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A substantial step forward in the realization of the ITER HNB system: The ITER NBI Test Facility
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A substantial step forward in the realization of the ITER HNB system: The ITER NBI Test Facility V. Toigo a,∗ , R. Piovan a , S. Dal Bello a , E. Gaio a , A. Luchetta a , R. Pasqualotto a , P. Zaccaria a , M. Bigi a , G. Chitarin a , D. Marcuzzi a , N. Pomaro a , G. Serianni a , P. Agostinetti a , M. Agostini a , V. Antoni a , D. Aprile a , C. Baltador a , M. Barbisan a , M. Battistella a , M. Boldrin a , M. Brombin a , M. Dalla Palma a , A. De Lorenzi a , R. Delogu a , M. De Muri a , F. Fellin a , A. Ferro a , C. Finotti a , A. Fiorentin a , G. Gambetta a , F. Gnesotto a , L. Grando a , P. Jain a , A. Maistrello a , G. Manduchi a , N. Marconato a , M. Moresco a , E. Ocello a , M. Pavei a , S. Peruzzo a , N. Pilan a , A. Pimazzoni a , M. Recchia a , A. Rizzolo a , G. Rostagni a , E. Sartori a , M. Siragusa a , P. Sonato a , A. Sottocornola a , E. Spada a , S. Spagnolo a , M. Spolaore a , C. Taliercio a , M. Valente a , P. Veltri a , A. Zamengo a , B. Zaniol a , L. Zanotto a , M. Zaupa a , D. Boilson b , J. Graceffa b , L. Svensson b , B Schunke b , H. Decamps b , M. Urbani b , M Kushwah b , J Chareyre b , M. Singh b , T. Bonicelli c , G. Agarici c , A. Masiello c , F. Paolucci c , M. Simon c , L Bailly-Maitre c , E. Bragulat c , G. Gomez c , D. Gutierrez c , G. Mico c , J.-F. Moreno c , V. Pilard c , M. Kashiwagi d , M. Hanada d , H. Tobari d , K. Watanabe d , T. Maeshima d , A. Kojima d , N. Umeda d , H. Yamanaka d , A. Chakraborty e , U. Baruah e , C. Rotti e , H. Patel e , M.V. Nagaraju e , N.P. Singh e , A. Patel e , H. Dhola e , B. Raval e , U. Fantz f , B. Heinemann f , W. Kraus f , S. Hanke g , V. Hauer g , S. Ochoa g , P. Blatchford h , B. Chuilon h , Y. Xue h , H.P.L. De Esch i , R. Hemsworth j , G. Croci k , G. Gorini k , M. Rebai k , A. Muraro l , M. Cavenago m , M. D’Arienzo n , S. Sandri o a
Consorzio RFX, Corso Stati Uniti 4, 35127 Padova, Italy ITER Organization, Route de Vinon sur Verdon, CS 90 046, 13067 St. Paul Lez Durance Cedex, France Fusion For Energy, C/o Josep Pla 2, 08019 Barcelona, Spain d National Institutes for Quantum and Radiological Science and Technology, 801-1 Mukoyama, Naka, Ibaraki-ken, 311-0193, Japan e Institute for Plasma Research, Nr. Indira Bridge, Bhat Village, Gandhinagar, Gujarat, 382428, India f IPP, Max-Plank-Institue fur Plasmaphysik, EURATOM Association, D-85748 Garching, Germany g KIT, Institute for Technical Physics, Eggenstein-Leopoldshafen, Germany h CCFE, Culham Science Centre, Oxfordshire, United Kingdom i CEA-Cadarache, IRFM, F-13108 Saint-Paul-lez-Durance, France j RSH Research Consultants Ltd, 12, Vallon de la Violette, 13820, Ensuès la Redonne, France k Dipartimento di Fisica “G. Occhialini”, Università di Milano-Bicocca, Milano, Italy l Istituto di Fisica del Plasma “P. Caldirola”, Milano, Italy m INFN-LNL, viale dell’Università n. 2, 35020 Legnaro, Italy n ENEA, National Institute of Ionizing Radiation Metrology, C.R. Casaccia, S. Maria di Galeria, Italy o ENEA Radiation Protection Institute, Frascati,Roma, Italy b c
∗ Corresponding author. E-mail address: [email protected] (V. Toigo). http://dx.doi.org/10.1016/j.fusengdes.2016.11.007 0920-3796/© 2016 Elsevier B.V. All rights reserved.
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h i g h l i g h t s • The ITER Neutral Beam Test Facility in Padova, Italy: substantial progress achieved.
• The realization of SPIDER, the ITER full-size negative ion source, is well advanced.
• Integrated tests of Power Supply and preparation of SPIDER operation starting now.
• Big progress on the realization of MITICA full-scale prototype of ITER HNB injector.
• MITICA operation planned to start in 2021, depending on the BS and BLC delivery.
a r t i c l e
i n f o
Article history: Received 3 October 2016 Accepted 15 November 2016 Available online xxx Keywords: ITER Heating Neutral Beam Injector (HNB) PRIMA: the ITER Neutral Beam Test Facility (NBTF) Spider Mitica
a b s t r a c t Substantial progresses have been achieved in the realization of the ITER Neutral Beam Test Facility (NBTF) hosted in Padova, Italy; the buildings, completed by the end of 2015, are being progressively filled with new systems and components. The realization of SPIDER, the ITER full-size negative ion source, is well advanced and important progress is also recorded for MITICA, the full-scale prototype of the ITER HNB injector. The paper gives an overview of the achieved results, highlighting the main challenges faced. © 2016 Elsevier B.V. All rights reserved.
1. Introduction The realization of the ITER Neutral Beam Test Facility (NBTF) and the start of its experimental phase are important tasks of the fusion roadmap, since the target requirements of injecting to the plasma a beam of deuterium atoms with a power up to 16.5 MW, at 1 MeV of energy and with a pulse length up to 3600 s have never been reached together before [1] The ITER NBTF, called PRIMA (Padova Research on ITER Megavolt Accelerator), is hosted in Padova, Italy. It includes two experiments: MITICA, the full-scale prototype of the ITER HNB injector, reproducing the whole geometry, and SPIDER, the full-size Radio Frequency (RF) negative-ions source [2,3]; the main parameters are summarized in Tables 1 and 2 respectively. The realization promoted by the ITER organization is carried out with the contribution of the European Union, channeled
Table 1 SPIDER requirements.
Beam energy Max beam source pressure Max deviation from uniformity Extracted current density Beam on time Co-extracted electron fraction (e− /H− ) and (e− /D− )
Unit
H
D
keV Pa % A/m2 s
100 0.3 ±10 >355 3600 <0.5
100 0.3 ±10 >285 3600 <1
Unit
H
D
keV A Pa mrad s
870 49 0.3 ≤7 3600 <0.5
1000 40 0.3 ≤7 3600 <1
through the Joint Undertaking for ITER (F4E), of the Consorzio RFX which also hosts the Test Facility, the Japanese and the Indian ITER Domestic Agencies (JADA and INDA) and several European laboratories, such as IPP-Garching, KIT-Karlsruhe, CCFE-Culham, CEA-Cadarache. The earliest start of SPIDER and MITICA experiments is pursued to maximize the fallout in terms of design optimization of the ITER HNB components and of preparation and then support to the ITER HNB use, planned during the Third Plasma stage, in 2031. SPIDER operation is expected to start in Q1 2018, thus several years of exploitation are planned toward the achievement of the target parameters of the RF ion source and improvements of its reliability and availability. Similar considerations apply also to MITICA, mainly devoted to optimize accelerator and Beam Line Components (BLC), which will enter in operation in 2021. Both experiments should provide key indications before the design of the different components of the ITER HNB is frozen. Fig. 1 shows a 3D CAD view of the PRIMA facility. Substantial progress has been achieved along all the work lines of the ITER NBTF realization. The paper highlights the main challenges encountered and gives an overview of the achieved results.
Table 2 MITICA requirements.
Beam energy Ion beam current Max beam source pressure Beamlet divergence Beam on time Co-extracted electron fraction (e− /H− ) and (e− /D− )
Fig. 1. 3D CAD view of the PRIMA facility.
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Fig. 2. Views of PRIMA cooling system components: pipes and pumps within the building (a); air coolers and cooling towers on the roof of the building (b).
Fig. 4. Overall CAD view of SPIDER.
2. Buildings and common plants 2.1. Buildings and auxiliaries
3. SPIDER
The construction of PRIMA buildings begun in October 2012 and was completed at the end of 2015; installation of components and plants is in progress since the end of 2014.
3.1. The SPIDER source
2.2. Cooling system The PRIMA cooling system shall cool and thermally control the experimental components and auxiliaries of SPIDER and MITICA [4] [5]. The maximum power to be exhausted by the system is about 70 MW when the two experiments are operating in parallel at nominal performance. As the maximum operating duty cycle is 25%, the heat is stored in water contained in two underground basins (1000 m3 ) and exhausted to the environment by cooling towers and air coolers; this solution allows limiting their rating to 17 MW. The plant units for SPIDER are almost completed (see Fig. 2) while the ones for MITICA are under installation. Commissioning and final acceptance tests are foreseen in June 2017 for SPIDER and in 2018 for MITICA plant units.
2.3. Gas and vacuum system The installation of the SPIDER gas and vacuum system was completed in May 2016 (see Fig. 3) and commissioning and site acceptance tests are presently going on. The SPIDER plant units will be finally available for integrated commissioning by the end of 2016. The system is expected to be completed with the MITICA plant units by the end of 2017.
Fig. 3. View of turbomolecular and cryogenic pumps installed around the SPIDER Vacuum Vessel.
An overall view of SPIDER is shown in Fig. 4, highlighting the main components: the Vacuum Vessel, the beam source, STRIKE (the high resolution (∼2 mm) calorimeter operating for short pulses, in the order of 5–10 s) and the water cooled Beam Dump. 3.1.1. Vacuum vessel The SPIDER Vacuum Vessel, fully assembled and tested on site in September 2015, is shown in Fig. 5. The manufacturing of a stainless steel vacuum vessel having a relatively large size (diameter 4 m, length 6 m) required optimized manufacturing/welding processes and very accurate machining and surface preparation to fulfil requirements for vacuum tightness, vacuum compatibility, precise positioning and opening/closing operations [6]. The vessel is installed on rails to facilitate the movements and lids are supported by special mechanical structures in order to facilitate opening. The vessel procurement package included three 100 kV bushings: one for electric connections (power and signal) and two for hydraulic pipes, see Fig. 6. They were installed and tested during the first part of 2016. 3.1.2. Beam source The procurement of the SPIDER Beam Source is in progress: manufacturing of parts/sub-assemblies by the various partners of the Supplier consortium has been completed (see Fig. 7) and the assembly in factory was started in May 2016 (see Fig. 8). Several issues had to be solved during manufacturing, mainly due to the very tight machining tolerances, high vacuum com-
Fig. 5. View of SPIDER Vacuum Vessel during vacuum tests on Site.
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Fig. 9. The beam dump for SPIDER long pulses: rear (a) and front (b) views. Fig. 6. View of the 100 kV Hydraulic bushings installed on the bottom side of the vacuum vessel.
Fig. 7. Views of parts/sub-assemblies of SPIDER Beam. Source: support frames (a)(b), RF driver (c), overall electrostatic shield (d) and plasma grid segments (e).
Table 3 ISEPS and AGPS main data ratings. ISEPS and AGPS power supplies
Output ratings
ISEPS: Extraction (EGPS) ISEPS: Radiofrequency (RFPS) ISEPS: Bias (BPS) ISEPS: PG filter (PGFPS) AGPS
−12.8 kV 140 A 4 units, 200 kW each f = 1 MHz 50 load ±30 V 600 A 15 V 5 kA –96 kV dc 71 A dc
3.1.3. Calorimeters The Beam Dump, designed to absorb and characterize a 6 MW ion beam for 1 h long pulses, was delivered by INDA [9–11]. The on-site tests were performed in June 2015 (see Fig. 9). After the installation of thermocouples for beam characterization, the component will be installed inside the vacuum vessel by the end of 2016. STRIKE is a high resolution, short pulse calorimeter, based on unidirectional carbon fiber composite (CFC) tiles, whose development required long R&D. STRIKE will be ready to operate on SPIDER during the first phase of experiments. 3.2. The SPIDER power supply The realization of the SPIDER Power Supply (PS) system is well advanced. It includes the Ion Source Power Supply (ISEPS), a heterogeneous system of electric power generators and the Acceleration Grid Power Supply (AGPS). As the ion source operates at −100 kV to ground, ISEPS is hosted in a Faraday cage, called HVD, air insulated with respect to ground and fed by an insulation transformer [12]. Table 3 reports the main rating data of the ISEPS and AGPS. AGPS is procured by INDA, all the other SPIDER PSs and all the other plants necessary to operate SPIDER are procured by F4E. 3.2.1. The ion source and extractor PS The installation and commissioning of the ISEPS [13] was completed with the final acceptance tests in July 2016 (Fig. 10). A wide-range test program was carried out [14], also due to the large variety of typology of the ISEPS components.
Fig. 8. The ion source chamber as assembled for the SPIDER Beam Source.
patibility, special processes and sequences required, including qualification and intermediate tests [7] [8]. Presently, some difficulties in achieving the required quality level have been recorded; corrective actions are under evaluation to limit the delay of the delivery date to a few months.
3.2.2. High voltage deck and TL The HVD is a wide cage (13 m (L) × 11 m (W) × 5 m (H)), mounted on supporting insulators and clad with a conductive metal sheet to reduce the electromagnetic interference (EMI). Its installation and acceptance tests were completed before summer 2015. The ISEPS power and signal connections to the Ion Source are realized by means of an unconventional High Voltage Transmission Line (TL), duly screened against EMI [15]; a cost-effective design based on air insulated unsealed solution was worked out. The Site
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Fig. 13. Data center to host both SPIDER and MITICA central servers and data storage.
Fig. 10. ISEPS inside HVD: on the right-hand side, view of the Extraction Grid PS (12.8 kV 140A).
Fig. 14. Overall view of the MITICA Injector with the main in-vessel components.
3.3. Instrumentation and control
Fig. 11. The TL in the final installation conditions: view from the PS building towards the SPIDER vessel.
Instrumentation and control (I&C) is procured through a dedicated F4E contract to develop and implement in three tiers the SPIDER conventional control (SPIDER CODAS), the protection (Interlock) and Safety systems [16,17]. SPIDER I&C are not required to comply with ITER Plant Control Design Handbook (no ITER plant systems). Nevertheless most hardware/software technologies prescribed by ITER for the implementation of plant system I&C have been used and tested. CODAS and Interlock plant systems have been procured and installed; Fig. 13 shows the common data center. In July 2016 the Site Acceptance Tests was performed and successfully completed. From autumn 2016, the integrated commissioning between control and plant systems will start. 4. MITICA 4.1. The MITICA injector
Fig. 12. The SPIDER AGPS transformers.
acceptance tests, concluded mid-2016, successfully verified the TL requirements in final installation conditions, shown in Fig. 11.
3.2.3. The acceleration grid PS The AGPS, whose rating is shown in Table 3, is based on pulse step modulation technology and is composed of three oil-insulated multi-secondary transformers and 150 switching modules. The AGPS, delivered on Site in April 2016, has been installed (transformers are shown in Fig. 12), and the commissioning phase is in progress. Site acceptance tests are foreseen by the beginning of 2017.
An overall view of the MITICA Injector [2] is shown in Fig. 14, highlighting the main components. The Vacuum Vessel is a welded structure made of AISI 304 L, having overall dimensions 15m × 5m × 5 m (L × W × H). It is presently under construction and assembly at the Supplier’s factory. In order to optimize the overall MITICA schedule, the activities have been more concentrated so far on the part of the vessel containing the Beam Source (BSV), expected to be delivered and assembled on Site in March 2017. The construction of the remaining part of the vessel, containing the three beam line components, is going on in parallel with lower priority: final installation and tests of the whole vessel are foreseen by the end of 2017. The design of the Beam Line Components: (Neutralizer and Electron Dump (NED), Electrostatic Residual Ion Dump (ERID), Calorimeter), was completed in 2016 and the procurement tender will be launched by the beginning of 2017.
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V. Toigo et al. / Fusion Engineering and Design xxx (2016) xxx–xxx Table 4 AGPS voltage and current ratings. Stage
Voltage
Current
DCG1 DCG2 DCG3 DCG4 DCG5 Total power
200 kV 200 kV 200 kV 200 kV 200 kV 55 MW
66 A 64 A 59 A 56 A 54 A
4.2. The MITICA power supply The MITICA power supplies include three systems:
Fig. 15. Final design of the MITICA Beam Source.
The cryopump design, based on two cryosorption panels 8 m long operating at ∼5.5 K, is completed too, and the tender phase will be launched in 2017.
4.1.1. Beam source The MITICA/HNB Beam Source represents the most complex and critical component of the experiment; its design (see Fig. 15) was completed in 2015 [18]. Some critical parts, such as large ceramic post-insulators, thick Mo coated surfaces, connections of RF lines and heterogeneous joints, required significant R&D to verify the feasibility of manufacturing and to qualify in advance unconventional manufacturing processes. Now, revision of manufacturing procedures is in progress with the aim to fix them and start the construction, expected to last approximately 3 years, by the end of 2017.
- Acceleration Grid Power Supply (AGPS) producing the 1 MV dc voltage, in five stages, 200 kV each, to accelerate the Ion Beam. The main characteristics are reported in Table 4. - The Ion Source PS to feed the Ion Source, similar to the SPIDER ISEPS (see 3.2.1) - The Residual Ion Dump PS feeding the electric panel of the ERID. ISEPS and AGPS PSs are connected to the vacuum vessel through a special HV SF6 gas insulated Transmission Line (TL), 100 m long. HV components, including step-up transformers and diode rectifiers of AGPS, TL and 1 MV insulating transformer of ISEPS, are provided by JADA; all the other PS components by F4E. Fig. 16 gives a 3D view of the MITICA Power Supply system; in blue the components provided by JADA. 4.2.1. The Power Supply system procured by the EU Significant progress has been achieved on the EU procurement of the PS system for MITICA. The ISEPS design revision, based on the findings from the commissioning and acceptance tests of the SPIDER ISEPS, is well advanced. The detailed design of the AGPS Conversion System (CS) AGPSCS, was approved in August 2016 and also type tests on a first power module were successfully carried out, thus validating the solution adopted in view of the special requirements [19].
Fig. 16. 3D view of the MITICA Power Supply system.
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Fig. 19. View of the 1 MV Transmission Line.
Fig. 17. Factory acceptance tests on 1:5 HVD1 mock up.
soon. Some issues are still present about beam source manufacturing; corrective actions are under study to minimize the delay in the delivery, with the aim to start the SPIDER operation before the beginning of 2018. As for MITICA, the full-scale prototype of the ITER HNB injector, the delivery on Site of the HV Power Supply system of the 1 MV accelerator, provided by JADA, started in December 2015 and was followed by the challenging installation which will go on throughout 2016. The design of the MITICA injector components was completed at the beginning of 2016. The procurement of the Beam Source and Beam Line Components, the most critical parts, will be launched between 2016 and 2017 and are expected to be completed in time to start the MITICA operation in 2021. Acknowledgement and disclaimers Fig. 18. MITICA AGPS: view of external yard with step-up transformer and diode rectifiers under installation.
The detailed design phase of the Ground Related PS (GRPS) including the Residual Ion Dump PS (RIDPS) and the Correction Coils PS (CCPS) has been completed, too [20]. The HVD1 is a unique device, consisting of a two-floors metallic box hosting the ISEPS, operating as a Faraday cage, air insulated to ground for −1 MV dc by means of post insulators. The external size of the HVD1 is 12 m × 8 m × 10 m (L × W × H). The post insulators are around 6.5 m high. The ISEPS outputs are connected to the TL via an air to SF6 gas HV bushing installed under the HVD1. The design phase of the HVD1 and HV bushing was completed in June 2016 and the manufacturing and factory tests on prototypes are in progress [21]. Fig. 17 shows the set-up of the long-duration dc voltage withstand test at 1200 kV for 5 h on the 1:5 scaled-down HVD1 mock up, provided with full-scale post insulators. 4.2.2. The Power Supply system procured by JADA The delivery on Site of JADA HV components [22] started in December 2015. The challenging installation, requiring preloading of the interested areas and special solutions for the alignment of the parts, is now well advanced. By the end of 2016 about 80% of components will be installed. In 2017 1 MV insulation tests will start. Figs. 18 and 19 show JADA components under installation. 5. Conclusions Substantial progress has been achieved toward the realization of the ITER NBTF. The building construction, begun in October 2012, was completed by the end of 2015. The realization of SPIDER, the ITER full-size negative ion source, is well advanced: the on-site commissioning of Power Supplies (PS) and auxiliary plant systems are almost completed and integrated tests are planned to start
The work leading to this publication has been funded partially by Fusion for Energy (F4E). This publication reflects the views only of the authors, and F4E cannot be held responsible for any use which may be made of the information contained therein. The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. References [1] ITER Physics Basis Editors et al., Nucl. Fusion, 39, 2495 (1999). [2] V. Toigo, et al., Progress in the realization of the PRIMA neutral beam test facility, Nucl. Fusion 55 (2015). [3] U. Fantz, et al., Towards 20 A negative hydrogen ion beams for up to 1 h: achievements of the ELISE test facility, Rev. Sci Instrum. 87 (2016) 02B307. [4] F. Fellin, et al., Proposal of cooling plant for SPIDER and MITICA experiments, Fusion Eng. Design 86 (2011) 843–846. [5] F. Fellin, et al., Manufacturing and assembly of the cooling plant for SPIDER experiment, 29th SOFT (2016). [6] P. Zaccaria, et al., Fusion Eng. and Design 96–97 (2015) 383–387. [7] D. Marcuzzi, et al., Detail design of the beam source for the SPIDER experiment, Fusion Eng. Des. 85 (2010) 1792–1797. [8] M. Pavei, et al., Manufacturing of the full size prototype of the ion source for the ITER neutral beam injector −The SPIDER beam source, Fusion Eng. Des. 96–97 (2015) 319–324. [9] C. Rotti, et al., Design of beam dump for SPIDER facility, Proceedings of 2013 IEEE 25th Symposium on Fusion Engineering (SOFE), June (2013). [10] M. Zaupa, et al., SPIDER beam dump as diagnostic of the particle beam, Rev. Sci. Instrum. 87 (2016) 11D415. [11] H. Patel, et al., Manufacturing experience of beam dump for SPIDER facility, Proceedings of 2015 IEEE 26th Symposium on Fusion Engineering, June (2015). [12] E. Gaio, et al., The alternative design concept for the ion source power supply of the ITER neutral Beam Injector, Fusion Eng. Des. 83 (2008) 21–29. [13] M. Bigi, et al., Design, manufacture and factory testing of the Ion Source and Extraction Power Supplies for the SPIDER experiment, Fusion Eng. Des. 96–97 (2015) 405–410. [14] M. Bigi, et al., Installation and site testing of the Ion Source and Extraction Power Supplies for the SPIDER experiment, 29th SOFT, 2016. [15] M. Boldrin, et al., The Transmission Line for the SPIDER Experiment: from design to installation, 29th SOFT (2016). [16] A. Luchetta, et al., Commissioning and first operation of the SPIDER control and data acquisition system, 29th SOFT (2016).
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[20] A. Ferro, et al., The design of the residual ion dump power supply for ITER neutral beam injector, 29th SOFT (2016). [21] M. Boldrin, et al., Final design of the high voltage deck 1 and bushing for the ITER neutral beam injector, 29th SOFT (2016). [22] H. Tobari, et al., Progress on design and manufacturing of DC ultra-high voltage component for ITER NBI, 29th SOFT (2016).
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A substantial step forward in the realization of the ITER HNB system: The ITER NBI Test Facility V. Toigo a,∗ , R. Piovan a , S. Dal Bello a , E. Gaio a , A. Luchetta a , R. Pasqualotto a , P. Zaccaria a , M. Bigi a , G. Chitarin a , D. Marcuzzi a , N. Pomaro a , G. Serianni a , P. Agostinetti a , M. Agostini a , V. Antoni a , D. Aprile a , C. Baltador a , M. Barbisan a , M. Battistella a , M. Boldrin a , M. Brombin a , M. Dalla Palma a , A. De Lorenzi a , R. Delogu a , M. De Muri a , F. Fellin a , A. Ferro a , C. Finotti a , A. Fiorentin a , G. Gambetta a , F. Gnesotto a , L. Grando a , P. Jain a , A. Maistrello a , G. Manduchi a , N. Marconato a , M. Moresco a , E. Ocello a , M. Pavei a , S. Peruzzo a , N. Pilan a , A. Pimazzoni a , M. Recchia a , A. Rizzolo a , G. Rostagni a , E. Sartori a , M. Siragusa a , P. Sonato a , A. Sottocornola a , E. Spada a , S. Spagnolo a , M. Spolaore a , C. Taliercio a , M. Valente a , P. Veltri a , A. Zamengo a , B. Zaniol a , L. Zanotto a , M. Zaupa a , D. Boilson b , J. Graceffa b , L. Svensson b , B Schunke b , H. Decamps b , M. Urbani b , M Kushwah b , J Chareyre b , M. Singh b , T. Bonicelli c , G. Agarici c , A. Masiello c , F. Paolucci c , M. Simon c , L Bailly-Maitre c , E. Bragulat c , G. Gomez c , D. Gutierrez c , G. Mico c , J.-F. Moreno c , V. Pilard c , M. Kashiwagi d , M. Hanada d , H. Tobari d , K. Watanabe d , T. Maeshima d , A. Kojima d , N. Umeda d , H. Yamanaka d , A. Chakraborty e , U. Baruah e , C. Rotti e , H. Patel e , M.V. Nagaraju e , N.P. Singh e , A. Patel e , H. Dhola e , B. Raval e , U. Fantz f , B. Heinemann f , W. Kraus f , S. Hanke g , V. Hauer g , S. Ochoa g , P. Blatchford h , B. Chuilon h , Y. Xue h , H.P.L. De Esch i , R. Hemsworth j , G. Croci k , G. Gorini k , M. Rebai k , A. Muraro l , M. Cavenago m , M. D’Arienzo n , S. Sandri o a
Consorzio RFX, Corso Stati Uniti 4, 35127 Padova, Italy ITER Organization, Route de Vinon sur Verdon, CS 90 046, 13067 St. Paul Lez Durance Cedex, France Fusion For Energy, C/o Josep Pla 2, 08019 Barcelona, Spain d National Institutes for Quantum and Radiological Science and Technology, 801-1 Mukoyama, Naka, Ibaraki-ken, 311-0193, Japan e Institute for Plasma Research, Nr. Indira Bridge, Bhat Village, Gandhinagar, Gujarat, 382428, India f IPP, Max-Plank-Institue fur Plasmaphysik, EURATOM Association, D-85748 Garching, Germany g KIT, Institute for Technical Physics, Eggenstein-Leopoldshafen, Germany h CCFE, Culham Science Centre, Oxfordshire, United Kingdom i CEA-Cadarache, IRFM, F-13108 Saint-Paul-lez-Durance, France j RSH Research Consultants Ltd, 12, Vallon de la Violette, 13820, Ensuès la Redonne, France k Dipartimento di Fisica “G. Occhialini”, Università di Milano-Bicocca, Milano, Italy l Istituto di Fisica del Plasma “P. Caldirola”, Milano, Italy m INFN-LNL, viale dell’Università n. 2, 35020 Legnaro, Italy n ENEA, National Institute of Ionizing Radiation Metrology, C.R. Casaccia, S. Maria di Galeria, Italy o ENEA Radiation Protection Institute, Frascati,Roma, Italy b c
∗ Corresponding author. E-mail address: [email protected] (V. Toigo). http://dx.doi.org/10.1016/j.fusengdes.2016.11.007 0920-3796/© 2016 Elsevier B.V. All rights reserved.
Please cite this article in press as: V. Toigo, et al., A substantial step forward in the realization of the ITER HNB system: The ITER NBI Test Facility, Fusion Eng. Des. (2016), http://dx.doi.org/10.1016/j.fusengdes.2016.11.007
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h i g h l i g h t s • The ITER Neutral Beam Test Facility in Padova, Italy: substantial progress achieved.
• The realization of SPIDER, the ITER full-size negative ion source, is well advanced.
• Integrated tests of Power Supply and preparation of SPIDER operation starting now.
• Big progress on the realization of MITICA full-scale prototype of ITER HNB injector.
• MITICA operation planned to start in 2021, depending on the BS and BLC delivery.
a r t i c l e
i n f o
Article history: Received 3 October 2016 Accepted 15 November 2016 Available online xxx Keywords: ITER Heating Neutral Beam Injector (HNB) PRIMA: the ITER Neutral Beam Test Facility (NBTF) Spider Mitica
a b s t r a c t Substantial progresses have been achieved in the realization of the ITER Neutral Beam Test Facility (NBTF) hosted in Padova, Italy; the buildings, completed by the end of 2015, are being progressively filled with new systems and components. The realization of SPIDER, the ITER full-size negative ion source, is well advanced and important progress is also recorded for MITICA, the full-scale prototype of the ITER HNB injector. The paper gives an overview of the achieved results, highlighting the main challenges faced. © 2016 Elsevier B.V. All rights reserved.
1. Introduction The realization of the ITER Neutral Beam Test Facility (NBTF) and the start of its experimental phase are important tasks of the fusion roadmap, since the target requirements of injecting to the plasma a beam of deuterium atoms with a power up to 16.5 MW, at 1 MeV of energy and with a pulse length up to 3600 s have never been reached together before [1] The ITER NBTF, called PRIMA (Padova Research on ITER Megavolt Accelerator), is hosted in Padova, Italy. It includes two experiments: MITICA, the full-scale prototype of the ITER HNB injector, reproducing the whole geometry, and SPIDER, the full-size Radio Frequency (RF) negative-ions source [2,3]; the main parameters are summarized in Tables 1 and 2 respectively. The realization promoted by the ITER organization is carried out with the contribution of the European Union, channeled
Table 1 SPIDER requirements.
Beam energy Max beam source pressure Max deviation from uniformity Extracted current density Beam on time Co-extracted electron fraction (e− /H− ) and (e− /D− )
Unit
H
D
keV Pa % A/m2 s
100 0.3 ±10 >355 3600 <0.5
100 0.3 ±10 >285 3600 <1
Unit
H
D
keV A Pa mrad s
870 49 0.3 ≤7 3600 <0.5
1000 40 0.3 ≤7 3600 <1
through the Joint Undertaking for ITER (F4E), of the Consorzio RFX which also hosts the Test Facility, the Japanese and the Indian ITER Domestic Agencies (JADA and INDA) and several European laboratories, such as IPP-Garching, KIT-Karlsruhe, CCFE-Culham, CEA-Cadarache. The earliest start of SPIDER and MITICA experiments is pursued to maximize the fallout in terms of design optimization of the ITER HNB components and of preparation and then support to the ITER HNB use, planned during the Third Plasma stage, in 2031. SPIDER operation is expected to start in Q1 2018, thus several years of exploitation are planned toward the achievement of the target parameters of the RF ion source and improvements of its reliability and availability. Similar considerations apply also to MITICA, mainly devoted to optimize accelerator and Beam Line Components (BLC), which will enter in operation in 2021. Both experiments should provide key indications before the design of the different components of the ITER HNB is frozen. Fig. 1 shows a 3D CAD view of the PRIMA facility. Substantial progress has been achieved along all the work lines of the ITER NBTF realization. The paper highlights the main challenges encountered and gives an overview of the achieved results.
Table 2 MITICA requirements.
Beam energy Ion beam current Max beam source pressure Beamlet divergence Beam on time Co-extracted electron fraction (e− /H− ) and (e− /D− )
Fig. 1. 3D CAD view of the PRIMA facility.
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Fig. 2. Views of PRIMA cooling system components: pipes and pumps within the building (a); air coolers and cooling towers on the roof of the building (b).
Fig. 4. Overall CAD view of SPIDER.
2. Buildings and common plants 2.1. Buildings and auxiliaries
3. SPIDER
The construction of PRIMA buildings begun in October 2012 and was completed at the end of 2015; installation of components and plants is in progress since the end of 2014.
3.1. The SPIDER source
2.2. Cooling system The PRIMA cooling system shall cool and thermally control the experimental components and auxiliaries of SPIDER and MITICA [4] [5]. The maximum power to be exhausted by the system is about 70 MW when the two experiments are operating in parallel at nominal performance. As the maximum operating duty cycle is 25%, the heat is stored in water contained in two underground basins (1000 m3 ) and exhausted to the environment by cooling towers and air coolers; this solution allows limiting their rating to 17 MW. The plant units for SPIDER are almost completed (see Fig. 2) while the ones for MITICA are under installation. Commissioning and final acceptance tests are foreseen in June 2017 for SPIDER and in 2018 for MITICA plant units.
2.3. Gas and vacuum system The installation of the SPIDER gas and vacuum system was completed in May 2016 (see Fig. 3) and commissioning and site acceptance tests are presently going on. The SPIDER plant units will be finally available for integrated commissioning by the end of 2016. The system is expected to be completed with the MITICA plant units by the end of 2017.
Fig. 3. View of turbomolecular and cryogenic pumps installed around the SPIDER Vacuum Vessel.
An overall view of SPIDER is shown in Fig. 4, highlighting the main components: the Vacuum Vessel, the beam source, STRIKE (the high resolution (∼2 mm) calorimeter operating for short pulses, in the order of 5–10 s) and the water cooled Beam Dump. 3.1.1. Vacuum vessel The SPIDER Vacuum Vessel, fully assembled and tested on site in September 2015, is shown in Fig. 5. The manufacturing of a stainless steel vacuum vessel having a relatively large size (diameter 4 m, length 6 m) required optimized manufacturing/welding processes and very accurate machining and surface preparation to fulfil requirements for vacuum tightness, vacuum compatibility, precise positioning and opening/closing operations [6]. The vessel is installed on rails to facilitate the movements and lids are supported by special mechanical structures in order to facilitate opening. The vessel procurement package included three 100 kV bushings: one for electric connections (power and signal) and two for hydraulic pipes, see Fig. 6. They were installed and tested during the first part of 2016. 3.1.2. Beam source The procurement of the SPIDER Beam Source is in progress: manufacturing of parts/sub-assemblies by the various partners of the Supplier consortium has been completed (see Fig. 7) and the assembly in factory was started in May 2016 (see Fig. 8). Several issues had to be solved during manufacturing, mainly due to the very tight machining tolerances, high vacuum com-
Fig. 5. View of SPIDER Vacuum Vessel during vacuum tests on Site.
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Fig. 9. The beam dump for SPIDER long pulses: rear (a) and front (b) views. Fig. 6. View of the 100 kV Hydraulic bushings installed on the bottom side of the vacuum vessel.
Fig. 7. Views of parts/sub-assemblies of SPIDER Beam. Source: support frames (a)(b), RF driver (c), overall electrostatic shield (d) and plasma grid segments (e).
Table 3 ISEPS and AGPS main data ratings. ISEPS and AGPS power supplies
Output ratings
ISEPS: Extraction (EGPS) ISEPS: Radiofrequency (RFPS) ISEPS: Bias (BPS) ISEPS: PG filter (PGFPS) AGPS
−12.8 kV 140 A 4 units, 200 kW each f = 1 MHz 50 load ±30 V 600 A 15 V 5 kA –96 kV dc 71 A dc
3.1.3. Calorimeters The Beam Dump, designed to absorb and characterize a 6 MW ion beam for 1 h long pulses, was delivered by INDA [9–11]. The on-site tests were performed in June 2015 (see Fig. 9). After the installation of thermocouples for beam characterization, the component will be installed inside the vacuum vessel by the end of 2016. STRIKE is a high resolution, short pulse calorimeter, based on unidirectional carbon fiber composite (CFC) tiles, whose development required long R&D. STRIKE will be ready to operate on SPIDER during the first phase of experiments. 3.2. The SPIDER power supply The realization of the SPIDER Power Supply (PS) system is well advanced. It includes the Ion Source Power Supply (ISEPS), a heterogeneous system of electric power generators and the Acceleration Grid Power Supply (AGPS). As the ion source operates at −100 kV to ground, ISEPS is hosted in a Faraday cage, called HVD, air insulated with respect to ground and fed by an insulation transformer [12]. Table 3 reports the main rating data of the ISEPS and AGPS. AGPS is procured by INDA, all the other SPIDER PSs and all the other plants necessary to operate SPIDER are procured by F4E. 3.2.1. The ion source and extractor PS The installation and commissioning of the ISEPS [13] was completed with the final acceptance tests in July 2016 (Fig. 10). A wide-range test program was carried out [14], also due to the large variety of typology of the ISEPS components.
Fig. 8. The ion source chamber as assembled for the SPIDER Beam Source.
patibility, special processes and sequences required, including qualification and intermediate tests [7] [8]. Presently, some difficulties in achieving the required quality level have been recorded; corrective actions are under evaluation to limit the delay of the delivery date to a few months.
3.2.2. High voltage deck and TL The HVD is a wide cage (13 m (L) × 11 m (W) × 5 m (H)), mounted on supporting insulators and clad with a conductive metal sheet to reduce the electromagnetic interference (EMI). Its installation and acceptance tests were completed before summer 2015. The ISEPS power and signal connections to the Ion Source are realized by means of an unconventional High Voltage Transmission Line (TL), duly screened against EMI [15]; a cost-effective design based on air insulated unsealed solution was worked out. The Site
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Fig. 13. Data center to host both SPIDER and MITICA central servers and data storage.
Fig. 10. ISEPS inside HVD: on the right-hand side, view of the Extraction Grid PS (12.8 kV 140A).
Fig. 14. Overall view of the MITICA Injector with the main in-vessel components.
3.3. Instrumentation and control
Fig. 11. The TL in the final installation conditions: view from the PS building towards the SPIDER vessel.
Instrumentation and control (I&C) is procured through a dedicated F4E contract to develop and implement in three tiers the SPIDER conventional control (SPIDER CODAS), the protection (Interlock) and Safety systems [16,17]. SPIDER I&C are not required to comply with ITER Plant Control Design Handbook (no ITER plant systems). Nevertheless most hardware/software technologies prescribed by ITER for the implementation of plant system I&C have been used and tested. CODAS and Interlock plant systems have been procured and installed; Fig. 13 shows the common data center. In July 2016 the Site Acceptance Tests was performed and successfully completed. From autumn 2016, the integrated commissioning between control and plant systems will start. 4. MITICA 4.1. The MITICA injector
Fig. 12. The SPIDER AGPS transformers.
acceptance tests, concluded mid-2016, successfully verified the TL requirements in final installation conditions, shown in Fig. 11.
3.2.3. The acceleration grid PS The AGPS, whose rating is shown in Table 3, is based on pulse step modulation technology and is composed of three oil-insulated multi-secondary transformers and 150 switching modules. The AGPS, delivered on Site in April 2016, has been installed (transformers are shown in Fig. 12), and the commissioning phase is in progress. Site acceptance tests are foreseen by the beginning of 2017.
An overall view of the MITICA Injector [2] is shown in Fig. 14, highlighting the main components. The Vacuum Vessel is a welded structure made of AISI 304 L, having overall dimensions 15m × 5m × 5 m (L × W × H). It is presently under construction and assembly at the Supplier’s factory. In order to optimize the overall MITICA schedule, the activities have been more concentrated so far on the part of the vessel containing the Beam Source (BSV), expected to be delivered and assembled on Site in March 2017. The construction of the remaining part of the vessel, containing the three beam line components, is going on in parallel with lower priority: final installation and tests of the whole vessel are foreseen by the end of 2017. The design of the Beam Line Components: (Neutralizer and Electron Dump (NED), Electrostatic Residual Ion Dump (ERID), Calorimeter), was completed in 2016 and the procurement tender will be launched by the beginning of 2017.
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V. Toigo et al. / Fusion Engineering and Design xxx (2016) xxx–xxx Table 4 AGPS voltage and current ratings. Stage
Voltage
Current
DCG1 DCG2 DCG3 DCG4 DCG5 Total power
200 kV 200 kV 200 kV 200 kV 200 kV 55 MW
66 A 64 A 59 A 56 A 54 A
4.2. The MITICA power supply The MITICA power supplies include three systems:
Fig. 15. Final design of the MITICA Beam Source.
The cryopump design, based on two cryosorption panels 8 m long operating at ∼5.5 K, is completed too, and the tender phase will be launched in 2017.
4.1.1. Beam source The MITICA/HNB Beam Source represents the most complex and critical component of the experiment; its design (see Fig. 15) was completed in 2015 [18]. Some critical parts, such as large ceramic post-insulators, thick Mo coated surfaces, connections of RF lines and heterogeneous joints, required significant R&D to verify the feasibility of manufacturing and to qualify in advance unconventional manufacturing processes. Now, revision of manufacturing procedures is in progress with the aim to fix them and start the construction, expected to last approximately 3 years, by the end of 2017.
- Acceleration Grid Power Supply (AGPS) producing the 1 MV dc voltage, in five stages, 200 kV each, to accelerate the Ion Beam. The main characteristics are reported in Table 4. - The Ion Source PS to feed the Ion Source, similar to the SPIDER ISEPS (see 3.2.1) - The Residual Ion Dump PS feeding the electric panel of the ERID. ISEPS and AGPS PSs are connected to the vacuum vessel through a special HV SF6 gas insulated Transmission Line (TL), 100 m long. HV components, including step-up transformers and diode rectifiers of AGPS, TL and 1 MV insulating transformer of ISEPS, are provided by JADA; all the other PS components by F4E. Fig. 16 gives a 3D view of the MITICA Power Supply system; in blue the components provided by JADA. 4.2.1. The Power Supply system procured by the EU Significant progress has been achieved on the EU procurement of the PS system for MITICA. The ISEPS design revision, based on the findings from the commissioning and acceptance tests of the SPIDER ISEPS, is well advanced. The detailed design of the AGPS Conversion System (CS) AGPSCS, was approved in August 2016 and also type tests on a first power module were successfully carried out, thus validating the solution adopted in view of the special requirements [19].
Fig. 16. 3D view of the MITICA Power Supply system.
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Fig. 19. View of the 1 MV Transmission Line.
Fig. 17. Factory acceptance tests on 1:5 HVD1 mock up.
soon. Some issues are still present about beam source manufacturing; corrective actions are under study to minimize the delay in the delivery, with the aim to start the SPIDER operation before the beginning of 2018. As for MITICA, the full-scale prototype of the ITER HNB injector, the delivery on Site of the HV Power Supply system of the 1 MV accelerator, provided by JADA, started in December 2015 and was followed by the challenging installation which will go on throughout 2016. The design of the MITICA injector components was completed at the beginning of 2016. The procurement of the Beam Source and Beam Line Components, the most critical parts, will be launched between 2016 and 2017 and are expected to be completed in time to start the MITICA operation in 2021. Acknowledgement and disclaimers Fig. 18. MITICA AGPS: view of external yard with step-up transformer and diode rectifiers under installation.
The detailed design phase of the Ground Related PS (GRPS) including the Residual Ion Dump PS (RIDPS) and the Correction Coils PS (CCPS) has been completed, too [20]. The HVD1 is a unique device, consisting of a two-floors metallic box hosting the ISEPS, operating as a Faraday cage, air insulated to ground for −1 MV dc by means of post insulators. The external size of the HVD1 is 12 m × 8 m × 10 m (L × W × H). The post insulators are around 6.5 m high. The ISEPS outputs are connected to the TL via an air to SF6 gas HV bushing installed under the HVD1. The design phase of the HVD1 and HV bushing was completed in June 2016 and the manufacturing and factory tests on prototypes are in progress [21]. Fig. 17 shows the set-up of the long-duration dc voltage withstand test at 1200 kV for 5 h on the 1:5 scaled-down HVD1 mock up, provided with full-scale post insulators. 4.2.2. The Power Supply system procured by JADA The delivery on Site of JADA HV components [22] started in December 2015. The challenging installation, requiring preloading of the interested areas and special solutions for the alignment of the parts, is now well advanced. By the end of 2016 about 80% of components will be installed. In 2017 1 MV insulation tests will start. Figs. 18 and 19 show JADA components under installation. 5. Conclusions Substantial progress has been achieved toward the realization of the ITER NBTF. The building construction, begun in October 2012, was completed by the end of 2015. The realization of SPIDER, the ITER full-size negative ion source, is well advanced: the on-site commissioning of Power Supplies (PS) and auxiliary plant systems are almost completed and integrated tests are planned to start
The work leading to this publication has been funded partially by Fusion for Energy (F4E). This publication reflects the views only of the authors, and F4E cannot be held responsible for any use which may be made of the information contained therein. The views and opinions expressed herein do not necessarily reflect those of the ITER Organization. References [1] ITER Physics Basis Editors et al., Nucl. Fusion, 39, 2495 (1999). [2] V. Toigo, et al., Progress in the realization of the PRIMA neutral beam test facility, Nucl. Fusion 55 (2015). [3] U. Fantz, et al., Towards 20 A negative hydrogen ion beams for up to 1 h: achievements of the ELISE test facility, Rev. Sci Instrum. 87 (2016) 02B307. [4] F. Fellin, et al., Proposal of cooling plant for SPIDER and MITICA experiments, Fusion Eng. Design 86 (2011) 843–846. [5] F. Fellin, et al., Manufacturing and assembly of the cooling plant for SPIDER experiment, 29th SOFT (2016). [6] P. Zaccaria, et al., Fusion Eng. and Design 96–97 (2015) 383–387. [7] D. Marcuzzi, et al., Detail design of the beam source for the SPIDER experiment, Fusion Eng. Des. 85 (2010) 1792–1797. [8] M. Pavei, et al., Manufacturing of the full size prototype of the ion source for the ITER neutral beam injector −The SPIDER beam source, Fusion Eng. Des. 96–97 (2015) 319–324. [9] C. Rotti, et al., Design of beam dump for SPIDER facility, Proceedings of 2013 IEEE 25th Symposium on Fusion Engineering (SOFE), June (2013). [10] M. Zaupa, et al., SPIDER beam dump as diagnostic of the particle beam, Rev. Sci. Instrum. 87 (2016) 11D415. [11] H. Patel, et al., Manufacturing experience of beam dump for SPIDER facility, Proceedings of 2015 IEEE 26th Symposium on Fusion Engineering, June (2015). [12] E. Gaio, et al., The alternative design concept for the ion source power supply of the ITER neutral Beam Injector, Fusion Eng. Des. 83 (2008) 21–29. [13] M. Bigi, et al., Design, manufacture and factory testing of the Ion Source and Extraction Power Supplies for the SPIDER experiment, Fusion Eng. Des. 96–97 (2015) 405–410. [14] M. Bigi, et al., Installation and site testing of the Ion Source and Extraction Power Supplies for the SPIDER experiment, 29th SOFT, 2016. [15] M. Boldrin, et al., The Transmission Line for the SPIDER Experiment: from design to installation, 29th SOFT (2016). [16] A. Luchetta, et al., Commissioning and first operation of the SPIDER control and data acquisition system, 29th SOFT (2016).
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