IFMIF Target Assembly System

Status of the activities for the development of the RH techniques
           for the maintenance of IFMIF Target system

 G. Miccichè, D. Bernardi, P. Agostini - CR ENEA Brasimone Italy
        K. Nakamura, S. Niitsuma JAEA Tokay-site Japan

     ISLA 2011 - Princeton April 27th – 29th 2011

 Overview on the IFMIF target assembly system
  • European TA concept
  • Japanese TA concept
 The refurbishment process of the TA
 RH strategy
  • On-line refurbishment
  • Off-line refurbishment
 Remote Handling Equipment and tools
 Conclusions
Overview of the IFMIF TA System

           The IFMIF Li Target Assembly :

            deliveres the neutron irradiation flux to Test
           Modules (TMs) for testing fusion candidate
           materials up to 150 dpa ( 50 dpa/y) of damage

            is located in side of the Test Cell Cavern that
           is the most critical area of IFMIF facility (dose
           rate expected: 105 Sv/h on the BP at the
           shutdown );

          Maintenance of the TA requires use of
          sophisticated Remote Handling technologies
                   Overview of the IFMIF TA System

                       Item                               Parameter
Target Material                          RAFM ( Eurofer or F82H)
Fluid                                    Lithium
                                         Lip seal and/or Clamped Flanges with
Sealing system of the connecting pipes
                                         metallic gasket
Sealing system of the Backplate          Metallic Gasket only for the EU concept
Working temperature                      250- 300 °C
Li speed                                 10 ÷20 m/s
Li Flow rate                             135 l/s
Damage rate                              50 dpa/fpy
Erosion/corrosion rate                   1µm /year
Pressure in the target chamber           10-3 Pa (TBC)
                                         10-1 Pa (TBC)
Pressure in the test cell

TC Atmosfere in Maintenance              Ar (1 atm ) and H2O < 250 ppm (TBC)

Replacement interval for the BP          11 months

Target life time                         TBD
            The IFMIF Target Assembly

                   RH Maintenance Requirements

Objective: perform all the RH activities within the intervention times
to fulfil the stringent requirement of the plant availability.

 Availability of Target Assembly: 95% of IFMIF plant availability 
7600 hrs in scheduled operation time

 Intervention Time for all scheduled tasks   (Preventive maintenance)
for IFMIF is : 720 hrs

 Intervention time for all scheduled tasks for the refurbishment of the
TA : 168 hrs

Two Target Assembly design concepts are under investigation :
 The European Concept (Bayonet Concept -BC)
The Japanese Concept (Integral Concept - IC)
               Bayonet TA Concept (EU Design)

                                  The EU TA system is equipped
                   Li Inlet
                                  with a removable Backplate
                                  ( Bayonet Concept). It:
                                   Simplifies        the backplate
                                      replacement operation
   Nozzle                          Reduces       the    amount    of
                                      material for disposal
                                   Improves the duty cycle of the
Beam Ducts                            plant
                                   Allows       to    perform    its
                                      replacement operation in-situ.

                                  Sealing of the BP: Low delta
                                   seal HNV200 Helicoflex gasket

                                 It is connected to the Li loop and
                                 with the beam ductby means of
                                 Quick Disconnecting System (QDS)
 Quench Tank                     Selaing of the Flanges : Helicoflex
                                 HN 100 (TBC)
              Integrated TA Concept (JA Design)

 Integrated TA (JA plan) is integrated with Back Plate and has
several connections for replacement .
                                                   Dissimilar welding (off-site)
 Integrated Target Assembly                        -Welding by TIG welding or another
 (integrated with Back Plate)                       method at off-site
                                    F82H           -Dissimilar materials : 316L/F82H
 Beam Ducts                         316L

                                                   Lip-seal welding & cutting (on-site)
                                                   -Liquid lithium flow channel
                       Inlet Pipe          316L
                                                   -Welding & cutting by remote
                                                     handling because of on-site
                                                   -Similar materials : 316L
                                                   - Connection support by clamping
   Tank                                Mechanical-seal ( Quick Disconnecting system)
                                       - Lithium vapor atmosphere
                                       - The lithium doesn't touch direct in the seal part
        Overview of
       Integrated TA
             The Refurbishment Process of the TA

N°                      Task description                                    Note
1    Removal of the insulation from flanges                QDS will be provided with a system
                                                           allowing an easy removal of the
2    Disconnection of the Heating system                   Connectors not yet designed
3    Removal of the TA
4    Removal of the Backplate                              In situ removal (only EU option)
5    Cleaning of the interface frame and flanges from Li
     solid deposition
6    Inspection of the target body:                        Nozzle substitution
     5.1 status of the nozzle                               (somewhat impossible to be
     5.2 status of TA’s frame support in the area where    performed online);
         the gasket acts;
     5.3 status of diagnostics
7    Installation of a new backpalte                       In situ Only (EU concept)

8    Installation of the target                            Wiring connection; place insulation..
9    Testing of the target                                 1) Heating system;
                                                           2) Leak/pressure test;
                                                           3) Precision of BP installation (EU
                                                           4) Li leak test
                              Remote Handling strategy

Two potential approaches:
 On-line TA Refurbishment (only the EU target concept);
 Off-line TA Refurbishment ( EU and JA concepts);

                Target area

                                   On line TA Refurbishment
 Test Modules
                                    Intervention time for the replacement of the BP
                                   bayonet concept is < 2 days
                                   ( cleaning, inspection and test are not included)
         Cables and pipes

                                    Not all tasks can be performed ( nozzle exch. )
                                    Minimum space in front of the back plate is
                                   needed ( shift of 70÷100 mm the test modules)
                                    Preferable to be implemented if a significant
                                   misalignment between the replacement times of
                                   the Backplate and the Test Modules will occur.
                 Remote Handling Strategy

     Off-line TA’s Refurbishment ( preventive maintenance)
 Replacement of the TA was planned every (30 years CDR) (10 years PSAR);
 Expected TA life time is still uncertain due to the erosion/corrosion of the nozzle that
  could be shorter than expected;
 The refurbishment of the TA should be performed off-line in a hot cell

                     The Off-line strategy allows to:
                      make the maintenance in much safer and relaxed conditions;
                      test all the assembled components
                      improve the safety of the system ( new gaskets each time)
                     This strategy relies on the availability of a new target ( previusly
                     refurbished) ready to be installed.
          Integral target RH procedure

                        moving image was
                                        Target guide
             Target                     rail


①   Target assembly          Target assembly           Target assembly
                        ②                         ③
    Lifting up Start        Guide Free position          Lifting end     11
            Quick Disconnecting system (QDS)

 Design, qualification and validation of a new Quick disconnecting System
(QDS) for RH;
 Qualify the Helicoflex gasket : Li corrosion; vacuum and leak rate achievable ,
and other specific tests ( TBD with Garlock);

                                    Easy and rapid to assemble and disassemble
                                     Reduced number of bolting points
                                     Compact size (reduction of size)
                                    Good efficiency (limitation of torque)
                                     usable in restricted area

This system permits to replace the TA within the intervention time foreseen for
the BP exchange ( i.e < 2 days- cleaning and other operations not included)

Shared R&D Program ENEA- Garlock GmbH
           Quick Disconnecting system (QDS)

The Design and R&D activities include the:
 Selection of the sealing system (one or two gaskets)
 Li leak detection system
 detachment system for the QDS in case of failure
 System for the removal of the insulation from the flanges
 Validation of the QDS will be performed in Garlock (France) and in ENEA
     RH test (ENEA Facility)
     test of the QDS in Li environment (ENEA Loop/Garlock Factory)

      Rigs for test of the Gaskets           Test of the QDS apparatus

 The QDS is designed according to ASME or RCC-MRx codes
              RH procedures and Tooling
Whatever approaches will be selected suitable procedures and tools have to be
deleloped for:
1) Li cleaning process
2) Inspection and test of the target
3) Pre-heating of the target at the start up of the loop ( thermal stress),
4) BP and Target exchange

Almost all the RH Validation tasks for the European Target, including the R&D for
the QDS qualification, will be performed at CR ENEA at Brasimone (DRP Facility)
in the next 2 years. JAEA is performing the RH activities for the IC.

                                                           Simulation of Solid
                                                           Lithium deposition
Cleaning Procedure

      A thin coating of lithium (few µm) is expected on
      the interface frame and on the connecting
      flanges as well.
      The cleaning procedure      has   already   been
      developed and tested:
      CH3COOH+ H2O2 + CH3CH2OH [ratio (1:1:1)]

       A few
                    Cleaning Procedure

 A NEW Cleaning tool is under development.
 Main Features are:
  provided with a belt system
  virgin tape always in contact with the area to be cleaned
  integrated sprying system for the adduction of the cleaning solution
  low force system
  modus horizontal
  easy removal of the end effector ( requirement)

                                             Take up spool
                            Delivery spool

Telerobot (Genova -Italy)

                                                             Gripper interface

                    Belt conveyor
Bolting tool and Robotic Arm

           Manipulator Arm System:
          ( used for almost all the Refurbishment tasks)
           Six degrees of freedom
           Arm payload ( 200 Kg)
           Positional Accurancy ±0,5 mm
           lifter integrated (Payload 1,5 T)

          Design of the Manipulator Arm will start in June
          2011. Manufacturing in late 2011.

           Bolting Tool
           ( used for the backlate and target replacement )
            Controlled in angle and torque
            Torque range 3÷80 Nm
            Accuracy 2%

           A radhard version of this tool is under design
                Concept of Remote Handling System

                                            Manipulator Subsystem
Remote Handling System consists of:
 Manipulator Subsystem
 - Transporting Laser Subsystem
    to TTC vessel.
 - Setting Laser Subsystem to lip
 Laser Subsystem
 - Clamping inlet pipe of TA.                     Manipulator
 - Cutting & welding lip seal
   flange by fiber Laser.

                                Laser Subsystem
                    Outline of Laser Subsystem

Laser Subsystem is transported by manipulator , installed near lip
seal flange and cutting /welding operation is carried out by remote

     Inlet pipe              power & gas       Laser Head
      (316L)                 supply cable      Cutting Position
                                               & Welding position
                                  Lip seal
                                  flange                            Li inlet piping Lip seal
Subsystem                      Integrated TA
Beam Ducts

                                               Laser Head             Clamping
                                                                      Portion to
                                               Welding Position

        Installation of Laser Subsystem
                 Status of LF05-JA Remote Handling

Laser Subsystem has six axis which are driven by AC servo motor,
reduction device, ballscrew and so on, therefore laser head position
can be controlled precisely.

This prototype was already fabricated in Mar. 2011.
 Axis          Function                  Method
                                                              Laser Head
                               ・Trapezoideal Screw                         θ
        Pipe clamping          ・Reduction Device                                          X
                               ・AC Servo Motor
                               ・TCG (Trochoid Cam Gear)
 W-                            ・LM Guide ( Ballscrew )                                Z
        Laser head revolving
                               ・Reduction Device
                               ・AC Servo Motor
  X-    Laser head moving      ・LM Guide ( Ballscrew )
 axis   straightly             ・AC Servo Motor
  Y-    Laser head moving      ・LM Guide ( Ballscrew )
 axis   straightly             ・AC Servo Motor
  Z-    Laser head moving      ・LM Guide ( Ballscrew )
 axis   straightly
                                                                      Pipe clamping
                               ・AC Servo Motor
  Θ-                           ・AC Servo Motor
        Laser head rotating                                         Weight:127 Kg
 axis                          ・Reduction Device
            Procedure of Laser Subsystem Installation

                                                                       Standby position
                      Sub System

                                         moving image was prepared

     Laser Sub System                  Laser Sub System         Laser Sub System
①                                  ②                      ③
    Installation position                   Setting              Operating state   21
         Status of LF05-JA Remote Handling

 Mock-up test by prototype of Laser Subsystem
  - Validation of Fiber Laser cut & re-welding by Laser Subsystem

           (simulating Li inlet pipe with lip seal)

                                                         Test stand

                                        Prototype of
                                      Laser Subsystem

 The maintenance of the IFMIF TA system is a rather complex activity
  which requires a wide R&D program for the validation of the TA
  concepts, from the RH viewpoint, and of the RHEs and tools to be

 The RH experimental activities are progressing even if the RH strategy
  has not fixed yet. However there are several common RH tasks that
  could help to take the final choice on the refurbishment approaches to
  be adopted. ( Qualification of the QDS system and final design of the
  RH for Test Modules for instance)

 There are still several open points on the design of the RHEs and tools
 to be used (not described in the presentation): use of Rad Hard
 technology is mandatory ; viewing systems capable to withstand to the
 high dose rate expected in the test cell and in the other facilities as


I would like also to thank the: Japanese colleagues, Telerobot ( Genova)-
Italy, Garlock GmBH–France, Tekva (Milano)–Italy ,(Karlsruhe Institute of
Technology)–Germany and University of Palermo-Italy

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