Proposal of Integrated Test Facility for in-Vessel Thermofluid Safety of Fusion Reactors

A vacuum vessel (VV) of a tokamak fusion reactor like the International Thermonuclear Experimental Reactor (ITER) consists the first confinement barrier that includes the largest amount of radioactive materials such as tritium and activation products. The ingress of coolant event (ICE) is a design basis event in the ITER where water is used as the coolant. The loss of vacuum event (LOVA) is also considered as an independent design basis event. Based on the results of ICE and LOVA preliminary experiments, an integrated in-vessel thermofluid test is being planned and conceptual design of the facility is in progress. The main objectives of the integrated test are to investigate the consequences of possible interaction of the ICE and the LOVA and to validate the analytical model of thermofluid events in the VV of the fusion reactor. This paper introduces a conceptual design of the integrated test facility and a testing plan.     

Exchange Flow Characteristics in a Tokamak Vacuum Vessel of Fusion Reactor Under the Loss-of-Vacuum Conditions

When a Tokamak vacuum vessel of fusion reactor is broken, buoyancy-driven exchange flows will take place through breaches after the inside pressure of the vacuum vessel (VV) becomes equal to the outside pressure. The exchange flow may bring a mixture of activated dusts and tritium from the inside of the VV to the outside through the breaches. Moreover, the exchange flow may remove decay heat from the plasma-facing components. A preliminary LOVA (Loss Of VAcuum event) apparatus was constructed to investigate quantitative heat transfer characteristics of the exchange flows through the breaches under the LOVA conditions. The results of this study, the relationship between Froude numbers and breach locations in the VV was determined and empirical correlations for the average Froude numbers were derived.     

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.     

Experimental and numerical analysis of the air inflow technique for dust removal from the vacuum vessel of a tokamak machine

In fusion facilities, the dust production inside the plasma chamber is a concern from the viewpoint of both machine performance and safety. To the purpose of a correct handling of the experimental devices the problem of its removal must be properly solved. This work deals with the experiments carried out in the STARDUST facility by using as dust removal technique an air inflow into the volume representing the vacuum vessel. The goal was to evaluate the effectiveness of such an approach, less invasive as compared to all the others so far. These experiments, performed by using characterized carbon, tungsten and stainless steel dusts, show that the mobilization capability of the air inflow is between few percent and 100%, mainly depending on dust type of and deposit shape. The capture efficiency in a filter reached a maximum of about 7.5% in the STARDUST geometrical configuration. In conclusion, this simple and clean (from the radioactive point of view) removing technique needs particular care to be more effective and is not the perfect solution due to its low efficiency in the collection of removed powder in proper surfaces (i.e., filters). Nevertheless improvements are possible and worthwhile.     

ITER articulated inspection arm (AIA): R&d progress on vacuum and temperature technology for remote handling

This paper is part of the remote handling (RH) activities for the future fusion reactor ITER. The aim of the R&D program performed under the European Fusion Development Agreement (EFDA) work program is to demonstrate the feasibility of close inspection tasks such as viewing or leak testing of the Divertor cassettes and the Vacuum Vessel (VV) first wall of ITER.It is assumed that a long reach, limited payload carrier penetrates the ITER chamber through the openings evenly distributed around the machine such as In-Vessel Viewing System (IVVS) access or through upper port plugs.To perform an intervention a short time after plasma shut down, the operation of the robot should be realised under ITER conditioning i.e. under high vacuum and temperature conditions (120 °C).The feasibility analysis drove the design of the so-called articulated inspection arm (AIA) which is a 8.2 m long robot made of five modules with a 11 actuated joints kinematics. A single module prototype was designed in detail and manufactured to be tested under ITER realistic conditions at CEA-Cadarache test facility.As well as demonstrating the potential for the application of an AIA type device in ITER, this program is also dedicated to explore the necessary robotic technologies required to ITER's IVVS deployment system.This paper presents the whole AIA robot concept, the first results of the test campaign on the prototype vacuum and temperature demonstrator module.     

A preliminary assessment of beryllium dust oxidation during a wet bypass accident in a fusion reactor

A beryllium dust oxidation model has been developed at the Idaho National Laboratory (INL) by the Fusion Safety Program (FSP) for the MELCOR safety computer code. The purpose of this model is to investigate hydrogen production from beryllium dust layers on hot surfaces inside a fusion reactor vacuum vessel (VV) during in-vessel loss-of-cooling accidents (LOCAs). This beryllium dust oxidation model accounts for the diffusion of steam into a beryllium dust layer, the oxidation of the dust particles inside this layer based on the beryllium–steam oxidation equations developed at the INL, and the effective thermal conductivity of this beryllium dust layer. This paper details this oxidation model and presents the results of the application of this model to a wet bypass accident scenario in the ITER device.     

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.     

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.     

Real-time measurement of hydrogen generation level during beryllium dust oxidation by steam depending on the dust arrangement geometry

The paper concentrates on the safety issues in the International Thermonuclear Experimental Reactor (ITER) and describes the experiment on the measurement of hydrogen generation rate in case of Ingress of Coolant Event (ICE)—leak inside the vacuum vessel during interaction between water and beryllium (Be) dust. The ICE situation in ITER was simulated in a facility; the active spectroscopy was used to define the hydrogen content by the dynamics of oxidant concentration at a sampling frequency up to 10 Hz. Hydrogen release in time at temperatures of 500-900 °C is investigated, and different versions of dust arrangement are considered, i.e. on the surface and in a slot between armoring tiles at different initial density. The obtained results are compared with the known experiments.     

Study of large gap 200 kV breakdowns in vacuum with high stored energy for ITER neutral beam accelerator

In the context of the ITER contract “ITER/CT/07/219–200 kV Stored Energy Tests”, electrical breakdown tests have been performed in vacuum with a stored energy of up to 425 J. The experiments have been conceived and performed with the collaboration of Consorzio RFX. The tests are being performed in the 1 MV test facility at IRFM, CEA-Cadarache. They should simulate the conditions that will be found in the ITER Neutral Beam accelerator, at 200 kV. This paper presents the set-up of the test bed, the choice of critical components, the diagnostic equipments and the results obtained with 200 kV applied on the anode electrode.     

The design of the assembly tools for the ITER tokamak

The conceptual design of the purpose-built assembly tools required for ITER tokamak assembly is given. The ITER machine assembly is sub-divided into five major activities: lower cryostat, sector sub-assembly, sector assembly, ex-vessel, and in-vessel [1]. The core components, vacuum vessel (VV) and toroidal field coil (TFC), are assembled from nine 40° sub-assemblies, each comprising a 40° VV sector, two TFCs, and the associated VV thermal shield (VVTS). The lower cryostat activities must be completed prior to sector assembly in pit to prepare the foundations for the core components, and to locate the lower components to be trapped once the core components installation begins. In-vessel and ex-vessel activities follow completion of sector assembly. To perform these assembly activities requires both massive, purpose-built tools, and standard heavy handling and support tools. The tools have the capability of supporting and adjusting the largest of the ITER components; with maximum linear dimension 19 m and mass 1200 tonne, with a precision in the low mm range. Conceptual designs for these tools have been elaborated with the collaboration of the Korean Domestic Agency (KO DA). The structural analysis was performed as well using ANSYS code.     

RAMI analysis of the ITER Central Safety System

ITER is the first worldwide international project aiming to design a facility to produce nuclear fusion energy. The technical requirements of its plant systems have been established in the ITER Project Baseline. In the project, the Reliability, Availability, Maintainability and Inspectability (RAMI) approach has been adopted for technical risk control to help aid the design of the components in preparation for operation and maintenance. A RAMI analysis was performed on the conceptual design of the ITER Central Safety System (CSS). A functional breakdown was prepared in a bottom-up approach, resulting in the system being divided into 2 main functions and 20 sub-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. Initial and expected scenarios were analyzed to define risk-mitigation actions. The inherent availability of the ITER CSS expected after implementation of mitigation actions was calculated to be 99.80% over 2 years, which is the typical interval of the scheduled maintenance cycles. This is consistent with the project required value of 99.9 ± 0.1%. 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 of the plasma operation. This analysis defined when risk mitigation actions were required in terms of design, testing, operation procedures and/or maintenance to reduce the risk levels and increase the availability of the main functions.     

Korean high heat flux test facility by using electron beam system for ITER first wall semi-prototype

A Korean high heat flux test facility for the semi-prototype (SP) qualification of an ITER first wall (FW) will be constructed to evaluate the fabrication technologies required for the ITER FW, and the acceptance of these developed technologies will be established for the ITER FW manufacturing procedure. Korea participated in this qualification program, and is responsible for suitable arrangements for the heat flux test of our fabricated SPs. Qualification testing can be started provided that adequate quality and control measures are implemented and validated by the ITER Organization (IO). The controlling measures required for all heat flux tests shall be concrete and demonstrate the satisfaction of the IO test programs. Each country shall provide a test plan covering the quality and controlling measures in the high heat flux test facility to be implemented throughout the test program. Korean high heat flux testing for these ITER plasma facing materials will be performed by using a 60 kV electron beam and a power supply system of 300 kW, where the allowable target dimension is 70 cm × 50 cm in a vacuum chamber. In addition, this facility needs a cooling system for a high-temperature target and decontamination system for beryllium filtration.     

Neutronics analysis and nuclear heating measurement up to the TFC in a mock-up of the ITER inboard shield

A mock-up of ITER including the inboard shield, the vacuum vessel and the coil region, was set up at ENEA Frascati and irradiated with 14 MeV neutrons produced by the Frascati Neutron Generator (FNG). The mock-up dimensions and materials composition are consistent with the current ITER design.The primary objective of the experiment was to validate the MCNP calculations (C) of nuclear heating measured (E) in the region corresponding to the ITER Toroidal Field (TF) coil. An accuracy on C/E ratio ≤±10% was required.The neutronics and shielding properties of the mock-up were also studied throughout the measurement of selected activation reaction rates up to about 1 m depth. Due to the very low activity induced in the foils, the measurements in the deepest experimental positions were performed at the underground low background facility of the Laboratori Nazionali del Gran Sasso, using ultra-low background high purity germanium (HPGe) detectors.The measured reaction rates and nuclear heating were thus compared with the results of the Monte Carlo code MCNP5 coupled with the FENDL-2.1 library.     

Fusion Safety Research and Development in JAERI

This paper describes the current status and future plans of the fusion safety research and development regarding to the developments of the dust removal system and safety analysis code and the thermofluid experiments in the Japan Atomic Energy Research Institute (JAERI) for a fusion experimental reactor. The containment of the radioactive material is the key to achieve fusion safety. In the event of accidents, the source terms need to be evaluated with sufficient accuracy. Therefore, in JAERI, the dust characterization have been investigated and the dust removal system using electric force has been developed and tested. A safety analysis code including both thermal and plasma transient analyses under the various event sequences has been developed. Moreover, the preliminary experiments of thermofluid transients in the vacuum vessel such as Ingress of Coolant Event (ICE) and Loss of Vacuum Event (LOVA) have been started and the experimental results using preliminary LOVA/ICE apparatus during 1995–1996 are summarized in this paper.     

The JET technology program in support of ITER

This paper presents an overview of the current and planned technological activities at JET in support of ITER operation and safety. The scope is very broad and it ranges from analysis of components from the ITER-like Wall (ILW) to determine material erosion and deposition, dust generation and fuel retention to neutronics measurements and analyses. Preliminary results are given of the post-mortem analyses of samples exposed to JET plasmas during the first JET-ILW operation in 2011–2012, and retrieved during the following in-vessel intervention. JET is the only fusion machine capable of producing significant neutron yields, up to nearly 10¹⁹ n/s (14.1 MeV) in DT operations. Recently, the technological potential of a new DT campaign at JET in support of ITER has been explored and the outcome of this assessment is presented. The expected 14 MeV neutron yield, the use of tritium, the preparation and implementation of safety measures will provide a unique occasion to gain experience in several ITER relevant technological areas. A number of projects and experiments to be conducted in conjunction with the DT operation have been identified and they are described in this paper.     

Effect of transient heating loads on beryllium

Beryllium will be used as a plasma facing material for ITER first wall. It is expected that erosion of beryllium under transient plasma loads such as the edge-localized modes (ELMs) and disruptions will mainly determine a lifetime of ITER first wall. The results of recent experiments with the Russian beryllium of TGP-56FW ITER grade on QSPA-Be plasma gun facility are presented. The Be/CuCrZr mock-ups were exposed to upto 100 shots by deuterium plasma streams with pulse duration of 0.5 ms at ∼250 °C and average heat loads of 0.5 and 1 MJ/m². Experiments were performed at 250 °C. The evolution of surface microstructure and cracks morphology as well as beryllium mass loss are investigated under erosion process.     

High heat flux testing of mock-ups for a full tungsten ITER divertor

In order to evaluate the option to start the ITER operation with a full tungsten (W) divertor, the EU-DA launched an extensive R&D program. It consisted in its initial phase in the high heat flux (HHF) testing of W mock-ups and medium scale prototypes up to 20 MW/m² in the AREVA FE 200 facility (F). Critical heat flux (CHF) experiments were carried out on the items which survived the above thermal fatigue testing.After 1000 cycles at 10 MW/m², the full W Plasma Facing Components (PFCs) mock-ups successfully sustained either 1000 cycles at 15 MW/m² or 500 cycles at 20 MW/m².However, some significant surface melting, as well as the complete melting of a few monoblocks, occurred during the HHF thermal fatigue testing program representative of the present ITER requirements for the strike point region, namely 1000 cycles at 10 MW/m² followed by 1000 cycles at 20 MW/m².The results of the CHF experiments were also rather encouraging, since the tested items sustained heat fluxes in the range of 30 MW/m² in steady-state conditions.