Shield Module Research Articles

Design, performance, and grounding aspects of the International Thermonuclear Experimental Reactor ion cyclotron range of frequencies antenna

ITER's Ion Cyclotron Range of Frequencies (ICRF) system [Lamalle et al., Fusion Eng. Des. 88, 517–520 (2013)] comprises two antenna launchers designed by CYCLE (a consortium of European associations listed in the author affiliations above) on behalf of ITER Organisation (IO), each inserted as a Port Plug (PP) into one of ITER's Vacuum Vessel (VV) ports. Each launcher is an array of 4 toroidal by 6 poloidal RF current straps specified to couple up to 20 MW in total to the plasma in the frequency range of 40 to 55 MHz but limited to a maximum system voltage of 45 kV and limits on RF electric fields depending on their location and direction with respect to, respectively, the torus vacuum and the toroidal magnetic field. A crucial aspect of coupling ICRF power to plasmas is the knowledge of the plasma density profiles in the Scrape-Off Layer (SOL) and the location of the RF current straps with respect to the SOL. The launcher layout and details were optimized and its performance estimated for a worst case SOL provided by the IO. The paper summarizes the estimated performance obtained within the operational parameter space specified by IO. Aspects of the RF grounding of the whole antenna PP to the VV port and the effect of the voids between the PP and the Blanket Shielding Modules (BSM) surrounding the antenna front are discussed. These blanket modules, whose dimensions are of the order of the ICRF wavelengths, together with the clearance gaps between them will constitute a corrugated structure which will interact with the electromagnetic waves launched by ICRF antennas. The conditions in which the grooves constituted by the clearance gaps between the blanket modules can become resonant are studied. Simple analytical models and numerical simulations show that mushroom type structures (with larger gaps at the back than at the front) can bring down the resonance frequencies, which could lead to large voltages in the gaps between the blanket modules and perturb the RF properties of the antenna if they are in the ICRF operating range. The effect on the wave propagation along the wall structure, which is acting as a spatially periodic (toroidally and poloidally) corrugated structure, and hence constitutes a slow wave structure modifying the wall boundary condition, is examined.

Mechanical Performance of the ITER ELM Coils' Bracket Material of Inconel 625

The effects of edge localized modes (ELMs) in ITER Tokamak device are being designed to be addressed by the ELM coils. The designed ELM coils include nine toroidal sectors of three (upper, midplane, and lower) six-turn stainless steel jacketed mineral insulated coils. They will be mounted to the vacuum vessel wall behind the blanket shield modules, and fixed by a series of brackets. Mechanical performance of the brackets should achieve the design requirements to resist with the special challenges, such as the nuclear radiation (~ 3000 MGy), high temperature (~ 200°C), as well as bearing the additional loads from ELM coils. Inconel 625 is designed to manufacture the ITER ELM coils' brackets. This paper focuses on the mechanical performance of Inconel 625 materials after forging and heat treatment, especially the fatigue performances. The tensile properties and the fatigue crack growth rate of Inconel 625 after forging and heat treatment have been tested at room temperature. The test results show that the mechanical properties of the Inconel 625 material fit the design requirement.

Development of the breeding blanket and shield model for the fusion power reactors system SYCOMORE

SYCOMORE, a fusion reactor system code based on a modular approach is under development at CEA. Within this framework, this paper describes the relevant sub-modules which have been implemented to model the main outputs of the breeding blanket and shield block of the system code: tritium breeding ratio, peak energy deposition in toroidal field coils, reactor layout and power deposition, blanket pressure drops and materials inventory.Blanket and shield requirements are calculated by several sub-modules: the blanket assembly and layout sub-module, the neutronic sub-module, the blanket design sub-module (thermal hydraulic and thermo-mechanic pre-design tool). A power flow module has also been developed which is directly linked to the blanket thermo-dynamic performances, which is not described in this paper.For the blanket assembly and layout and the blanket module design sub-modules, explicit analytic models have been developed and implemented; for the neutronic sub-module neural networks that replicate the results of appropriate simplified 1D and 2D neutronic simulations have been built. Presently, relevant model for the Helium Cooled Lithium Lead is available.Sub-modules have been built in a way that they can run separately or coupled into the breeding blanket and shield module in order to be integrated in SYCOMORE.In the paper, the objective and main input/output parameters of each sub-module are reported and relevant models discussed. The application to previous studied reactor models (PPCS model AB, DEMO-HCLL 2006–2007 studies) is also presented.

Prototyping of the Blanket Shield Module for the ITER EC H&CD Upper launcher

The design of the ITER Electron Cyclotron Heating and Current Drive (ECH&CD) Upper launcher is recently in the first of two final design phases. The first phase deals with the finalization of all FCS (First Confinement System) components as well as with specific design progress for the remaining In-vessel components.The most outstanding structural In-vessel component of an ECH&CD Upper launcher is the Blanket Shield Module (BSM) with the First Wall Panel (FWP). Both of them form the plasma facing part of the launcher, which has to meet strong demands on dissipation of nuclear heat loads and mechanical rigidity. Nuclear heat loads from 3MW/m3 at the First Wall Panel’ surface, decaying down to a tenth in a distance of 0.5m behind of it will affect the BSM and the FWP. Additional heating of maximum 0.5MW/m2 due to plasma radiation must be dissipated from the FWP.To guarantee save and homogenous removal of such extensive heat loads, the BSM is designed as a welded steel-case with specific cooling channels inside its wall structure. Attached to its face side is the FWP with a high-power cooling structure.Based on computational analysis the optimum cooling channel geometry has been investigated. Specific pre-prototype tests have been made and associated assembly parameters have been determined in order to identify optimum manufacturing processes and joining techniques, which guarantee a robust design with maximum geometrical accuracy.This paper describes the design, manufacturing and testing of a full-size mock-up of the BSM. The study was carried out in an industrial cooperation with MAN Diesel and Turbo SE.

The remote handling compatibility analysis of the ITER generic upper port plug structure

The ITER diagnostics generic upper port plug (GUPP) is developed as a standardized design for all diagnostic upper port plugs, in which a variety of payloads can be mounted. Here, the remote handling compatibility analysis (RHCA) of the GUPP design is presented that was performed for the GUPP final design review. The analysis focuses mainly on the insertion and extraction procedure of the diagnostic shield module (DSM), a removable cassette that contains the diagnostic in-vessel components. It is foreseen that the DSM is a replaceable component – the procedure of which is to be performed inside the ITER hot cell facility (HCF), where the GUPP can be oriented in a vertical position.The DSM removal procedure in the HCF consists of removing locking pins, an M30 sized shoulder bolt and two electrical straps through the use of a dexterous manipulator, after which the DSM is lifted out of the GUPP by an overhead crane. For optimum access to its internals, the DSM is mounted in a handling device. The insertion of a new or refurbished DSM follows the reverse procedure.The RHCA shows that the GUPP design requires a moderate amount of changes to become fully compatible with RH maintenance requirements.

Multiaxial fatigue analysis for IMIC of ITER upper ELM coil

Inconel Jacketed Mineral Insulated Conductor (IMIC) is a very important component of International Thermonuclear Experimental Reactor (ITER) Edge Localized Modes (ELM) coils, which are located between the vacuum vessel (VV) and blanket shield modules and subject to high radiation levels, high temperature and high magnetic field. These coils will experience thermal pulsed, cyclic electromagnetic (EM) load during operation. They are designed to sustain at 1.5e8 total stress cycles and shall have sufficient strength and excellent fatigue to transport and bear the high cyclic load. For IMIC, multiaxial fatigue analysis is used to evaluate failure. Two methods based on the alternating stress and mean stress in American Society of Mechanical Engineers (ASME) code provide the design codes for multiaxial fatigue evaluation: constant principal stress direction and variation of principal stress direction. Results show that using the two methods obtains basically the same equivalent alternating stress. Both of them can be recommended for the ELM coils and IMIC can meet the fatigue criteria.

Progress of the ECRH Upper Launcher design for ITER

The design of the ITER ECRH system provides 20MW millimeter wave power for central plasma heating and MHD stabilization. The system consists of an array of 24 gyrotrons with power supplies coupled to a set of transmission lines guiding the beams to the four upper and the equatorial launcher. The front steering upper launcher design described herein has passed successfully the preliminary design review, and it is presently in the final design stage. The launcher consists of a millimeter wave system and steering mechanism with neutron shielding integrated into an upper port plug with the plasma facing blanket shield module (in-vessel) and a set of ex-vessel waveguides connecting the launcher to the transmission lines.Part of the transmission lines are the ultra-low loss CVD torus diamond windows and a shutter valve, a miter bend section and the feedthroughs integrated in the plug closure plate. These components are connected by corrugated waveguides and form together the first confinement system (FCS). In-vessel, the millimeter-wave system includes a quasi-optical beam propagation system including four mirror sets and a front steering mirror. The millimeter wave system is integrated into a specifically optimized upper port plug providing structural stability to withstand plasma disruption forces and the high heat load from the plasma side with a dedicated blanket shield module. A recent update in the ITER interface definition has resulted in the recession of the upper port plug first wall panels, which is now integrated into the design. Apart from the millimeter wave system the upper port plug houses also a set of shield blocks which provide neutron shielding. An overview of the actual ITER ECRH Upper Launcher is given together with some highlights of the design.

Optimization of millimeter wave system in ITER Equatorial EC H&CD Launcher

A high power (20MW) and CW millimeter wave (mm-wave) injection is planned for Electron Cyclotron Heating and Current Drive (EC H&CD) in ITER. An optimization of the mm-wave system for the ITER EC H&CD Equatorial Launcher (EL) is performed. The optimization of the system is aimed to obtain the maximum transmission efficiency on the condition that 1.8MW injection per waveguide, ∼20cm in beam radius at the resonance layer and narrow opening of the Blanket Shielding Module (BSM). The transmission efficiency of 99.1% from the end of the waveguide inside the launcher to the output of the BSM is achieved.The mm-wave propagation with high order modes is also calculated by using an experimentally obtained high power mm-wave beam pattern that includes 95%HE11, 0.6%LP11, 0.2%LP02 and 4.2% other higher order modes. The analysis predicts the 1–2% additional loss will be induced by the high order modes.

Investigation and analysis on ITER in-vessel coils’ raw-materials

The ITER in-vessel coils (IVCs) consist of 27 coils edge localized modes (ELM) and 2 coils vertical stabilization (VS) which are all mounted on the vacuum vessel wall behind the shield modules. The IVCs design and manufacturing work is being conducted in between Institute of Plasma Physics Chinese Academy of Sciences (ASIPP) and Princeton Plasma Physics Laboratory (PPPL). Because the position of ELM and VS coils is close and face to the plasma, the IVCs must undergo a severe environment, such as the high dose of radiation and high operation temperature, thus the conventional electrical insulation materials cannot be used. And the technology of “Stainless Steel Jacketed Mineral Insulated Conductor” (SSMIC) is deemed as the best choice to provide the necessary radiation resistance and compatibility strength in ITER's vacuum vessel. While mineral insulated conductor technology is not new, and is similar to the mineral insulated cable used in industrial. Some difficulties still need to be solved, such as searching for the proper raw-materials to make sure that the conductor have the properties of high current carrying capability, the necessary radiation resistance, the proper strength, at the same time, it must be come true in manufacture technology. This paper described the analysis of the materials for VS and ELM coil conductor.

Lessons learned from the design and fabrication of the baffles and heat shields of Wendelstein 7-X

The baffles and heat shields of the wall protection of the Wendelstein 7-X stellarator are actively water cooled components based on the same technology. Fine grain graphite tiles are clamped onto a CuCrZr heat sink, which is vacuum brazed to a stainless steel tube. The baffles are part of the divertor and improve the divertor pumping efficiency. The heat shields protect the plasma vessel wall, water piping, cables and the integrated diagnostics. The 170 baffles with 25 variants and 162 heat shield modules with 85 variants comprise a total surface of 33m2 and 51m2, respectively. Design guidelines enabled as much as possible the standardization of the fabrication to allow for a more efficient work organization. Individual jigs have been manufactured for each variant in order to weld, bend and mill the different parts of the baffles and heat shields to the required 3D accuracy. At the end of the manufacturing process, each component has been checked and documented according to a detailed quality plan.

The ITER EC H&CD Upper Launcher: Analysis of vertical Remote Handling applied to the BSM maintenance

This paper deals with Remote Handling activities foreseen on the Blanket Shield Module, the plasma facing component of the ITER Electron Cyclotron Heating and Current Drive Upper Launcher. The maintenance configuration considered here is the Vertical Remote Handling, meaning gravity acting along the launcher radial axis. The plant, where the maintenance under consideration is occurring, is the Hot Cell Facility Work Cell.The study here reported has been carried out within the presently ongoing EFDA Goal Oriented Training program on Remote Handling (GOT-RH), which aims to support ITER activities. This document and its contents have to be considered as part of a more vast RAMI analysis to be developed within the GOT-RH, which aims to maximize the Electron Cyclotron Heating and Current Drive system availability.The Baseline CAD model of the Electron Cyclotron Heating and Current Drive Upper Launcher is currently in its preliminary design phase and does not provide enough details for developing a fully detailed maintenance strategy. Therefore, through a System Engineering approach, a set of assumptions was conceived on the launcher structure, as a basis for development of a Remote Handling strategy. Moreover, to compare different design solutions related to the possibility of integrating a quasi-optical component into the Blanket Shield Module, a Trade-Off was made, and its contents are shown here.The outcome of this System Engineering approach has been formalized into Task Definition Forms whose contents are reported here. The Remote Handling strategy presented in this work will be tested in the near future both through Virtual Reality simulations and through prototype experiments.

Preliminary design of the ITER ECH Upper Launcher

The design of the ITER electron cyclotron launchers recently reached the preliminary design level - the last major milestone before design finalization. The ITER ECH system contains 24 installed gyrotrons providing a maximum ECH injected power of 20MW through transmission lines towards the tokamak. There are two EC launcher types both using a front steering mirror; one equatorial launcher (EL) for plasma heating and four upper launchers (UL) for plasma mode stabilization (neoclassical tearing modes and the sawtooth instability). A wide steering angle range of the ULs allows focusing of the beam on magnetic islands which are expected on the rational magnetic flux surfaces q=1 (sawtooth instability), q=3/2 and q=2 (NTMs).In this paper the preliminary design of the ITER ECH UL is presented, including the optical system and the structural components. Highlights of the design include the torus CVD-diamond windows, the frictionless, front steering mechanism and the plasma facing blanket shield module (BSM). Numerical simulations as well as prototype tests are used to verify the design

Challenges of ITER diagnostic electrical services

Diagnostic electrical services provide the electrical infrastructure to serve diagnostic components installed on the ITER tokamak. This infrastructure is composed of cables, connectors, cable tails, looms, conduits and feedthroughs. The diagnostic services offer as well a shelter for various instrumentations – vacuum vessel (VV), blanket and divertor. The diagnostic sensors are located on the inner and outer VV wall, on blanket shield modules, divertor cassettes and in port plugs. They require electrical cabling to extract the measurement and, in some cases, to supply electrical power to the sensors. These cables run from the sensors to feedthroughs on the VV and the port interspace or cryostat.The design and integration of all components that are part of diagnostic electrical services is an important engineering activity that is being challenged by the multiple requirements and constraints which have to be satisfied while at the same time delivering the required diagnostic performance. The positioning of the components must correlate not only with their functional specifications but also with the design of the major ITER components. This is a particular challenge because not all systems have reached the same level of design maturity.This paper outlines the engineering challenges of ITER diagnostics electrical services. The environmental conditions inside the VV will have an important impact. Leading risks to these components include poor electrical contact at connectors, the effects of exposure to nuclear irradiation, such as material transmutation, heating, and generation of spurious electrical signals etc., failure due to electromagnetic forces and electrical interference due to the noisy environment. Last but not least are the challenges for confinement and vacuum requirements set up on electrical feedthroughs. It will focus as well on the design and structural assessment of all components, and their requirements. Besides the integration limitations, the loads are the main design driver.

Retractable tube design issues in ITER CXRS UPP #3

The retractable tube is located in the upper port plug #3 of ITER core charge exchange recombination spectroscopy (cCXRS), where it is surrounded by a set of mirrors, diagnostic shielding module (DSM), outer shell, cleaning device and shutter. Accordingly to the recent port plug concept the tube is an optional unit that carries the cleaning system of the first mirror. The cleaning device shall be a compact instrument at the tube head that influences the tube diameter primarily. Independently of the cleaning device the tube cooling channels and its proper support concept has to be developed.Various manufacturing methods are investigated for the proper layout of the tube cooling structure. They are the gun-drilled deep holes, the solid state bonded sheets forming cooling channels between the welded layers, ‘tube-in-tube’ approach. Most of them were analyzed in view of their thermal conditions.The tube support system design is a complex task, that has to take into account several boundary conditions and limitations. The tube must be compatible with the assumed ITER generic installation procedure, withstand the electromagnetic (EM) and thermal loads. Furthermore, the tube has to be exchanged several times during its lifetime.The paper summarizes the tube cooling layout possibilities and the assumptions on its support concepts.

Results of an integration study of a diagnostics port plug in ITER

Diagnostics in ITER are mandatory to characterize the parameters of plasma and study its interactions with plasma-facing components. Diagnostics components in the vicinity of the plasma are supported by metallic structures called port plugs. At the tokamak mid-plane, these components are installed in port plugs through intermediate structures called drawers. Apart from hosting the diagnostics, the port plugs act as shielding against neutrons and gammas, in order to limit the nuclear loads in crucial components (such as diagnostics and superconducting coils) as well as the dose levels in the controlled zones of the tokamak. The radiation shielding function of the port plugs is ensured through an optimized mixture of heavy metallic materials and water, forming shielding blocks surrounding the diagnostics and called Diagnostic Shield Modules (DSMs). These DSMs constitute the rear part of the drawers (the front part being composed of the Diagnostic First Wall). This paper presents the main results of a study performed in Europe on the integration of a particular diagnostics port plug, the Equatorial Port Plug 1 (EPP1). The paper first provides the results of the EPP1 diagnostics integration analysis. In a second step it focuses on the design of the EPP1 DSMs and summarizes the major results of a thorough set of analyses aiming at studying the DSMs behaviour under different loads, suggesting recommendations to improve their current design.

Influence of the blanket shield modules geometry on the operation of the ITER ICRF antenna

Three-dimensional electromagnetic simulations of the ITER ICRF antenna have been recently performed with the commercial code CST Microwave Studio® (MWS) [1]. A detailed model imported from the CATIA® file has been considered: it includes the 24 straps array (CY3.1 geometry [2]) and the surrounding blanket shield modules. The transient solver in MWS has detected the presence of a very localized peak in the input impedance matrix at a frequency of approximately 51MHz in vacuum conditions. The presence of such a resonance in the ITER operating range of frequency is of concern and should be understood as previous analysis reported in [3] concluded that TEM and non-TEM modes are not expected in this frequency band as long as the antenna is grounded to the port at 1m back from the antenna front face. By using a simplified model of the geometry we demonstrate that the resonance is a consequence of the considered geometry of the blanket shield modules and in particular of the cavity at the back of the modules made of the module attachment and the port plug outer face. We show that the presence of such a cavity locally increases the coaxial line impedance and allows for a TEM mode in the band. This physical analysis is supported by a transmission line model where the system made of the antenna and its surrounding port is approximated by a rectangular coaxial line.

Fast shutter concepts for the new ITER core CXRS upper port plug baseline considering the actuator located inside and outside the port plug

For the ITER core charge exchange recombination spectroscopy (CXRS) upper port plug #3 (UPP) diagnostics, a fast shutter is necessary for the first optical mirrors. The shutter concept for the reference CXRS layout has been well developed and studied focusing on the structure dynamic behavior. This paper presents two shutter concepts for the new baseline layout. Concept-1 is similar to the reference concept, including the helium actuator attached to the diagnostic shielding module (DSM) in the primary vacuum. Concept-2 considers the actuator outside the primary vacuum. It is attached to the back side of the UPP and connected to the shutting mechanism with a push–pull rod. Assembly and disassembly, actuator location, and actuation type are key issues for concept assessment. For a feasibility study, two different leak cases for the shutter concepts have also been analyzed. Concept-1 requires a specialized actuator design compatible with the in-vessel conditions. The actuator size is limited by the lack of available space in the DSM. This option needs complex procedures to access the actuator for maintenance. Concept-2 allows the use of standard pneumatic/hydraulic actuators and other industrial components. Space allocation is needed inside the UPP to accommodate the push–pull rod system. Concept-2 allows independent maintenance procedures for the actuator(s) and the shutting mechanism. It was generally concluded that both options are suitable for the new baseline layout, and are to be studied in detail.

The ITER EC H&CD upper launcher: Design, analysis and testing of a bolted joint for the Blanket Shield Module

The final design of the structural system for the ITER EC H&CD upper launcher is in progress. Many design features of the preliminary design are under revision with the aim to achieve the built-to-print-status. This paper deals with design and analysis of a bolted joint for the Blanket Shield Module with special perspective on Remote Handling capability. The BSM of the ECH Launcher is attached to the Launcher Main Frame by a bolted joint conceived so that in the Hot Cell Facility, RH maintenance can be performed on internal components. The joint must be capable to resist very high Electro-Magnetic loads from disruptions, while it has to sustain substantial thermal cycling during operation. Thus the need for a rigid and reliable design is essential. Beside the set of pre-stressed bolts the flanges were therefore equipped with additional shear keys to divert radial moments away from the bolts. Main focus of the work performed was the mechanical design of the joint and the assessment of the structural integrity with respect to the loads applied and its capability for maintenance by RH procedures. To fulfill a major aspect of the RH requirements, the bolts were designed as “captive” in order to avoid their accidental removal from the joint. The captive bolt design is based on a concept that uses a dedicated spring ring, a standard spiral spring and a tensioning screw with two threads to secure the bolts in a form-locking stop. The final approval phase of the RH compatibility foresees simulations in Virtual Reality and physical tests on prototypes.

The ITER EC H&CD Upper Launcher: Maintenance concepts

Maintenance of the ITER EC H&CD Upper Launcher (UL) shall be performed through the use of Remote Handling (RH) in the ITER Hot Cell Facility (HCF). The UL design will have to be fully compliant with ITER RH maintenance requirements and the set of RH tooling and services available in the HCF. This paper describes the development of an overall maintenance strategy for the UL, starting from a listing of all conceivable maintenance operations, including hands-on tasks. Components for which design concepts are discussed in this paper are the Blanket Shield Module (BSM), the steering mirror (M4), the mid optics (M1, M2) and the waveguide (WG) feed-through plate. Aspects related to RH documentation, overall maintenance strategy and design concepts for optimizing the maintainability of the UL are presented.

Electromagnetic analysis of ITER diagnostic equatorial port plugs during plasma disruptions

ITER diagnostic port plugs perform many functions including structural support of diagnostic systems under high electromagnetic loads while allowing for diagnostic access to the plasma. The design of diagnostic equatorial port plugs (EPP) are largely driven by electromagnetic loads and associate responses of EPP structure during plasma disruptions and VDEs. This paper summarizes results of transient electromagnetic analysis using Opera 3d in support of the design activities for ITER diagnostic EPP. A complete distribution of disruption loads on the diagnostic first walls (DFWs), diagnostic shield modules (DSMs) and the EPP structure, as well as impact on the system design integration due to electrical contact among various EPP structural components are discussed.