swiss industries - 20 th june 2012 1 divertor and blanket systems: design, required technologies and...
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Swiss Industries - 20th June 2012 1
Divertor and Blanket Systems:
Design, Required technologies and Schedule
M. MerolaHead of the Internal Components Division
The views and opinions expressed herein do not necessarily reflect those of the ITER Organization.
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ITER Internal Components
• Divertor and Blanket directly face the thermonuclear plasma and cover an area of about 210 + 620 m2, respectively.
• All these removable components are mechanically attached to the Vacuum Vessel or Vessel Ports.
• Max heat released to the internal components during nominal pulsed operation: ~850 MW
• Removed by four independent water loops at 4 MPa water pressure, ~70 (inlet), ~120 (outlet) °C
Blanket
Divertor
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Overview of Material Mass
Material Application Mass (ton)
Divertor components
W Armor material 53
CFC Armor material 3
Cu and Cu alloy Pipes, heat sink, functional material 10
Steel Structural parts, pipes 430
Ni Al bronze Knuckle & Nose, pins 21
Blanket components
Be Armor material 10
Cu and Cu alloy Pipes, heat sink, functional material 85
Steel Structural parts, pipes 1400
Ni Al bronze Pads, etc. tbc
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Divertor system main functions :
• Exhaust the major part of the plasma thermal power (including alpha power)
• Minimize the helium and impurities content in the plasma
ITER Divertor
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54 Cassettesin a circular array held in position by two concentric radial rails .
Divertor Cassette Layout
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Divertor System
Scope- 54 Divertor assemblies- 4320 Heat flux elements- 5 Major systems:
Cassette Body + Integration
Outer Vertical Target
Inner Vertical Target
Dome
Plasma-Facing Comp Tests
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Power HandlingHIGH HEAT FLUX
COMPONENTSFOSSILE FIREDBOILER WALL
(ABB)
FISSION REACTOR
(PWR) CORE
ITER DIVERTOR
DESIGN
12/15 mm ID/OD
HEAT FLUX
- average MW/m2
- maximum MW/m2
0.20.3
0.71.5
3 – 510 – 20
Max heat load MJ/m2
Lifetime yearsNr. of full load cyclesNeutron damage dpaMaterials
-25
8000-
Ferritic-Martens. steel
-4
1010
Zircaloy - 4
10~ 5-8
3000 - 160000.2
CuCrZr & CFC/W
Coolant- pressure MPa- temperature °C- velocity m/s- leak rate g/s
Water-Steam28
280-6003
<50
Water15
285-3255
<50(SG)
Water4
100 – 1509 – 11<10-7
Comparisons
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• First Divertor (CFC/W) is well into procurement phase (5 PAs)
− PFCs: Last PA signed March 2010. Definition of QA for all parties done. Preparation for prototype manufacturing.
− HHF Testing facility in RFDA: PA signed March 2010. Commissioning planned July 2012.
− Cassette Body and integration: PA signature 8th May 2012
Status of Divertor
HHF testing of Plasma Facing Units
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400 mm
Tungsten
CFC
All 3 Domestic Agencies have been qualified.
CFC Armoured Areas1000 cycles at 10 MW/m2
1000 cycles at 20 MW/m2
W Armoured Areas1000 cycles at 3 MW/m2
1000 cycles at 5 MW/m2
Divertor Qualification Prototypes
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Status of W Technology R&D in EU
2000 cycles at 15 MW/m2 on W
Most of all the W repaired monoblocks behaved like not-repaired ones
200°C, 0.1 and 0.5 dpa in tungsten- Successfully tested up to 18 MW/m2
Unirradiated- 1000 cycles x 20 MW/m2 – no failure
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Blanket System Functions
Main functions of ITER Blanket System:
• Exhaust the majority of the plasma power.
• Contribute in providing neutron shielding to superconducting coils.
• Provide limiting surfaces that define the plasma boundary during startup and shutdown.
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Mod
ules
1-6
Modules 7-10
Mod
ules
11-
18
~1240 – 2000 mm
~85
0 –
1240
mm
Shield Block (semi-permanent)
FW Panel (separable) Blanket Module50% 50% 50% 40%10%
Blanket System
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Design Heat load on blanket
• Group 1 : 1 – 2 MW/m²Normal heat flux panels
• Group 2 : 3.5 – 5 MW/m²Enhanced heat flux panels
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First Wall Finger Design
SS Back Plate
CuCrZr AlloySS Pipes
Be tiles
Be tiles
Normal Heat Flux Finger:• q’’ = ~ 1-2 MW/m2 • Steel Cooling Pipes• HIP’ing
Enhanced Heat Flux Finger:• q’’ < ~ 5 MW/m2 • Hypervapotron• Explosion bonding (SS/CuCrZr) + brazing
(Be/CuCrZr)
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– Each DA must demonstrate technical capability prior to start procurement.
– 2 phase approach:
I. Demonstration/validation joining of Be/CuCrZr and SS/CuCrZr joint (done)
II. Semi-prototype production/validation of large scale components (on-going)
FW Pre-Qualification Requirements
6 Fingers in 1 to 1 scale
2 slopes, 4 facets
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Shield Block Design
• Slits to reduce EM loads and minimize thermal expansion and bowing • Poloidal coolant arrangement.• Cut-outs at the back to accommodate many interfaces (Manifold,
Attachment, In-Vessel Coils).• Basic fabrication method from either a single or multiple-forged steel blocks
and includes drilling of holes, welding of cover plates of water headers, and final machining of the interfaces.
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Blanket Manifold
• A multi-pipe configuration has been chosen, with each pipe feeding one or two BM’s replacing the previous baseline with a large single pipe feeding several BM’s
- Higher reliability due to drastic reduction of number of welds and utilization of seamless pipes.
- Higher mechanical flexibility of pipes.
- Superior leak localization capability due to larger segregation of cooling circuits.
- Well established manifold technologies.
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Tolerances
General Tolerances described in Standards do NOT always meet our requirementsISO 2768-1:1989 Tolerances for linear and angular dimensions …ISO 2768-2:1989 Geometrical tolerances ...
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Key Technology AreasWelded structures made of austenitic steels:
NG-TIG, EB, Laser, TIG, MIG, …
High heat flux joining technologies (Tungsten, Beryllium, CuCrZr):HIP’ing, brazing, casting, EB
Heat Flux Testing of actively cooled components
Non-destructive Examinations RX, UT, …
Piping, flexible supports for pipes
Insulating coatings, Low friction coatings, Anti-size coatings
Precise machining, metrology
High-Vacuum technologies, Pressure Tests, He Leak Tests
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Manufacturing / Welding Qualifications
Qualification of Welding Procedure Specification (WPS)
• WPS according to EN ISO 15607 and EN ISO 15609-nn• Preliminary WPS is qualified according to EN ISO 15614-nn• Qualification if quality level B achieved
• EN ISO 5817 for arc welding• EN ISO 13919 serie for power Beam welding
• Welding Procedure Qualification Record (WPQR)
Other equivalent national or international standards and codes may be acceptable subject to the IO’s written approval.
The welding qualification for Quality Class 1 components shall be witnessed by ITER recognized Independent Inspection Authority, e.g. Third Party Inspector.
Welders, operators and NDT personnel shall be qualified (EN 287/ EN1418/ EN 473)
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NDT of welds in Steel Supports
N.B. ITER Vacuum Handbook requirement: use of qualified liquid penetrants
o Radiographic test for welds (EN 1435)o Ultrasonic Test for welds (EN 22825)
o Visual Test for welds (EN 970)o Liquid Penetrant Test for welds (EN 571)
Volumetric examination
Other equivalent national or international standards and codes may be acceptable subject to the IO’s written approval.
o Quality level B of EN ISO5817/ EN ISO 13919o ITER Vacuum Handbook Attachment 1: Welding
Surface crack examination
Acceptance Criteria
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Engineering Support Services
Design supporting analysis (Electro-Magnetic, thermal, mechanical)
Development of component design, including the production of 2D drawings and 3D models. This activity requires the possibility to receive and deliver CAD files in of CATIA_V5 format.
Good knowledge and understanding of the codes, standards, and design criteria used in ITER.
The work may require the presence of the Contractor’s personnel at the working site of the ITER Organization, for extended periods of time, for the purpose of design review and data gathering.
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Divertor Procurement Schedule
• 17.P2C.RF Divertor Dome: signed 9th June 2009
• 17.P2A.JA Divertor Outer Target: signed 17th June 2009
• 17.P2D.RF Divertor Heat Flux Tests: signed 23rd February 2010
• 17.P2B.EU Divertor Inner Target: signed 22nd March 2010
• 17.P1.EU Divertor Cassette and Integration: signed 8th May 2012
• 17.P2E.EU Divertor Rails: September 2014
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Blanket Procurement Schedule
• 16.P1A.CN/EU/RF Blanket First Wall: November 2013
• 16.P1B.CN/KO Blanket Shield Block: November 2013
• 16.P3.RF Blanket Module Connections: July 2014
• 15.P1A.EU Blanket Manifolds: March 2014
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• The ITER plasma facing components are one of the most technically challenging components of the ITER machine
• An extensive R&D effort has been carried out world-wide to develop suitable high heat flux technologies
o Divertor plasma-facing componentso Blanket First Wall
• The ITER Divertor design and R&D has reached a stage of maturity to allow the start of procurement in June 2009
• Substantial engineering effort (design and analysis) is planned for the Blanket System in 2012
• Key technology areas includes: o Austenitic steel welding (Divertor cassette, Blanket shield block)o Piping (Blanket manifold)o Precise machining of metallic materials (Divertor rails)
Summary and Conclusions