RAMI analysis of the ITER CIS

ITER is the first worldwide international project aiming to design a device that proves the physics and technological basis for fusion power plants to produce nuclear fusion energy. In the project, the RAMI approach (reliability, availability, maintainability and inspectability) has been adopted for technical risk control to guide the design of components in preparation for operation and maintenance. RAMI analysis of the ITER central interlock system (CIS), which shall provide investment protection for the ITER systems was performed on the conceptual design. A functional breakdown was prepared in a bottom-up approach, resulting in the system being divided into 5 main functions and 7 sub-functions which are described using the IDEFØ method. Reliability block diagrams (RBDs) were prepared to estimate the reliability and availability of each function under stipulated operating conditions. Initial and expected scenarios were analyzed to define risk-mitigation actions. The inherent availability of the ITER CIS expected after implementation of mitigating actions was calculated to be 99.86% over 2 years, which is the typical interval of the scheduled maintenance cycles. A failure modes, effects and criticality analysis (FMECA) was performed to initiate risk mitigation action. Criticality matrices highlight the risks of the different failure modes with regard to the probability of their occurrence and impact on operations. It was assessed that the availability of the ITER CIS, with appropriate mitigating actions applied, meets the project availability requirement for the system.     

RAMI Analysis of HCCB TBS for ITER

ITER is the first worldwide international experimental nuclear fusion facility, which aims to prove the physics and technological basis for future fusion power plants. As main stages of ITER technical risk control, the reliability, availability, maintainability and inspectability (RAMI) approach should be applied to all ITER components during their design phase to reduce potential technical risks. Test blanket modules play a key role in ITER. Helium cooled ceramic breeder (HCCB) TBM is one of TBM concepts which were proposed by China. HCCB TBM and its ancillary system are called HCCB test blanket system (TBS). The RAMI analysis was performed on the conceptual design of the ITER HCCB TBS in this paper. A functional breakdown was prepared in a bottom-up approach, resulting in the system being divided into 3 main functions, 1 support function, 14 sub-functions and 50 basic functions. These functions were described using the IDEF0 method. Reliability block diagrams were prepared to estimate the reliability and availability of each function under the stipulated operating conditions. The inherent availability of the HCCB TBS expected after implementation of mitigation actions was calculated to be 94.69 % over 2 years. A failure modes, effects and criticality analysis was performed with criticality charts highlighting the risk level of the different failure modes with regard to their probability of occurrence and their effects on the availability.     

ITER operational availability and fluence objectives

The ITER availability objective is to reach for the machine operation in H phase an inherent availability of 60% and an operational availability of 32% assuming three 8 h plasma shifts operating mode and typically 8-month major shutdown after each 16-month experimental campaign. A functional analysis of the overall ITER machine from highest level functions down to main operational functions has been developed. The inherent availability (A_I) objective of ITER has been defined on the basis of a bottom-up approach and using the results of reliability, availability maintainability and inspectability (RAMI) analyses. The ITER strategy in terms of operational availability (A_O), Plasma pulse availability (A_P) and fluence objectives is not only to improve reliability by optimizing the design but also to gain the maximum of operation time by decreasing the scheduled downtime for preventive maintenance and increasing the maintainability of the operational functions, thus decreasing the frequency and the time to maintain or/and to repair.     

Designing and manufacturing of the coil support structure of W7-X

Wendelstein 7-X (W7-X) is a fully optimized low-shear stellarator and shall demonstrate the reactor potential of this fusion plant. It is presently under construction at the Greifswald Branch Institute of IPP. The superconducting magnet system will allow continuous operation, limited only by the plasma exhaust system whose capacity is designed for 30 min full power operation. The Wendelstein 7-X (W7-X) coils and structures are part of the largest superconducting fusion device being constructed at present. They represent a technical challenge at industrial level and the need for proven techniques and manufacturing processes in accordance to the highest quality standards. The production of these components requires a management of monitoring for quality and tests. The coil system consists of 20 planar and 50 non-planar coils. They are supported by a pentagonal 10 m diameter, 2.5 m high coil support structure (CSS). The CSS is divided into five modules. Each module consists of two equal half modules. The manufacturing status of the CSS and the main project management and technical challenges will be presented. The lessons learned in the large scale production of this difficult kind of support structure will be presented as relevant experience for the realization of similar systems for future fusion devices, such as ITER.     

RAMI Analysis Program Design and Research for CFETR (Chinese Fusion Engineering Testing Reactor) Tokamak Machine

Chinese Fusion Engineering Testing Reactor (CFETR) is a test reactor which shall be constructed by National Integration Design Group for Magnetic Confinement Fusion Reactor of China with an ambitious scientific and technological goal. The reactor has the equivalent scale compared with ITER, but has the complementary function to ITER. CFETR is a demonstration of long pulse or steady-state operation with duty cycle time not less than 0.3–0.5 and the full cycle of tritium self-sustained with TBR not less than 1.2. At the same time it will be exploring options for DEMO blanket and divertor with an easy changeable core by remote handling way. To be able to reach its scientific and technological objectives, as one of technical risks control methods, RAMI analysis need to be done during the hold lifetime of CFETR, from conception design to decommissioning. Base on stating of CFETR lifetime and preliminary operational programme, the RAMI analysis program and process are designed and discussed, it consists of five major steps: (1) functional analysis are performed, (2) calculating reliability block diagrams, (3) analyzing failure mode, effects and criticality analysis, (4) risk mitigation actions are taken to ensure every system is compatibility with RAMI objectives, (5) All the RAMI analysis are integrated as the final RAMI analysis reports to be reviewed in the system final design review. Along with the elements of the analysis the vacuum vessel (VV) system was performed to provide as examples, detailed showing how the CFETR RAMI analysis is carried out. CFETR RAMI analysis guidelines were designed and established, after constantly revised and improved these analysis criteria and programs will become the basis standards for CFETR RAMI analysis. Preliminary RAMI analysis of CFETR VV system was obtained, which will be updated with the VV system design progresses.     

Development and application of high volume remote handling systems in support of JET and ITER

The Joint European Torus (JET) Remote Handling System has evolved from a small scale maintenance capability to one of high efficiency large volume installations. The Enhanced Performance 2 shutdown 2010–2011 for example, required the replacement of many thousands of components ranging from about 100 g to 130 kg in weight. The scale of this type of operation and the necessity to maximise operational availability intensified the demands for high productivity whilst maintaining the necessary high standards for precision, reliability, cleanliness, and operational security.This paper discusses the developments in design, control, maintenance, preparation and operation of the current state of the art remote handling facilities at JET. It explores how the experience of over 20,000 h of operations has developed the applied methodology and how this could be appropriate to ITER and other facilities requiring complex remote maintenance, where extensive, high productivity remote handling operations will be essential. It also discusses the advances that have been made in management and presentation of operational data within the command, control and human machine interfaces (HMI) systems, along with the supporting operational databases.     

The negative ion source test facility ELISE

The ITER neutral beam system is using inductively coupled radio frequency (RF) ion sources, that have demonstrated the required ITER parameters on (small) sources with extraction areas up to 200 cm². As a next step towards the full size ITER source IPP is presently constructing the test facility ELISE (“Extraction from a Large Ion Source Experiment”) operating with a “half-size” source which has approximately the width but only half the height of the ITER source. The modular driver concept is expected to allow a further extrapolation to the full size in one direction to be made. The main aim of this experiment is to demonstrate the production of a large uniform negative ion beam with ITER relevant parameters in stable conditions up to one hour.Plasma operation of the source is foreseen to be performed continuously for 1 h; extraction and acceleration of negative ions up to 60 kV is only possible in pulsed mode (10 s every 180 s) due to limitations of the existing IPP HV system. The design of the source and extraction system implements a high experimental flexibility and a good diagnostic access while still staying as close as possible to the ITER design. The main differences are the source operating in air and the use of a large gate valve between the source and the target chamber.ELISE is expected to start operation at the end of 2011 and is an important step for the development of the ITER NBI system; the experience gained early will support the design as well as the commissioning and operating phases of the PRIMA NBI test facilities and the ITER neutral beam system.     

Waste management strategy focused on maintenance,storage and recycling

Waste is generated at the moment when the operation of a fusion reactor is halted and maintenance is started for periodic replacement of blanket modules and divertor. Used blanket and divertor need to be replaced shortly after the shutdown for high plant availability, as long as high surface dose rate and decay heat of the blanket and divertor can be handled. In this sense, nuclear characteristics of the blanket and divertor need to be understood for a reasonable maintenance scheme. For the purpose, neutronic calculations were carried out on the blanket and divertor using a THIDA-2 code with FENDL-2.0. For a SlimCS DEMO reactor, the calculated decay heat for each 1/12-sector was as high as 5 MW just after the shutdown and 0.3 MW one month later. For the maintenance, a cooled shielding structure (CSS) was proposed to remove the decay heat and to shield gamma-rays from the sector. When maintenance is done one month after the shutdown, the sector temperature is maintained to be 550 °C or lower with the cooling by the CSS of 50 °C. In order to avoid tritium release from the sector during the maintenance, a cask should be used to transport the sector. For efficient use of resources, breeding and neutron multiplying materials should be reused or recycled. A possible strategy for reuse or recycle is also presented.     

Design progress on ITER port plug test facility

To achieve the overall ITER machine availability target, the availability of diagnostics and heating port plugs shall be as high as 99.5%. To fulfill these requirements, it is mandatory to test the port plugs at operating temperature before installation on the machine and after refurbishment.The ITER port plug test facility (PPTF) provides the possibility to test upper and equatorial port plugs before installation on the machine. The port plug test facility is composed of several test stands. These test stands are first used in the domestic agencies and on the ITER Organization site to test the port plugs at the end of manufacturing. Two of these stands are installed later in the ITER hot cell facility to test the port plugs after refurbishment. The port plugs to be tested are the Ion Cyclotron (IC) heating and current drive antennas, Electron Cyclotron (EC) heating and current drive launchers, diagnostics and test blanket modules port plugs.Test stands shall be capable to perform environmental and functional tests. The test stands are composed of one vacuum tank (3.3 m in diameter, 5.6 m long) and the associated heating, vacuum and control systems. The vacuum tank shall achieve an ultimate pressure of 1 × 10^?5 Pa at 100 °C containing a port plug. The heating system shall provide water at 240 °C and 4.4 MPa to heat up the port plugs. Openings are provided on the back of the vacuum tank to insert probes for the functional tests.This paper describes the tests to be performed on the port plugs and the conceptual design of the port plug test facility. The configuration of the standalone test stands and the integration in the hot cell facility are presented.     

Completion of designing and manufacturing of the coil support structure of W7-X

In February 2000, the project called coil support structure for the Wendelstein 7-X fusion machine was started. Since October 2009 the full production of this big (80 tons) and complex component is now completed and delivered at IPP Greifswald. The W7-X coil system consists of 20 planar and 50 non-planar coils. They are supported by a pentagonal 10 m diameter, 2.5 m high called coil support structure (CSS). The CSS is divided into five modules and each module consists of two equal half modules around the radial axis. Currently, the five modules were successfully assembled with the coils meeting the tight manufacturing tolerances. Designing, structural calculation, raw material procurement, welding & soldering technologies, milling, drilling, accurate machining, helium cooling pipe forming, laser metrology, ultra sonic cleaning and vacuum test are some of the key points used all along this successful manufacturing process. The lessons learned in the large scale production of this difficult kind of support structure will be presented as relevant experience for the realization of similar systems for future fusion devices, such as ITER.     

High voltage power supplies for ITER RF heating and current drive systems

The RF heating and current drive (H&CD) systems to be installed for the ITER fusion machine are the electron cyclotron (EC), ion cyclotron (IC) and, although not in the first phase of the project, lower hybrid (LH). These systems require high voltage, high current power supplies (HVPS) in CW operation.These HVPS should deliver around 50 MW electrical power to each of the RF H&CD systems with stringent requirements in terms of accuracy, voltage ripple, response time, turn off time and fault energy. The PSM (Pulse Step Modulation) technology has demonstrated over the past 20 years its ability to fulfill these requirements in many industrial facilities and other fusion reactors and has therefore been chosen as reference design for the IC and EC HVPS systems.This paper describes the technical specifications, including interfaces, the resulting constraints on the design, the conceptual design proposed for ITER EC and IC HVPS systems and the current status.     

Proposed high voltage power supply for the ITER relevant lower hybrid current drive system

In the framework of the EFDA task HCD-08-03-01, the ITER lower hybrid current drive (LHCD) system design has been reviewed. The system aims to generate 24 MW of RF power at 5 GHz, of which 20 MW would be coupled to the plasmas. The present state of the art does not allow envisaging a unitary output of the klystrons exceeding 500 kW, so the project is based on 48 klystron units, leaving some margin when the transmission lines losses are taken into account. A high voltage power supply (HVPS), required to operate the klystrons, is proposed. A single HVPS would be used to feed and operate four klystrons in parallel configuration. Based on the above considerations, it is proposed to design and develop twelve HVPS, based on pulse step modulator (PSM) technology, each rated for 90 kV/90 A. This paper describes in details, the typical electrical requirements and the conceptual design of the proposed HVPS for the ITER LHCD system.     

The WEST project: Testing ITER divertor high heat flux component technology in a steady state tokamak environment

The WEST project recently launched at Cadarache consists in transforming Tore Supra in an X-point divertor configuration while extending its long pulse capability, in order to test the ITER divertor technology. The implementation of a full tungsten actively cooled divertor with plasma facing unit representative of ITER divertor targets will allow addressing risks both in terms of industrial-scale manufacturing and operation of such components. Relevant plasma scenarios are foreseen for extensive testing under high heat load in the 10–20 MW/m² range and ITER-like fluences (1000 s pulses). Plasma facing unit monitoring and development of protection strategies will be key elements of the WEST program.WEST is scheduled to enter into operation in 2016, and will provide a key facility to prepare and be prepared for ITER.     

Operational experience with forced cooled superconducting magnets

Force-cooled concept has been chosen for ITER superconducting magnet to get reliable coil insulation using vacuum-pressure impregnation (VPI) technology. However 17 breakdowns occurred during operation of six magnets of this type or their single coil tests at operating voltage < 3 kV, while ITER needs 12 kV. All the breakdowns started on electric, cryogenic and diagnostic communications (ECDCs) by the high voltage induced at fast current variations in magnets concurrently with vacuum deterioration, but never on the coils, though sometimes the latter were damaged too. It suggests that simple wrap insulation currently employed on ECDCs and planned to be used in ITER is unacceptable. Upgrade of the ECDC insulation to the same level as on the coils is evidently needed. This could be done by covering each one from ECDCs with vacuum-tight grounded stainless steel casings filled up with solid insulator using VPI-technology. Such an insulation will be insensitive to in-cryostat conditions, excluding helium leaks and considerably simplifying the tests thus allowing saving time and cost. However it is not accepted in ITER design yet. So guarantee of breakdown prevention is not available.     

Operation of an ITER relevant inspection robot on Tore Supra tokamak

Robotic operations are one of the major maintenance challenges for ITER and future fusion reactors. CEA has developed a multipurpose carrier able to realize deployments in the plasma vessel without breaking the Ultra High Vacuum (UHV) and temperature conditioning. A 6 years R&D programme was jointly conducted by CEA-LIST Interactive Robotics Unit and the Institute for Magnetic Fusion Research (IRFM) in order to demonstrate the feasibility and reliability of an in-vessel inspection robot relevant to ITER requirements.The Articulated Inspection Arm robot (AIA) is an 8-m long multilink carrier with a payload up to 10 kg operable between plasma under tokamak conditioning environment; its geometry allows a complete close inspection of Plasma Facing Components (PFCs) of the Tore Supra vessel.Different tools are being developed by CEA to be plugged at the front head of the carrier. The diagnostic presently in operation consists in a viewing system offering accurate visual inspection of PFCs. Leak detection of first wall based on helium sniffing and laser compact system for carbon co-deposited layers characterizations or treatments are also considered for demonstration.In April 2008, the AIA robot equipped with its vision diagnostic has realized a complete deployment into Tore Supra and the first closed inspection of the vessel under UHV conditions. During the upcoming experimental campaign, the same operation will be performed under relevant conditions (10^?6 Pa and 120 °C) after a conditioning phase at 200 °C to avoid outgassing pollution of the chamber.This paper describes the different steps of the project development, robot capabilities with the present operations conducted on Tore Supra and future requirements for making the robot a tool for tokamak routine operation.     

ASDEX Upgrade enhancements in view of ITER application

The aim of the ASDEX Upgrade (AUG) programme is to support the design, prepare the physics base and develop regimes beyond the baseline of ITER and for DEMO. Its ITER-like geometry, poloidal field system, versatile heating system and power fluxes make AUG particularly suited.After the transition to fully tungsten coated plasma facing components AUG could be operated without prior boronizations and a low permanent deuterium retention was found qualifying W as wall material. ITER-like baseline H-modes (H₉₈ ～ 1, β_N ～ 2) were routinely achieved up to 1.2 MA plasma currents. W concentrations could be kept at an acceptable level of <5 × 10^?5 by central wave heating (enhancing impurity outward transport) and ELM pacing with gas puffing. The compatibility of high performance improved H-modes, the ITER hybrid scenario, with an un-boronized W wall was demonstrated achieving H₉₈ ～ 1.1 and β_N up to 2.6 at modest triangularities δ ≤ 0.3. This performance is reached despite the gas puffing needed for W influx control. Increasing δ to 0.35 allowed at even higher puff rates still a H₉₈ ～ 1.1.Reliable plasma operation in support of ITER comprised the demonstration of ECRF assisted low voltage plasma start-up and current rise at toroidal electric fields below 0.3 V/m resulting in a ITER compatible range of plasma internal inductance of 0.71–0.97. Disruption mitigation is feasible using strong gas puffs, and the achieved electron densities approach values needed for runaway suppression.Present hardware extensions in support of ITER include the upgrading of ECRH by a 4 MW/10 s system with large deposition variability (tuneable frequency between 105 and 140 GHz, real-time steerable mirrors) for central heating and MHD mode control. A powerful system of 24 in-vessel coils produces error fields up to toroidal mode number n = 4 for ELM suppression and mode rotation control. In connection with a close conducting wall they will open up the road for RWM stabilization in advanced scenarios. For those we are considering LHCD for current drive and profile control with up to 500 kA driven current. The tungsten sources are dominated by sputtering from intrinsic light impurities, and the W influx from the outboard limiters are the main source for the core plasma. ICRH induced electric fields accelerate light impurities, restricting the use of ICRH to just after boronization. 4-strap antennas imbedded in extended wall structures might solve this problem. Finally, doubling the plasma volume with plasma currents above 2 MA in AUG could be the solution for a needed ITER satellite.     

RF modeling of the ITER-relevant lower hybrid antenna

In the frame of the EFDA task HCD-08-03-01, a 5 GHz Lower Hybrid system which should be able to deliver 20 MW CW on ITER and sustain the expected high heat fluxes has been reviewed. The design and overall dimensions of the key RF elements of the launcher and its subsystem has been updated from the 2001 design in collaboration with ITER organization. Modeling of the LH wave propagation and absorption into the plasma shows that the optimal parallel index must be chosen between 1.9 and 2.0 for the ITER steady-state scenario. The present study has been made with n_|| = 2.0 but can be adapted for n_|| = 1.9. Individual components have been studied separately giving confidence on the global RF design of the whole antenna.     

Modification,enhancement and operation of a water detritiation facility at the Tritium Laboratory Karlsruhe

For the design and development proposal of the European procurement package of the Water Detritiation System (WDS) for ITER, an experimental WDS was installed at the Tritium Laboratory Karlsruhe (TLK) to investigate the process and various components of the system. The WDS facility at TLK uses the Combined Electrolysis Catalytic Exchange (CECE) process and consists of two Solid Polymer Electrolyte (SPE) electrolysis cells and a stainless steel Liquid Phase Catalytic Exchange (LPCE) column with an effective length of 8 m. After installation and commissioning, the first experimental runs were performed with a tritium concentration up to 0.6 GBq kg^?1 in the feed water to test the operation modes of the facility, all the safety installations and procedures and the performance of the LPCE column during a runtime of up to 130 h.Regarding the final design of the WDS for ITER, the first experiments indicated several aspects which had to be modified in order to enhance the procedural and operating performance of the facility.     

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 20 MW 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