804461d4 - 1.0 - UWAVS System Design Description.pdf

ITER UPPER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA System Design Description for UWAVS-35 (UP2, 8, 11, and 14)

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory Under Subcontract No: S013437

Prepared by General Atomics

304243-R00017 Revision A

GA Project 30424

PPPL APPROVAL

VERSION Date Signatory QA Engineer SE External

ITER

Reviewer

Approver

1.0 7/22/2024

Mark Smith Patrick Temple Pete Dugan N/A Ravinder Bhatia

SEE EDRM

Notification

N/A

304243-R00017 Revision A

ITER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA SYSTEM DESIGN DESCRIPTION FOR

UWAVS-35 (UP2, 8, 11, AND 14)

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory

Under Subcontract No: S013437

Prepared by General Atomics PO Box 85608

San Diego, CA 92186-5608

GA PROJECT 30424

R el ea se d

4/

/1

R eleased 2024/07/18

55.GA SDD for UWAVS-35 (UP2, 8, 11 and 14) 304243-R00017/A ii

REVISION HISTORY

Revision Date Description of Changes

A See Watermark Initial Release

POINT OF CONTACT INFORMATION

PREPARED BY:

Name Position Email Phone

Sean McCartney Engineer Sean.McCartney@ga.com 858-455-6652

APPROVED BY:

Name Position Email Phone

David Chan Quality Engineer David.Chan@ga.com 858-455-3532

Sean McCartney Lead Engineer Sean.McCartney@ga.com 858-248-6652

Anthony Gattuso Program Manager Anthony.Gattuso@ga.com 858-455-2910

R el ea se d

4/

/1

R iii

TABLE OF CONTENTS

REVISION HISTORY .................................................................................................................. II

POINT OF CONTACT INFORMATION ....................................................................................... II

ACRONYMS .............................................................................................................................. X

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Definitions

2 REQUIREMENTS

3 SAFETY

4 DESIGN ARCHITECTURE

4.1 Global Design Architecture

4.2 Functional Architecture

4.3 Subsystem Design Architecture

5 DESIGN METHODOLOGY

5.1 Requirements

5.2 Optical Model

5.3 Mechanical Design Approach

5.4 Skeleton Design Methodology

6 SUBSYSTEM DESIGN DESCRIPTIONS

6.1 Front End Optical Modular System

6.2 Interspace Optics Tube

6.3 Bioshield Optical Labyrinth

6.4 Back End Optics and Cameras

7 SYSTEM PERFORMANCE

7.1 Optical Performance

7.2 IR Measurement

7.3 Visible Measurement

7.4 Tolerances Analysis

7.5 STOP Analysis

7.6 Active Alignment

8 CALIBRATION

8.1 Calibration Strategy

8.2 Back-end Calibration Design

8.3 Transmission Filament Design

9 MIRROR CLEANING RF DESIGN

9.1 Mirror Cleaning System RF Design Overview

9.2 Prematcher

9.3 RF Generator and Active Matching Network

9.4 Notch Filter

9.5 Transmission Lines

10 INSTRUMENTATION AND CONTROL ARCHITECTURE

11 INTERFACES

12 ASSEMBLY STRATEGY

R el ea se d

4/

/1

R iv

12.1 Installation Sequence

12.2 Factory Assembly

12.3 Factory Qualification Testing

12.4 Onsite Assembly

12.5 Alignment Method

12.6 Alignment Requirement Verification

12.7 Port Plug Testing at PPTF

12.8 Onsite Testing and Commissioning

13 REMOTE HANDLING

13.1 Remote Handling Compatibility Assessment

13.2 Plant Definition

13.3 Task Definition Forms

14 RISK ANALYSIS

14.1 Fire Assessment

14.2 Visible Species Measurements

14.3 Heat Flux Measurement

14.4 Front-to-End Calibration (F2E)

14.5 Ghost Images

14.6 Neutron Damage of Ceramics

14.7 Stepper Motors Selection

14.8 MIC Coax Thermo-nuclear Load

14.9 Mirror Cleaning Long-term Redeposition

14.10 RF Transmission Loss

14.11 DSM Surface Tolerances

14.12 In-Vessel Mirror Fabrication

14.13 In-Vacuum Mirror Module Fabrication

14.14 In-Vessel Mirror Module Stability

14.15 Ex-Vessel Condensation

14.16 Blackbody Heat Management

14.17 Use of Cadmium

14.18 Dust Protection

15 PROTOTYPES

15.1 Mirror Cleaning Prototype

15.2 First Mirror Prototype

15.3 Transmission Filament Prototype

15.4 Shutter Prototype

REFERENCES

APPENDIX A UWAVS SYSTEM DIAGRAMS ........................................................................ A-1

APPENDIX B OPTICALLY SIGNIFICANT INTERFACES ...................................................... B-1 el ea se d

4/

/1

R v

LIST OF FIGURES

Figure 1. Coverage of divertor from a) one UWAVS diagnostic and b) five Upper Port UWAVS diagnostics

Figure 2. DET-07077-D, 55.GA CM model to USDA

Figure 3. 55.GA Enovia tree for UP02 and UP08

Figure 4. 55.GA Enovia tree for UP11 and UP14

Figure 5: 55.GA Diagnostic System

Figure 6. UWAVS system architecture

Figure 7. In-Vessel optics provide large FOV imager and optical relay

Figure 8. Interspace mirrors provide alignment mirrors and a second optical relay

Figure 9. Port cell optics provide beam splitting, shaping, and correcting optics

Figure 10. FEOMS decomposition and functional interfaces

Figure 11. Bullnose decomposition and functional interfaces

Figure 12. IOT decomposition and functional interfaces

Figure 13. BOL decomposition and functional interfaces

Figure 14. BEOC decomposition and functional interfaces

Figure 15. UWAVS Optical Model

Figure 16. CATIA optics CSKE

Figure 17. PPAD and PCAD references linked to UPP RSKE

Figure 18. PCAD virtual coordinate system established 11 degrees off axis of PPAD

Figure 19. FEOMS modules and optics in the DSM

Figure 20. UWAVS-35 Bullnose assembly (Front Mirror Unit)

Figure 21. In-vessel shutter architecture

Figure 22. In-vessel shutter cross-sectional view

Figure 23. Shutter operational states (a) Full closed, (b) Full open, (c) Closed internal state, (d) Open internal state

Figure 24. FEOMS mirror module design

Figure 25. Beam path through A30 mirror modules

Figure 26. Exploded views of A30 mirror modules a) A30M1 and b) A30M2

Figure 27. Exploded views of A30 mirror modules a) A30M3 and b) A30M4

Figure 28. IOT subsystem (a-b) in context and (c) isolated with primary assemblies annotated

Figure 29. BOL between the IOT (left) and the BEOC (right)

Figure 30. BOL dogleg with light beam visible (left) top-down view of dogleg layout (right)

Figure 31. Back-End Optics and Cameras (doors removed for clarity)

Figure 32. BEOC main optical layout

Figure 33. IR measurement data flow and processing scheme

Figure 34. UWAVS mirror module interfaces to DSM

Figure 35. FEA and RBM contributions to spot size increment by component and for assemblies

Figure 36. IR-1 Camera objective with the materials listed

Figure 37. Example calibration timeline

R el ea se d

4/

/1

R vi

Figure 38. Calibration optical layout

Figure 39. Preliminary transmission filament design

Figure 40. Comparison of filament light source positions and light back to sensor

Figure 41. Filament on shutter blade inside the Bullnose

Figure 42. Simplified RF mirror cleaning system schematic Figure 43 Mechanical assembly of the bullnose with key RF components identified

Figure 44. The fixed prematcher board layout (left) with the signal trace shown in brown and ground plane shown in gray. Calculated S-parameters of the prematcher

Figure 45 Commercial 60 MHz, 1 kW RF generator

Figure 46 Active Matching Network and Smith chart for 1 of the 3 available tuning ranges

Figure 47 Compact NF Assembly

Figure 48 HFSS Analysis of the compact NF with the slider at the middle position

Figure 49 Technical data for the selected ex-vessel coaxial cable type

Figure 50. Illustration of plant layout showing cubicle locations and anticipated cable runs for RF transmission lines

Figure 51. Illustration of the instrumentation and controls for 55.GA single port

Figure 52. 55.GA design breakdown into subsystems

Figure 53. UWAVS installation process sequence

Figure 54. FEOMS mirror modules subassemblies

Figure 55. FEOMS mirror modules mechanical inspection

Figure 56. Assembled bullnose used for validation of mirror cleaning system

Figure 57. Shutter assembly setup on a test bench

Figure 58. FEOMS setup for optical axis verification

Figure 59. FEOMS transmitted wavefront verification

Figure 60. IOT imaging performance test configuration

Figure 61. IOT distortion and magnification test configuration

Figure 62. a) Exploded and b) assembled pictorial views of the FEOMS within the DSM

Figure 63. Installation sequence of ex-vessel subsystems in the Interspace and Port Cell

Figure 64. Laser tracker and nest mounted spherical mounted retroreflectors (SMRs)

Figure 65. Example laser tracker metrology of (a) PCSS frame, (b) tenant location on PCSS, and (c) ISS and PCSS installed in Upper Port

Figure 66. Laser tracker with (a) T-probe stylus used with (b) integrated fiducials

Figure 67. ISS and PCSS trolley SMR locations for final subsystem positional requirements verification

Figure 68. Optical axis alignment test configuration for the installed FEOMS

Figure 69. Imaging performance test configuration for the installed FEOMS

Figure 70. Image performance verification of (a) IOT using an interferometer and (b) BEOC using fiber lasers mounted to a curved fiducial

Figure 71. Fishbone diagram of perquisites for System Commissioning

Figure 72. Breakdown of the UWAVS-35 Remote Handling Documents

Figure 73. Removal of the A20 mirror module

Figure 74. Port Cell loading conditions in case of fire

Figure 75. Volumetric swelling in Alumina due to neutron fluence (E > 0.1MeV)

R el ea se d

4/

/1

R vii

Figure 76. Radiation hardened stepper motors integrated onto the A40M2 mirror assembly

Figure 77. Max body forces imposed on magnetic components due to the ITER magnetic field during a plasma shot (17MA-DINA2019-01). a) X,Y, Z components b) magnitude

Figure 78. Bullnose with MIC9 coax

Figure 79. Illustration showing benefit of relocating UP02 and UP17 RF generators to NE Shielded Corner

Figure 80. Thermal calibration temperature plot of internal ambient air temperature taken at IR blackbody source location

Figure 81. Surface temperature plots for thermal calibration of (a) IR blackbody source and (b) IR cameras

Figure 82. UWAVS ISS-PCSS shroud (a) in bioshield (b) components and size

Figure 83. Mirror Cleaning Prototype hardware

Figure 84. Comparison of the Prototype Bullnose (left) to the UWAVS-35 Bullnose (right)

Figure 85. The prototype Bullnose with key elements identified

Figure 86. Comparison of the prototype mirror (left) with the UWAVS-35 A10 mirror (right)

Figure 87. Detailed view of the prototype mirror assembly

Figure 88. Cross-section view of the prototype mirror assembly

Figure 89. RF connection between the mirror and the prematcher PCB

Figure 90. S-Shaped NF (left) and C-Shaped NF with VCR fittings (right)

Figure 91. NF performance when tee onto a 50 ohm transmission line

Figure 92. Prototype bullnose with the NF in its rotated orientation

Figure 93. Measured smith chart of mockup notch filter (red line) with HFSS results overlayed (green line). Note impedance values are given normalized to 50 ohms

Figure 94. Plasma Impedance measurement diagram

Figure 95. Reflectivity of Pt coated specimens before and after simulated steam ingress event showing minimal loss of reflectivity

Figure 96. Diffuse and specular reflectivity of Pt coated samples before and after mirror cleaning showing minimal degradation

Figure 97. Prototype test apparatus a) conceptual layout b) existing hardware

Figure 98. Representation of filament life cycle test

Figure 99. UWAVS system architecture. ................................................................................. A-1

Figure 100. FEOMS decomposition and functional interfaces. ................................................ A-2

Figure 101. Bullnose decomposition and functional interfaces. ............................................... A-3

Figure 102. IOT decomposition and functional interfaces. ....................................................... A-4

Figure 103. BOL decomposition and functional interfaces. ...................................................... A-5

Figure 104. BEOC decomposition and functional interfaces. ................................................... A-6

Figure 105. Simplified RF mirror cleaning system schematic. ................................................. A-7

Figure 106. Illustration of the instrumentation and controls for 55.GA single port .................... A-8

Figure 107. UWAVS installation process sequence. ............................................................... A-9 ea se d

4/

/1

R viii

LIST OF TABLES

Table 1. Applicable CAD Models

Table 2. Annex-B Measurement Parameter Overview with Conditions and Required Accuracies for Primary Measurements

Table 3. Annex-B Measurement Parameter Overview with Conditions and Required Accuracies for Secondary Measurements

Table 4. Diagnostic System Classifications per Annex B

Table 5. Overview of key optical performance requirements

Table 6. Generic DSM mechanical tolerances

Table 7. Critical DSM interface tolerances

Table 8. ISS and PCSS Installation Tolerances

Table 9. UWAVS component tolerances

Table 10. Optic tolerance budget

Table 11. Overview of UWAVS tolerance analyses and results (Vis-1 channel)

Table 12. Imaging resolution error contribution by tolerances for all channels

Table 13. Displacements and rotations at module attachment points

Table 14. Mirror Displacements and Rotations

Table 15. A20 and A30 Mirror Displacement and Rotation Estimates

Table 16. Spot size increment due to surface FEA and RBM

Table 17. List of IOT materials used in thermal analysis

Table 18. List of IOT optic materials and thickness

Table 19. Effect of IOT thermal expansion on spot size

Table 20. List of Material and CTE as used in Zemax Simulations

Table 21. RMS Spot Radius Increment for BEOC at 37°C with and without A40 Active Alignment

Table 22. RMS spot increment for the IR-1 channel at 37°C, with and without compensation

Table 23. Thermal compensators for VIS-1 and IR-1 channels

Table 24. Final system compensator range for IR-1 and Vis-1 channels

Table 25. RMS Spot Radius Increment for Operational Load

Table 26. Overview of active alignment system Analysis Results

Table 27. Estimated Cable Lengths and Associated Power Loss

Table 28. 55.GA Interface Sheets

Table 29. 55.GA Piping & Instrumentation Diagrams

Table 30. 55.GA Cabling Diagrams

Table 31. 55.GA Process Flow Diagrams

Table 32. 55.GA Single Line Diagrams

Table 33. PPTF Test Sequence

Table 34. List of UWAVS-35 Remote Handling Task Definition Forms

Table 35. IOT Quantified Materials and Melting Points

Table 36. BOL Quantified Materials and Melting Points

Table 37. BEOC Quantified Materials and Melting Points

R el ea se d

4/

/1

R ix

Table 38. IOT Combustible materials within the Port Cell Interspace

Table 39. BOL Combustible materials within the Port Cell Interspace

Table 40. BEOC Combustible materials within the Port Cell

Table 41. Ceramic Materials used in Bullnose

Table 42. Body forces on the A40 mirror actuator assemblies

Table 43. Estimated mass of Co in UWAVS system due to stepper motors

Table 44. Improvement to Cable Runs by Relocating RF Generators

Table 45. Optically significant interfaces of the FEOMS .......................................................... B-1

Table 46. Optically significant interfaces of the IOT ................................................................. B-2

Table 47. Optically significant interfaces of the BEOC............................................................. B-3 ea se d

4/

/1

R x

ACRONYMS

Acronym Description

AE Algorithms and External Data

ALARA As Low as Reasonably Achievable

BE Back End

BEOC Back End Optics & Cameras

BOL Bioshield Optical Labyrinth

BP-HiPIMS Bipolar High Power Impulse Magnetron Sputtering

CDA Clean Dry Air

COTS Commercial-Off-the-Shelf

CP Closure Plate

CSKE Component Skeleton

DFW Diagnostic First Wall

DSM Diagnostic Shield Module

EM Electromagnetic

F2E Front-to-End

FEOMS Front End Optical Modular Systems

FDR Final Design Review

FMU First Mirror Unit

HCC Hard Core Components

HCF Hot Cell Facility

HFSS High Frequency Simulation Software

IO ITER Organization

IOT Interspace Optics Tube

ISS Interspace Support Structure

PC Port Cell

PC-I Port Cell Interspace

PCSS Port Cell Support Structure

PDR Preliminary Design Review

PIC Protection Important Component

PID Piping & Instrumentation Diagram

PPTF Port Plug Test Facility

R el ea se d

4/

/1

R xi

Acronym Description

PSKE Positional Skeleton

QC Quality Class

RH Remote Handling

RSKE Reference Skeleton

SDD System Design Description

SDDR Shut Down Dose Rate

SI International System of Units

TCS Test and Conditioning State

TCWS Tokamak Cooling Water System

TM Transmission Monitoring

UPP Upper Port Plug

UWAVS Upper Wide Angle Viewing System

UWS Universal Work Station

VV Vacuum Vessel

WFE Wavefront Error ea se d

4/

/1

R

1 INTRODUCTION

The 55.GA Upper Port Wide Angle Viewing System (UWAVS) images the divertor surface in sections and provides machine protection (monitoring for overheating of surfaces), plasma control

(basic and advanced), and physics measurement roles. UWAVS is located in UP 2/8 (RFDA), UP

11/14 (USDA) and UP 17 (EUDA). The UWAVS coverage of the divertor is shown in Figure 1.

Figure 1. Coverage of divertor from a) one UWAVS diagnostic and

b) five Upper Port UWAVS diagnostics.

1.1 Purpose

This document provides the System Design Description (SDD) of the 55.GA diagnostic system at the preliminary design phase of the program.

1.2 Scope

This document provides high-level definitions of the UWAVS-35 system architecture, functions, decomposition, and performance. This document does not include discussion of the UWAVS-17 system. However, the ex-vessel systems are designed to be common for both UWAVS-17 and

UWAVS-35 designs. This report does not include a summary of the Structural Integrity

Reports ( [1], [2]).

The high-level summaries in the SDD reference additional documents that include further detail into the optical design, mechanical design, I&C architecture, system integration, assembly and verification testing strategy. The report also includes content not captured in other documentation including general safety considerations, details of the RF mirror cleaning design, status of prototype activities, and a risk analysis.

R el ea se d

4/

/1

R

1.3 Definitions

1.3.1 Units

The units of the international system (SI) are used unless otherwise stated.

1.3.2 Coordinate Systems

Coordinate system references are consistent with the ITER Tokamak Global Coordinate System

[3] unless otherwise stated.

1.3.3 Geometry

The official configuration management (CM) models provided by USDA for all 55.GA ports is listed in Table 1 below and shown for reference in Figure 2. Table 1 also lists the native 55.GA CAD geometry and versions referenced throughout this report.

Table 1. Applicable CAD Models.

Model CAD File

55.GA CM model to

USDA

DET-07077-D_CMM_DIR_12-7-2023

Baseline Optical Model in CATIA

TNO2022_V010_42_20221209_SOLID_BEAM.CATPart, A.4

CATIA skeleton of optics elements

UWAVS_OPTICS_ELEMENTS_CSKE.CATPart, A.23

FEOMS CATIA files UWAVS_FEOMS_SUBYSYSTEM_ASSY.CATProduct, A.75

Bullnose CATIA files UWAVS35_BULLNOSE_ASSY.CATProduct, A.7

IOT CATIA File UWAVS_IOT_SUBYSYSTEM_ASSY.CATProduct, A.192

BOL CATIA File UWAVS_BOL_SUBYSYSTEM_ASSY.CATProduct, A.26

BEOC CATIA File UWAVS_BEOC_SUBSYSTEM_ASSY.CATProduct, A.40

Upper Port Plug CSKE references

15_52_55_UPORT_PLUG_RSKE#2P38ES-Y.CATPART

R el ea se d

4/

/1

R

Figure 2. DET-07077-D, 55.GA CM model to USDA.

1.3.4 ENOVIA Trees

The associated ENOVIA tree geometry for the 55.GA at PDR are shown below for UP02 and

UP08 in Figure 3, and UP11 and UP14 in Figure 4.

R el ea se d

4/

/1

R

Figure 3. 55.GA Enovia tree for UP02 and UP08

Figure 4. 55.GA Enovia tree for UP11 and UP14.

ea se d

4/

/1

R

2 REQUIREMENTS

55.GA diagnostic measurement parameters are essentially the stakeholder requirements that drive the design of the system. 55.GA measurement roles are described in the Sub-System

Requirement Document sSRD-55.GA (IR Cameras: Vis/IR TV (Upper) [4]), and in the 55.GA PA

Annex B [5]. Detailed description and analysis are provided in 55.GA UWAVS-35 System Detailed

Performance Definition [6].

Table 2 provides an overview of the primary role measurements of the 55.GA diagnostic. In addition, it indicates which parameters are determined directly by the UWAVS system and which measurement parameters require additional processing and interpretation. In the latter case, measurement algorithms are not yet available and assumed to be provided later by ITER. Hence the accuracy of these measurement parameters cannot be established at this stage.

Table 2. Annex-B Measurement Parameter Overview with Conditions and Required Accuracies for Primary Measurements

Table 3 provides an overview of the measurements with supplementary or back-up roles for the

UWAVS diagnostic.

ea se d

4/

/1

R

Table 3. Annex-B Measurement Parameter Overview with Conditions and Required Accuracies for Secondary Measurements

For species influx measurement, UWAVS inherently provides a line integrated intensity measurement, based on a single spectral line integrated intensity. This will be the target deliverable data for UWAVS. To determine species influx a combination of plasma model, plasma measurement data, and 3D-tomography are required. The calibration factors are needed to derive the absolute line intensities from the raw signals provided by UWAVS.

R el ea se d

4/

/1

R

Determining the heat load and particle fluxes requires additional input from IO. UWAVS will provide wall radiance and temperature as the inputs for determination of the heat flux. These measurements will be addressed during the final design phase.

R el ea se d

4/

/1

R

3 SAFETY

The 55.GA design follows the Project Requirements [7] and Safety Roombook [8] guidelines for general safety objectives, occupational safety (ALARA), zoning, and Protection/Safety Important

Component (PIC/SIC) classifications. The 55.GA in-vessel and ex-vessel subsystems are separated by two primary confinement barriers consisting of 1) a double-window assembly for transmission of light, and 2) a valve box for pneumatic application of an in-vessel shutter. All the opto-mechanical hardware is located within the Vacuum Vessel (VV), Interspace, and Port Cell.

Therefore, secondary barrier components associated with penetrations from the Port Cell to

Gallery, and Gallery to Diagnostic Hall are not within the scope of 55.GA. PIC/SIC components and assemblies from Annex [5] are summarized in Table 4 and classified per [9]

Table 4. Diagnostic System Classifications per Annex B

Subsystem Description

Diagnostic Component Safety Class Seismic Class

Quality Class

Vacuum Class

Window Primary Vac Double Window Assembly Inner

Window

SIC-1 (Confinement) SC1 QC-1 VQC-1

Window SVS Connections SIC-1 (Confinement) SC1 QC-1 VQC-1

Window Primary Vac Double Window Assembly Outer

Window

SIC‐2 (Second Confinement barrier)

SC1 QC-1 VQC-1

Port Plug Seal Plate system

1st isolation valve for gas feed close to closure plate

SIC-1 (Confinement) SC1 QC-1 VQC-1

Port Plug Seal Plate system

2nd valve further away from closure plate

SIC-1 (Confinement) SC1 QC-1 VQC-1

The SIC-1 double-window assembly is an IO design for 55.GA and controlled with an interface sheet [10]. The confinement barrier must withstand 2 bar differential peak pressure, seismic, electromagnetic, and accident loads, in additional to thermal loading from nuclear heating, bakeout, and fire accident temperatures per the load specification [11]. The window assembly is continuously monitored by PBS.31.SV for possible leaks. In addition, the temperature rise due to

ECH loads on the windows is monitored for overheating on the external housing by 55.NW and the I&C port integrator systems (PBS.55.Q0/U0).

An in-vessel, pneumatically actuated shutter utilizes a valve box assembly, located in the Port

Cell alcove, with two redundant SIC-1 safety valves to operate and protect the vacuum from the positive pressure of the pneumatic shutter actuation. The gas valve box (GVB) also includes two

SIC-2 isolated controls for each SIC-1 valve. The GVB provides the double confinement barriers

R el ea se d

4/

/1

R required per vacuum handbook [12]. Refer to Piping and Instrumentation Diagrams (PID) for the

SIC-1 an SIC-2 shutter actuation GVB. The GVB design is out of scope for this PDR.

The sensors for monitoring the SIC systems components are defined in the PID for each port [13], [14], [15], and [16]. The independence of the SIC-1 control valves are indicated by the Train A and Train B designation in the Cabling diagram for each port [17], [18], [19], and [20].

Fire sectors within the Tokamak Building segregate regions between the Port Cell and Gallery, and Gallery to Diagnostic Hall, and are classified as SIC-2. For 55.GA, the design and qualification of penetrations for these boundaries fall under the primary responsibility of port integrators and

IO. However, 55.GA supports designs of safety critical components and penetrations by selecting

IO approved cables [21] and interface sheets to ensure adequate safety measures are established. A preliminary fire assessment of 55.GA components per the ITER Fire Safety

Approach document [22] is included in section 14.1.

Radioactive waste management encompasses the systematic handling, treatment, storage, and disposal of materials that contain radioactive elements. 55.GA is designed to operate such that it minimizes radioactive waste by selection of approved ITER materials, the use of nuclear shielding materials to minimize exposure, and the use of a modular design architecture to ease waste management during decommissioning [23].

R el ea se d

4/

/1

R

4 DESIGN ARCHITECTURE

4.1 Global Design Architecture

UWAVS 55.GA architecture is based on a modular approach that includes key physical and functional subsystems both inside and outside of the Vacuum Vessel (VV) as shown in Figure 5.

Figure 5: 55.GA Diagnostic System.

In-vessel mirrors mounted in actively-cooled assemblies make up the Front End Optical Modular

System (FEOMS), and install in the Diagnostic Shield Module (DSM) that inserts into the Upper

Port Plug (UPP) and ultimately, the VV. They are designed mounted on removable mirror modules that are compatible with remote handling (RH) equipment in the hot cell. The vacuum window is the final in-vessel optic. The two tilted sapphire windows provide the required double barrier safety protection at the vacuum boundary as discussed in Section 3.

The interspace subsystems comprise of the Interspace Optical Tube (IOT) and the Bioshield

Optical Labyrinth (BOL). The IOT includes two actuated mirrors to provide active beam steering and correct for thermal deformations of the VV. The aft dog legs in the IOT relay the image from the FEOMS through the BOL to the BEOC. The BOL serves as the final dog leg with two tip and tilt gimbals that provide coarse alignment of IOT to BEOC. The BOL is housed inside the bio shield wall.

The BEOC subsystem encloses beam splitting, shaping, and correcting optics for camera imaging. It includes two visible and two infrared cameras and optical paths. It houses calibration source equipment and RF matching electronics. The BEOC is surrounded with protective shielding layers to absorb neutron, gamma, and electromagnetic radiation to protect sensitive electronics.

R el ea se d

4/

/1

R

Figure 6 (landscape version in Figure 99 of APPENDIX A) shows the UWAVS system architecture and key interfaces. Color codes and line types are noted in the legend.

Figure 6. UWAVS system architecture.

4.2 Functional Architecture

Very similar with the physical architecture, the functional architecture of the system can be decomposed into functional subsystems.

4.2.1 Functions of In-Vessel Optics

The in-vessel optics, collectively known as the FEOMS, primarily act as the large field of view

(FOV) imager and an optical relay. The diverter is initially imaged through an 18 mm aperture by two off-axis spherical mirrors, A10-M1 and A10-M2. These mirrors image the large FOV to the space just beyond A10-M2. A10-M1 and A10-M2 exist in a volume with direct exposure to the

ITER plasma and A10-M1 has an unimpeded line of sight to the plasma. Following the A10 mirror group is an optical dog-leg, A20-M1 and A20-M2. These mirrors provide a break in the neutron line of sight, so shielding can be installed to reduce nuclear loads on downstream optics. Since

A10-M1 and A10-M2 form the divertor image directly after A10-M2, an optical relay is needed to transfer the image further downstream, towards the cameras. This function is performed by the

A30 mirror group, which consists of 4 mirrors and serves to correct some of the aberrations caused by the divertors tilted orientation. Finally, the FEOMS is sealed inside the UPP with a pair of wedged sapphire vacuum windows (A35 VW1/ A35 VW2). All mirrors inside the FEOMS are made from ITER grade stainless steel and are water cooled. A10-M1 and A10-M2 are coated with a platinum metal coating, to aid in longevity of repeated plasma cleanings, while remaining mirrors are coated in a protected aluminum coating. An image of the FEOMS optics and beam path are shown in Figure 7.

R el ea se d

4/

/1

R

Figure 7. In-Vessel optics provide large FOV imager and optical relay.

4.2.2 Functions of Interspace Optics

After the light leaves the VV and port plug enclosure, it enters the IOT. First, a set of flat, remote actuated, dog-leg mirrors (A40-M1 and A40-M2) provide the means to compensate for thermal expansion in the VV, as well as another opportunity to shield downstream optics from neutron streaming. Next, a set of four mirrors in the A50 mirror group relay the image from the FEOMS in the VV, to the BEOC in the Port Cell (PC). These mirrors also provide additional corrections to the beam, to compensate for upstream aberrations. Leaving the IOT, the beam passes through the BOL. Here, a set of flat, remote actuated mirrors, A60-M1 and A60-M2, provide the means for aligning the IOT to the BEOC. This dogleg sits in the bioshield, again utilizing the offset beam path to provide neutron shielding to downstream optics and electronics. These mirrors are not integrated into an active control loop; they only provide a user determined update to system alignment. An image of the IOT mirrors and beam path are shown in Figure 8.

Figure 8. Interspace mirrors provide alignment mirrors and a second optical relay el ea se d

4/

/1

R

4.2.3 Functions of Port Cell Optics

Within the BEOC there are a series of common optics before the chromatic split between the infrared and visible channels. First, a thin sapphire window (A70W1) is used for correcting chromatic aberration induced by the sapphire vacuum windows in the UPP. Next, another thin sapphire beam splitter (A70S1) is used introduce the calibration sources and respective optical legs. Finally, the dichroic beamsplitter A70S2, a fused silica optic, splits the infrared from the visible channels, with the infrared reflecting off the first surface and the visible transmitting through the optic. The entire BEOC enclosure is shielded to reduce neutron, gamma, and electromagnetic radiation incident upon sensitive electronics.

The infrared channel starts with a compound field lens, comprised of A80-L1 and A80-L2, optimized to reduce pupil aberration at the cold stop of the infrared cameras. Here, the two infrared channels are split with another dichroic A80-S1, a silicon optic splitting lower band from higher band, with the lower band reflecting off the beamsplitter and the higher band transmitting.

Each infrared channel then reflects off a gold coated N-BK7 fold mirror, towards the infrared imager lens, A80-M1 and A90A for the low IR band, and A80-M2 and A90B for the high band.

These compound lenses are identical for each infrared channel and consist of 7 individual lenses assembled into a lens tube. In the low infrared band, the imaging lens is followed by two filters

A90A-W1 and A90A-W2. The specifics of these filters are not finalized, one is allocated for low

IR bandpass filter, the other is allocated for a neutral density filter if needed. Filters in the high IR band are similar, A90B-W1 and A90B-W2, with the bandpass filter passing only the spectrum of interest. Finally, infrared light passes through the cold stop of the IR cameras, then to the sensor.

Similarly to the infrared channels, the two visible channels pass through a common achromatic doublet lens (A100-L1/2) before splitting into the two visible channels. This doublet helps correct chromatic aberrations over the large visible range (400-750nm) and limit beam size further downstream in the visible channel. The visible beamsplitter, A100-S1, splits the two visible channels, with the reflected path going towards the high resolution visible channel, and the transmitted path going towards the high speed visible channel. Each channel utilizes a silver coated folding mirror, A100-M1 for the high resolution channel, and A100-M2 for the high speed channel. Each channel has a set of 3 filter wheels after the fold mirrors. Two of the filter wheels contain spectral filters to enable isolating specific elemental spectral lines. The third wheel contains a series of increasing attenuation neutral density filters to aid keeping intensities within the dynamic range of the cameras. After spectral filtering and intensity normalization, each visible channel has a compound lens optimized for different magnifications, A110A for the high resolution channel and A110B for the high speed channel. An image of the BEOC optics and beam path are shown in Figure 9.

R el ea se d

4/

/1

R

Figure 9. Port cell optics provide beam splitting, shaping, and correcting optics.

4.3 Subsystem Design Architecture

55.GA subsystems can also be decomposed further using the modular approach.

The FEOMS consists of six different subassemblies that support and house water cooled focusing mirrors. The first two mirrors are housed in the First Mirror Unit (FMU) or Bullnose, nested inside the Diagnostic First Wall (DFW). This assembly mounts into a cavity at the front of the DSM.

Figure 10 (landscape version in Figure 100 of APPENDIX A) shows the FEOMS block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 10. FEOMS decomposition and functional interfaces.

Two additional groups of water-cooled mirror assemblies are located behind shielding panels nested between the DSM partitions that comprise the rest of the front-end optical module

SHUTTER A10-M1

DFW

APERTURE

A10-M2

PREMATCHER PREMATCHER

A20-M1 A20-M2 A30-M1 A30-M2 A30-M3 A30-M4

DSM

RH BULLNOSE

A20 FIXED

BLOCK

A30 FIXED

BLOCK 1

A30 FIXED

BLOCK 2

A30 FIXED

BLOCK 3

A30 FIXED

BLOCK 4

COOLANT FLOW

SYSTEM BOUNDARY

DATA SIGNAL

POWER INTERFACE

LEGEND

IO

INTERFACES

55.GA

SUBASSEMBLY

PHYSICAL CONNECTION

OPTICAL PATH

GAS PRESSURE (N2)

OPTICAL

COMPONENT

Front End Optical Module System (FEOMS)

A20 RH

MODULE

A30 RH

MODULE 1

A30 RH

MODULE 2

A30 RH

MODULE 3

A30 RH

MODULE 4

CLOSURE PLATE

NOTCH

FILTER

NOTCH

FILTER

R el ea se d

4/

/1

R assemblies. These serve as the support structure for the in-vessel optical doglegs that relay the image through the rest of the DSM, backfill, and shielding.

The A20 group consists of two water cooled mirrors located in the same module in DSM bay 2 forming the first optical dogleg.

The A30 group consists of four modules each containing a single water-cooled mirror in a zigzag configuration spanning DSM bay 4 through 7. The architecture of each module is similar, though each requires a unique design to accommodate the beam path shape, position, and direction.

The Bullnose is the front mirror unit that houses the A10 small hole imaging mirrors. These mirrors act as wide-angle imagers that collimate a beam back to the rest of the FEOMS. The aperture is small to minimize contamination from exposure to the plasma. A shutter is also mounted on the back of the aperture and closed as required for protection during events such as Glow Discharge

Conditioning (GDC), Ion Cyclotron Wall Conditioning (ICWC), and Electron Cyclotron Wall

Conditioning (ECWH). UWAVS is capable of transmission monitoring between shots and the first two mirror units are designed with in-situ RF plasma cleaning capability. Figure 11 (landscape version in Figure 101 of APPENDIX A) shows the UWAVS Bullnose block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 11. Bullnose decomposition and functional interfaces.

The IOT subsystem resides in the Interspace, supported by the Interspace Support Structure

(ISS). At the fore end (Tokamak Global Coordinate System, TGCS negative X-direction), the IOT resides immediately next to the UPP Closure Plate (CP) and provides a mechanically passive interface with the VV window. At the aft end, the IOT projects the UWAVS line of sight into the

R el ea se d

4/

/1

R

BOL subsystem. Surrounding the IOT will be shielding, other diagnostic equipment, and various forms of ITER infrastructure. Figure 12 (landscape version in Figure 102 of APPENDIX A) shows the IOT subsystem block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 12. IOT decomposition and functional interfaces.

The BOL sits within the Bioshield and maintains alignment between the IOT and BEOC after maintenance periods when the ISS or Port Cell Support Structure (PCSS) are reinstalled. This is done using two actuated mirror mount assemblies. The two assemblies also create an optical dogleg within the Bioshield to reduce neutron streaming through the 55.GA diagnostic beam path.

Figure 13 (landscape version in Figure 103 of APPENDIX A) shows the BOL subsystem block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 13. BOL decomposition and functional interfaces.

A40-M1 A40-M2 A50-M1 A50-M2 A50-M4

INTERSPACE SUPPORT STRUCTURE (ISS)

IOT OPTICAL BENCH

INTERSPACE OPTICAL TUBE (IOT)

BOLFEOMS A50-M2

COOLANT FLOW

SYSTEM BOUNDARY

DATA SIGNAL

POWER INTERFACE

LEGEND

IO

INTERFACES

55.GA

SUBASSEMBLY

PHYSICAL CONNECTION

OPTICAL PATH

AIR PRESSURE

OPTICAL

COMPONENT

BIOSHIELD OPTICAL LABYRINTH (BOL)

COOLANT FLOW

SYSTEM BOUNDARY

DATA SIGNAL

POWER INTERFACE

LEGEND

IO

INTERFACES

55.GA

SUBASSEMBLY

PHYSICAL CONNECTION

IR/VIS LIGHT

AIR PRESSURE

IR LIGHT

VIS LIGHT

OPTICAL

COMPONENT

FROM

IOT

A60-M1

BOL BOTTOM PLATE

BOL ENCLOSURE

BOL BREADBOARD

A60-M1 GIMBAL A60-M2 GIMBAL

A60-M2

TO

BEOC

INTERSPACE SUPPORT STRUCTURE (ISS) BIOSHIELD

R el ea se d

4/

/1

R

The BEOC is located behind the Bioshield in the Port Cell (PC), the BEOC mounts to the Port

Cell Support Structure (PCSS) via an interface plate and shielded enclosure designed to protect the sensitive electronics and optics from radiation and contamination ingress.

Light enters the BEOC through a shielded shroud from the Bioshield Optical Labyrinth (BOL) and passes through a series of windows and mirrors that split the full spectral range into two wavelength bands (Visible and IR). Both IR and visible legs of the optical system consist of two cameras, and have lens doublets and respective fold mirrors and energy splitters to separate the light into two required camera channels. Finally, the wavelength bands are focused onto camera detectors via IR and visible lens arrays. The BEOC also houses calibration sources and optics.

Figure 14 (landscape version in Figure 104 of APPENDIX A) shows the BEOC subsystem block diagram that highlights function, decomposition, and key mechanical, optical, electrical, and cooling interfaces. Color codes and line types are noted in the legend.

Figure 14. BEOC decomposition and functional interfaces.

el ea se d

4/

/1

R

The modular architecture provides several key benefits. It provides initial FAT testing to be done at a modular level. This helps pinpoint alignment and assembly issues early in fabrication and verification tests. It also supports decommissioning requirements.

R el ea se d

4/

/1

R

5 DESIGN METHODOLOGY

5.1 Requirements

The Design Compliance Matrix (DCM) [24] tabulates how each requirement in the Sub-System

Requirements Document (sSRD) [4] is met at the preliminary design.

The Technical Data List (TDL) is used to address all required IO applicable documents that are used throughout the design to meet requirements of the sSRD [4].

The ITER Vacuum Handbook [12] is used to guide vacuum component design and will be leveraged through fabrication. The Material Design Handbook [25] is used to establish a common source of material data. 55.GA leverages the SDC-IC [26] and the associated materials design limit data [27] for in-vessel, and the RCC-MRx [28] for ex-vessel design verification analysis.

The ITER cable catalogue [29] cables and in-vessel connectors [30] are leveraged throughout the design to meet requirements of vacuum, radiation exposure, fire risks.

5.2 Optical Model

The optical model provides the starting point for mechanical design and integration. Optics are designed inside the 55.GA. space claim with optimized prescriptions to meet diagnostic performance, and typically sized 5-10% larger than the beam path. The margin reduces risk in performance losses from mechanical tolerances and thermal displacements that occur during operation. The system of optics is designed to minimize aberrations for both for both visible light

(400-700nm) and mid-wave infrared light (3-4.5µm). The baseline optical model includes all optics of the diagnostic from the first in vessel mirror back to the cameras. The optical model is referenced in section 1.3.3, and shown in Figure 15.

Figure 15. UWAVS Optical Model.

el ea se d

4/

/1

R

5.3 Mechanical Design Approach

Once the baseline optical design is established the UWAVS mechanical designs take form to support the optics and provide system functions and meet load specification requirements.

Parametric links are used for locating optical mounts and design of subsequent interfacing structures and mechanisms.

5.4 Skeleton Design Methodology

The design approach for developing the UWAVS subsystems is to utilize skeleton hierarchy per

[31] in conjunction with IO space claim models to locate and design optical mounts and support structures. The optics Component Skeleton (CSKE) contains the beam path and mirror S1 surfaces as shown in Figure 16.

Figure 16. CATIA optics CSKE.

Key IO interfaces are critical to established positional constraints of the UWAVS design. The UPP

Reference Skeleton (RSKE) contains key orientation and positioning planes. These elements setup the FEOMS, IOT, BOL, and BEOC CSKEs which publish the driving elements for the aperture cutouts, captured fastener locations, and mirror orientation planes for each subsystem.

Figure 17 shows UPP CSKE references (see Table 1) and Figure 18 shows the Port Plug

Assembly Datum (PPAD) and Port Cell Assembly Datum (PCAD) in reference to IOT and FEOMS subassemblies.

R el ea se d

4/

/1

R

Figure 17. PPAD and PCAD references linked to UPP RSKE.

Figure 18. PCAD virtual coordinate system established 11 degrees off axis of PPAD.

Key 55.GA interfaces such as fasteners are established using Positioning Skeletons (PSKE) to minimize mate errors. RSKEs can be used to leverage the same approach for pipes and fastener interfaces with Port Integrators in final design.

R el ea se d

4/

/1

R

6 SUBSYSTEM DESIGN DESCRIPTIONS

High level summaries of each 55.GA subsystem components and functions are included in the following sections (6.1-6.4). Detailed design descriptions and interfaces for each are discussed in the associated technical design descriptions and referenced as appropriate.

6.1 Front End Optical Modular System

The primary function of the FEOMS subsystem is to image a wide angle view of the divertor surface through a pinhole aperture of the DFW, and relay that image through a zigzag of dog leg mirror pairs back to the ex-vessel optics and cameras.

The mirrors are mounted on removable mirror modules that are compatible with remote handling tools in the hot cell in case maintenance is required. The modules also aid in neutron and gamma ray absorption and function as shielding. The mirror modules and where they reside in the DSM are shown in Figure 19.

Figure 19. FEOMS modules and optics in the DSM.

6.1.1 Bullnose

A detailed design description is available in the 55.GA Bullnose Technical Design Description

(TDD) [32] The related structural assessment of the design is documented in both structural integrity report [1], and in more detail in the 55.GA Bullnose calculation note [33].

The Bullnose (Front Mirror Unit) depicted in Figure 20 contains the A10 mirror group and the system aperture. Wide-angle light enters the system through the aperture at the lower front end

R el ea se d

4/

/1

R of the bullnose and reflects off the A10M1 and A10M2 mirror assemblies before exiting through the rear. Both A10 mirrors include a Radio Frequency (RF) cleaning system which allows for the removal of contaminates via plasma sputtering. RF power is fed to the mirrors through a series of mineral insulated cables (MIC) and through a RF pre-matcher printed circuit board (PCB) located directly behind them. Leakage of the RF power through the cooling water feed pipes is prevented through the use of a notch filter assembly mounted on the side of the housing. Additional details of the RF design are captured in Section 9. The housing consists of a machined block with gun drilled water channels throughout to manage the thermal load. A pneumatic shutter allows the aperture to be closed and resistive filaments are located on the back of the shutter blade for transmission monitoring. The bullnose is remotely handled for installation, featuring alignment pins on the back surface, and mounting with four large, forward facing RH bolts. Interfaces for cooling water, pneumatic, and electrical connections are established at the rear of the bullnose.

Figure 20. UWAVS-35 Bullnose assembly (Front Mirror Unit).

6.1.2 In-Vessel Shutter

A detailed design description is available in the 55.GA Shutter TDD [34]. The related structural assessment of the design is documented in both structural integrity report [1], and in more detail in the 55.GA in-vessel shutter calculation note [35].

The in-vessel shutter sits behind the aperture of the bullnose and protects the first two in-vessel mirrors from contamination during events such as Glow Discharge Conditioning (GDC), Ion

Cyclotron Wall Conditioning (ICWC), and Electron Cyclotron Wall Conditioning (ECWH).

Sitting on the base of the bullnose, the shutter is primarily comprised of a pneumatic actuator weldment which drives a linkage arm holding the aperture blade. The design utilizes a preload

R el ea se d

4/

/1

R spring coupled with the bellow to realize a non-actuated aperture open state. Upon pressurization of the pneumatic actuator chamber, the bellow hydraulic area coupled with restrained axial movement drives a center pintle to initiate movement of the linkage arm through kinematic joints.

The linkage arm holds the aperture blade which fully obstructs the aperture opening within the bullnose structure thereby protecting the mirrors and sensitive components internal to the bullnose. Figure 21 depicts the in-vessel shutter without the transmission source and the power cables.

Figure 21. In-vessel shutter architecture

The in-vessel shutter is designed to use a gas control box concept from Diagnostic 55.E2 to drive the pneumatic bellow actuator. Movement of the actuator uses the pressure differential across a thin-walled bellow which is constrained such that its hydraulic area creates an axial force which drives the pintle motion shown in Figure 22. The calculated thermal environment [35], allows passive cooling of the shutter assembly, which captures some of the active cooling of the bullnose through mounting of the actuator housing. Component materials are chosen in accordance with

[12] and based on actual testing results of similarly designed shutters within in-vessel Tokamak environments.

Pneumatic Actuator

Linkage Arm

Gas Inlet

Bullnose mount

Aperture Blade

Kinematic Joints

R el ea se d

4/

/1

R

Figure 22. In-vessel shutter cross-sectional view.

Internal to the bellow, the actuator pressure is the base pressure of VQC1 Tokamak components, 10-7-10-4 Pa (10-12-10-9 bar). The hydraulic chamber created by the actuator housing and the bellow wall is connected to the gas inlet line. Gas line pressurization during shutter open condition is at 0.1 bar (103 Pa). When pressurized to 2.0 bar (200kPa), the bellow compresses thereby axially moving the pintle to displace a single kinematic joint within the linkage arm. This linear displacement is translated to a rotational movement of the linkage arm thereby moving the aperture blade through a nominal 33.0mm range that provides line of sight coverage of the bullnose aperture opening and unobstructed view of the bullnose aperture opening. The range of motion is shown in Figure 23.

Bellow

Pintle Support

Gas Inlet

Pintle

Bushing

Pintle

Housing

Linkage Arm

Kinematic Joint

Pneumatic Actuator Motion

R el ea se d

4/

/1

R

Figure 23. Shutter operational states (a) Full closed, (b) Full open,

(c) Closed internal state, (d) Open internal state.

The shutter design pictured in Figure 22 satisfies multiple design requirements by protecting the bellow through restricting its range of motion and by biasing the design to fail open through multiple failure modes. The housing weldment protects the bellow to meet ITER Vacuum

Handbook [12] criteria. Exception to a double wall bellow requiring a monitored interspace is accepted since the gas system contains redundant SIC-1 and SIC-2 safety valves. In the case of a bellow failure, the system is contained and protected by the safety valves. The shutter remains inoperable but fails open due to the double redundant spring setup provided by the bellow and internal compression spring.

6.1.3 Front End Optical Modules

A detailed design description is available in the 55.GA FEOMS TDD [36]. The related structural assessment of the design is documented in both structural integrity report [1], and in more detail in the 55.GA FEOMS calculation note [37].

The rest of the in-vessel mirror assemblies are designed leveraging a common modular architecture and described here as mirror module assemblies. Although sometimes referred to as shielding or backfill modules, the primary UWAVS function is optical. The basic assembly consists of a fixed module and, a removable module that supports one or two mirrors (see A20 example in Figure 24). All three major components are actively cooled to manage thermo-nuclear heat

(a) (b)

(c) (d)

(a)

(a)

2.5mm 2.5mm

33.0mm

R el ea se d

4/

/1

R loads. The mirrors are attached to the removable modules using an adjustable kinematic mechanism to achieve fine tip/tilt positioning. The kinematic mechanism is cooled only through conduction out to the interfaces.

Figure 24. FEOMS mirror module design

The mirror modules are…