Fabrication and high heat flux test of large mockups for ITER first wall semi-prototype

The main topic of an ITER blanket first wall procurement is to qualify whether each party has the key technology needed for the fabrication and joining of first wall components. A semi-prototype qualification project will be released requiring that the single components of a full-scale first wall must be fabricated and successfully pass high heat flux tests using a hypervapotron cooling channel. In this work, various mockup types have been modeled and fabricated to develop the joining technology for a semi-prototype. The semi-prototype, which has three double-fingered panels, is a scaled-down component of a full-size first wall. The standard or slit mockups with a 80 mm × 80 mm single beryllium tile joined to a CuCrZr heat sink were fabricated to qualify our HIP (Hot Isostatic Pressing) technology for the joining of semi-prototype. These standard mockups were installed to perform a high heat flux test in the Korea heat load test facility (KoHLT). For a preliminary test of a semi-prototype, thermo-hydraulic mockups of 710 mm × 100 mm were designed and fabricated to verify the Cu/SS cooling performance, such as hypervapotron. For the high heat flux test in our KoHLT facility, the normal cycle is based on an expected heat flux of 300 s in accordance with the ITER qualification specifications. These tests will be performed to qualify the joining technologies, which is required for an ITER blanket first wall and a semi-prototype.     

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.     

Infrared thermography inspection of the ITER vertical target qualification prototypes manufactured by European industry using SATIR

High heat flux loaded components which will be installed in the ITER Divertor require a heat flux removal capability in the range 5–10 MW/m² at steady-state and up to 20 MW/m² in transients. Within the ITER plasma facing components procurement context, each party should demonstrate its technical capability to carry out the manufacturing with the required quality. This is achieved through the successful manufacturing and testing of medium-size qualification prototypes. Each Qualification Prototype consists of three high heat flux units mounted onto an actively cooled supporting structure. Currently, the SATIR method has been identified by the ITER Organization as the basic test to decide upon the final acceptance of the ITER Divertor components. SATIR testing was performed on each CFC part of European HHF units prior to the insertion of the twisted tape and prior to assembling the units onto the steel support structure. The paper deals with SATIR results of all qualification prototypes manufactured by European industry.     

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.     

Verification test results of a cutting technique for the ITER blanket cooling pipes

For replacement of the first wall (FW) of the international thermonuclear experimental reactor (ITER), cutting and welding tools for the cooling pipes must be able to access a pipe from the surface side of the FW and cut/weld the pipe from the inside the cooling pipe (inner diameter: 42.72 mm, thickness: 2.77 mm). The cutting tool for the pipe end is required to cut a flat plate circularly from the surface side of the FW (cutting diameter: approximately 44 mm, plate thickness: 5 mm). To determine the specifications for both the tools and the blanket hydraulic connections, the ITER Organization (IO) and the Japan Domestic Agency (JADA) conducted research and development activities regarding the FW replacement. This paper describes the current status of the development of cutting tools for the cooling pipe connection.     

Fabrication and high heat flux test with the first wall mockups for developing the KO TBM

Korea has proposed and designed a helium cooled molten lithium (HCML) test blanket module (TBM) to be tested in the ITER, in which Ferrite Martensite steel (FMS) and Be were used as the structural and armor materials of the first wall (FW), respectively. In order to develop the fabrication technology for a TBM structure, joining of FMS to FMS was developed and proved through the high heat flux (HHF) test in the previous study. Then, joining of Be to FMS has been developed with several interlayers and mockups were fabricated with hot isostatic pressing (HIP) in the present study. Mockups with Be joined to the FMS were successfully fabricated with a HIP (580 °C, 100 MPa, 2 h) by trying the different interlayers (1 μm-Ti/0.5 μm-Cr/5 μm-Cu and 1 μm-Cr/5 μm-Cu). The HHF tests with a Korea Heat Load Test (KoHLT-1 facility) were performed with 1000 cycles under 0.5 MW/m² heat flux. The test conditions were determined with ANSYS-11 and the test results were compared with the preliminary analysis ones. During the test, there was no sudden increase of temperature but UT and DT results after the test showed a delamination in the case of using Ti/Cr/Cu interlayer. But the mockup with the Cr/Cu interlayer showed a sound joining even after HHF test. Moreover, large mockups considering the TBM FW were designed and started their fabrication for developing the fabrication methods and procedure.     

Russian development of enhanced heat flux technologies for ITER first wall

Recently the ITER first wall (FW) design has been significantly upgraded to improve resistance to electromagnetic loads, to facilitate FW panel replacement and to increase FW ability to withstand higher (up to 5 MW/m²) surface heat loads. The latter has made it necessary to re-employ technologies previously developed for the now-abandoned port limiters. These solutions are related to the cooling channel with CuCrZr–SS bimetallic walls and hypervapotron type cooling regime, optimization of Be-tiles dimensions and Be to CuCrZr joining technique. A number of representative mockups were tested at high heat flux (HHF) at the Tsefey electron-beam facility to verify the thermo-hydraulic characteristics of the reference cooling channel design at moderate water flow velocities (V = 1–3 m/s, P = 2–3 MPa, T = 110–170 °C). The heat flux was gradually varied in the range of 1–10 MW/m² until the critical heat flux was registered. The mockups of hypervapotron structure demonstrated the required cooling efficiency and critical heat flux margin (1.4) at a water velocity of ≥2 m/s. Dimensions of Be armor tiles strongly affect the thermo-mechanical stresses both in the CuCrZr cooling wall and at the Be–CuCrZr interface. Results of tile dimensions optimization (variable in the range 12 mm × 12 mm × 6 to 50 mm × 50 mm × 8 mm) obtained by the HHF (variable in the range of 3–8 MW/m²) experiments are presented and compared with analysis. It is shown that optimization of the tile geometry and joining technology provides the required cyclic fatigue lifetime of the reference FW design.     

Development of water-cooled solid breeder test blanket module in JAEA

One of the most important missions of ITER is to provide a test bed for breeding blanket modules, which are called as test blanket module (TBM). JAEA has been extensively developing a water-cooled solid breeder test blanket module (WCSB TBM) for ITER. JAEA developed fabrication technology of F82H rectangular cooling tubes, and has successfully fabricated the near-full scale first wall mock-up of WCSB TBM by hot isostatic press (HIP) technique, which is fully made of F82H. The mock-up has been high-heat flux tested in the DATS facility in JAEA, which is an ion beam test facility. The inlet temperature of the cooling water is about 280 °C with 15 MPa, which is almost the same as the WCSB TBM design conditions. The mock-up has endured a heat load of 0.5 MW/m², 30 s for 80 thermal cycles. Neither hot spots nor thermal degradation have been observed.     

R&D activities of the liquid breeder blanket in Korea

A liquid breeder blanket has been developed in parallel with the International Thermonuclear Experimental Reactor (ITER) Test Blanket Module (TBM) program in Korea. The Korea Atomic Energy Research Institute (KAERI) has developed the common fields of a solid TBM such as design tools, structural material, fabrication methods, and He cooling technology to support this concept for the ITER. Also, other fields such as a liquid breeder technology and tritium extraction have been developed from the designed liquid TBM. For design tools, system codes for safety analysis such as Multi-dimensional Analysis of Reactor Safety (MARS) and GAs Multi-component Mixture Analysis (GAMMA) were developed for He coolant and liquid breeder. For the fabrication methods, Ferritic Martensitic Steel (FMS) to FMS and Be to FMS joinings with a Hot Isostatic Pressing (HIP) were developed and verified with a high heat flux test of up to 0.5–1.0 MW/m². Moreover, three mockups were successfully fabricated and a 10-channel prototype is being fabricated to make a rectangular channel FW. For the integrity of the joining, two high heat flux test facilities were constructed, and one using an electron beam has been constructed. With the 6 MPa nitrogen loop, a basic heat transfer experiment for code validation was performed. From the verification of the components such as preheater and circulator, a 9 MPa He loop was constructed, and it supplies high temperature (500 °C) and pressure (8 MPa) He to the high heat flux test facility. For an electromagnetic (EM) pump development for circulating the liquid breeder, magnetohydrodynamic (MHD) experiment, and flow corrosion test, a PbLi breeder loop was constructed. From the performance test, the EM pump and magnet show their capability, and flow and static corrosion tests including oxide coating for corrosion protection were performed. For tritium extraction from the liquid breeder, a gas–liquid contact method was adopted and a tritium extraction chamber was constructed. For measurement of the tritium amount in the liquid breeder, permeation sensors have been developed.     

Feasibility study of an intense D–T fusion source: “The New Sorgentina”

The international community agrees on the importance to build a large facility devoted to test and validate materials to be used in harsh neutron environments. Such a facility, proposed by ENEA, reconsiders a previous study known as “Sorgentina” but takes into account new technological development so far attained. The “New Sorgentina” Fusion Source (NSFS) project is based upon an intense D–T 14 MeV neutron source achievable with T and D ion beams impinging on 2 m radius rotating targets. NSFS produces about 1 × 10¹³ n cm⁻² s⁻¹ over about 50 cm³. Larger volumes of lower neutron flux will be available (e.g. for TBM experiments) as well as collimated channels to study some features of the ITER neutron camera. The NSFS facility will overcome problems related to the ion source and accelerating system, by means of an upgraded version of the JET–PINI ion beams. NSFS has to be intended as an European facility that may be realized in a few years, once provided a preliminary technological program devoted to the operation of the ion source in continuous mode, target heat loading/removal, target and tritium handling, inventory as well as site licensing. In this contribution, the main characteristics of NSFS project will be presented.     

Status of the IDTF high-heat-flux test facility

The ITER Divertor Test Facility (IDTF) was designed for the high heat flux tests of outer vertical targets, inner vertical targets and domes of the ITER divertor. This facility was created in the Efremov Institute under the Procurement Arrangement 1.7.P2D.RF (high heat flux tests of the plasma facing units of the ITER divertor).The heat flux is generated by an electron-beam system (EBS), 800 kW power and 60 kV maximum accelerating voltage. The component to be tested is mounted on a manipulator in the vacuum chamber capable of testing objects up to 2.5 m long and 1.5 m wide. The pressure in the vacuum chamber is about 3*10⁻³ Pa. The parameters of the cooling system and the water quality (deionized water) are similar to the cooling conditions of the ITER divertor. The integrated control system regulates all IDTF subsystems and data acquisition from all diagnostic devices, such as pyrometers, IR-cameras, video cameras, flow, pressure and temperature sensors.Started in 2008, the IDTF was commissioned in 2012 with the testing the outer vertical full-scale prototypes and the completion of the PA 1.7.P2D.RF task. This paper details the main characteristics of the IDTF.     

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.     

A subcooled boiling heat transfer predictive model for ITER EHF FW designs

Recent experimental data from the ITER critical heat flux (CHF) mock-ups was used to benchmark a 3D CFD code concerning subcooled boiling heat transfer for high heat flux removal. The predicted temperatures show good agreement with experimental measurements for a range of operating parameters and of cooling configurations. Specifically, it applies to a hypervapotron channel exposed to a 5 MW/m² surface heat load and cooled by velocity of 2 m/s. Such flow geometry and operating condition seem necessary for ITER-enhanced heat flux first wall modules if an adequate design margin in CHF is needed. A detailed CFD and heat transfer analysis performed on a prototyped CAD model provided a higher confidence on the design and is deemed a desirable feature for continued design exploration and optimization processes. This is particularly crucial in regard to flow distribution among the FW fingers.     

Model validation of GAMMA code with heat transfer experiment for KO TBM in ITER

By considering the requirements for a DEMO-relevant blanket concept, Korea (KO) has proposed a He cooled molten lithium (HCML) test blanket module (TBM) for testing in ITER. A performance analysis for the thermal–hydraulics and a safety analysis for the KO TBM have been carried out using a commercial CFD code, ANSYS-CFX, and a system code, GAMMA (GAs multicomponent mixture analysis), which was developed by the gas cooled reactor in Korea. To verify the codes, a preliminary study was performed by Lee using a single TBM first wall (FW) mock-up made from the same material as the KO TBM, ferritic martensitic steel, using a 6 MPa nitrogen gas loop. The test was performed at pressures of 1.1, 1.9 and 2.9 MPa, and under various ranges of flow rate from 0.0105 to 0.0407 kg/s with a constant wall temperature condition. In the present study, a thermal–hydraulic test was performed with the newly constructed helium supplying system, in which the design pressure and temperature were 9 MPa and 500 °C, respectively. In the experiment, the same mock-up was used, and the test was performed under the conditions of 3 MPa pressure, 30 °C inlet temperature and 70 m/s helium velocity, which are almost same conditions of the KO TBM FW. One side of the mock-up was heated with a constant heat flux of 0.3–0.5 MW/m² using a graphite heating system, KoHLT-2 (Korea heat load test facility-2). Because the comparison result between CFX 11 and GAMMA showed a difference tendency, the modification of heat transfer correlation included in GAMMA was performed. And the modified GAMMA showed the strong parity with CFX 11 calculation results.     

Damage and fatigue crack growth of Eurofer steel first wall mock-up under cyclic heat flux loads. Part 1: Electron beam irradiation tests

Recently, the idea of bare steel first wall (FW) is drawing attention, where the surface of the steel is to be directly exposed to high heat flux loads. Hence, the thermo-mechanical impacts on the bare steel FW will be different from those of the tungsten-coated one. There are several previous works on the thermal fatigue tests of bare steel FW made of austenitic steel with regard to the ITER application. In the case of reduced-activation steel Eurofer97, a candidate structural material for the DEMO FW, there is no report on high heat flux tests yet. The aim of the present study is to investigate the thermal fatigue behavior of the Eurofer-based bare steel FW under cyclic heat flux loads relevant to DEMO operation. To this end, we conducted a series of electron beam irradiation tests with heat flux load of 3.5 MW/m² on water-cooled mock-ups with an engraved thin notch on the surface. It was found that the notch root region exhibited a marked development of damage and fatigue cracks whereas the notch-free surface manifested no sign of crack formation up to 800 load cycles. Results of extensive microscopic investigation are reported.     

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.     

Architecture of SPIDER control and data acquisition system

The ITER Heating Neutral Beam injectors will be implemented in three steps: development of the ion source prototype, development of the full injector prototype, and, finally, construction of up to three ITER injectors. The first two steps will be carried out in the ITER neutral beam test facility under construction in Italy. The ion source prototype, referred to as SPIDER, which is currently in the development phase, is a complex experiment involving more than 20 plant units and operating with beam-on pulses lasting up to 1 h. As for control and data acquisition it requires fast and slow control (cycle time around 0.1 ms and 10 ms, respectively), synchronization (10 ns resolution), and data acquisition for about 1000 channels (analogue and images) with sampling frequencies up to tens of MS/s, data throughput up to 200 MB/s, and data storage volume of up to tens of TB/year. The paper describes the architecture of the SPIDER control and data acquisition system, discussing the SPIDER requirements and the ITER CODAC interfaces and specifications for plant system instrumentation and control.     

Overview of recent developments in pellet injection for ITER

Pellet injection is the primary fueling technique planned for core fueling of ITER burning plasmas. Also, the injection of relatively small pellets to purposely trigger rapid small edge localized modes (ELMs) has been proposed as a possible solution to the heat flux damage from larger natural ELMs likely to be an issue on the ITER divertor surfaces. The ITER pellet injection system is designed to inject pellets into the plasma through both inner and outer wall guide tubes. The inner wall guide tubes will provide high throughput pellet fueling while the outer wall guide tubes will be used primarily to trigger ELMs at a high frequency (>15 Hz). The pellet fueling rate of each injector is to be up to 120 Pa m³/s, which will require the formation of solid D–T at a volumetric rate of ～1500 mm³/s. Two injectors are to be provided for ITER at the startup with a provision for up to six injectors during the D–T phase. The required throughput of each injector is greater than that of any injector built to date, and a novel twin-screw continuous extrusion system is being developed to meet the challenging design parameters. Status of the development activities is presented, highlighting recent progress.     

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.