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Overview of JSC “NIKIET” activity on ITER Procurement Arrangements
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Overview of JSC “NIKIET” activity on ITER Procurement Arrangements A.Yu. Leshukov a,∗ , Yu. G. Dragunov a , Yu. S. Strebkov a , S.Yu. Kirillov a , S.V. Makarov a , P.D. Trofimovich a , G.V. Dubinin a , V.A. Maksimov a , M.N. Sviridenko a , A.V. Razmerov a , E.V. Parshutin a , S.E. Khomyakov a , V.Yu. Kolganov a , A.V. Zhmakin a , V.A. Belyakov b , I.V. Mazul b , A.A. Gervash b , V.M. Safronov c , A.N. Romannikov c , R. Eaton d , K. Egorov d a Joint-Stock Company “N.A. Dollezhall Research and Development Institute of Power Engineering”, (JSC “NIKIET”), 107140, Malaya Krasnoselskaya 2/8, Moscow, Russia b JSC “NIIEFA” (D.V. Efremov Institute), 189631, Doroga na Metallostroy, 3, S. Peterburg, Russia c Institution “Project Center ITER”,123182, Square of Academic Kurchatov 1, Moscow, Russia d ITER Organization, Route de Vinon sur Verdon CS 90 046 − 13067 Saint Paul lez Durance, France
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Article history: Received 30 August 2015 Received in revised form 9 March 2016 Accepted 10 March 2016 Available online xxx
a b s t r a c t The two following ITER blanket-relevant Procurement Arrangements (PA) were signed by Russian Federation and ITER Organization in 2014: 1) 1.6.P1ARF.01 “Blanket First Wall” (signed on 14-th of February, 2014); 2) 1.6.P3.RF.01 “Blanket Module Connections” (signed on 19-th of December, 2014). The first PA is devoted to the development, manufacturing, testing and procuring to ITER site of 179 Enhanced Heat Flux (EHF) First Wall (FW) Panels. These FW panels are intended to withstand the heat flux from plasma up to 4.7 MW/m2 , and there are two institutions in Russian Federation responsible for the manufacturing, testing and delivering of these panels on the ITER site: JSC “NIIEFA” (Efremov Institute) and JSC “NIKIET”. JSC “NIIEFA” (Efremov Institute) will manufacture the plasma-facing components (PFC) of EHF FW Panels and perform the final assembling of the panels while JSC “NIKIET” will manufacture the FW beam structures, load-bearing structures of PFC and the all the elements of panel attachment system. As for the second PA (“Blanket Module Connectors”) the JSC “NIKIET” is the alone official Supplier and will manufacture and procure blanket flexible supports, electrical insulating key pads and shield block/vacuum vessel electrical connectors. This article briefly describes the joint activity of JSC “NIKIET” and Efremov Institute in the framework of 1.6.P1ARF.01 “Blanket First Wall” Procurement Arrangement and the material on the activity on the second PA. The main achievements on both PAs (during the period of 2014–2015) are presented and also critical issues and plans are underlined. © 2016 Elsevier B.V. All rights reserved.
1. Introduction The following ITER blanket-relevant Procurement Arrangements (PAs) were signed between Institution “Project Center ITER (Russian Federation ITER Domestic Agency) and ITER Organization (IO):
∗ *Corresponding author. E-mail address: [email protected] (A.Yu. Leshukov).
1) PA 1.6.Р1A.RF.01 ‘Enhanced Heat Flux First Wall Panels’ on 14-th of February, 2014 [1]; 2) PA 1.6.P3.RF.01 “Blanket Module Connections” on 19-th of December, 2014 [2]. Russian Federation Domestic Agency (RF DA) has been created in 2009 and is an authorized organization in RF which is responsible for the RF in-kind contribution into the ITER project in accordance with ITER Agreement. It is necessary to underline that the realization of PA 1.6.Р1A.RF.01 is shared between two official Suppliers—JSC “NIKIET” (according to Order No. 1/96-П of “Rosatom”) and JSC “NIIEFA” (D.V.Efremov Institute, according to Order No. 1/505-П of “Rosatom” dated 15/06/2011). Also the Order
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1046 dated 13 December 1999, and consequently excluded from the ESPN order. According to PA 1.6.Р1A.RF.01 [1] RF DA shall manufacture, test and procure on the ITER site one full-scale EHF FW prototype (FSP) per the applied manufacturing technology and 179 serial panels (1 spare panel shall be provided for each row, 8 spare panels in total) which are indicated with Blanket Module (BM) numbers and quantity of respective FW panels in Fig. 1. The FW panel is an assembly unit which includes the following components: plasma-facing components (FW fingers), FW beam, Central Slot Insert (CSI), mechanical attachment system and two electrical straps. The general views of EHF FWP (major options that should be developed by RF DA) are presented in Figs. 2–7. In accordance with sharing of responsibilities between JSC “NIIEFA” and JSC “NIKIET” in the framework of PA 1.6.Р1A.RF.01 JSC “NIKIET” shall manufacture and transfer to JSC “NIIEFA” for final assembling and acceptance testing the following FWP components: -
semi-products of FW beams; semi-products of plasma facing components (fingers); FW mechanical attachment system on the SB; FW/SB electrical straps (ES).
2.1. Design and analysis of EHF FW Panels (major options)
Fig. 1. Numbers of blanket modules and quantity of corresponding panels that shall be fabricated and procured by Russian Federation in accordance with Procurement Arrangement 1.6.Р1ARF.01.
No. 1/96-П defines JCS “NIKIET” as single Official Supplier on the PA 1.6.P3.RF.01 “Blanket Module Connections” [2]. According to Technical Specifications [1,2] now both PAs of NIKIET’s responsibility are on the Phase II “Supplier disclosure and pre-production documentation”. The Quality Plan (QP) of JSC “NIKIET” on the PA 1.6.Р1A.RF.01 [3] and QP on the PA 1.6.P3.RF.01 [4] have been approved by IO on the 4-th of November, 2014 and on 24-th of April, 2015 respectively. The general assembly drawings for FWP and BMC prototypes will be sent to IO for approval at the end of 2015 and in the middle of 2016 respectively. This article briefly describes the realization of the above mentioned PAs by NIKIET’s specialists. Some critical issues on the PAs implementation and further plans are also presented and indicated in this paper.
2. Activity on PA 1.6.Р1A.RF.01 “Blanket First wall” The Enhanced Heat Flux (EHF) FW panels are plasma-facing Blanket System components which are which is mechanically fixed to the front part of the shield blocks (SB) by the attachment system and intended to withstand the heat flux from plasma up to 4.7 MW/m2 . EHF FW panels are non-Safety Important Components (non-SIC) because no safety function is credited to the Blanket System. EHF FW including all the parts and materials are assigned to Quality Class 1 according to ITER Quality Classification Determination. The EHF FW components and materials that are the “pressure/vacuum” boundary are classified as VQC1A according ITER Vacuum Design Handbook [5], However the FW components of attachment and electrical connection systems are classified as VQC1B. EHF FWP as Blanket System components are excluded from the application of the decree on pressurized equipment, No 99-
The design development of EHF FWPs in JSC “NIKIET” now is performing for major design options. In total the number of major EHF FW options is 15, while 17 minor options. The present status of design development is briefly summarized below. The engineering model of FWP#7 type A (Fig. 2) is under development. It is necessary to receive the new configuration management model (CMM) of this panel from IO. The expected date of the official transfer procedure starting of detailed Catia model for FW#7 type A is March, 2016. The design of FWP#8 type A (Fig. 3) is ready, DCM has been sent to IO for pre-transfer checking on 15/06/2015. For FWP#8 type the thermal hydraulic analysis has been performed (water coolant pressure is 4 MPa, inlet temperature is 75 ◦ C, mass flow rate—6.5744 kg/s, uniform surface heat flux—1 MW/m2 ). Total coolant pressure drop is 378 kPa (FWP itself + coolant branchpipes) and does not exceed the allowable recommended value (0.4 MPa). Mass flow rate distribution is on acceptable level: maximum decreasing from nominal value (0.4696 kg/s) in finger’s pair is −6.7% and does not exceed the allowable value (−10%). Thermal analysis for the FWP#8 type A is in process. The engineering model of FWP#9 type A (Fig. 4) is available however the new CMM is required. The expected date of the official transfer procedure starting of DCM for FW#9 type A is March, 2016. The hydraulic analysis of the FWP#9 type A cooling path has been performed (water coolant pressure is 4 MPa, inlet temperature is 75 ◦ C, mass flow rate—8.53 kg/s). The pressure drop in FWP#9 type A is 342 kPa (without coolant branch-pipes) and does not exceed the recommended allowable of 0.4 MPa. It is necessary to decrease the pressure drops in coolant branch-pipes (175.5 kPa), in beam coolant path (165.9 kPa) and in fingers (176 kPa). Maximum decreasing of mass flow rate in finger pairs from nominal value (0.533 kg/s) is −4.1% and does not exceed the allowable value (−10 %). The design of FWP#14 type A (Fig. 5) has agreed with IO as fullscale prototype. The DCM has been approved by IO on 17/06/2015 and the milestone of annual working plan (AWP-2015) is achieved. Several design modifications and further analyses were performed for the FWP#14 type A. The pressure drop in FWP#14 type A is 265 kPa (without coolant branch-pipes) It is necessary to decrease the pressure drops in coolant branch-pipes (160 kPa).
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Fig. 2. General view of FWP#7 type A.
All the considered criteria of static and fatigue strength are satisfied for FWP#14 type A. The design of FWP#14 type NDL (Non-Dog-Leg type of Fist wall, Fig. 6) is ready and the official transfer procedure of DCM will be started in September, 2015. The attachment system of FWPs includes the special barrel with the central bolt arranged inside, 4 radial and 4 lateral contact pads. The central bolt should be screwed into the SB and preloaded with axial force specified according to the electromagnetic loads acting on the particular FWP. Radial contact pads carry the bolt preload pressing the FWP on the SB frontal surface while lateral pads are intended the reacting of the radial torque, vertical and lateral forces. In 2014 the welded option of barrel has been replaced by the threaded one due to the following advantages: - simplification of assembling/disassembling process; - preventing the damage of components with electrical insulation during welding and cleaning procedures; - improving the maintainability of elements located inside the barrel. Also the negative results of experimental assessment for the welded barrel system are presented in Section 2.2 of this paper. The design of EHF FWP attachment system with threaded barrel has been updated in order to provide the locking (avoiding of selfunscrewing) of all the used threaded joints. The developed design solutions were integrated into FWPs#14-17 (Fig. 8a), FWPs#7-9
and FWP#18 (Fig. 8b). The barrels of FWPs#7-9 and FWP#18 are equipped with М150х4 external thread and screwed directly into the FW beam while for outboard FWPs the barrels are screwed into an immediate collar fixed on the FW beam by TIG-welding on the М145х4 external thread. It is necessary to underline that electromagnetic forces acting on the FWPs#7-9 during plasma disruptions are significantly higher than on the FWP#14-18 according to [6]. For this reason the preload force for the top panels is increased up to 600 kN (for FWP#14 type A preload force is 260 kN). The design and technological approach proposed by NIKIET’s specialists on the ES is to unify as much as possible the design and manufacturing technology for FWP/SB and BM/VV electrical straps. The results of ES electrical testing (Section 3.2) shown that it is necessary to have the CuCrZr/CuCrZr electrical contact interface in order to prevent the burning on steel/bronze-interface at the current specified for Category III plasma disruptions. [7]. Taking into account the results of electrical testing and technological capabilities the “monolithic” ES design (Fig. 9) has been proposed by NIKIET instead of brazed and mechanically attached (Fig. 10) options proposed by IO and NIKIET in 2014 respectively. The “monolithic” ES could be manufactured from CuCrZr bar or rod by the electrical discharge technique. This design allows to simplify the manufacturing technology and to eliminate lamellas brazing which requires the availability of special equipment and methods of non-destructive (NDT) inspection for brazed joints.
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Fig. 3. General view of FWP#8 type A.
Fig. 4. General view of FWP#9 type A.
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Fig. 6. General view of FWP#14 type NDL.
Fig. 5. General view of FWP#14 type A.
The analysis has been performed for both ES options adopted to the FWP#14 type A application. The analysis results for both ES options being integrated into the FWP#14 type A include: - currents and Joule heating distributions at plasma disruptions; - transient temperature fields; - stress distributions and axial forces in attachment elements (bolts). The results Joule heating and difference of potential for ES options with various options of contact on ES/pedestal interface are presented in Table 1. Table 2 contains the results of transient temperature analysis for the same ES design options. The equivalent stress distribution is ES with mechanical attachment of lamellas at the plasma disruption (end of plasma burn) is presented in Fig. 11. Maximum equivalent stress is 848 MPa and takes place in central flange bolt. The axial force in central flange bolt (preload value is 120 kN) decreases on 13.4%, 4.9% and 14.1% in plasma burn, pause and at plasma disruption respectively. The axial force in lateral flange bolts decreases (preload value is 20 kN for each bolt) on 3.7%, 0.9% and 3.1% in plasma burn, pause and at plasma disruption respectively. The equivalent stress distribution in “monolithic” ES is presented in Fig. 12. Maximum stress is 512 MPa and takes place in central flange bolt. Maximum equivalent stress in ES itself is 329 MPa (zone of lamellas matting with central flange) and does not exceed the allowable value of 3 × Sm = 341 МПɑ [8]. The “ratcheting” criteria is satisfied according to SDC-IC [9]. The axial force in central flange bolt (preload value is 120 kN) decreases on 25.7% and 14.1% in plasma burn and pause respectively. The axial force in lat-
eral flange bolts decreases (preload value is 20 kN for each bolt) on 6.7%, and 3.8% in plasma burn and pause respectively. The decreasing of axial forces in the attachment elements of “monolithic” ES is higher than in the ES with mechanical attachment of lamellas at plasma burn. It is reasonable to use the spring washers under the bolt heads in order to provide the axial forces in these bolts on the required level. The equivalent stress level is the same for both options and it is necessary to modify the lamellas shape in order to decrease the stresses. 2.2. Manufacturing technology development and experimental assessment for EHF FWPs components During the period of 2014–2015 on the Phase II “Supplier disclosure and pre-production documentation” of the PA 1.6.Р1A.RF.01 implementation NIKIET’s specialists have developed the manufacturing technology processes for the EHF FWP components. The following full-scale mock-ups and semi-products have been fabricated: 1) full-scale mock-ups of contact pads with electrical insulation (Al2 O3 ) on the conical lateral surface (Fig. 13); Electrical insulating coating (EIC) has been deposited by plasma spraying method, pad’s structural material is NiAl-bronze. The process of EIC deposition is a special one and for this reason it’s qualification shall be performed in accordance with technical specification (to be developed by JSC “NIKIET” as a supplier). At the present time this specification is under preparing basing upon the requirements of IO technical specification [10]. 2) full-scale mock-ups of FWP central bolt with conical threaded insert for threaded joint locking (Fig. 14). Structural material of central bolt and spherical washer is UNS N0771, while conical threaded insert is fabricated from UNS Number S66286. Central bolt mock-ups were fabricated by the electrical discharge tech-
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Fig. 7. General view of FWP#18 type E.
Table 1 Electric potential (V) and Joule heating (W/mm3 ) in lamellas for “FWP/SB” ES options. ES design option
Difference of potentials, V
Joule heating, W/mm3
ES with mechanical attachment of lamellas With bimetallic (SS 316LN-IG/CuCrZr) pedestal from FWP side SS 316LN-IG pedestal from FWP side
0.117 0.203
0.128 0.231
“Monolithic” ES With bimetallic (SS 316LN-IG/CuCrZr) pedestal from FWP side
0.102
0.087
Table 2 Results of transient temperature analysis for “FWP/SB” ES design options. Element
ES with mechanical attachment of lamellas, SS 316LN-IG pedestal
“Monolithic” ES, bimetallic pedestal
◦
Maximum temperature (plasma burn “Inductive I”-mode), C 277.2 Lamellas 297.7 Central flange bolt 281.5 Lateral flange bolt
271.2 329.8 275.8
Heat-up at the transient from plasma burn to plasma disruption, ◦ C Lamellas 9.8
2.7
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Fig. 8. Mechanical attachment system of FWPs.
Fig. 9. “Monolithic” option of FWP/SB ES.
heat treatment. The welds of coolant channel lids were performed on the electron-beam welding (EBW) facility. These welds are on the vacuum/pressure boundary and shall be butttype with full penetration according to the requirements of EN ISO 13919-1 (level B) [11]. The developed welding mode of beam lids: facility power—40 kW, welding current—60/70/90 mA (for lid thicknesses of 8, 10 и 12 mm respectively), welding torch velocity—600 mm/min, focusing current—700 mA, transversal deviation of electron beam—2%. 4) 6 full-scale mock-ups of load-bearing casings for fingers (Fig. 16, geometry and dimensions for FWP#14 type A). The developed welding mode of back channel lid with finger casing: facility power—40 kW, welding current—47 mA, welding torch velocity—600 mm/min, focusing current—700 mA. The developed heat treatment mode for stress relieving: temperature—480–485 ◦ C, exposure duration—12 h, then cooling down in furnace to room temperature. These semi-products (3 finger’s pairs, 6 items in total) will be delivered to JSC “NIIEFA” for further welding of bimetallic lids, hypervaportron (HVP) channels bonding and beryllium tiles brazing. 5) mock-up of welded barrel (Fig. 17) for FWP attachment system. This mock-up (structural material—steel 316LN-IG) has been fabricated by thermal in inert gas (TIG) welding and thus it was proved that welded barrel option is not able to operation because the central bolt could not be screwed into the parking thread due to welding distortions. It was the valuable reason to use the threaded barrel in the FWP attachment system. 6) full-scale mock-up of ES “EHF FW panel/SB” (Fig. 18, position 1); this mock-up (“monolithic” ES option) has been fabricated on electrical discharge machine from CuCrZr-bronze rod. This agreeing of this manufacturing approach in IO is in process.
Fig. 10. ES option with mechanical attachment of lamellas.
nique and the document describing this manufacturing process is sent to IO approval in August, 2015. 3) full-scale mock-up of FWP#14 type A beam (Fig. 15). This mockup (structural material—steel 316LN-IG) is intended for the development of machining, welding of coolant channel lids and
The activity on experimental assessment of EHF FWP components has been mainly devoted to the attachment system − testing of contact pads with EIC (Fig. 13) and central bolt locking system (Fig. 14). Thermal vacuum testing (Fig. 19) has been performed at the temperature of 270 ◦ C (24 cycles), the results are as follows:
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Fig. 14. Central bolts of FWP attachment system with spherical washers and conical threaded inserts. Fig. 11. Equivalent stresses in ES with mechanical attachment of lamellas (plasma disruption), MPa.
Fig. 15. Mock-up of FWP beam with welded lids of coolant channels.
Fig. 12. Equivalent stress distribution in “monolithic” ES (plasma burn, Inductive I mode), MPa.
Fig. 16. Mock-up of fingers pair (structural material—steel 316LN-IG).
3. Activity on PA 1.6.P3.RF.01 “Blanket Module Connections” 3.1. Scope of PA 1.6.P3.RF.01 and BMC design BMC are the components of Blanket System with the following functionality: Fig. 13. Pads with EIC for EHF FWP attachment system.
1) the ability to operation of central bolt locking system (conical threaded insert which is screwed into the perforated part of bolt threaded end) is verified. The unscrewing torque on threaded insert is 550 Nm that is equal to the preload value; 2) electrical insulating properties and integrity of Al2 O3 coating on contact pads are provided after testing.
- fixing the BMs on VV internal wall; - electrical insulation of BMs from VV in the locations of possible metal/metal contact; - grounding of halo and eddy currents induced in BMs on VV; - bearing of loads induced by BMs weight, non-uniform and cyclic thermal fields and plasma disruptions. According to PA 1.6.P3.RF.01 [2] RF DA shall procure to ITER site the BMC for all the 440 BMs. BMC comprise the following components and assemblies with indicating of respective quantity:
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Fig. 20. Flexible cartridge assembly (outboard blanket).
Fig. 17. Mock-up of welded barrel.
Fig. 21. Inter-modular (ITM) poloidal key pad assembly and Standard centering key pad assembly (in ellipse).
Fig. 18. Electrical straps that have been fabricated from the solid piece of CuCrZrbronze on the electrical discharge machine: (1)—ES “EHF FW panel/SB”, (2)—ES “BM/VV”, (3)—ES “BM/VV” with two groups of lamellas.
Fig. 22. Stub key pad assembly.
Fig. 19. FWP contact pads with fixing tool, central bolt locking system with SB threaded insert and cylindrical pads of inboard blanket inside the vacuum chamber.
- flexible cartridge assemblies (Fig. 20)—2109 items; - inter-modular (ITM) poloidal key pad and standard centering key pad assembles (Fig. 21)—866 and 425 items respectively; - stub key pad assemblies (Fig. 22)—1067 items; - ITM centering key pad assembly (for three BMs#4, Fig. 23)—8 items;
- ES assemblies and ES pedestals (Fig. 24)—1052 items each.
As part Blanket System BMCs are Non—Protection Important Components (non-PIC) in accordance with Order dated 7 February 2012 relating to the general technical regulations applicable to nuclear installations. BMCs including all the parts and materials are assigned a Quality Class 1 according to ITER Quality Classification Determination and belong to VQC1B group on Vacuum Classification.
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Fig. 23. ITM centering key pad assembly for BM#4.
Fig. 26. Mock-up of flexible cartridge assembly (inboard blanket).
Fig. 24. ES assembly and ES pedestal.
Fig. 27. Stub-key prismatic pads (EIC is deposited by detonation gun technique).
Fig. 25. “BM/VV” ES with mechanical attachment of lamellas (JSC “NIKIET” proposal of 2014).
3.2. Manufacturing and testing activity on BMC components In order to develop the technological processes of BMC prototypes manufacturing the following mock-ups were fabricated by JSC “NIKIET”: full-scale mock-ups of “BM/VV” ES with mechanical attachment of lamellas (Fig. 25). Two groups of lamellas are performed in order to provide the ability to operation of this unit in case of lamellas rupture in one of ES parts. These mock-ups were tested mechanically and electrically and the results are described below. two full-scale mock-ups of flexible cartridge assembly (inboard blanket) for further mechanical cyclic testing. Cartridge is fabri-
cated with maximum eccentric of central bolt hole (8.5 mm) and the flange for contact with SB is inclined on 1.43◦ (Fig. 26). The material of cartridge, central bolt, spherical washer and conical nut is UNS N0771 while the SB threaded insert is fabricated from UNS No.C63200. Conical nut and SB threaded insert (face for contact with cartridge) are equipped with EIC (plasma-sprayed Al2 O3 , 0.35 mm thickness, roughness—Ra1.6). 1) stub key prismatic pads with EIC (Al2 O3 ) deposited by detonation gun technique (Fig. 27) and plasma spraying (Fig. 28). 2) mock-ups of “monolithic” ES option for BM/VV with one (Fig. 18, position 2) and two (Fig. 18, position 3) groups of lamellas. The thermal mechanical testing of ES (Fig. 18, position 2) is in process. The “monolithic” ES option with two groups of lamellas (Fig. 18, position 3) will be considered as advanced solution which could be used both for BM/VV and FWP/SB. The testing activity of JSC “NIKIET” on BMC mainly was devoted to the works:
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Fig. 30. Mock-up of flexible cartridge assembly (inboard blanket) after mechanical cyclic testing.
Fig. 28. Stub-key prismatic pads (EIC is deposited by plasma spraying).
Fig. 31. Mock-up of “BM/VV” ES after 330 pulses of 137 kA current (pulse duration is 0.3 s). Fig. 29. Mock-up of BM/VV ES after mechanical testing.
1) mechanical cyclic testing of ES with mechanical attachment of lamellas (Fig. 25) and flexible cartridge assemblies (Fig. 26); 2) electrical testing of the ES (Fig. 25). Mechanical cyclic testing of ES (three mock-ups) have been performed on the Instron 8802 hydraulic testing machine. It is obtained that the life-time of ES design is up to 60,000 loading cycles (initial displacement is 1.7 mm, cyclic displacements are ±1.0 mm). The required number of loading cycles for BM/VV ES is 30,000 for this reason the design fatigue strength on cycles number is provided. One mock-up has been tested with initial displacement of 1.9 mm with further cyclic loading by ±1.9 mm displacement (Fig. 29) and ES life-time for these loading conditions is 15,000 cycles. Mechanical cyclic testing of two inboard flexible cartridge assemblies (Fig. 26) were performed on the Instron 8806 hydraulic testing machine in accordance with qualification and acceptance testing requirements which are presented in [2]: axial tension/compression force- ±800 kN, lateral displacement—up to 3 mm, angular inclination—up to 3 mrad. The tested mock-ups provide 20-times static strength margin on the loading cycles number, 2-times margin on the displacements and 1.5-times margin on maximum force. The electrical insulation of cartridge assembly is provided during testing. The mock-up after testing (up to the damage in order to evaluate the life-time) is presented in Fig. 30. Electrical testing of ES mock-up (Fig. 25) are intended to assess experimentally the ability to operation of “BM/VV” ES in the blanket-relevant conditions (current up to 137 kA, duration—300 ms). Two ES mock-ups electrically connected in
series have been tested. The contact interface “bronze/bronze” has been provided on the ES central flange while the on lateral flanges the interface was “bronze/steel”. Preload torque on central flange bolt is 400 Nm, the bolts on lateral flange are preloaded on 56 Nm torque. Both mock-ups were exposed to 330 pulses of 137 kA current (alternating current amplitude is 194 kA). Maximum temperature of 267 ◦ C has been obtained during testing on the “bronze/steel” interface of lateral flange. The burn and melting takes place on the steel contact surfaces while the traces of burn are on the bronze contact surfaces but deformation and melting is absent. There are no traces of oxidation or burn on the “bronze/bronze” contact interface. The decreasing of preload torque on lateral flange bolts is detected after testing. There are no loss of preload torque on central flange bolt and stud-bolts joining the lamellas. The ES mock-up after 330 testing cycles is presented in Fig. 31 4. Conclusion 1. The Procurements Arrangements 1.6.P1ARF.01 “Blanket First Wall” and 1.6.P3.RF.01 “Blanket Module Connections” are signed between the ITER Organization and Russian Federation in 2014 in order to provide the in-kind contribution into ITER project in accordance with ITER Agreement. 2. JSC “NIKIET” is defined as official Supplier on the PA 1.6.P1ARF.01 and PA 1.6.P3.RF.01. The Quality Plans of JSC “NIKIET” as an official supplier on the above mentioned PAs are approved by IO in November, 2014 and April, 2015 respectively.
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3. The implementation of both PAs by JSC “NIKIET” is on the Phase II “Supplier disclosure and pre-production documentation”. 4. The realization of PA 1.6.P1ARF.01 “Blanket First Wall” is shared between JSC “NIKIET” and JSC “NIIEFA” (second official supplier). JSC “NIKIET” is responsible for manufacture and transfer to JSC “NIIEFA” for final assembling and acceptance testing the following FWP components: a. semi-products of FW beams; b. semi-products of plasma facing components (fingers); c. FW mechanical attachment system on the SB; d. FW/SB electrical straps. 5. The collaboration between JSC “NIKIET” and JSC “NIIEFA” is under development: the three fabricated pairs of plasmafacing components (semi-products of load-bearing cases) will be transferred to JSC “NIIEFA” for the final assembling (welding of bimetallic lids, coolant pipes, bonding of HVP-channel, brazing of Be-tiles). 6. Design and analysis of FWP major options is in progress in collaboration with specialists of JSC “NIIEFA”. The design of full-scale prototype (FSP) is approved by IO on 17-th of June, 2015. FWP#14 type A is defined as FSP in the framework of PA 1.6.P1ARF.01 “Blanket First Wall” PA 1.6.P1ARF.01 “Blanket First Wall”. 7. The development of manufacturing processes and qualification procedures for the FW FSP is in progress in JSC “NIKIET”. 8. The experimental results verified the ability to operation of the FWP attachment components: central bolt locking system and contact pads. 9. The “monolithic” ES options have been developed and fabricated by JSC “NIKIET” for both PA 1.6.P1ARF.01 and PA 1.6.P3.RF.01. 10. In further activities NIKIET intends to develop the ES “monolithic” option in order to provide the integrity of currentconducting elements (lamellas) for all the ITER operating conditions.
11. The mock-ups of inboard cartridge assembly provide the static strength on the loading cycles number, displacements and loading force. The electrical insulation of cartridge assembly is provided during testing. Disclaimer The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. References ¨ ¨ [1] IO ITER Technical SpecificationAnnex B to Procurement Arrangement 1.6.P1A.RF.01, ITER D GHVBGL, v.1.1, 2014. ¨ ¨ [2] I.O. ITER Technical SpecificationAnnex B. to Procurement Arrangement 1.6.P3.RF.01, ITER UID PUKQPB v1.1. [3] I.O. ITER “Quality Plan for First wall components supply (Procurement Arrangement 1.6.P1A.RF.01)”, ITER D P9G245, v.1.1. [4] I.O. ITER “Quality Plan for Blanket Module Connections (Procurement Arrangement 1.6.P3.RF.01)”, ITER D QYNSCU, v.1.0. [5] ITER IO. “ITER Vacuum Handbook”, ITER D 2EZ9UM. ¨ system Load Specification¨, ITER D 3NSGK2, v.2.1, 2013. [6] IO ITER Blanket [7] IO ITER I¨TER Vacuum Vessel Load Specification¨, ITER D 2F52JY, v.3.3, 2014. ¨ A, Materials design limit data¨, ITER D 222RLN, v.3.2, 2012. [8] IO ITER Appendix [9] IO ITER I¨n-vessel Components, SDC-IC¨, ITER D 222RHC, v.3.0, 2012. [10] IO ITER “Technical Specification. 2015 Insulating coatings for the blankets system components”, ITER D 25QF6, Version 1.4. [11] E. N ISO 13919-1, Welding. Electrons and laser beam welded joints. Guidance on quality levels for imperfections. Part 1: steel.
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Overview of JSC “NIKIET” activity on ITER Procurement Arrangements A.Yu. Leshukov a,∗ , Yu. G. Dragunov a , Yu. S. Strebkov a , S.Yu. Kirillov a , S.V. Makarov a , P.D. Trofimovich a , G.V. Dubinin a , V.A. Maksimov a , M.N. Sviridenko a , A.V. Razmerov a , E.V. Parshutin a , S.E. Khomyakov a , V.Yu. Kolganov a , A.V. Zhmakin a , V.A. Belyakov b , I.V. Mazul b , A.A. Gervash b , V.M. Safronov c , A.N. Romannikov c , R. Eaton d , K. Egorov d a Joint-Stock Company “N.A. Dollezhall Research and Development Institute of Power Engineering”, (JSC “NIKIET”), 107140, Malaya Krasnoselskaya 2/8, Moscow, Russia b JSC “NIIEFA” (D.V. Efremov Institute), 189631, Doroga na Metallostroy, 3, S. Peterburg, Russia c Institution “Project Center ITER”,123182, Square of Academic Kurchatov 1, Moscow, Russia d ITER Organization, Route de Vinon sur Verdon CS 90 046 − 13067 Saint Paul lez Durance, France
a r t i c l e
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Article history: Received 30 August 2015 Received in revised form 9 March 2016 Accepted 10 March 2016 Available online xxx
a b s t r a c t The two following ITER blanket-relevant Procurement Arrangements (PA) were signed by Russian Federation and ITER Organization in 2014: 1) 1.6.P1ARF.01 “Blanket First Wall” (signed on 14-th of February, 2014); 2) 1.6.P3.RF.01 “Blanket Module Connections” (signed on 19-th of December, 2014). The first PA is devoted to the development, manufacturing, testing and procuring to ITER site of 179 Enhanced Heat Flux (EHF) First Wall (FW) Panels. These FW panels are intended to withstand the heat flux from plasma up to 4.7 MW/m2 , and there are two institutions in Russian Federation responsible for the manufacturing, testing and delivering of these panels on the ITER site: JSC “NIIEFA” (Efremov Institute) and JSC “NIKIET”. JSC “NIIEFA” (Efremov Institute) will manufacture the plasma-facing components (PFC) of EHF FW Panels and perform the final assembling of the panels while JSC “NIKIET” will manufacture the FW beam structures, load-bearing structures of PFC and the all the elements of panel attachment system. As for the second PA (“Blanket Module Connectors”) the JSC “NIKIET” is the alone official Supplier and will manufacture and procure blanket flexible supports, electrical insulating key pads and shield block/vacuum vessel electrical connectors. This article briefly describes the joint activity of JSC “NIKIET” and Efremov Institute in the framework of 1.6.P1ARF.01 “Blanket First Wall” Procurement Arrangement and the material on the activity on the second PA. The main achievements on both PAs (during the period of 2014–2015) are presented and also critical issues and plans are underlined. © 2016 Elsevier B.V. All rights reserved.
1. Introduction The following ITER blanket-relevant Procurement Arrangements (PAs) were signed between Institution “Project Center ITER (Russian Federation ITER Domestic Agency) and ITER Organization (IO):
∗ *Corresponding author. E-mail address: [email protected] (A.Yu. Leshukov).
1) PA 1.6.Р1A.RF.01 ‘Enhanced Heat Flux First Wall Panels’ on 14-th of February, 2014 [1]; 2) PA 1.6.P3.RF.01 “Blanket Module Connections” on 19-th of December, 2014 [2]. Russian Federation Domestic Agency (RF DA) has been created in 2009 and is an authorized organization in RF which is responsible for the RF in-kind contribution into the ITER project in accordance with ITER Agreement. It is necessary to underline that the realization of PA 1.6.Р1A.RF.01 is shared between two official Suppliers—JSC “NIKIET” (according to Order No. 1/96-П of “Rosatom”) and JSC “NIIEFA” (D.V.Efremov Institute, according to Order No. 1/505-П of “Rosatom” dated 15/06/2011). Also the Order
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1046 dated 13 December 1999, and consequently excluded from the ESPN order. According to PA 1.6.Р1A.RF.01 [1] RF DA shall manufacture, test and procure on the ITER site one full-scale EHF FW prototype (FSP) per the applied manufacturing technology and 179 serial panels (1 spare panel shall be provided for each row, 8 spare panels in total) which are indicated with Blanket Module (BM) numbers and quantity of respective FW panels in Fig. 1. The FW panel is an assembly unit which includes the following components: plasma-facing components (FW fingers), FW beam, Central Slot Insert (CSI), mechanical attachment system and two electrical straps. The general views of EHF FWP (major options that should be developed by RF DA) are presented in Figs. 2–7. In accordance with sharing of responsibilities between JSC “NIIEFA” and JSC “NIKIET” in the framework of PA 1.6.Р1A.RF.01 JSC “NIKIET” shall manufacture and transfer to JSC “NIIEFA” for final assembling and acceptance testing the following FWP components: -
semi-products of FW beams; semi-products of plasma facing components (fingers); FW mechanical attachment system on the SB; FW/SB electrical straps (ES).
2.1. Design and analysis of EHF FW Panels (major options)
Fig. 1. Numbers of blanket modules and quantity of corresponding panels that shall be fabricated and procured by Russian Federation in accordance with Procurement Arrangement 1.6.Р1ARF.01.
No. 1/96-П defines JCS “NIKIET” as single Official Supplier on the PA 1.6.P3.RF.01 “Blanket Module Connections” [2]. According to Technical Specifications [1,2] now both PAs of NIKIET’s responsibility are on the Phase II “Supplier disclosure and pre-production documentation”. The Quality Plan (QP) of JSC “NIKIET” on the PA 1.6.Р1A.RF.01 [3] and QP on the PA 1.6.P3.RF.01 [4] have been approved by IO on the 4-th of November, 2014 and on 24-th of April, 2015 respectively. The general assembly drawings for FWP and BMC prototypes will be sent to IO for approval at the end of 2015 and in the middle of 2016 respectively. This article briefly describes the realization of the above mentioned PAs by NIKIET’s specialists. Some critical issues on the PAs implementation and further plans are also presented and indicated in this paper.
2. Activity on PA 1.6.Р1A.RF.01 “Blanket First wall” The Enhanced Heat Flux (EHF) FW panels are plasma-facing Blanket System components which are which is mechanically fixed to the front part of the shield blocks (SB) by the attachment system and intended to withstand the heat flux from plasma up to 4.7 MW/m2 . EHF FW panels are non-Safety Important Components (non-SIC) because no safety function is credited to the Blanket System. EHF FW including all the parts and materials are assigned to Quality Class 1 according to ITER Quality Classification Determination. The EHF FW components and materials that are the “pressure/vacuum” boundary are classified as VQC1A according ITER Vacuum Design Handbook [5], However the FW components of attachment and electrical connection systems are classified as VQC1B. EHF FWP as Blanket System components are excluded from the application of the decree on pressurized equipment, No 99-
The design development of EHF FWPs in JSC “NIKIET” now is performing for major design options. In total the number of major EHF FW options is 15, while 17 minor options. The present status of design development is briefly summarized below. The engineering model of FWP#7 type A (Fig. 2) is under development. It is necessary to receive the new configuration management model (CMM) of this panel from IO. The expected date of the official transfer procedure starting of detailed Catia model for FW#7 type A is March, 2016. The design of FWP#8 type A (Fig. 3) is ready, DCM has been sent to IO for pre-transfer checking on 15/06/2015. For FWP#8 type the thermal hydraulic analysis has been performed (water coolant pressure is 4 MPa, inlet temperature is 75 ◦ C, mass flow rate—6.5744 kg/s, uniform surface heat flux—1 MW/m2 ). Total coolant pressure drop is 378 kPa (FWP itself + coolant branchpipes) and does not exceed the allowable recommended value (0.4 MPa). Mass flow rate distribution is on acceptable level: maximum decreasing from nominal value (0.4696 kg/s) in finger’s pair is −6.7% and does not exceed the allowable value (−10%). Thermal analysis for the FWP#8 type A is in process. The engineering model of FWP#9 type A (Fig. 4) is available however the new CMM is required. The expected date of the official transfer procedure starting of DCM for FW#9 type A is March, 2016. The hydraulic analysis of the FWP#9 type A cooling path has been performed (water coolant pressure is 4 MPa, inlet temperature is 75 ◦ C, mass flow rate—8.53 kg/s). The pressure drop in FWP#9 type A is 342 kPa (without coolant branch-pipes) and does not exceed the recommended allowable of 0.4 MPa. It is necessary to decrease the pressure drops in coolant branch-pipes (175.5 kPa), in beam coolant path (165.9 kPa) and in fingers (176 kPa). Maximum decreasing of mass flow rate in finger pairs from nominal value (0.533 kg/s) is −4.1% and does not exceed the allowable value (−10 %). The design of FWP#14 type A (Fig. 5) has agreed with IO as fullscale prototype. The DCM has been approved by IO on 17/06/2015 and the milestone of annual working plan (AWP-2015) is achieved. Several design modifications and further analyses were performed for the FWP#14 type A. The pressure drop in FWP#14 type A is 265 kPa (without coolant branch-pipes) It is necessary to decrease the pressure drops in coolant branch-pipes (160 kPa).
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Fig. 2. General view of FWP#7 type A.
All the considered criteria of static and fatigue strength are satisfied for FWP#14 type A. The design of FWP#14 type NDL (Non-Dog-Leg type of Fist wall, Fig. 6) is ready and the official transfer procedure of DCM will be started in September, 2015. The attachment system of FWPs includes the special barrel with the central bolt arranged inside, 4 radial and 4 lateral contact pads. The central bolt should be screwed into the SB and preloaded with axial force specified according to the electromagnetic loads acting on the particular FWP. Radial contact pads carry the bolt preload pressing the FWP on the SB frontal surface while lateral pads are intended the reacting of the radial torque, vertical and lateral forces. In 2014 the welded option of barrel has been replaced by the threaded one due to the following advantages: - simplification of assembling/disassembling process; - preventing the damage of components with electrical insulation during welding and cleaning procedures; - improving the maintainability of elements located inside the barrel. Also the negative results of experimental assessment for the welded barrel system are presented in Section 2.2 of this paper. The design of EHF FWP attachment system with threaded barrel has been updated in order to provide the locking (avoiding of selfunscrewing) of all the used threaded joints. The developed design solutions were integrated into FWPs#14-17 (Fig. 8a), FWPs#7-9
and FWP#18 (Fig. 8b). The barrels of FWPs#7-9 and FWP#18 are equipped with М150х4 external thread and screwed directly into the FW beam while for outboard FWPs the barrels are screwed into an immediate collar fixed on the FW beam by TIG-welding on the М145х4 external thread. It is necessary to underline that electromagnetic forces acting on the FWPs#7-9 during plasma disruptions are significantly higher than on the FWP#14-18 according to [6]. For this reason the preload force for the top panels is increased up to 600 kN (for FWP#14 type A preload force is 260 kN). The design and technological approach proposed by NIKIET’s specialists on the ES is to unify as much as possible the design and manufacturing technology for FWP/SB and BM/VV electrical straps. The results of ES electrical testing (Section 3.2) shown that it is necessary to have the CuCrZr/CuCrZr electrical contact interface in order to prevent the burning on steel/bronze-interface at the current specified for Category III plasma disruptions. [7]. Taking into account the results of electrical testing and technological capabilities the “monolithic” ES design (Fig. 9) has been proposed by NIKIET instead of brazed and mechanically attached (Fig. 10) options proposed by IO and NIKIET in 2014 respectively. The “monolithic” ES could be manufactured from CuCrZr bar or rod by the electrical discharge technique. This design allows to simplify the manufacturing technology and to eliminate lamellas brazing which requires the availability of special equipment and methods of non-destructive (NDT) inspection for brazed joints.
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Fig. 3. General view of FWP#8 type A.
Fig. 4. General view of FWP#9 type A.
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Fig. 6. General view of FWP#14 type NDL.
Fig. 5. General view of FWP#14 type A.
The analysis has been performed for both ES options adopted to the FWP#14 type A application. The analysis results for both ES options being integrated into the FWP#14 type A include: - currents and Joule heating distributions at plasma disruptions; - transient temperature fields; - stress distributions and axial forces in attachment elements (bolts). The results Joule heating and difference of potential for ES options with various options of contact on ES/pedestal interface are presented in Table 1. Table 2 contains the results of transient temperature analysis for the same ES design options. The equivalent stress distribution is ES with mechanical attachment of lamellas at the plasma disruption (end of plasma burn) is presented in Fig. 11. Maximum equivalent stress is 848 MPa and takes place in central flange bolt. The axial force in central flange bolt (preload value is 120 kN) decreases on 13.4%, 4.9% and 14.1% in plasma burn, pause and at plasma disruption respectively. The axial force in lateral flange bolts decreases (preload value is 20 kN for each bolt) on 3.7%, 0.9% and 3.1% in plasma burn, pause and at plasma disruption respectively. The equivalent stress distribution in “monolithic” ES is presented in Fig. 12. Maximum stress is 512 MPa and takes place in central flange bolt. Maximum equivalent stress in ES itself is 329 MPa (zone of lamellas matting with central flange) and does not exceed the allowable value of 3 × Sm = 341 МПɑ [8]. The “ratcheting” criteria is satisfied according to SDC-IC [9]. The axial force in central flange bolt (preload value is 120 kN) decreases on 25.7% and 14.1% in plasma burn and pause respectively. The axial force in lat-
eral flange bolts decreases (preload value is 20 kN for each bolt) on 6.7%, and 3.8% in plasma burn and pause respectively. The decreasing of axial forces in the attachment elements of “monolithic” ES is higher than in the ES with mechanical attachment of lamellas at plasma burn. It is reasonable to use the spring washers under the bolt heads in order to provide the axial forces in these bolts on the required level. The equivalent stress level is the same for both options and it is necessary to modify the lamellas shape in order to decrease the stresses. 2.2. Manufacturing technology development and experimental assessment for EHF FWPs components During the period of 2014–2015 on the Phase II “Supplier disclosure and pre-production documentation” of the PA 1.6.Р1A.RF.01 implementation NIKIET’s specialists have developed the manufacturing technology processes for the EHF FWP components. The following full-scale mock-ups and semi-products have been fabricated: 1) full-scale mock-ups of contact pads with electrical insulation (Al2 O3 ) on the conical lateral surface (Fig. 13); Electrical insulating coating (EIC) has been deposited by plasma spraying method, pad’s structural material is NiAl-bronze. The process of EIC deposition is a special one and for this reason it’s qualification shall be performed in accordance with technical specification (to be developed by JSC “NIKIET” as a supplier). At the present time this specification is under preparing basing upon the requirements of IO technical specification [10]. 2) full-scale mock-ups of FWP central bolt with conical threaded insert for threaded joint locking (Fig. 14). Structural material of central bolt and spherical washer is UNS N0771, while conical threaded insert is fabricated from UNS Number S66286. Central bolt mock-ups were fabricated by the electrical discharge tech-
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Fig. 7. General view of FWP#18 type E.
Table 1 Electric potential (V) and Joule heating (W/mm3 ) in lamellas for “FWP/SB” ES options. ES design option
Difference of potentials, V
Joule heating, W/mm3
ES with mechanical attachment of lamellas With bimetallic (SS 316LN-IG/CuCrZr) pedestal from FWP side SS 316LN-IG pedestal from FWP side
0.117 0.203
0.128 0.231
“Monolithic” ES With bimetallic (SS 316LN-IG/CuCrZr) pedestal from FWP side
0.102
0.087
Table 2 Results of transient temperature analysis for “FWP/SB” ES design options. Element
ES with mechanical attachment of lamellas, SS 316LN-IG pedestal
“Monolithic” ES, bimetallic pedestal
◦
Maximum temperature (plasma burn “Inductive I”-mode), C 277.2 Lamellas 297.7 Central flange bolt 281.5 Lateral flange bolt
271.2 329.8 275.8
Heat-up at the transient from plasma burn to plasma disruption, ◦ C Lamellas 9.8
2.7
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Fig. 8. Mechanical attachment system of FWPs.
Fig. 9. “Monolithic” option of FWP/SB ES.
heat treatment. The welds of coolant channel lids were performed on the electron-beam welding (EBW) facility. These welds are on the vacuum/pressure boundary and shall be butttype with full penetration according to the requirements of EN ISO 13919-1 (level B) [11]. The developed welding mode of beam lids: facility power—40 kW, welding current—60/70/90 mA (for lid thicknesses of 8, 10 и 12 mm respectively), welding torch velocity—600 mm/min, focusing current—700 mA, transversal deviation of electron beam—2%. 4) 6 full-scale mock-ups of load-bearing casings for fingers (Fig. 16, geometry and dimensions for FWP#14 type A). The developed welding mode of back channel lid with finger casing: facility power—40 kW, welding current—47 mA, welding torch velocity—600 mm/min, focusing current—700 mA. The developed heat treatment mode for stress relieving: temperature—480–485 ◦ C, exposure duration—12 h, then cooling down in furnace to room temperature. These semi-products (3 finger’s pairs, 6 items in total) will be delivered to JSC “NIIEFA” for further welding of bimetallic lids, hypervaportron (HVP) channels bonding and beryllium tiles brazing. 5) mock-up of welded barrel (Fig. 17) for FWP attachment system. This mock-up (structural material—steel 316LN-IG) has been fabricated by thermal in inert gas (TIG) welding and thus it was proved that welded barrel option is not able to operation because the central bolt could not be screwed into the parking thread due to welding distortions. It was the valuable reason to use the threaded barrel in the FWP attachment system. 6) full-scale mock-up of ES “EHF FW panel/SB” (Fig. 18, position 1); this mock-up (“monolithic” ES option) has been fabricated on electrical discharge machine from CuCrZr-bronze rod. This agreeing of this manufacturing approach in IO is in process.
Fig. 10. ES option with mechanical attachment of lamellas.
nique and the document describing this manufacturing process is sent to IO approval in August, 2015. 3) full-scale mock-up of FWP#14 type A beam (Fig. 15). This mockup (structural material—steel 316LN-IG) is intended for the development of machining, welding of coolant channel lids and
The activity on experimental assessment of EHF FWP components has been mainly devoted to the attachment system − testing of contact pads with EIC (Fig. 13) and central bolt locking system (Fig. 14). Thermal vacuum testing (Fig. 19) has been performed at the temperature of 270 ◦ C (24 cycles), the results are as follows:
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Fig. 14. Central bolts of FWP attachment system with spherical washers and conical threaded inserts. Fig. 11. Equivalent stresses in ES with mechanical attachment of lamellas (plasma disruption), MPa.
Fig. 15. Mock-up of FWP beam with welded lids of coolant channels.
Fig. 12. Equivalent stress distribution in “monolithic” ES (plasma burn, Inductive I mode), MPa.
Fig. 16. Mock-up of fingers pair (structural material—steel 316LN-IG).
3. Activity on PA 1.6.P3.RF.01 “Blanket Module Connections” 3.1. Scope of PA 1.6.P3.RF.01 and BMC design BMC are the components of Blanket System with the following functionality: Fig. 13. Pads with EIC for EHF FWP attachment system.
1) the ability to operation of central bolt locking system (conical threaded insert which is screwed into the perforated part of bolt threaded end) is verified. The unscrewing torque on threaded insert is 550 Nm that is equal to the preload value; 2) electrical insulating properties and integrity of Al2 O3 coating on contact pads are provided after testing.
- fixing the BMs on VV internal wall; - electrical insulation of BMs from VV in the locations of possible metal/metal contact; - grounding of halo and eddy currents induced in BMs on VV; - bearing of loads induced by BMs weight, non-uniform and cyclic thermal fields and plasma disruptions. According to PA 1.6.P3.RF.01 [2] RF DA shall procure to ITER site the BMC for all the 440 BMs. BMC comprise the following components and assemblies with indicating of respective quantity:
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Fig. 20. Flexible cartridge assembly (outboard blanket).
Fig. 17. Mock-up of welded barrel.
Fig. 21. Inter-modular (ITM) poloidal key pad assembly and Standard centering key pad assembly (in ellipse).
Fig. 18. Electrical straps that have been fabricated from the solid piece of CuCrZrbronze on the electrical discharge machine: (1)—ES “EHF FW panel/SB”, (2)—ES “BM/VV”, (3)—ES “BM/VV” with two groups of lamellas.
Fig. 22. Stub key pad assembly.
Fig. 19. FWP contact pads with fixing tool, central bolt locking system with SB threaded insert and cylindrical pads of inboard blanket inside the vacuum chamber.
- flexible cartridge assemblies (Fig. 20)—2109 items; - inter-modular (ITM) poloidal key pad and standard centering key pad assembles (Fig. 21)—866 and 425 items respectively; - stub key pad assemblies (Fig. 22)—1067 items; - ITM centering key pad assembly (for three BMs#4, Fig. 23)—8 items;
- ES assemblies and ES pedestals (Fig. 24)—1052 items each.
As part Blanket System BMCs are Non—Protection Important Components (non-PIC) in accordance with Order dated 7 February 2012 relating to the general technical regulations applicable to nuclear installations. BMCs including all the parts and materials are assigned a Quality Class 1 according to ITER Quality Classification Determination and belong to VQC1B group on Vacuum Classification.
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Fig. 23. ITM centering key pad assembly for BM#4.
Fig. 26. Mock-up of flexible cartridge assembly (inboard blanket).
Fig. 24. ES assembly and ES pedestal.
Fig. 27. Stub-key prismatic pads (EIC is deposited by detonation gun technique).
Fig. 25. “BM/VV” ES with mechanical attachment of lamellas (JSC “NIKIET” proposal of 2014).
3.2. Manufacturing and testing activity on BMC components In order to develop the technological processes of BMC prototypes manufacturing the following mock-ups were fabricated by JSC “NIKIET”: full-scale mock-ups of “BM/VV” ES with mechanical attachment of lamellas (Fig. 25). Two groups of lamellas are performed in order to provide the ability to operation of this unit in case of lamellas rupture in one of ES parts. These mock-ups were tested mechanically and electrically and the results are described below. two full-scale mock-ups of flexible cartridge assembly (inboard blanket) for further mechanical cyclic testing. Cartridge is fabri-
cated with maximum eccentric of central bolt hole (8.5 mm) and the flange for contact with SB is inclined on 1.43◦ (Fig. 26). The material of cartridge, central bolt, spherical washer and conical nut is UNS N0771 while the SB threaded insert is fabricated from UNS No.C63200. Conical nut and SB threaded insert (face for contact with cartridge) are equipped with EIC (plasma-sprayed Al2 O3 , 0.35 mm thickness, roughness—Ra1.6). 1) stub key prismatic pads with EIC (Al2 O3 ) deposited by detonation gun technique (Fig. 27) and plasma spraying (Fig. 28). 2) mock-ups of “monolithic” ES option for BM/VV with one (Fig. 18, position 2) and two (Fig. 18, position 3) groups of lamellas. The thermal mechanical testing of ES (Fig. 18, position 2) is in process. The “monolithic” ES option with two groups of lamellas (Fig. 18, position 3) will be considered as advanced solution which could be used both for BM/VV and FWP/SB. The testing activity of JSC “NIKIET” on BMC mainly was devoted to the works:
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Fig. 30. Mock-up of flexible cartridge assembly (inboard blanket) after mechanical cyclic testing.
Fig. 28. Stub-key prismatic pads (EIC is deposited by plasma spraying).
Fig. 31. Mock-up of “BM/VV” ES after 330 pulses of 137 kA current (pulse duration is 0.3 s). Fig. 29. Mock-up of BM/VV ES after mechanical testing.
1) mechanical cyclic testing of ES with mechanical attachment of lamellas (Fig. 25) and flexible cartridge assemblies (Fig. 26); 2) electrical testing of the ES (Fig. 25). Mechanical cyclic testing of ES (three mock-ups) have been performed on the Instron 8802 hydraulic testing machine. It is obtained that the life-time of ES design is up to 60,000 loading cycles (initial displacement is 1.7 mm, cyclic displacements are ±1.0 mm). The required number of loading cycles for BM/VV ES is 30,000 for this reason the design fatigue strength on cycles number is provided. One mock-up has been tested with initial displacement of 1.9 mm with further cyclic loading by ±1.9 mm displacement (Fig. 29) and ES life-time for these loading conditions is 15,000 cycles. Mechanical cyclic testing of two inboard flexible cartridge assemblies (Fig. 26) were performed on the Instron 8806 hydraulic testing machine in accordance with qualification and acceptance testing requirements which are presented in [2]: axial tension/compression force- ±800 kN, lateral displacement—up to 3 mm, angular inclination—up to 3 mrad. The tested mock-ups provide 20-times static strength margin on the loading cycles number, 2-times margin on the displacements and 1.5-times margin on maximum force. The electrical insulation of cartridge assembly is provided during testing. The mock-up after testing (up to the damage in order to evaluate the life-time) is presented in Fig. 30. Electrical testing of ES mock-up (Fig. 25) are intended to assess experimentally the ability to operation of “BM/VV” ES in the blanket-relevant conditions (current up to 137 kA, duration—300 ms). Two ES mock-ups electrically connected in
series have been tested. The contact interface “bronze/bronze” has been provided on the ES central flange while the on lateral flanges the interface was “bronze/steel”. Preload torque on central flange bolt is 400 Nm, the bolts on lateral flange are preloaded on 56 Nm torque. Both mock-ups were exposed to 330 pulses of 137 kA current (alternating current amplitude is 194 kA). Maximum temperature of 267 ◦ C has been obtained during testing on the “bronze/steel” interface of lateral flange. The burn and melting takes place on the steel contact surfaces while the traces of burn are on the bronze contact surfaces but deformation and melting is absent. There are no traces of oxidation or burn on the “bronze/bronze” contact interface. The decreasing of preload torque on lateral flange bolts is detected after testing. There are no loss of preload torque on central flange bolt and stud-bolts joining the lamellas. The ES mock-up after 330 testing cycles is presented in Fig. 31 4. Conclusion 1. The Procurements Arrangements 1.6.P1ARF.01 “Blanket First Wall” and 1.6.P3.RF.01 “Blanket Module Connections” are signed between the ITER Organization and Russian Federation in 2014 in order to provide the in-kind contribution into ITER project in accordance with ITER Agreement. 2. JSC “NIKIET” is defined as official Supplier on the PA 1.6.P1ARF.01 and PA 1.6.P3.RF.01. The Quality Plans of JSC “NIKIET” as an official supplier on the above mentioned PAs are approved by IO in November, 2014 and April, 2015 respectively.
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3. The implementation of both PAs by JSC “NIKIET” is on the Phase II “Supplier disclosure and pre-production documentation”. 4. The realization of PA 1.6.P1ARF.01 “Blanket First Wall” is shared between JSC “NIKIET” and JSC “NIIEFA” (second official supplier). JSC “NIKIET” is responsible for manufacture and transfer to JSC “NIIEFA” for final assembling and acceptance testing the following FWP components: a. semi-products of FW beams; b. semi-products of plasma facing components (fingers); c. FW mechanical attachment system on the SB; d. FW/SB electrical straps. 5. The collaboration between JSC “NIKIET” and JSC “NIIEFA” is under development: the three fabricated pairs of plasmafacing components (semi-products of load-bearing cases) will be transferred to JSC “NIIEFA” for the final assembling (welding of bimetallic lids, coolant pipes, bonding of HVP-channel, brazing of Be-tiles). 6. Design and analysis of FWP major options is in progress in collaboration with specialists of JSC “NIIEFA”. The design of full-scale prototype (FSP) is approved by IO on 17-th of June, 2015. FWP#14 type A is defined as FSP in the framework of PA 1.6.P1ARF.01 “Blanket First Wall” PA 1.6.P1ARF.01 “Blanket First Wall”. 7. The development of manufacturing processes and qualification procedures for the FW FSP is in progress in JSC “NIKIET”. 8. The experimental results verified the ability to operation of the FWP attachment components: central bolt locking system and contact pads. 9. The “monolithic” ES options have been developed and fabricated by JSC “NIKIET” for both PA 1.6.P1ARF.01 and PA 1.6.P3.RF.01. 10. In further activities NIKIET intends to develop the ES “monolithic” option in order to provide the integrity of currentconducting elements (lamellas) for all the ITER operating conditions.
11. The mock-ups of inboard cartridge assembly provide the static strength on the loading cycles number, displacements and loading force. The electrical insulation of cartridge assembly is provided during testing. Disclaimer The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. References ¨ ¨ [1] IO ITER Technical SpecificationAnnex B to Procurement Arrangement 1.6.P1A.RF.01, ITER D GHVBGL, v.1.1, 2014. ¨ ¨ [2] I.O. ITER Technical SpecificationAnnex B. to Procurement Arrangement 1.6.P3.RF.01, ITER UID PUKQPB v1.1. [3] I.O. ITER “Quality Plan for First wall components supply (Procurement Arrangement 1.6.P1A.RF.01)”, ITER D P9G245, v.1.1. [4] I.O. ITER “Quality Plan for Blanket Module Connections (Procurement Arrangement 1.6.P3.RF.01)”, ITER D QYNSCU, v.1.0. [5] ITER IO. “ITER Vacuum Handbook”, ITER D 2EZ9UM. ¨ system Load Specification¨, ITER D 3NSGK2, v.2.1, 2013. [6] IO ITER Blanket [7] IO ITER I¨TER Vacuum Vessel Load Specification¨, ITER D 2F52JY, v.3.3, 2014. ¨ A, Materials design limit data¨, ITER D 222RLN, v.3.2, 2012. [8] IO ITER Appendix [9] IO ITER I¨n-vessel Components, SDC-IC¨, ITER D 222RHC, v.3.0, 2012. [10] IO ITER “Technical Specification. 2015 Insulating coatings for the blankets system components”, ITER D 25QF6, Version 1.4. [11] E. N ISO 13919-1, Welding. Electrons and laser beam welded joints. Guidance on quality levels for imperfections. Part 1: steel.
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