Swiss Industries - 20 th June 2012 1 Divertor and Blanket Systems: Design, Required technologies and...

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.


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


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


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


54 Cassettesin a circular array held in position by two concentric radial rails .

Divertor Cassette Layout


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


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


• 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


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


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


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.


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

http://www.iterkorea.org/

http://fusionforenergy.europa.eu/

http://www.iterrf.ru/


Design Heat load on blanket

• Group 1 : 1 – 2 MW/m²Normal heat flux panels

• Group 2 : 3.5 – 5 MW/m²Enhanced heat flux panels


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)


– 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


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.


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.


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 ...


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


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)


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


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.


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


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


• 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

Swiss Industries - 20 th June 2012 1 Divertor and Blanket Systems: Design, Required technologies and...

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