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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
Outline
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
rate;
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
Requirements
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
Pipe
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
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
Quench
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
insulation
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
only)
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
prepared
Target guide
Target rail
Assembly
① Target assembly Target assembly Target assembly
② ③
Lifting up Start Guide Free position Lifting end 11
Quick Disconnecting system (QDS)
Objectives:
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);
Advantages:
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
Brasimone:
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
seal
flange.
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
control.
Inlet pipe power & gas Laser Head
(316L) supply cable Cutting Position
Φ216.3
& Welding position
Manipulator
Lip seal
flange Li inlet piping Lip seal
flange
Laser
Subsystem Integrated TA
(F82H)
Beam Ducts
Φ330（min.)
Laser Head Clamping
Portion to
Welding Position
pipe
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
V-
Pipe clamping ・Reduction Device X
axis
・AC Servo Motor
V
・TCG (Trochoid Cam Gear)
Runner
W- ・LM Guide ( Ballscrew ) Z
Laser head revolving
axis
・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
Y
W
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
Manipulater
Laser
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
Work
(simulating Li inlet pipe with lip seal)
Test stand
Prototype of
Laser Subsystem
Conclusions
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
used;
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
well.
Acknowledgemnts
THANKS FOR YOUR ATTENTION
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
