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Materials & Manufacturing Technologies requirement for Cryostat & Vacuum Vessel In-wall shield System of ITER. Bharat Doshi Project Manager (ITER-India) Institute for Plasma Research,Gandhinagar,India. WSFT-IPR-Gandhinagar. 23 rd July 2008. Out line of the Presentation.

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slide1

Materials & Manufacturing Technologies requirement for Cryostat & Vacuum Vessel In-wall shield System of ITER

Bharat Doshi

Project Manager (ITER-India)

Institute for Plasma Research,Gandhinagar,India

WSFT-IPR-Gandhinagar.

23rd July 2008

slide2

Out line of the Presentation

  • Introduction to ITER & ITER Systems
  • Cryostat & In-wall Shield System description
  • Material requirements for Vacuum Vessel In-wall shield system
  • & Cryostat System
  • Manufacturing Technologies needed for Cryostat System
  • & Vacuum Vessel In-wall shield system
  • Summary

2

WSFT-IPR-Gandhinagar.

slide3

INTERNATIONAL THERMO-NUCLEAR EXPERIMENTAL REACTOR (ITER)

ITER is “one of its kind”, and it will be the first biggest nuclear fusion facility to be licensed in cadarache, France.

  • Major systems includes……..
  • Super conducting Magnets (CS,PF &TF)
  • Vacuum Vessel (plasma chamber)
  • First wall (Blanket modules, Divertor cassettes,Limiters etc.)
  • Cryostat,VVPSS & Thermal shields
  • Vacuum Pumping systems
  • Heating & current drive systems
  • Diagnostics
  • Cryoplant & Cryodistribution
  • Cooling water system
  • Tritium plant
  • Power supplies
  • CODAC

Fusion Power: 500 MW

Plasma Volume: 840 m3

Nominal Plasma Current: 15 MA

Typical Density: 1020 m-3

ITER construction is multidimensional,

multicultural and spread across many time zones

3

slide4

INDIAN CONTRIBUTION (9- PROCUREMENT PACKAGES)

Diagnostic Neutral Beam (WBS : 5.3.7)

RF sources & monitoring and control for IC H&CD (WBS : 5.1.3)

Gyrotrons for plasma start up(WBS :

Power supplies for DNB, RF, Gyrotrons (WBS : 5.1.4, 5.2.4, 5.5)

Cryostat

WBS : 2.4

Diagnostics (3.5%)

WBS : 5.5

Industrial Projects

Vacuum vessel in wall shields

WBS : 1.5

Cryo distribution & cryo line system (WBS : 3.4)

ITER heat rejection, component cooling and chilled water system

WBS : 2.6

R & D Projects

4

WSFT-IPR-Gandhinagar.

slide5

ITER Cryostat System

Cryostat

WSFT-IPR-Gandhinagar.

cryostat system functions
Cryostat System Functions
  • Cryostat shall form a vacuum tight container, surrounding the entire Tokamak Basic Machine. It shall provide the vacuum for the super-conducting magnets, and shall form part of the secondary confinement barrier for radioactive inventory inside VV. The cryostat shall include overpressure protection for itself.
  • Cryostat allows passive removal of decay heat, from VV & In vessel components.
  • Cryostat has penetrations for magnet feeders, water cooling pipes, instrumentation feed-through, cryostat pumping systems etc.
  • Cryostat has penetrations for access to the VV ports (45 ports).
  • Cryostat has penetrations for access, for maintenance equipment, into the cryostat.
  • Cryostat has penetrations for access to the CS & PF coil, for possible removal.
  • Cryostat shall transfer all the loads that derive from the tokamak basic machine, & from the cryostat itself, to the floor of the tokamak pit through its support structures (during the normal & off-normal operational regimes, and at specified accidental conditions).

WSFT-IPR-Gandhinagar.

cryostat system configuration
Cryostat System configuration
  • Cryostat is a cylindrical pressure vessel, with its axis vertical, and with a flat bottom and a tori-spherical top.
  • The maximum diameter of the outer cylindrical part shall be ~ 29 m.
  • The diameter of outer cylindrical part shall reduce to ~19 m below the VV divertor ports.
  • These two cylinders of different diameters shall be connected to a horizontal ring, which shall be the platform to cater for the TF magnets and the vacuum vessel.
  • The horizontal ring shall be supported by 18 pillars installed on the pit floor.
  • The port penetrations shall be connected to VV port ducts and bioshield port cells by metallic bellows to compensate all relative movements.
  • Cryostat bottom end shall be just above the pit floor level.
  • Cryostat shall be connected to vacuum pumps and the vacuum monitoring system.

WSFT-IPR-Gandhinagar.

design performance requirements
Design & Performance Requirements

WSFT-IPR-Gandhinagar.

cryostat performance requirements
Cryostat Performance Requirements

WSFT-IPR-Gandhinagar.

deliverables
Deliverables
  • One Full Cryostat
  • Factory fabrication + ITER Site
  • fabrication
  • + Tokamak hall installation
  • Top dome shaped upper head
  • Upper Cylinder
  • Lower Cylinder
  • Base Section
  • Cryostat penetrations
  • Cryostat support structure
  • Gravity support columns
  • Cryostat venting & overpressure
  • protection system

580.495 MT

616.037 MT

654.002 MT

1384.347 MT

WSFT-IPR-Gandhinagar.

factory fabrication
Factory Fabrication

Maximum size of 60degree segment.

·      Length : 10189.89mm

·      Width : 14520mm

·      Height : 3750mm

 Material: SS304L

Weight: 75496Kg

Maximum size of 60 degree segment.

·      Length : 14600mm

·      Width : 9085mm

·      Height : 2375mm

Material: SS304L

Weight: 88436Kg

Maximum size of 60 degree segment.

·      Length : 14600mm

·      Width : 9867.5mm

·      Height : 2375mm

 Material: SS304L

Weight: 88436Kg

·      Length : 4320 mm

·      Width : 1350 mm

·      Height : 1350 mm

Material: SS304

Qty. :18

Maximum size of 60 degree segment.

·      Length : 12639mm

·      Width : 14650mm

·      Height : 6155mm

Material: SS304L

Weight:183276 Kg

WSFT-IPR-Gandhinagar.

site fabrication
Site Fabrication

Lower Cylinder Assembly

Upper Cylinder Assembly

Base Section Assembly

Top Lid Assembly

12

WSFT-IPR-Gandhinagar.

site assembly in iter hall
Site Assembly in ITER hall

Each assembly being

moved in ITER hall

Field weld Joint in ITER hall

& NDT (~ 300 m)

ITER Tokamak building

With Cryostat Assembled

13

WSFT-IPR-Gandhinagar.

slide14

R&D in Welding Technology

3A. Hybrid Welded 316 LN 20 mm thick plate

1. NG-TIG weld in 40 mm thick SS316L plate

Hybrid Set-up

Hybrid Configuration

3B. 316 LN Tube Hybrid welded

4A. RPEB weld in 60 mm thick 316L

2B. Laser weld 20 mm AISI 304L plate

4B. RPEB welds

2A. Laser weld 60 mm SS in 13 passes

14

welding requirements
WELDING REQUIREMENTS
  • Total length of full penetration weld joints of 60 mm thick plate for site assembly ~ 350 m
  • Total weight of deposited metal during site assembly ~1200 Kg.
  • Many welding machines to operate in synchronization for these joints
  • Total length of full penetration weld joints of 60 mm for sub-assemblies = 700 m (approx.)
  • Total weight of deposited metal for sub-assemblies ~ 2100 Kg.
  • Requirement for welding automation (TIG, MIG, SMAW)
  • Various new welding technology like RPEBW, NGTIG needs to be developed.

WSFT-IPR-Gandhinagar.

iter vv iws blocks
ITER VV-IWS BLOCKS
  • To stop energetic neutron within vessel boundary and to reduce TF ripple.
  • ITER vacuum vessel is double wall construction. Space between outer shell and inner shell is used for placing VV-IWS Blocks.

Typical in-board VV-IWS Block

Out-board VV-IWS Blocks assembled

WSFT-IPR-Gandhinagar.

slide17

ITER VV-IWS BLOCKS ASSEMBLY

Shield block assembly

ITER VV SECTOR

ITER VV ASSEMBLY

VV In-wall shield segmentation

material requirements
Material Requirements
  • ~ 6000 blocks for VS and VS joints. Total weight of fabricated blocks is approximately 1777 t.
  • Following different materials are required for VV-IWS blocks
    • SS 304B4 (40 mm thick plates) : 1735 t
    • SS304B7 (40 mm thick plates) : 0134 t
    • SS430 (40 mm thick plates) : 350 t
    • SS 316 L(N)(IG2) (40-60 mm thick plates) : 100 t
    • XM-19 (30 – 50 mm diameter round bars) : 50 t

WSFT-IPR-Gandhinagar.

ss304 b4
SS304 B4
  • 304B4 type, Grade B austenitic stainless steel plates for neutron shielding inserts in the inboard region in the ITER

Vacuum Vessel, conform to ASTM A 887-89 (2004).

WSFT-IPR-Gandhinagar.

ss304 b7
SS304 B7
  • 304B7 type, Grade B austenitic stainless steel plates for neutron shielding inserts in the inboard region in the ITER

Vacuum Vessel, conform to ASTM A 887-89 (2004).

WSFT-IPR-Gandhinagar.

ss316ln ig2
SS316LN (IG2)

Unspecified elements contents as low as possible and not exceeding trace element level.

Ta + Nb + Ti 0.15 %

WSFT-IPR-Gandhinagar.

ss430
SS430

Chromium stainless steel plate type 430 (UNS S43000) for ferromagnetic inserts for the ITER Vacuum Vessel.

WSFT-IPR-Gandhinagar.

summary
Summary

Material required for Vacuum Vessel

In-wall Shield System & Cryostat of ITER

WSFT-IPR-Gandhinagar.

summary24
Summary

Manufacturing Technologies required to be developed for Cryostat & Vacuum Vessel In-wall Shield System of ITER

  • Advanced Cutting
  • Plasma
  • YAG Laser
  • Water jet
  • Welding Technology
  • NGTIG (Hot wire NGTIG)
  • MAG
  • RPEB
  • YAG LASER
  • (Wire-fill Laser without shielding gas/with shielding gas)
  • Laser-MIG Hybrid
  • NDT technology (RESTRICTED ACCESS)
  • UT(Augur, Phased Array, TOFD)
  • RT
  • PT

WSFT-IPR-Gandhinagar.

slide25

Thank you for your attention

25

WSFT-IPR-Gandhinagar.