge of the
FA tip. The measurement result is transmitted to the upper level of the APCS of
the FA assembly line.
Next, the CM gripper is lowered, it
is coupled with the FA head, and the FA is lifted from the retort. The CM moves
the FA upward until the middle of the lower spacing grid coincides with the
plane in which the spanner size is measured and stops lowering. Two opposite
faces of the spacing grid rim are scanned with laser sensors along lines
perpendicular to the FA axis.
Based on the results of scanning
the profile of the edges of the spacer grid rim and the distance between the
sensors, previously determined by the FA simulator, the "wrench" size
is calculated, and the result is saved. The CM lowers the FA to measure the
middle spacer grid and the "wrench" size is measured, then the
operations are repeated to control the upper spacer grid.
Upon
completion of the inspection of the upper spacer grid, the FA is lowered until
the upper edge of the FA head is in the inspection zone of the external
appearance inspection device, then the “Automated” mode switches to the
“External appearance inspection” section.
After this, the
operator of the
AWS
of the line control (controller) gives
permission to lift the FA and carries out visual inspection of the appearance
using video cameras of the appearance control device by comparing it with the
appearance of the control sample. When checking the appearance, it is possible
to stop lifting, lower the FA and change the image scale.
Upon completion of
the appearance control, the controller enters the control result, the
“Appearance Control” section is closed, and the installation is switched to the
“Automated” mode.
The
CM rotates the FA by 120° relative to the longitudinal axis. After this, the
operations of measuring the "wrench" size and checking the appearance
are repeated on other pairs of faces.
Then the CM rotates the FA to the
position of minus 120° relative to the initial one, after which the operations
of checking the remaining pairs of faces of the lower, middle and upper
lattices and checking the appearance of the remaining faces of the FA are
carried out. If the inspection results are positive, the FA is placed in a case
for shipment to the finished product warehouse. If the spanner size of at least
one pair of edges is outside the tolerance limits or if a discrepancy in
appearance is detected, the FA is sent to the defective product warehouse after
being cased [20].
Fig. 8.
Mnemonic diagram and 3D visualization of the installation for monitoring the
geometry and appearance of FA
Experience in using
three-dimensional models shows the relevance of using virtual reality
technologies in nuclear power engineering. Virtual reality software allows
creating models of technological equipment of nuclear power devices considering
anthropometric characteristics.
The use of reality assessment tools
such as Unity 3D allows us to create an environment for training and modeling
of technological lines, create computational models, and build models with
maximum proximity to reality.
The software and hardware tools in
this study allowed modeling the FA and control section. In this work, certain
FA
control
units were visualized, such as the FA section, the FA washing and drying unit,
the FA leakage control unit,
installation for monitoring the
surface contamination of FA, installation for monitoring the mass of FA,
monitoring the entry of FA into the slipway, the operability of the tail
control mechanism, the
movement of RCPS rods (for FA with RCPS
rods),
installation for monitoring the geometry and appearance of FA.
The results of visualization of
fuel element control installations allow:
– to clearly see the location of
the main components of FA and control.
– to observe the process and
sequence of operations performed during the control installations.
– manage assembly
and control technological operations using video frames.
The developed system
allows training specialists working in the nuclear industry to produce nuclear
power devices.
The
advantage of this development is that it is as close as possible to the
technologies of real equipment, is mobile and does not require large economic costs.
It also ensures a high level of radiation safety and in the future can be
implemented in personnel training centers in the nuclear industry.
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15.
Operation
manual 1099.604.000PE: Installation of head fastening on the frame of the FA
"Siberian Chemical Plant", 2015. - P. 28
16.
Operation
manual A.11.1232.000PE: Installation of unlocking and drying of the FA
"Siberian Chemical Plant", 2018. - P. 24
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Plant", 2016. – P. 31
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manual 1099.595.000RE: Fuel assemblies assembly and test section "Siberian
Chemical Plant", 2017. – P. 45
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50
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manual 1099.608.000RE: Installation for control of geometry and appearance of
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APCS
– automated process control system
AWS
– automated workstation.
BREST
– russian project of fast neutron reactors with lead coolant, dual-circuit heat
removal to the turbine and supercritical steam parameters
CM
– coordinate manipulator
RU
– reactor unit
FA
– fuel assembly
FE
– fuel element
LDST
– leak detector sensitivity threshold
SST
– system sensitivity threshold
LCS
– local control system
RCPS
– reactivity control and protection system rod
C#
– C Sharp programming language
VR
– virtual reality
2D
– two-dimensional space
3D
– three-dimensional space
