IWR-solution for the ITER vacuum vessel assembly

The assembly of ITER vacuum vessel (VV) is still a very big challenge as the process can only be done from inside the VV. The welding of the VV assembly is carried out using the dedicated robotic systems. The main functions of the robots are: (i) measuring the actual space between every two sectors, (ii) positioning of the 150 kg splice plates between the sector shells, (iii) welding the splice plates to the sector shells, (iv) NDT of the welds, (v) repairing, including machining of the welds, (vi) He-leak tests of the welds, and (vii) the non-planned functions that may turn out. This paper presents a reasonable method to assemble the ITER VV. In this article, one parallel mobile robot, running on the track rail fixed on the wall inside the VV, is designed and tested. The assembling process, carried out by the mobile robot together with the welding robot, is presented.     

Design progress of the ITER vacuum vessel and ports

Recent progress of the ITER vacuum vessel (VV) design is presented. As construction approaches, the VV design has been improved, simplified and developed in more detail. The VV support system has been improved, and the design of the VV shells and the blanket supports has been simplified. The VV design simplifications have been driven by manufacturing requirements and recommendations resulting from cooperation with industry. To simplify the manufacture/maintenance of the port structures, a single wall concept is used for some ports. Structural analyses have been performed to validate all design modifications.     

Design analysis of the hinge support for the ITER vacuum vessel

In order to verify design feasibility and structural integrity of a hinge type support for the ITER VV support system, the design analysis has been performed in detail, which includes heat transfer, elastic stress and limit analyses. The structural analyses were performed to confirm the transfer of forces through the supporting structure and to determine the maximum allowable loads according to the RCC-MR. From the heat transfer analysis for VV baking stage, total heat flow into the support was obtained to confirm the thermal heat flux into the cryostat under baking condition. In addition, the design modification was also discussed to enhance the structural performance of the supporting system.     

Lubricant coating of dowel for the ITER vacuum vessel gravity support

The ITER vacuum vessel gravity supports located in the lower level shall sustain loads in radial, toroidal and vertical directions. The hinge type VVGS consists of two hinges, upper and lower blocks and dowels. In order to develop the design concept and verify the structural integrity of the hinge system, the design analysis has been performed in detail. Inclination of 15° for the hinge based supporting system was introduced to provide centering force to make stable equilibrium state of the vacuum vessel. Due to this inclination the hinges are rotated by the radial expansion of the VV during operation and baking, respectively. If a dowel is seized in the hinge, the supporting system can be highly stressed due to the restrained displacement in the seized dowel. Therefore, solid lubricant coatings were suggested on dowels in order to avoid seizing in the sliding area. In this work, several sets of coupons were made with different coating materials to investigate the effect according to the selection of coating material. Also, a test facility was designed to cover the ITER relevant loading and boundary conditions, e.g. vacuum condition, temperature, contact pressure, cycles, etc. From those test results, the optimized coating method was found to avoid seizure of dowel in the ITER VVGS.     

Structural analyses for equatorial and lower ports of the ITER vacuum vessel

To investigate the structural integrity of the ITER vacuum vessel (VV) and ports, the structural analyses of the regular equatorial and the lower remote handling (RH) ports have been performed. The advanced design of the equatorial regular port adopting a pure friction type flange has been recommended as a reference design by the ITER International Organization. The structural integrity of the equatorial port flange, sealing unit, and connecting duct has been reviewed by conducting nonlinear finite element analyses. The advanced design of the regular equatorial port flange with proper pretension is acceptable in the structural design point of view.From the local analyses for a connecting duct and a sealing unit, it has been found that the stresses are less than the allowable values.The structural analyses of the lower RH port have been also performed to verify the capability for supporting the VV. Since high local stress occurs at the gusset and supporting block, the case study for the lower port has been conducted to mitigate the stress concentration and to modify the component design. The strength of the lower RH port structures can be improved by the design modification of poloidal and toroidal gusset.     

Mock-up of a support structure of the ITER vacuum vessel

The ITER vacuum vessel support systems located in the lower level sustain loads in radial and vertical direction. The support system consists of various sub-components like a linkage system, a pot type bearing, a vertical rope, a toroidal constraint, and dampers. In order to examine performance of the mechanism of the system, a mock-up of the linkage system which is comparatively complicated has been manufactured. Various fabrication methods were studied through the mock-up fabrication, and also several tests have been done using the mock-up. Those include assembly study, stroke test, static load test and fatigue test. In the full stroke test, the functional mechanism of the support structure has been demonstrated. In the structural test, the strength of the all components is evaluated by measuring reaction and strain of each component. In order to investigate the effect of tolerances and the damage due to the tests, the performance tests were conducted before and after the static and fatigue tests. The backlash for each stage is found from measured displacement hysteresis. As results of those tests, the performance of the ITER vacuum vessel support structure as well as its structural integrity has been evaluated in this study.     

Design finalization and start of construction of ITER vacuum vessel

The vacuum vessel (VV) design is being finalized including interface components, such as the support rails and feedthroughs of coils for mitigation of edge localized modes (ELM) and vertical stabilization (VS) of the plasma (ELM/VS coils). It was necessary to make adjustments in the locations of the blanket supports and manifolds to accommodate the design modifications in the ELM/VS coils. The lower port gussets were reinforced to keep a sufficient margin under the increased VV load conditions. The VV support design is being finalized as well, with an emphasis on structure simplification. The design of the in-wall shielding (IWS) has progressed, considering assembly and required tolerances. The layout of ferritic steel plates and borated steel plates will be optimized based on on-going toroidal field ripple analysis. The VV instrumentation was defined in detail. Strain gauges, thermocouples, displacement meters and accelerometers shall be installed to monitor the status of the VV in normal and off-normal conditions to confirm all safety functions are performed correctly. The ITER VV design was preliminarily approved, and the VV materials including 316L(N) IG were already qualified by the Agreed Notified Body (ANB) according to the procedure of Nuclear Pressure Equipment Order.     

Thermo-hydraulic design verification of the neutral beam liner for the ITER vacuum vessel

The ITER vacuum vessel has upper, equatorial and lower port structures used for equipment installation, utility feedthroughs, vacuum pumping and access inside the vessel for maintenance. A neutral beam (NB) port of equatorial ports provides a path of neutral beam for plasma heating and current drive. An internal duct liner is built in the NB ports, and copper alloy panels are placed in the top and bottom of the liner to protect duct surface from high-power heat loads. Global NB liner models for the upper panel and the lower panel have been developed, and flow field and conjugate heat transfer analyses have been performed to find out pressure drop and heat transfer characteristics of the liner. Heat loads such as NB power, volumetric heating and surface heat flux are applied in the analyses for beam steering and misalignment conditions. For the upper panel, it is found that unbalanced flow distribution occurs in each flow path, and this causes poor heat transfer performance as well. In order to improve flow distribution and to reduce pressure losses, hydraulic analyses for modified cooling path schemes have been carried out, and design recommendations are made based on the analysis results. For the lower panel, local flow distributions and pressure drop values at each header and branch of the tube are obtained by applying design coolant flow rate. Together with the coolant flow field, temperature and heat transfer coefficient distributions are also acquired from the analyses. Based on the analysis results, it is concluded that the lower panel for the NB liner is relatively well designed even though the given heat loads are very severe.     

CFD analysis of a regular sector of the ITER vacuum vessel. Part I: Flow distribution and pressure drop

The 3D steady-state Computational Fluid Dynamics (CFD) analysis of the ITER vacuum vessel (VV) regular sector #5 is presented, starting from the CATIA models and using a suite of tools from the commercial software ANSYS FLUENT^®. The peculiarity of the problem is linked to the wide range of spatial scales involved in the analysis, from the millimeter-size gaps between in-wall shielding (IWS) plates to the more than 10 m height of the VV itself. After performing several simplifications in the geometrical details, a computational mesh with ～50 million cells is generated and used to compute the steady-state pressure and flow fields from a Reynolds-Averaged Navier–Stokes model with SST k-ω turbulence closure. The coolant mass flow rate turns out to be distributed 10% through the inboard and the remaining 90% through the outboard. The toroidal and poloidal ribs present in the VV structure constitute significant barriers for the flow, giving rise to large recirculation regions. The pressure drop is mainly localized in the inlet and outlet piping.     

Software design of the hybrid robot machine for ITER vacuum vessel assembly and maintenance

A specific software design is elaborated in this paper for the hybrid robot machine used for the ITER vacuum vessel (VV) assembly and maintenance. In order to provide the multi-machining-function as well as the complicated, flexible and customizable GUI designing satisfying the non-standardized VV assembly process in one hand, and in another hand guarantee the stringent machining precision in the real-time motion control of robot machine, a client–server-control software architecture is proposed, which separates the user interaction, data communication and robot control implementation into different software layers. Correspondingly, three particular application protocols upon the TCP/IP are designed to transmit the data, command and status between the client and the server so as to deal with the abundant data streaming in the software. In order not to be affected by the graphic user interface (GUI) modification process in the future experiment in VV assembly working field, the real-time control system is realized as a stand-alone module in the architecture to guarantee the controlling performance of the robot machine. After completing the software development, a milling operation is tested on the robot machine, and the result demonstrates that both the specific GUI operability and the real-time motion control performance could be guaranteed adequately in the software design.     

ITER vacuum vessel: Design review and start of procurement process

The ITER vacuum vessel (VV) is one of the most critical components in the ITER project. It is on the critical path in the construction schedule and it is also a safety important class component (SIC), providing the first confinement barrier.As a result of reviews and the latest physics analyses, design requirements have been updated (e.g. ELM/VS coils) and a few design changes have to be implemented. This paper covers the updates of the VV vertical and horizontal EM load conditions during asymmetric VDEs, the design analysis of the ELM/VS coils and their interfaces to the VV, the blanket manifold design and the preparation of the technical specification in preparation for the procurement arrangement to be signed.     

CFD analysis of a regular sector of the ITER vacuum vessel. Part II: Thermal-hydraulic effects of the nuclear heat load

The 3D Computational Fluid Dynamic (CFD) steady state analysis of the regular sector #5 of the ITER vacuum vessel (VV) is presented in these two companion papers using the commercial software ANSYS-FLUENT®. The pure hydraulic analysis, concentrating on flow field and pressure drop, is presented in Part I. This Part II focuses on the thermal-hydraulic analysis of the effects of the nuclear heat load. Being the VV classified as safety important component, an accurate thermal-hydraulic analysis is mandatory to assess the capability of the water coolant to adequately remove the nuclear heat load on the VV. Based on the recent re-evaluation of the nuclear heat load, the steady state conjugate heat transfer problem is solved in both the solid and fluid domains. Hot spots turn out to be located on the surface of the inter-modular keys and blanket support housings, with the computed peak temperature in the sector reaching ～290 °C. The computed temperature of the wetted surfaces is well below the coolant saturation temperature and the temperature increase of the water coolant at the outlet of the sector is of only a few °C. In the high nuclear heat load regions the computed heat transfer coefficient typically stays above the 500 W/m² K target.     

Chatter suppression methods of a robot machine for ITER vacuum vessel assembly and maintenance

In the process of assembly and maintenance of ITER vacuum vessel (ITER VV), various machining tasks including threading, milling, welding-defects cutting and flexible hose boring are required to be performed from inside of ITER VV by on-site machining tools. Robot machine is a promising option for these tasks, but great chatter (machine vibration) would happen in the machining process. The chatter vibration will deteriorate the robot accuracy and surface quality, and even cause some damages on the end-effector tools and the robot structure itself. This paper introduces two vibration control methods, one is passive and another is active vibration control. For the passive vibration control, a parallel mechanism is presented to increase the stiffness of robot machine; for the active vibration control, a hybrid control method combining feedforward controller and nonlinear feedback controller is introduced for chatter suppression. A dynamic model and its chatter vibration phenomena of a hybrid robot is demonstrated. Simulation results are given based on the proposed hybrid robot machine which is developed for the ITER VV assembly and maintenance.     

Design assessment for manufacturability of supporting structures for IWS and ELM coil of ITER vacuum vessel

A vacuum vessel is one of the core facilities of ITER (International Thermonuclear Experimental Reactor) and basically all-welded structure. Korea is responsible for the procurement of sector 1 and 6 of the main vessel. Accordingly, the design review for the fabrication is in progress by ITER Korea and Hyundai Heavy Industries. Due to anticipated manufacturing problems such as the welding distortion, the design of some components of main vessel, IWS (In-Wall Shield) supporting rib and ELM (Edge Localized Mode) coil support, needs to be modified. To release the risk of welding distortion, the welding method called “bridge type” is suggested and the shape of weld joint is adjusted to secure the manufacturability of the issued components. The elastic and limit analyses with fatigue evaluation have been performed under the most critical loading condition to verify the structural integrity of modified design. Analysis results show that the proposed designs meet the design criteria of RCC-MR. The design deviation requests have been submitted to ITER Organization and ANB (Agreed Notified Body) for approval and their verification is currently in progress.     

Analyses of the ITER vacuum vessel with the use of a new modelling technique

The on-going design development of the ITER vacuum vessel (VV) has been supported and accompanied recently by extensive analytical studies of its different structural aspects. The use of a newly developed parametric model of the ITER VV sector with port structures has enabled various detailed assessments of this structure. Implementation of new features in the model and new approach for its generation has eased updates and modifications of the model, reducing the time necessary to introduce them into the model and allowing it to keep pace with discussions on planned design changes.     

A study of the influence of electron beam welding sequences on the ITER vacuum vessel prototype VATS

This paper presents a detailed finite element simulation of the welds of the prototype Vessel Advanced Technology Segment (VATS) by electron-beam welding. The flexible support housings are reinforcing cylinders of the pressure boundary of the ITER vacuum vessel. They connect inner and outer shells. Eight different simulation sequences were carried out to explain the different mechanisms that drive the distortion process during welding and to lead to an optimum sequence which minimizes the final distortions. The simulations were used to guide the manufacture of the final sequence of the VATS.     

Simulation of VDE under intervention of vertical stability control and vertical electromagnetic force on the ITER vacuum vessel

Vertical displacement events (VDEs) and disruptions usually take place under intervention of vertical stability (VS) control and the vertical electromagnetic force induced on vacuum vessels is potentially influenced. This paper presents assessment of the force that arises from the VS control in ITER VDEs using a numerical simulation code DINA. The focus is on a possible malfunctioning of the ex-vessel VS control circuit: radial magnetic field is unintentionally applied to the direction of enhancing the vertical displacement further. Since this type of failure usually causes the largest forces (or halo currents) observed in the present experiments, this situation must be properly accommodated in the design of the ITER vacuum vessel. DINA analysis shows that although the ex-vessel VS control modifies radial field, it does not affect plasma motion and current quench behavior including halo current generation because the vacuum vessel shields the field created by the ex-vessel coils. Nevertheless, the VS control modifies the force on the vessel by directly acting on the eddy current carried by the conducting structures of the vessel. Although the worst case was explored in a range of plasma inductance and pattern of VS control in combination with the in-vessel VS control circuit, the result confirmed that the force is still within the design margin.     

Parametric neutronic analysis of HCLL blanket for DEMO fusion reactor utilizing vacuum vessel ITER FDR design

Three-dimensional parametric neutronics calculations using the Monte Carlo code MCNP-4C have been performed for a DEMO-type reactor based on the Helium-Cooled Lithium-Lead (HCLL) blanket. The aim of the analysis was to minimize the radial blanket thickness, while ensuring tritium self-sufficiency and to assess the shielding performance of the reactor in terms of the radiation loads to the super-conducting toroidal field (TF) coils. It was found that tritium self-sufficiency can be achieved with a breeder zone thickness reduced to no more than 55 cm at a ⁶Li enrichment of 90%. Assuming a ⁶Li enrichment of 60%, a breeder zone thickness of 60 cm is required to achieve the target TBR of 1.10 which is assumed to be sufficient to cover potential tritium losses and uncertainties. With regard to the shielding performance it was found that the design limits for the radiation loads to the TF-coil can be met with radial blanket thicknesses of 75 cm, 60 cm and 55 cm utilizing a two-component shield of Eurofer steel and tungsten carbide between the breeder zone and the vacuum vessel. The blanket variants with larger radial breeder zone show better shielding performances due to the reduced Eurofer shielding material acting as gamma radiation emitter in between the breeder zone and the vacuum vessel. In particular the radiation dose absorbed in the Epoxy insulator was shown to be the most critical quantity in this regard.     

Use of a new methodology for prediction of weld distortion and residual stresses using FE simulation applied to ITER vacuum vessel manufacture

The ITER VV Sectors have to be manufactured to extremely tight tolerances, without the production of a prototype to establish the welding distortions. It is thus necessary to develop a (computationally) successful methodology for modelling weld process in order to predict welding distortion and residual stresses. Further, in order to optimise the manufacture sequence and method, the model should be able to rapidly assess the effect of using different sequences. Once the optimal sequence has been decided, then the method has also to be able to accurately predict the final shape.