KSTAR Conference 2014 Gangwan-do, Korea, 24-26th February 2014 Design of the Common Structure to Install the ITER Diagnostic Systems into the Vacuum Vessel S. Pak a , J-M Drevon b , R. Feder d , J. Guirao b , T. Giacomin b , S. Iglesias b , F. Josseaume b , G.D. Loesser d , P. Maquet b , M. Portales b , M. Proust b , S. Pitcher b , A. Serikov c , A. Suarez b , V. Udintsev b , C. Vacas b , M.J. Walsh b , Y. Zhai d a National Fusion Research Institute, Daejeon, Korea b ITER Organization, St Paul-lez-Durance, France c Karlsruhe Institute of Technology, Eggenstein-Leopoldshafen, Germany d Princeton Plasma Physics Lab, Princeton, NJ, USA KSTAR Conference 2014 1/20 24-26 February 2014
Outline Introduction to ITER port- based diagnostics Generic port plug for diagnostics Engineering challenges • Structural integrity • Port plug handling for installation • Neutron shielding • Maintenance by remote handling • French regulations: nuclear pressure equipment (ESPN), safety (Order 1984) • Manufacturing • Interface with VV port seal flange Summary KSTAR Conference 2014 2/20 24-26 February 2014
Introduction to ITER Port-based Diagnostics ITER has approximately 45 diagnostic systems to measure the plasma and condition of the first-wall KSTAR Conference 2014 3/20 24-26 February 2014
Introduction to ITER Port-based Diagnostics Among 18 ports at the upper and equatorial level, 10 Upper Ports and 8 Equatorial Ports are dedicated to diagnostics. These port plugs host 80 % of ITER diagnostics. KSTAR Conference 2014 4/20 24-26 February 2014
Introduction to ITER Port-based Diagnostics Port-based diagnostics are installed in three distinct areas: Port plug, interspace, and port cell. Port Plug Interspace Port Cell Systems Tenant DA Design Level VUV KO CDR NAS KO CDR UVNC RF Pre-CDR Port Integration in upper port #18 KSTAR Conference 2014 5/20 24-26 February 2014
Generic Port Plug for Diagnostics The port plug structure is a common platform to install the in-port plug diagnostic components. 1.9 m 3.1 m 1.3 m 6 m 1.3 m 2.4 m 25 tons 45 tons Upper Port Plug Equatorial Port Plug KSTAR Conference 2014 6/20 24-26 February 2014
Generic Port Plug for Diagnostics The port plug consists of diagnostic first wall (DFW), diagnostic shield module (DSM), and port plug structure. A simple metal box, but a leading component for DFW/DSM and diagnostic design. Final Design Review done by IO in June 2013 No major issue (no Cat I chit) This talk focuses on the upper port plug (UPP) structure. KSTAR Conference 2014 7/20 24-26 February 2014
Engineering Challenges UPP size satisfying conflicting requirements UPP size is constrained by the VV port and the gap in-between. Gap around UPP (+) Gap around UPP (-) • Port plug handling for installation • Neutron streaming • Manufacturing tolerance • Space for diagnostic • Structural deflection due to external integration in the port plug loads (EM, seismic, etc): cantilever with a heavy payload at the front KSTAR Conference 2014 8/20 24-26 February 2014
Neutron Streaming Shut-Down Dose Rate 12 Days After Operation: Target in Interspace < 100 μ Sv/hr Maintenance issue Total dose limit in ITER: 500 mSi- person/year KSTAR Conference 2014 9/20 24-26 February 2014
Neutron Streaming Current SDDR 108 μ Sv/hr in the interspace of the upper port KSTAR Conference 2014 10/20 24-26 February 2014
Port Plug Tolerance Study • Manufacturing tolerance of VV, blankets and PP • Assembly procedure • Port plug handling tolerance • UPP deflection (max. 12mm) KSTAR Conference 2014 11/20 24-26 February 2014
Load combination for Structural Assessment concatenat # of 1. Dead Weight (DW) - The dead weight of the UPP Operating Initiating Comment (4) ed events conditions event Cat and its modules is 25 tons max, where 25 tons is the (1) events dry weight limit imposed by the Remote Handling DW, PresO, THO I.1 -- -- I 30000 BOLT / PIN PRE-TENSION Cask System. DW, PresB, THB I.2 -- -- I 500 2. Plasma Disruption Electromagnetic Loads - The BOLT / PIN PRE-TENSION dominate load on the UPP structure is the DW, PresO, THO I.3 MD I -- I 2600 BOLT / PIN PRE-TENSION electromagnetic (EM) load associated with plasma DW, PresB, THB disruptions. Several DINA disruption scenarios have 1 (2) II.1 SL-1 -- II BOLT / PIN PRE-TENSION been studied, the worst of which with respect to UPP To envelop all the combinations DW, PresO, THO Coolant II.2 MDII II 400 loading are VDE_UP_LIN36 and Accident (3) related, the number of events is BOLT / PIN PRE-TENSION conservatively assumed to be the VDE_UP_SLOW_FAST. DW, PresO, THO Coolant same as the frequency of MD II VDE II (5) II.3 II 300 Accident (3) BOLT / PIN PRE-TENSION and VDEII, respectively. 3. Category II Seismic Loads (SL-1) – Weaker seismic DW, PresO, THO 1 (2) II.4 SL-1 MD I II event, assumed to be equal as a first approximation to BOLT / PIN PRE-TENSION SL-2 / 3. DW, PresB, THB III.1 SMHV III - BOLT / PIN PRE-TENSION 4. Category III Seismic Loads (SMHV) – The most DW, PresO, THO III.2 SL-1 MD II III - BOLT / PIN PRE-TENSION penalizing earthquake liable to occur over a period of about 1000 years, assumed to be equal to SL-2 DW, PresO, THO III.3 SL-1 VDE II III - BOLT / PIN PRE-TENSION multiplied by a factor 0.73 as a first approximation. Coolant DW, PresO, THO III.4 SMHV III - 5. Category IV Seismic Loads (SL-2) – Strong seismic BOLT / PIN PRE-TENSION Accident (3) event, defined by two spectra: SMS and PALEO DW, PresO, THO Coolant III.5 (6) VDE III (5) III - Accident (3) BOLT / PIN PRE-TENSION spectra. DW, PresB, THB IV.1 SL-2 IV - 6. Operating Thermal Loads (THO) – Thermal BOLT / PIN PRE-TENSION expansion stresses associated with normal full power DW, PresO, THO Coolant IV.2 MD IV IV - Accident (3) BOLT / PIN PRE-TENSION plasma operation (water coolant at 70 C or 100 C). DW, PresO, THO Coolant VDE IV (5) IV.3 IV - 1. Baking Thermal Loads (THB) – Thermal expansion Accident (3) BOLT / PIN PRE-TENSION stresses associated with vacuum baking (baking water DW, PresO, THO IV.4 SL-1 MD III IV - BOLT / PIN PRE-TENSION at 240 C). DW, PresO, THO Coolant IV.5 SL-2 IV - Accident (3) BOLT / PIN PRE-TENSION KSTAR Conference 2014 12/20 24-26 February 2014
Structural Assessment Worst load combination: Dead Weight +Thermal load + Seismic load (SL-1) + EM load (VDE II) KSTAR Conference 2014 13/20 24-26 February 2014
Structural Assessment Worst load combination: Dead Weight +Thermal load + Seismic load (SL-1) + EM load (VDE II) Max. Displacem ent = 12.5 mm KSTAR Conference 2014 14/20 24-26 February 2014
DSM mounting Design requirements • Transfer large EM load from DFW/DSM to UPP structure • DSM insertion without jamming • Achievable assembly tolerance • Accommodate thermal gradient (50 C) between UPP structure and DSM 80% of EM load occurs in DFW/DSM KSTAR Conference 2014 15/20 24-26 February 2014
Cooling and Heating • Gun-drilled water channels minimized wet welding and single wall structure • Jumper channels between four plates • Plug welding KSTAR Conference 2014 16/20 24-26 February 2014
Manufacturing French regulation • Nuclear pressure equipment (ESPN): (Agreed) Notified Body, In-service inspection every 4 years Activities on ESPN exemption are on-going. • Safety important component (French order 1984) Manufacturing by RCC-MR ITER vacuum handbook ESR (Electro-slag remelting) material SS 316 L(N)-IG to satisfy the radiation requirement (radiowaste, dose rate) in ITER according to ALARA (as low as reasonably achievable) KSTAR Conference 2014 17/20 24-26 February 2014
Maintenance by Remote Handling RH operation in Hot Cell UPP Installation by RH cask - Gripping point - Space reservation for rails and skids KSTAR Conference 2014 18/20 24-26 February 2014
Interface with Port Seal flange • Maintenance • leak test • in-service inspection Lip Seal (Current baseline) Gasket seal option The seal flange has impact on the UPP design, but it will require only the geometrical modification which is not relevant to the structural integrity of UPP. KSTAR Conference 2014 19/20 24-26 February 2014
Summary FDR of the UPP structure was successfully conducted in June 2013 without major issue (no Cat. I chit). It means that the structural infrastructure has been provided to enable the diagnostic design & integration to move forward. Even though the design is finalized, a potential possibility of the UPP design change exists due to the interface change of other PBSs. Now we move to the manufacturing stage and the call for tender is expected this year through international bidding. KSTAR Conference 2014 20/20 24-26 February 2014
Thank you very much for your attention !! KSTAR Conference 2014 21/20 24-26 February 2014
Back Slides KSTAR Conference 2014 22/20 24-26 February 2014
Design of Diagnostic GUPP Assembly sequence 1. Assemble DFW + DSM + Diagnostics 2. Insert the DFW/DSM assembly into GUPP from the plasma side
Design of Diagnostic GUPP DSM fixation
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