806a76de - 1.0 - Front End Optical Modular System, FMU Technical Design Description.pdf

ITER UPPER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA UWAVS-35 TECHNICAL DESIGN DESCRIPTION FOR

FRONT END OPTICAL MODULAR SYSTEM

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

Under Subcontract No: S013437

Prepared by General Atomics

304243-R00025 Revision A

GA Project 30424

PPPL APPROVAL

VERSION Date Signatory QA Engineer SE External

ITER

Reviewer

Approver

1.0 6/6/2024

Mark Smith Patrick Temple Pete Dugan N/A Ravinder Bhatia

SEE EDRM

Notification

N/A

304243-R00025 Revision A

ITER UPPER WIDE ANGLE VIEWING SYSTEM

PROJECT

55.GA UWAVS-35 TECHNICAL DESIGN

DESCRIPTION FOR FRONT END OPTICAL

MODULAR SYSTEM A20-A30

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

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55.GA UWAVS-35 TDD for FEOMS A20-A30 304243-R00025/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 858-248-6652

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 ea se d

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TABLE OF CONTENTS

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

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

ACRONYMS ............................................................................................................................. VI

1 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Definitions

1.3.1 Units

1.3.2 Coordinate Systems

1.3.3 Geometry

2 SUBSYSTEM OVERVIEW

2.1 Key Functions

2.2 Primary Components

2.3 Functional Block Diagram

2.4 Size, Weight, and Volume

3 DETAILED DESIGN DESCRIPTION

3.1 Mirror Module Assemblies

3.1.1 Removable Module Subassemblies

3.1.2 Mirror Weldments

3.1.3 Kinematic Adjustment Mechanisms

3.1.4 Fixed Module Subassemblies

3.2 Cooling Circuit Approach

4 INTERFACES

4.1 DSM to Fixed Module Interfaces

4.2 DSM Cooling Interfaces

4.3 DSM Shielding Tray Interfaces

5 INSTRUMENTATION

6 ASSEMBLY AND INTEGRATION

6.1 Factory Welds

6.2 Port Integration Welds

6.3 Remote Handling Approach

6.3.1 Location Devices

6.3.2 Captured Fasteners

6.3.3 LEVI Connectors

6.3.4 RH Lift Tooling

6.3.5 Remote Handing Welds

7 REFERENCES

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LIST OF FIGURES

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

Figure 2. 55.GA UWAVS diagnostic system

Figure 3. FEOMS modules and optics in the DSM

Figure 4. FEOMS decomposition and interfaces

Figure 5. Physical dimensions of the A20 mirror module

Figure 6. Physical dimensions of the A30 mirror modules a) A30M1 and b) A30M2

Figure 7. Physical dimensions of the A30 mirror modules a) A30M3 and b) A30M4

Figure 8. FEOMS mirror module design

Figure 9. Beam path through A30 mirror modules

Figure 10. Exploded views of A30 mirror modules a) A30M1 and b) A30M2

Figure 11. Exploded views of A30 mirror modules a) A30M3 and b) A30M4

Figure 12. A20 removable module

Figure 13. A30 removable modules a) A30 M1 and b) A30 M2

Figure 14. A30 removable modules a) A30 M3 and b) A30 M4

Figure 15. Mirrors in FEOMS designed with common architecture

Figure 16. (a) Pictorial, (b) section, and (c-e) component views of the common FEOMS mirror kinematic mount mechanism

Figure 17. A20 fixed module subassembly

Figure 18. A30 fixed module subassemblies a) A30 M1 and b) A30 M2

Figure 19. A30 fixed module subassemblies a) A30 M3 and b) A30 M4

Figure 20. A20 module cooling circuit

Figure 21. A30 module cooling circuit a) A30M1 and b) A30M2

Figure 22. A30 module cooling circuit a) A30M3 and b) A30M4

Figure 23. Fixed module assembly to DSM interface

Figure 24. DSM to FEOMS supply and return interfaces

Figure 25. Proposed shielding tray interfaces to FEOMS A20 mirror module

Figure 26. Proposed shielding tray interfaces to FEOMS A30M2 mirror module

Figure 27. A20 mirror module thermocouple integration

Figure 28. A20 module to mirror jumper factory welds

Figure 29. A20 fixed module to removable module factory welds

Figure 30. A20 module to DSM inlet and outlet pipe weld

Figure 31. Section view of captured fasteners

Figure 32. a) FEOMS A30-M2 module highlights example of limitations using b) standard RH torque tool interface

Figure 33. Section view of LEVI connector

Figure 34. Concepts of lift tooling for RH modules

Figure 35. RH weld A20 removable module to fixed module return pipe

Figure 36. RH weld A20 module inlet pipe

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Figure 37. RH clamp tool minimizes or eliminates room for contingency weld operations in a) upper pipe and b) lower pipe

Figure 38. Recommended pipe cross section dimensions for RH orbital welds

LIST OF TABLES

Table 1. Applicable CAD models

Table 2. Mass and volume of FEOMS modules

Table 3. FEOMS Pipe Specifications

Table 4. Material Specification Table ...................................................................................... A-1 ea se d

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ACRONYMS

Acronym Description

BEOC Back End Optics & Cameras

BOL Bio-Shield Optical Labyrinth

CM Control Model

CP Closure Plate

DFW Diagnostic First Wall

DSM Diagnostic Shield Module

EUDA European Union Domestic Agency

FEOMS Front End Optical Modular Systems

FMU Front Mirror Unit

IOT Interspace Optics Tube

LEVI Loom Electrical Vacuum Interface

MIC Mineral Insulated Cable

PC Port Cell

PPTF Port Plug Test Facility

QC Quality Class

RH-TDF Remote Handling Task Definition Form

RFDA Russian Federation Domestic Agency

UP Upper Port

UPP Upper Port Plug

USDA United States Domestic Agency

UWAVS Upper Wide Angle Viewing System

VV Vacuum Vessel ea se d

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1 INTRODUCTION

The 55.GA Upper Port Wide Angle Viewing System (UWAVS) views the divertor in sections and provides machine protection (monitoring for overheating of surfaces), plasma control (basic and advanced), and physics measurement roles. UWAVS is located in Upper Ports (UP) 2/8 (RFDA), 11/14 (USDA) and 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 technical design description of the Front End Optical Module System

(FEOMS), the in-vessel subsystem of the 55.GA Upper Port Wide Angle Viewing System. The

UWAVS FEOMS is located in Upper Ports 2/8 (RFDA) and 11/14 (USDA).

1.2 Scope

This document provides detailed component design architecture, function, and methodology for the FEOMS subsystem of the UWAVS at the preliminary design phase. This document only includes the A20 and A30 mirror modules of the FEOMS. Structural and thermal analysis are not discussed in this document but are available in [1].

High-level definitions of the UWAVS system architecture, decomposition, and functions are described in the UWAVS System Design Description Document [2].

The bullnose subassembly is housed in within the DSM but included in a separate document due to complexity of the design, multiple functions, and unique components driven by the first mirror requirements [3]. It is only discussed in this document for context.

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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

[4] unless otherwise stated.

1.3.3 Geometry

The CAD geometry referenced throughout this report is listed below in Table 1.

Table 1. Applicable CAD models.

Model CAD File

Native CATIA File UWAVS_FEOMS_SUBYSYSTEM_ASSY.CATProduct, A.75 ea se d

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2 SUBSYSTEM OVERVIEW

The UWAVS is a visible/infrared light viewing system for real-time imaging of portions of the vessel diverter’s outer target, outer baffle, inner baffle, and dome. Its primary function is to provide measurements of the diverter and first wall surface temperature and luminance for machine protection, basic and advanced control, and physics measurement purposes. It consists of five separate instances positioned in upper ports 2, 8, 11, 14, and 17. The UWAVS architecture is based on a modular approach that includes key functional subsystems in and outside of the

Vacuum Vessel (VV) as shown in Figure 2.

Figure 2. 55.GA UWAVS diagnostic system

The FEOMS is the in-vacuum subsystem that resides in the Diagnostic Shield Module (DSM) of upper ports 2, 8, 11, and 14 (UWAVS-35 configuration). The FEOMS comprises the structures that support the in-vessel mirrors to capture light from the divertor and plasma and relay it back to the ex-vessel subsystems and cameras for imaging.

2.1 Key Functions

The primary function of the FEOMS subsystem is to image a wide angle view of the divertor surface through a pin hole aperture of the Diagnostic First Wall (DFW), and relay that image through a zig-zag 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 aid in neutron and gamma ray absorption and function as shielding. The UWAVS system is capable of transmission monitoring, and due to higher risk of contamination, the first two mirror units are designed with in-situ RF plasma cleaning capability. The internal aperture of the FEOMS is also designed adjacent to a

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R remotely operated shutter to reduce unnecessary exposure risk during planned conditioning events.

The vacuum windows are the final optics in-vessel of the FEOMS. The two tilted sapphire windows provide required double barrier safety protection at the vacuum boundary.

2.2 Primary Components

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

Diagnostic Shield Module (DSM).

Figure 3. FEOMS modules and optics in the DSM

Two additional groups of water-cooled mirror assemblies are located behind shielding panels nested between the DSM partitions that form the mirror modules often described as backfill assemblies. These serve as the support structure for the 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 bays 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.

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2.3 Functional Block Diagram

Figure 4 shows the UWAVS FEOMS block diagram that highlights function, decomposition, and interfaces. Color codes and line types are noted in the legend.

Figure 4. FEOMS decomposition and interfaces

2.4 Size, Weight, and Volume

An assembled view of each FEOMS module is shown in Figure 5, Figure 6, and Figure 7 to provide physical dimensions of each subassembly.

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

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Figure 5. Physical dimensions of the A20 mirror module

Figure 6. Physical dimensions of the A30 mirror modules a) A30M1 and b) A30M2

Figure 7. Physical dimensions of the A30 mirror modules a) A30M3 and b) A30M4 ea se d

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Table 2 provides the mass and volume of the FEOMS components and assemblies.

Table 2. Mass and volume of FEOMS modules ea se d

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3 DETAILED DESIGN DESCRIPTION

3.1 Mirror Module Assemblies

The mirror assemblies are designed leveraging the 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 8). All three major components are actively cooled to manage thermo-nuclear heat 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 8. FEOMS mirror module design

The mirror modules are comprised of removable modules and fixed modules. The removable modules are Remote Handling (RH) compatible for maintenance and replacement. The fixed modules are not RH compatible or maintainable, and are permanently bolted to the DSM floor interface. Both the fixed and removable modules, interface with the DSM shielding panels on one side and are designed with stepped interfaces to minimize direct streaming of neutrons.

While the A20 Module consists of two mirror mounts and an optical dogleg managed within the one bay module, each A30 module has a single mirror mount and the optical dog legs are created in pairs of modules. The apertures in and out of each module are sized appropriately to clear the optical beam through each bay, as shown in Figure 9.

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Figure 9. Beam path through A30 mirror modules

Exploded views of all A30 mirror module designs are shown in Figure 10 and Figure 11.

Figure 10. Exploded views of A30 mirror modules a) A30M1 and b) A30M2

Figure 11. Exploded views of A30 mirror modules a) A30M3 and b) A30M4 el ea se d

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3.1.1 Removable Module Subassemblies

The removable module includes a tunneled block structure that provides a beam path to mirrors that are mounted with adjustable locking mechanisms. It also supports the male Loom Electrical

Vacuum Interface (LEVI) connector that services thermocouples to the mirrors. A long ball pin first engages locating holes in the fixed block to minimize jamming during insertion, followed by a tapered guide pin to position the assembly to final clocking during installation or RH maintenance.

A286 Stainless fasteners normally captured in the fixed block fasten into Al-Ni-Br (C63200) threaded inserts of the removable module to minimize the risk of galling.

The removable module is designed to be light weight and stiff to minimize deflection during normal operation and reduce stress under accident loading conditions. The locating pins are positioned opposite to the clamped joint interfaces to distribute reaction forces and minimize deflection of the heavy components. The removable block of the module is made from SS316L(N). A detailed view of the A20 removable module is shown in Figure 12 and a summary view of the A30 removable modules are shown in Figure 13 and Figure 14.

Figure 12. A20 removable module el ea se d

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Figure 13. A30 removable modules a) A30 M1 and b) A30 M2

Figure 14. A30 removable modules a) A30 M3 and b) A30 M4

3.1.2 Mirror Weldments

The FEOMS mirrors are designed with a common architecture and manufacturing approach. The mirrors leverage three mounting flanges equally opposed from the optic center. A backing plate machined with spiral channels is furnace brazed to mirror top plate. A full penetration weld around the perimeter provides the VQC-1A boundary weld (water to vacuum boundary). Final surface and prescription of each mirror will be machined, or diamond turned after braze, weld, and stress

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R relief heat treatment. The internal passages leverage cross flow to meet near the optic center and minimize thermal gradients in the optical surface (see Figure 15)

Figure 15. Mirrors in FEOMS designed with common architecture

Initial manufacturability assessment in preliminary design activity determined the inspection process will be critical. Both radiographic and ultrasonic testing options are recommended with subscale prototypes before commencing with manufacturing at full scale. Alternative manufacturing approaches are being explored for performance and costs benefits in prototype activities. Alternate approaches include gun drilled channels with weld closeouts, or a monolithic mirror with tubes brazed on aft surface. The goal is to have a common approach for all in-vessel mirrors after first mirror development prototype efforts finish.

3.1.3 Kinematic Adjustment Mechanisms

The FEOMS mirrors are secured to the removable modules using a kinematic mechanism that provides fine adjustment at factory assembly to minimize tolerance impact on performance.

The kinematic mount mechanism is a multicomponent feature designed to provide a repeatable and robust kinematic constraint of the mirrors, with in-situ initial alignment adjustability. The key components of the kinematic mount are the v-groove, sphere-cylinder nut, and threaded cone, stacked upon one another as shown in Figure 16.

Stacking the v-groove, sphere-cylinder nut, and cone creates a true kinematic constraint, but also maintains lower contact stresses via line or annular contact regions.

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Figure 16. (a) Pictorial, (b) section, and (c-e) component views of the common FEOMS mirror kinematic mount mechanism.

Three mounting interfaces per mirror complete the kinematic constraint of the mirror. The local vertical adjustment of the three kinematic mounts using the M14 threads provides in-situ alignment in three degrees of freedom: tip, tilt, and piston.

3.1.4 Fixed Module Subassemblies

The fixed module subassembly includes a hollowed block structure (fixed block), the female LEVI connector, and captured fasteners to achieve remote handling compliance of the removable module. The fixed block has installed pins and fasteners that position and permanently secure the assembly to the DSM bay floor. A detailed view of the A20 fixed module subassembly is shown in Figure 17 and a summary view of the A30 fixed module subassembly are shown in Figure 18 and Figure 19.

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Figure 17. A20 fixed module subassembly

Figure 18. A30 fixed module subassemblies a) A30 M1 and b) A30 M2 el ea se d

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Figure 19. A30 fixed module subassemblies a) A30 M3 and b) A30 M4

The fixed block is designed to provide optical support structure, but also aid in neutron and gamma absorption similar to backfill shielding without optics in DSM bays. Therefore, the block is designed to maximize volume and weight but maintain high stiffness to minimize overall deflections under operational and accident loads. The block is machined hollow to allow insertion of the removable module and accommodate the beam path access. It also has machined hole and slot features to provide repeatable positioning and alignment of the removable module. The block has gun drilled passages for cooling and provides the permanent mounting point for the

FEOMS modules. The fixed block is made from SS316L(N).

3.2 Cooling Circuit Approach

The cooling circuit for the FEOMS modules is designed to cool the most critical components first but also must maintain RH compliance. The mirrors are the most critical component of the assembly. The inlet water from the DSM passes into the removable module where branches off parallel flow to feed the mirrors near the inlet source. After passing through both mirrors and the removable module in parallel, the fluid recombines near the removable module outlet. This approach provides the coolest water to the mirrors and leverages pressure drop to maximize flow into the mirrors.

After flowing through the mirrors and the removable a module a jumper pipe takes the fluid into the inlet of the fixed module. The cooling passages are localized near critical interfaces to minimize deflection of supported optical surfaces during operation. Ultimately the fluid returns to the DSM return circuit on the side opposite the inlet pipe.

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A detailed view of the A20 cooling circuit is shown in Figure 20 and a summary view of the A30 cooling circuits are shown in Figure 21 and Figure 22.

Figure 20. A20 module cooling circuit

Figure 21. A30 module cooling circuit a) A30M1 and b) A30M2 el ea se d

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Figure 22. A30 module cooling circuit a) A30M3 and b) A30M4

A table of design pipe sizes and RH compliance requirements are noted in Table 3.

Table 3. FEOMS Pipe Specifications

Description Pipe Size OD/ID RH Compliant

DSM TO REMOVABLE MODULE INLET DN 8, 10S 13.7mm/10.4mm Yes

REMOVABLE MODULE TO FIXED

BLOCK JUMPER

DN8, 10S 13.7mm/10.4mm Yes

MIRROR JUMPER N/A 8.0mm/6.0mm No

FIXED BLOCK TO DSM OUTLET DN8, 10S 13.7mm/10.4mm No ea se d

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4 INTERFACES

This section provides a brief, high-level summary the FEOMS subsystem external interfaces and service requirements. Detailed interface descriptions and associated data can be found in the following interface sheets for each Upper Port Plug (UPP):

55.GA IS for UPP-02 [5]

55.GA IS for UPP-08 [6]

55.GA IS for UPP-11 [7]

55.GA IS for UPP-14 [8]

4.1 DSM to Fixed Module Interfaces

The fixed module interfaces to the floor of the DSM with Inconel 718 M14 bolts that fasten into

Al-Ni-BR (C63200) threaded inserts to minimize the risk of galling. Locating pins in the fixed block engage with locating holes in the DSM for positioning and alignment during installation. Features interfacing between the fixed block and the DSM are shown in Figure 34.

Figure 23. Fixed module assembly to DSM interface

4.2 DSM Cooling Interfaces

Cooling requirements of PBS-55.GA are provided in interface sheets for each port. They provide cooling needs for the Bullnose and the mirror modules in Bays 2, 4, 5, 6, & 7. Preliminary heat loads, flowrates, temperature, and the pressure drop parameters are listed in the interface sheets.

The supply and return interfaces of the FEOMS design are shown in Figure 24 for reference.

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Figure 24. DSM to FEOMS supply and return interfaces

4.3 DSM Shielding Tray Interfaces

The detailed interface requirement for the shielding tray interfaces of PBS-55.GA are also provided in interface sheets for each port. They provide the defined interface control model (CM) for boundary definition to achieve optimized shielding. The stepped interface design on the fixed and removable module interfaces to the shielding trays requires design iteration with port integrators. Detailed interfaces cannot be locked until RH tooling is finalized and pipe interfaces are locked. The iterative process is in work as indicated by Figure 25 and Figure 26.

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Figure 25. Proposed shielding tray interfaces to FEOMS A20 mirror module

Figure 26. Proposed shielding tray interfaces to FEOMS A30M2 mirror module ea se d

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5 INSTRUMENTATION

This section provides a brief overview of the FEOMS subsystem instrumentation. Additional details are captured in the cabling diagrams, the piping & instrumentation diagrams, and the instrumentation and control specifications listed below.

55.GA UWAVS Instrumentation and Control Architecture [9]

55.GA UWAVS I&C System Requirement Specification [10]

55.GA UWAVS I&C System Design Specification [11]

55-GA-A0 IR Cameras: VIS/IR TV (Upper) UPP02 Cabling [12]

55-GA-B0 IR Cameras: VIS/IR TV (Upper) UPP08 Cabling [13]

55-GA-C0 IR Cameras: VIS/IR TV (Upper) UPP11 Cabling [14]

55-GA-D0 IR Cameras: VIS/IR (Upper) UPP14 Cabling [15]

55-GA-A0 IR Cameras: VIS/IR TV (Upper) UPP02 PID [16]

55-GA-B0 IR Cameras: VIS/IR TV (Upper) UPP08 PID [17]

55-GA-C0 IR Cameras: VIS/IR TV (Upper) UPP11 PID [18]

55-GA-D0 IR Cameras: VIS/IR TV (Upper) UPP14 PID [19]

55-GA-A0 IR Cameras: Vis/IR TV (Upper) UPP02 PFD [20]

55-GA-B0 IR Cameras: Vis/IR TV (Upper) UPP08 PFD [21]

55-GA-C0 IR Cameras: Vis/IR TV (Upper) UPP11 PFD [22]

55-GA-D0 IR Cameras: Vis/IR TV (Upper) UPP14 PFD [23]

In short, thermocouples within the FEOMS mirror modules provide temperature measurements of each optic to ensure an unexpected temperature rise is not the source of the UWAVS measurement error. Mineral insulated thermocouple probes are pre-bent to shape and pushed in contact with the bottom of a small bore located at the aft mirror surface and secured with a clip functioning as a preloaded spring flexure. See typical example of thermocouple integration in

Figure 27. Other options including a soldered interface can be explored in final design.

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Figure 27. A20 mirror module thermocouple integration el ea se d

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6 ASSEMBLY AND INTEGRATION

Preliminary manufacturing, assembly, and integration considerations in the FEOMS designs are documented in the following sections. All FEOMS modules will be fully assembled at factory. They are to be integrated into the DSM during port integration, and functionally tested at the Port Plug

Test Facility (PPTF). Additional details of port integration, PP testing, and optical verification checks are described in detail in the following documents.

55.GA UWAVS-35 Factory Qualification Test Plan [24]

55.GA UWAVS-35 Port Integrator Assembly Plan for the FEOMS [25]

55.GA UWAVS-35 Test Plan in Port Plug Test Facility (PPTF) [26]

55.GA UWAVS-35 Onsite Testing and Commissioning Plan [27]

6.1 Factory Welds

All removable modules are assembled and welded to the mirrors and fixed modules at the factory.

The 8mm outer diameter (OD) mirror pipe interfaces are accessible using standard COTS

Swagelok micro weld tools (SWS-8MRH) as shown in Figure 28. The larger DIN 10 pipes

(13.7mm OD) are accessible using a standard orbital welder model from Orbitalum (Orbiweld 19) as shown in Figure 29.

Figure 28. A20 module to mirror jumper factory welds ea se d

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Figure 29. A20 fixed module to removable module factory welds

6.2 Port Integration Welds

Port integration welds require careful consideration. There are two types of port integration welds.

There are the initial installation welds that can leverage more standard orbital welders and then there are the maintenance welds that require the use of RH compatible cutting, welding, and clamping tools. During port integration, the mirror module assemblies are installed into the appropriate bays and secured to the DSM interface. Then, the DSM pipe stems are welded to each mirror module assembly inlet and outlet pipes. These welds are permanent, and RH accessibility is not required. The DIN 10 pipes are also accessible for these welds using a standard orbital welder model from Orbitalum (Orbiweld 19) as shown in Figure 30.

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Figure 30. A20 module to DSM inlet and outlet pipe weld

6.3 Remote Handling Approach

In the case a long-term maintenance event requires the extraction of FEOMS mirrors, the removable modules are designed to be extracted using standard or unique bespoke tools. Each removable module is designed to be extracted from a side that best supports the beam path and adjacent diagnostics of the DSM.

The RH design features of the FEOMS are included this section and based on guidance from the

RH code of practice [28]. Relevant remote handling reports, forms and specific tasks are detailed in the following documents:

55.GA UWAVS-35 Remote Handling Compatibility Assessment Report [29]

55.GA UWAVS-35 RH-PDF for FEOMS Mirror Module Installation/Removal [30]

55.GA UWAVS-35 RH-TDF for Installation of the Bay 2 Mirror Module [31]

55.GA UWAVS-35 RH-TDF for Removal of the Bay 2 Mirror Module [32]

55.GA UWAVS-35 RH-TDF for Installation of the Bay 5 Mirror Module [33]

55.GA UWAVS-35 RH-TDF for Removal of the Bay 5 Mirror Module [34]

55.GA UWAVS-35 RH-TDF for Installation of the Bay 4 Mirror Module [35]

55.GA UWAVS-35 RH-TDF for Removal of the Bay 4 Mirror Module [36]

55.GA UWAVS-35 RH-TDF for Installation of the Bay 7 Mirror Module [37]

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55.GA UWAVS-35 RH-TDF for Removal of the Bay 7 Mirror Module [38]

55.GA UWAVS-35 RH-TDF for Installation of the Bay 6 Mirror Module [39]

55.GA UWAVS-35 RH-TDF for Removal of the Bay 6 Mirror Module [40]

6.3.1 Location Devices

As previously mentioned, the RH interface between the removable and fixed modules include a long ball pin that first engages locating holes in the fixed block to minimize jamming during insertion, followed by a tapered guide pin to position the assembly to final clocking during installation or RH maintenance. The locating pins are designed to engage prior to the LEVI connectors.

6.3.2 Captured Fasteners

All RH fasteners are captured in components that also have supporting counter torque slots for

RH bolting tools. See a cross section of the capture fastener both retracted and engaged in Figure

31.

Figure 31. Section view of captured fasteners

The need for bespoke tools is probable because the standard interface dimension of 60mm [41] may not be achievable for all RH fasteners of the UWAVS FEOMS mirror modules. In these cases, a longer bespoke tool maybe required to move the counter torque slot further away from tightly packed fastening patterns. An example is shown in Figure 32.

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Figure 32. a) FEOMS A30-M2 module highlights example of limitations using b) standard RH torque tool interface

6.3.3 LEVI Connectors

Thermocouple connector interfaces between RH components and permanent components are managed using standard IO LEVI connectors [42] and the manufacturing assessment guidance per [43]. Figure 33 shows a typical example of the male and female interfaces of the LEVI connector, both engaged and retracted in the FEOMS design. The Mineral Insulated Cable (MIC) is routed in the removable modules to the male LEVI connectors at factory assembly. MIC cables are to be routed in the DSM by port integrators up to the female LEVI connector interface of each mirror module per [44]. In the event of a maintenance event, the locating pins of the removable module ensure positional alignment prior to seating the LEVI connection.

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Figure 33. Section view of LEVI connector

6.3.4 RH Lift Tooling

Considerations for RH lift and extraction features are shown in Figure 34.

Figure 34. Concepts of lift tooling for RH modules

The intent is to design unique Plant System tooling that interfaces the modules using a combination of locating pins, RH M16 bolts, and interfaces to PBS.23 standard lift equipment. The tooling locates the pintle at the center of gravity of the load (tools and equipment).

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6.3.5 Remote Handing Welds

Remote handling compliant welds are required for each mirror module of the FEOMS. Only the

A20 mirror module is included in this assessment as it highlights the general challenges and feasibility. Other bays are discussed in the specific Remote Handling Task Definition Form

(RH-TDF) listed above. Each bay requires two pipes cuts prior to extraction and two pipe welds after reinstallation of the replaced RH removable module.

The RH pipe interfaces are DN8. The DN8 pipe tool set [45] used for the preliminary feasibility assessment includes the cutting tool, clamp tool, and welding tool. The pipe tools fit for both RH welds as indicated in Figure 35 and Figure 36, and the straight length requirement of 170 mm [46] does not limit remote handling access. However, the tool itself leaves inadequate space for multiple cut and weld positions on the same section of pipe.

Figure 35. RH weld A20 removable module to fixed module return pipe el ea se d

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Figure 36. RH weld A20 module inlet pipe

In some cases, there is no room for a contingency weld and only one maintenance operation

(cut/weld) is possible. See example of A20 bay RH weld assessments highlighting limitations in

Figure 37.

Figure 37. RH clamp tool minimizes or eliminates room for contingency weld operations in a) upper pipe and b) lower pipe

The RH compatibility working group is aware of challenges and working on updates to the tools.

Bespoke RH tools maybe required in final design.

To reduce cost and use more standard welding equipment the FEOMS pipes are designed with schedule 10 pipes. However, the desired cross section for weld prep laid out in Figure 38 is

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Figure 38. Recommended pipe cross section dimensions for RH orbital welds ea se d

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7 REFERENCES

[1] 55.GA UWAV-35 Engineering Calculation Note for FEOMS A20-A30, 304243-R00020, Rev A, ITER_D_WL7LFH, v1.0.

[2] System Design Description for 55.GA for Installation in UP2, 8, 11, and 14 (UWAVS-35), 304243-R00017, Rev A, ITER_D_WL5RAE, v1.0.

[3] 55.GA UWAVS-35 Technial Design Description for Bullnose, 304243-R00024, Rev A, ITER_D_ATY3SB, v1.0.

[4] ITER Coordinate Systems, ITER_D_2A9PXZ, v3.7.

[5] IS-55.GA-55.U2-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#2, ITER_D_X5W4BE, v1.2.

[6] IS-55.GA-55.U8-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#8, ITER_D_X838G5, v1.2.

[7] IS-55.GA-55.UB-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port #11, ITER_D_XWR3MD, v1.0.

[8] IS-55.GA-55.UE-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#14, ITER_D_X8XM6S, v1.0.

[9] 55.GA UWAVS Instrumentation and Control Architecture, 304243-R00030, Rev A, ITER_D_AU4W6P, v1.0.

[10] 55.GA UWAVS I&C System Requirement Specification, 304243-S00024, Rev A, ITER_D_ARRY56, v1.0.

[11] 55.GA UWAVS I&C System Design Specification, 304243-S00025, Rev A, ITER_D_ARS734, v1.0.

[12] 55-GA-A0 IR Cameras: VIS/IR (Upper) UPP02 Cabling, ITER_D_3QQP6T, v2.2.

[13] 55-GA-B0 IR Cameras: VIS/IR (Upper) UPP08 Cabling, ITER_D_3QSJ6B, v2.4.

[14] 55-GA-C0 IR Cameras: VIS/IR (Upper) UPP11 Cabling, ITER_D_596WA5, v2.0.

[15] 55-GA-D0 IR Cameras: VIS/IR (Upper) UPP14 Cabling, ITER_D_3QSD6R, v2.0.

[16] 55-GA-A0 IR Cameras: VIS/IR TV (Upper) UPP02 PID, ITER_D_PJ4JFG, v2.0.

[17] 55-GA-B0 IR Cameras: VIS/IR TV (Upper) UPP08 PID, ITER_D_PJAC7P, v1.0.

[18] 55-GA-C0 IR Cameras: VIS/IR TV (Upper) UPP11 PID, ITER_D_PJCAT5, v1.0.

[19] 55-GA-EO IR Cameras: Vis/IR TV (Upper) UPP14 PID, ITER_D_PJB95T, v1.0.

[20] 55-GA-A0 IR Cameras: Vis/IR TV (Upper) UPP02 PFD, ITER_D_3QRZQ8, v1.0.

[21] 55-GA-B0 IR Cameras: Vis/IR TV (Upper) UPP08 PFD, ITER_D_FA247Z, v1.0.

[22] 55-GA-C0 IR Cameras: Vis/IR TV (Upper) UPP11 PFD, ITER_D_FA49ZM, v1.0.

[23] 55-GA-D0 IR Cameras: Vis/IR TV (Upper) UPP14 PFD, ITER_D_FAA8Y4, v1.0.

[24] 55.GA UWAVS-35 Factory Qualification Test Plan, 304243-N00004, Rev A, ITER_D_WL65RC, v1.0.

[25] 55.GA UWAVS-35 Port Integrator Assembly Plan for the FEOMS, 304243-N00006, Rev A, ITER_D_WL6CDG, v1.0.

[26] 55.GA UWAVS-35 Test Plan in Port Plug Test Facility, 304243-N00008, Rev A, ITER_D_WL76ZM , v1.0.

[27] 55.GA UWAVS-35 Onsite Testing and Commissioning Plan, 304243-N00011, Rev A, ITER_D_WL7A5Y, v1.0.

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[28] ITER Remote Handling Code of Practice, ITER_D_2E7BC5, v1.2.

[29] 55.GA UWAVS-35 Remote Handling Compatibility Assessment Report, 304243-R00019, Rev. A, ITER_D_WL6SN7, v1.0.

[30] 55.GA UWAVS-35 RH-PDF for FEOMS Mirror Module Installation/Removal, 304243- S00009, Rev A, ITER_D_AK7F5C, v1.0.

[31] 55.GA UWAVS-35 RH-TDF for Installation of the Bay 2 Mirror Module, 304243-S00013, Rev A, ITER_D_ARTR43, v1.0.

[32] 55.GA UWAVS-35 RH-TDF for Removal of the Bay 2 Mirror Module, 304243-S00014, Rev A, ITER_D_ARTSYG, v1.0.

[33] 55.GA UWAVS-35 RF-TDF for Installation of the Bay 5 Mirror Module, 304243-S00015, Rev A, ITER_D_ATQ8Q2, v1.0.

[34] 55.GA UWAVS-35 RH-TDF for Removal of the Bay 5 Mirror Module, 304243-S00016, Rev A, ITER_D_ATVQ6A, v1.0.

[35] 55.GA UWAVS-35 RH-TDF for Installation of the Bay 4 Mirror Module, 304243-S00017, Rev A, ITER_D_AS4P23, v1.0.

[36] 55.GA UWAVS-35 RH-TDF for Removal of the Bay 4 Mirror Module, 304243-S00018, Rev A, ITER_D_AS4XGY, v1.0.

[37] 55.GA UWAVS-35 RH-TDF for Installation of the Bay 7 Mirror Module, 304243-S00019, Rev A, ITER_D_ATXDWX, v1.0.

[38] 55.GA UWAVS-35 RH-TDF for Removal of the Bay 7 Mirror Module, 304243-S00020, Rev A, ITER_D_ATXF5V, v1.0.

[39] 55.GA UWAVS-35 RH-TDF for Installation of the Bay 6 Mirror Module, 304243-S00021, Rev A, ITER_D_ATWLMC, v1.0.

[40] 55.GA UWAVS-35 RH-TDF for Removal of the Bay 6 Mirror Module, 304243-S00022, Rev A, ITER_D_ATX52T, v1.0.

[41] DDD 23-05 APPENDIX H Design of Generic Tools, ITER_D_A2HS4L, v1.0.

[42] IN.55.NE.LEVI - LEVI CAD modeling Guideline for component integration in PP, ITER_D_X7R2HY.

[43] IN-55.NE.LEVI - Manufacturability Assessment, ITER_D_X7R3KT, v4.2.

[44] Technical Description for LEVI RH Connectors, ITER_D_5FKEX9, v2.0.

[45] DN8 Pipe Tool Set, ITER_D_AMLE6B.

[46] PBS 23.06.CM - Tool Specification Sheet for Pipe Maintenance, ITER_D_9PQ86C, v1.4.

[47] IS-55.GA-55.UH-001 Physical and Functional Interfaces between VisIr. And Diagnostics Upper Port UPP#17, ITER_D_UDQG3P, v1.0.

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A-1

APPENDIX A

MATERIAL SPECIFICATION

Table 4. Material Specification Table

Component Material

Fixed block SS316L(N)

Fixed block fasteners Inconel 718

Fixed block to DSM inserts Al-Ni-Br (C63200)

Kinematic mechanism (cone, sphere/cylinder, v-groove) SS316L(N)

Kinematic mechanism (bolt and Nord-lock washer) Inconel 718

Mirrors SS316L(N)

Removable block SS316L(N)

RH fasteners A286 Stainless Steel

RH module inserts Al-Ni-Br (C63200) ea se d

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