Assembly and Disassembly EMAD Harold P Gerrish Jr Marshall Space Flight Center June 28 2017 2 History The EMAD complex was designed to provide for assembly disassembly and post operative examination of hot nuclear reactors following test operations ID: 783181
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Slide1
1
NERVA Engine
Maintenance Assembly and Disassembly (E-MAD)
Harold P. Gerrish Jr
Marshall Space Flight Center
June
28, 2017
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History
The E-MAD complex was designed to provide for assembly, disassembly, and post operative examination of hot nuclear reactors following test operationsLocation is Area 25 of the Nevada Test Site. ~25 acresDesign radiation level was on the order of 1x10
6
R/hr
Construction completed 1965. Total cost $50M (1965)
1992 Assessment of EMAD estimated complete replacement value of facility $2.5B and refurbishment $52.3M (>$93M today)
Currently undergoing closure
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E-MAD Aerial Views
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Overall Statistics
80’ high (to highest roof point) and 75,000 ft2 of floor space.Heated, ventilated and cooled by 11 separate systems.600 kW lighting
75,000 gallon water storage tank
31 power operated shield doors
40 lead glass shield windows
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First Floor Plan
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Cold Bay
140’ long x 72’ wide x 60’ high40 ton bridge crane
34’ diameter turntable with railroad track handles 100 ton
Contains engine assembly stand
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Hot Bay
140’ long, 66’ wide, and 74’ high.Walls 5-6’ thick, ceiling 32” nominal thickness.40 ton overhead crane with 10 ton auxiliary remotely operated.
Handling system with special tools and fixtures to facilitate remote assembly and disassembly operations.
Work stations at viewing windows are provided with master slave manipulators and detail inspection tables.
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Engine Installation Vehicle (EIV)
and Manned Control Car (MCC)EIV-vehicle used in conjunction with MCC to install and remove the NTP from the test stand.
EIV can inch the engine with six degrees of freedom, cameras, remote manipulator system, and nozzle closure system
MCC- Shield cab with life support for two operators for 4 hours
EIV
MCC
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Wall Mounted Handling System (WMHS)
Two identical articulated traveling boom assemblies33’ reach and can remotely interchange manipulator headsMaximum load carrying capacity in any position 600 lbs
Rotational torque of the wrist 400 ft-lbs
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Overhead Positioning System (OPS)
Consists of traveling bridge, carriage, telescoping mast, and auxiliary manipulator. Head fixture provides rotationBridge travel 47’, mast extension 40’, manipulator 11’ extensionMast capacity 40,000 lbs, manipulator can handle 600 lbs
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Other Manipulators
Process cells and hot cells are used to disassemble reactor core into basic components.Bridge mounted rectilinear manipulator and master slave manipulators