W ,7(5 3 E G I GI      préface

Bernard BIGOT Haut-commissaire à l’Energie Atomique, Coordonnateur national du projet ITER Président du Comité Industriel ITER High Commissioner for Atomic Energy France Representant for ITER Chairman of the French ITER Industrial Committee

Le Comité Industriel ITER (C2I)

Le projet de recherche ITER, mené dans le cad- Pôle Nucléaire Bourgogne, Pôle Optique- re d’une coopération internationale exemplaire, Photonique, Route des Lasers, MIPI,

est une étape essentielle sur le chemin d’une TRIMATEC, S2E2, ViaMeca... ; énergie abondante, durable et respectueuse de • Des acteurs institutionnels nationaux, l’environnement à long terme, l’énergie de fu- Ministère de l’Economie, des Finances et de sion. l’Emploi, Ministère de l’Enseignement Ce partenariat mondial tente de relever un en- Supérieur et de la Recherche, OSEO semble de défis scientifiques et technologiques Innovation, Réseau UBIFRANCE / Missions majeurs. Il s’inscrit dans une dynamique Economiques… et de la Région Provence- d’investissements qui vise la mise en œuvre de Alpes-Côte d’Azur capacités industrielles de production élec- Des groupes de travail se sont constitués autour trogène de grande dimension à l’horizon de la des principaux défis technologiques d’ITER : seconde moitié du XXIe siècle. ce rapport est le fruit de leurs travaux. Il vise à La construction de l’installation qui est au cœur apporter sa contribution à la réflexion de du projet ITER nécessitera, pendant les dix l’ensemble des futurs partenaires d’ITER, et à prochaines années, un engagement fort et un permettre aux entreprises, particulièrement les partenariat étroit entre la communauté scienti- PME-PMI, d’en appréhender les enjeux clés. Il fique de la fusion et les entreprises industrielles. est donc destiné à être largement diffusé, tant Afin de répondre à ces enjeux, l’Etat français a aux industriels qu’aux acteurs de la gouvern- décidé en juillet 2006 de mettre en place le ance du projet. “Comité Industriel ITER” que j’ai actuellement Nous avons souhaité réunir, à l’occasion de l’honneur de présider, après mon prédécesseur, l’ITER Business Forum 2007, IBF/07, toutes les Mr François d’Aubert, ministre et ambassadeur, entreprises et tous les partenaires potentiels du en tant que Haut représentant français pour projet ITER. Ce Forum industriel international, ITER. organisé conjointement par le Comité industri- Sa mission est de mobiliser l’industrie et les so- el ITER et le CEA, se veut un lieu de rencontre ciétés de service et d’ingénierie françaises, et entre les futurs acteurs du projet : industriels, au-delà les entreprises européennes, et de leur sous traitants, laboratoires de recherche, asso- offrir la capacité de mieux appréhender, en ciations Euratom et structures de gouvernance. amont des appels d’offres, les exigences Ce projet scientifique unique au monde, estimé d’ingénierie et le potentiel d’apport des entre- à 10 milliards d’euros, et regroupant actuelle- prises à ce projet. ment 34 pays, devrait engendrer d’importantes Le comité réunit 3 types d‘acteurs : retombées économiques. Quelle que soit la • Des industriels : Air Liquide, Areva, Alstom, taille de votre entreprise, je vous invite à saisir Astrium Space Transportation, Sagem Défense cette formidable opportunité de développe- Sécurité, Schneider Electric, Siemens, Suez, ment et de croissance que représente ITER pour Thalès, Technip... et associations ou syndicats les entreprises françaises et européennes, pour professionnels : AFOP, FIM, FIIE, GIIN, l’économie nationale et régionale, pour la cr- GIMELEC, SERCE… ; oissance et pour l’emploi. • Des organismes de recherche scientifique et des Pôles de Compétitivité : CEA, Capenergies, Bernard BIGOT

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W ,7(5 3 E G I GI      The French ITER Industrial Committee

The ITER research project, led within the frame- Agency), Capenergies, Nuclear Pole Bourgogne, work of an exemplary international coopera- Pole Optique-Photonique, Road of Lasers, MIPI,

tion, is an essential stage on the road of an en- TRIMATEC, S2E2, ViaMeca... ; ergy source which can be used to produce . National institutional actors, Ministry of electricity in a safe, sustainable and environ- Economics, Finances and Labour, Ministry of mentally benign way, with abundant fuel re- the Higher Education and the Research, OSEO sources, the so-called fusion power. innovation, Network UBIFRANCE / Economic This world partnership tries to meet a set of ma- Missions and for the Region Provence-Alpes- jor scientific and technological challenges. It Côte d'Azur. joins in a dynamics of investments which aims Working groups have been established about to provide the know-how to build subsequently the main technological challenges of ITER: this the first electricity-generating power station on report is the fruit of their works. It aims at mak- the horizon of the second half of the XXIth cen- ing its contribution on second thought of all the tury. future partners of ITER, and at allowing compa- The construction of the installation which is in nies, particularly small and medium businesses, the heart of the project ITER will require, during to arrest the key stakes. It is thus intended to be the next ten years, a strong commitment and a widely spread, both to the manufacturers and narrow partnership between the scientific com- to the actors of the governance of the project munity of the fusion and the industrial con- ITER. cerns. We wished to gather during the ITER business To answer these stakes, the French Government forum 2007, IBF/2007, all the companies and decided in July, 2006 to set up the “Industrial all the potential partners of the project ITER. ITER committee” that I have at present the hon- This international industrial Forum, organized or to chair, after it was it by my predecessor, Mr collectively by the industrial Committee for François d'Aubert, Minister and ambassador, as ITER and the CEA, wants a meeting place be- High French representative for ITER. tween the future actors of the project: manufac- Its mission is to mobilize the French industries turers, subcontractors, research laboratories, and the engineering and services companies, Euratom associations and structures of and beyond the European companies, and to governance of the project. offer them the capability to address better, up- This unique scientific project to the world, es- stream to invitations to tender, the engineering timated at 10 billion euros, and currently group- requirements and the companies potential con- ing 34 countries, should engender important tribution to the ITER project. economic fallouts. The committee gathers 3 kinds of actors: Whatever is the size of your company, I invite · Manufacturers: Air Liquide, Areva, Alstom, you to seize this tremendous opportunity of de- Astrium Space Transportation, Sagem Défense velopment and growth which represents ITER Sécurité, Schneider Electric, Siemens, Suez, for the French and European companies, for the Thalès, Technip etc and trade associations, national and regional economy, for the growth AFOP, FIM, FIIE, GIIN, GIMELEC, SERCE; and for the employment. · Scientific research agencies and Competitiveness clusters, CEA (Atomic energy Bernard BIGOT

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W ,7(5 3 E G I GI      W ,7(5 3 E G I GI      sommaire

ITER Assembly 1 Codac 9 Cryogenics 27 Diagnostics and Optics 39 Engineering and Services 45 In Vessel Components 51 Magnets System 65 Vacuum Vessel 79 Robotics and Remote handling 95 Power Supply 115

Annex: members of C2I 119

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W ,7(5 3 E G I GI      ITER ASSEMBLY

An Overview of the ITER Machine Assembly Plan

Major Assembly Tools

Upending and Sub-Assembly Tools

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W ,7(5 3 E G I GI      Sector Lifting Tools

In-Pit Support and Alignment Tools

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W ,7(5 3 E G I GI      ITER ASSEMBLY

have to deal with technical aspects, complex logistics, Conclusion nuclear safety and international contracts issues. of the group work Even if ITER is not the first tokamak to be assembled, the size and weight of the elements is makes it The analysis done by the working group through 7 exceptional. meetings shows that the French Industry has full know how for the assembly of the Tokamak. The The whole assembly process has a planned duration techniques to be used are mastered by several highly of 5 years on site, and several components will be skilled companies on which the main contactor can manufactured and pre-assembled in different rely on. The group identified the main contract risk countries all around the world in the same time. The and proposed areas where it can be reduced. The assembly process will need use of Remote Handling ITER assembly is an engineering challenge that will tools, that have to be developed in the same time.

ITER components

Cryostat Central Solenoid 24m high, 28 m dia 6 modules

Vacuum Vessel 18 Torroidal Fields 9 sectors coils

6 Poloidal Field coils

18 Upper ports

15 Equatorial ports Up. & Eq. Port Plugs + 3 neutral Beam heating/current Injector Ports drive, test blankets limiters/RH diagnostics 18 Divertor ports 440 Blanket Modules

50 Divertor Casettes

8 Cryopumps

Machine mass: 23350t (cryostat + VV + magnets) • shielding, divertor and manifolds: 7945 t + 1060 port plugs • magnet systems: 10150 t, cryostat: 820 t

Cegelec, CETIM, COFATHEC, COMEX List of participants NUCLEAIRE, CYBERNETIX, DCNS, AIR LIQUIDE Gaz industriels Services Institut de Soudure, Competitiveness Cluster APAVE, AREVA NP, AREVA TA, MIPI, Competitiveness Cluster VIAMECA, AREVA TN International, ASTRIANE, SODITECH, SPIE NUCLEAIRE, TRACETBEL ASTRIUM Space Transportation, ENGINEERING, TECHNIP

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W ,7(5 3 E G I GI      The Assembly work group has been involved this year in the first steps of understanding what assembling the ITER machine means. During the different meetings that occur during the year, the assembly of the Tokamak Tore Supra was presented by Jean-Jacques Cordier (IO-Project Office Senior Engineer) in order to give an experience feedback on the challenges that have to be faced. An overview of the ITER machine was given through the CEA expert to the group and this lead to some questions, coming from the different industry representatives, concerning technical aspects, complex logistics, nuclear safety and international contracts issues. As a consequence, a meeting was organized to ask these questions to ITER representated by Robert Shaw (IO-Assembly Section Leader) and Jean-Jacques Cordier. This was the opportunity for IO and for the French industrials to have a common discussion and sharing on the different aspects of ITER assembly.

50 % budget (FDR 2001), standard tools and Questions to Mr Robert conrol and support facilities, to FUND. SHAW (ITER Organization) 7th meeting of C2I group Assembly Methodology, organization 7th of November, 2007 - Cadarache It's written in the PDD chapter 2.10: "components will be cleaned prior to entry, personnel will be Technical Aspects of the Assembly appropriately dressed, and dirty processes and tooling specifically excluded from the area." Have the constraints of global assembly Which methodology and process are planned in available means throughout the world for order to (it's a logistic question): handling, positioning and assembling) been taken • Save time during cleaning operation (Several into account for global design of ITER machine components should be introduce each day in the or is assembly concept a pure consequence working area) of ITER design ? • Save time during Admittance and exit of workers in the working area. • Clarify the different responsibilities between numerous constaints influence the ITER design Purchasers, Consignors, Consignees, for assembly; assembling - contractors, local transport to the site is a major consideration; In order to give more flexibility during final maintenance of clean conditions shapes philosopy assembling, is it planned to perform Pre- and permissible operations; assembling of components in the near area of lift capacity, building size and height are major cost Cadarache? drivers; assembly concept is consequence of these requirements vary acc. to delivery status; constraints, and the basic tokamak design. for deliveries, incoming inspection may also be included; few major components cf. facility footprint Who will build the jibs, rollers, positioning systems (~ 40 x 45 m); for the assembly of the different sectors pre-assy / preparation of some components on the of the tokamak to Cadarache? What are site (cryostat, BM, divertor cassettes) - off-site the possible nuances of steels for these prefabrication desirable subject to transportation equipments - carbon steels with buttering with stainless steel, or only stainless steel ? constraints. What will be the applicable codes and standards for these heavy equipments? How the TK assembly supply of purpose-built tools for sub-assembling, is interfaced with the rest of the TK? and assembling the sectors is scope of PP 2.2-2A, by KO DA; matrixing with main WBS groups (liaison selection of materials is driven by considerations engineer); of functionality and cost: TKM Department level; • ex-vessel tools; structure in carbon steels, effectiveness is variable (personality dependent); non-powdering, epoxy paint. Contact surfaces in more needs to be done to formalize this stainless steel, alu alloy for vacuum compatibility arrangement; • in-vessel tools; in alu alloy (light duty), or stainless matrix needs to be extended to include other steel; Departments.

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During the detailed erection engineering phase More generally, what should be the regulations of first of a kind complex installation, component for Health & Safety on the yard ? design modification can show-up as an evidence to ease erection work. According to the overall occupational safety (Be, radiation, ...) to be schedule, will it be possible to influence components design for erection purposes ? addressed.

ongoing process started during EDA; limited to TKM components; internal / project level design reviews, DWO; Contractual aspects, including procurement arrangements. towards Domestic Agencies

Technical Aspect : at this stage of the ITER Project, What about on-site temporary storage is it possible to define what should include and materials flow management? the "Main Assembly Contract" ? If yes, can you tell us more on what covers the MAC ? site layout under discussion, and study will be launched early 2008 to be addressed; scope is in-cryostat assembly, including preparation and sub-assembly; Do you intend to use workforce sent in-vessel assembly will require separate workers, by other parties, like Russia, Pakistan and may be separate contract; and other do for CERN ? possibility to include plant installation. Absolutely on-site engineering support during assembly for Could you precise the limits and interface between most PPs; the VV procurement which intend to involve on-site assembly / installation for specific PPs (eg. a single Korean-European consortium with VV); responsibility on VV assembly, and the assembly performance of specialized procedures (eg. magnet contract ? feeds); no safety related work; • the following sharing of activities is under Main Assembly Contract ? discussion: ITER Organization a) Positioning of the VV Sectors and Ports Rules, codes, standards b) Position control & measurements of inner splice plate dims and regulations, safety h) Control of the in-wall shielding after assembly i) Measurements of the inner splice plate dimensions What will be the applicable codes and standards for the assembly: ASME, CODAP, n) Final dimension survey RCC-MR, RCC-MX... others ? Following the location of the elements in the tokamak VV Fabricator building, will it be necessary to use different codes c) Machining of the outer splice plate pieces & standards for the assembly ? d) Welding of the outer splice plates e) Grinding of the welding zone system related; f) Inspection of the outer welded joints multi-code approach (operating conditions g) Assembly of the in-wall shield blocks and loads, unique features, cost); j) Machining of the inner splice plate pieces one code per component; k) Welding of the inner splice plates ASME, EN, RCC-MR + ITER addendum, l) Grinding of welding zone SDC-MC, SDC-IC..... m) Inspection of the inner welded joints

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W ,7(5 3 E G I GI      Does the assembly contract include Does the current technical review on ITER project the management of the RH tools which should have an impact on the Main assembly contract be used and tested for the assembly ? philosophy? Could you clarify how the ITER IO How should the interfaces and the responsibilities sees this point ? be managed ? currently, no impact on the MAC philosophy has two types of RH tool: RH (w adaptation for assy), been identified assy variant RH tools; generally in-vessel tools; (IVT, divertor handling, transfer casks,…); The equipments to be installed are coming from RH section: various advanced technologies. Will the designers • technological development of all tools; or manufacturers provide a kind of technical • procurement of RH and adapted tools; assistance to assembly organization to achieve components connections ? In any case, how • on-site, in-situ commissioning, operation, responsibilities will be managed between evaluation of RH and adapted tools; Designers, Manufacturers, Assemblers ? Assembly section: • procurement of variant tools - (split responsibility engineering support (DA / supplier) is expected and cost); for most systems; • mechanical installation of RH and adapted tools split of responsibilities on a case by case basis, (with RH support); defined in PA. • operation of variant tools

Who is responsible of the conformity of About the VV assembly, what is the current components and of the assembly on-site: situation with the procurement arrangement the Domestic Agency or the supplier? scheme ? (evolution from the 11th of May meeting held in Cadarache) IO has no direct contractual relationship with the supplier for in-kind contribution; no direct involvement at this stage; generally, incoming inspection will be carried out opinions in IO / EFDA are variable; on the ITER site; next meeting November 2007. components will be formally accepted / rejected by IO; specific procedure (case by case) where DA is responsible for installation.

Thematic Working Groups Report 2007 08

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W ,7(5 3 E G I GI      CODAC

sub-contractors, hardware manufacturers, software Executive summary editors and system integrators. Their experience in operating large projects with international distribu- ITER Control, Data Access and Communication ted activities and industrial cooperation processes (CODAC) will be a key component in the success of would fit perfectly to the multicultural environment this challenging international project. ITER facility of ITER. will rely greatly on information technology to ensure the safety of this nuclear installation, to monitor and Ultimately, the local presence will be an advantage supervise the installation on a day to day basis and whenever applying the enhancements inherent both to control the pulses. Acquiring, processing and ma- to an ever moving IT industry and to a research faci- king available to scientists throughout the world a lity. Proximity will allow for processing the long term huge amount of experimental data will allow to foster maintenance of ITER for two decades either on the the development of fusion and will be a key perfor- centrally delivered Systems or the remotely provided mance indicator of the success of this ITER program- Plant Systems. ITER is operating on the French ter- me. ritory and will be compliant to the French regula- tions. Understanding the international safety rules French Information Technology industry as a whole and the National Safety Authorities culture, its rules has the capability to deliver CODAC Systems and and practices will be key in the licensing process. presents an amazing number of companies able to This paper presents a summary of the real time infor- deal with ITER at every level: Consultancy services mation technology required for ITER and a panora- companies, Engineering companies, Systems integra- ma of the French nuclear industry and its informa- tors companies able to deal as prime contractors or tion technology suppliers.

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W ,7(5 3 E G I GI      Summary Real time information technology for ITER P13 Information technology systems missions P13 Problem definition P13 Presentation of the specificities of a Tokamak Command Control p13 Specific constraints for ITER CODAC p13 The french information technology industry experience P14 General introduction P14 Nuclear industry P14 Clusters (”pôles de compétitivité”) dynamics P17 System@tic p17 Minalogic p18 Secured Communicating Solutions p18 Aeronautics, Space & Embedded Systems p18

The complexity management p19 Main references p19 Technical capability for ITER p20 Avallable experiences & references p21 • Tore Supra p21 • EDF N4 p21 • Embedded command control p22 • Tore Supra containment p22 • Plasma turbulence p22 • Large integration Projects p22 • MOX - a benchmark project in industrial computing p23

Added value of the french IT industry p24

Thematic Working Groups Report 2007 12

W ,7(5 3 E G I GI      CODAC

amplitude dynamics), measurements acquisition, Real time information monitoring and recording multiple data (diagnos- technology for ITER tic), and controlling multiple actuators. The plasma control carried out in a Tokamak like Tore Supra requires the inter-reaction of many sub- Information technology systems of the machine. These controls use complex systems missions calculus algorithms which have to be set and dia- gnosed by the team in charge of the experiments. A precise synchronization between the different Information Technology is at the heart of ITER. The subsystems and Plant Systems, a precise time stam- missions dedicated to IT will be to enable to inte- ping of the data throughout the machine are requi- grate all the components of this large and complex red for the experiments management and for the facility, to operate it safely, to make it available to data analysis. the scientific community and to feed research with The command control of a Tokamak is part of the high quality data. plant, experiments and people safety. The automa- Information Technology will be deployed in the Sa- tion systems used on the running Tokamaks are fety Systems, in the Interlocks systems, in the Plant standard products available on the industrial mar- Systems and in the central Control and Data Acqui- ket. The Tokamak command supervision is also ma- sition and Communication System (CODAC). de with industrial products, but interfaced with to- ols developed specifically, such as experiments settings. Problem definition Due to high-level automated systems, a small num- ber of operators is required for the technical com- ITER CODAC defines the Information Technology mand of the experiments on a Tokamak. Neverthe- part of ITER in charge of the supervision of the Plant less, this command requires a work planning and Systems of ITER, of the command of the experimen- responsibilities, adapted to an high end research tal machine, and of the computer communication equipment. The efficiency of this organization is an infrastructure. important parameter for the success of the experi- Actually, CODAC supervises the different machine ments, the command and diagnostic tools of CO- Plant Systems, it is a command station and the hu- DAC will have to be adapted to these requirements. man machine interface of ITER. Specific constraints for ITER CODAC Presentation of the specificities of a Tokamak ITER is a worldwide project involving 7 Domestic Command Control Agencies around the world. We have chosen to list hereunder the specificities Due to this constraint, its scientific driving and the of a controlled fusion experimental plant informa- experiments analysis will have to be remotely pos- tion technology means, and we have used the Tore sible, using a gateway. Supra project from CEA as a reference. The environmental constraints close to the machi- A Tokamak is dedicated to carry out physical phe- ne, associated with radiations and neutrons produ- nomena and very complex processes, with time ced during the experiments, but also with the tri- constants over 9 decades (1µs to 1000s). The tech- tium used, are ranking ITER as INB (Basic Nuclear nical or scientific Plant Systems of the machine can Installation), CODAC will take into account these have, for some of them, a very significant industrial Nuclear Safety requirements, such as security access aspect; for others, a very experimental aspect; and and hardware immunity. One of the current difficul- for most of them, they will be defined by the assem- ties to apply the Nuclear Safety requirements on the bly of industrial technologies and prototypical ones. ITER Tokamak, is that there is not enough knowled- CODAC will supervise all the control functions of ge feedback on the existing machines usable for the these systems, apart from safety systems and invest- definition of the interfaces close to the machine. ment protection managed by the Interlocks Sys- In the CODAC ITER work breakdown, sensors and tems. CODAC will carry out, in particular, the real diagnostics are out of the project scope. time control loops functions required for plasma A Tokamak such as ITER project has a very long control, with highly dynamical sensors (time and development and operation timescale (around

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W ,7(5 3 E G I GI      30 years). This duration constraint requires to take Nuclear industry into account the technological obsolescence and changes which will obviously occur. This obsoles- Activities in the nuclear industry cence management (some of them are already fore- The nuclear industry constitutes today an industrial casted) requires some particular CODAC architec- advanced sector in the economy and one of the ture choices (modular architecture, technological pillars of the French energy policy. This sector gathe- choice for hardware and software, documents, Inte- red a continuous improvement since the creation of grated Logistic Support, Product Lifecycle Manage- the French nuclear agency so called “Commissariat ment). à l’Énergie Atomique” (CEA) in the year 1945. The For the preliminary architecture of ITER CODAC major programs in the nuclear sector, been directed project, the exchange between the different com- by the CEA, AREVA and Electricité De France mand control levels have to use a Master / Slave re- (EDF), have made it possible to structure an indus- lation, therefore the synchronization is a complex trial field of activity, for the implementations of the task to be managed. nuclear applications, in medicine, in energy and in During the project, the ITER command control de- the deterrent weapon systems. velopment teams have to use standards in order to carry out what will be the ITER CODAC. However, works is in progress on standards evolution regar- Nuclear energy ding hardware and software interfaces in automa- tion, supervision and industrial computing, ITER From 1978 to 1999, 58 electro-nuclear power project could take place into the development and plants with three levels of power (900, 1.300 and the trending of some standards (supervision, 1.450 MWe), built on 20 sites for an investment networks, communication interfaces, and so on...). of 65 billion euros (value 2003), were coupled CODAC is a transverse ITER project. This architec- with the electrical distribution network; ture choice is an advantage for CODAC because it 78% of electric kWh produced in France is co- allows having a global view on ITER project, but it ming from electro-nuclear generators; requires to take into account potential problems of The nuclear overall installed park power interfaces and responsibilities between the sub- amounts to 63 GWe; assemblers. Validation, simulation, integration, ope- France is the 2nd actor in the world on the civil rating support and maintenance means represent a nuclear field, behind the USA; huge part of CODAC tasks. The capital budget of the nuclear overall ins- talled park is about 77 billion Euros (2003); The European Pressurised reactor (EPR): this electro-nuclear generator of the third generation was designed and developed by AREVA NP joint The french information venture of AREVA and Siemens AG during years technology industry 1990 and 2000. In 2005 in Finland the first EPR construction has been started in Finland in 2005 experience and in Flamanville in 2007. The cost of the EPR with Flamanville is announced to 3,3 Billion €. General introduction

In this section, we analyse how the French industry could cope with the ITER IT challenges highlighted in the previous section. In addition to the hardware market estimated at ¤45 billion, the French software and IT services market is estimated at €30 billion and is still a growing market. There are more than 6,000 French compa- nies active in this market sector employing around 300,000 professionals.

EPR electro-nuclear power generator

Thematic Working Groups Report 2007 14

W ,7(5 3 E G I GI      CODAC

For more than 50 years, the CEA and EDF have star- ted and put into service about fifty critical mock- The PWR fuel cycle up or experimental electro-nuclear power reactors or propulsion reactors. The cycle of nuclear fuel indicates the whole ope- The power reactors are fitted with digitalised moni- rations necessary to supply out of fuel the toring and Safety Parameter display systems. The electro-nuclear power generator then to store, 1450 MW N4 nuclear power plants have been reprocess and recycle this fuel. France has on its equipped with the first fully digitalised main control territory all the required facilities for these va- room in the world. rious operations: the control of this cycle is or- ganised in France as from the years 1960, around the CEA then of the COGEMA which become AREVA NC COMURHEX facility located in Pierrelatte for manufacturing of uranium hexafluoride starting from the ore. EURODIF facility located in Marcoule, open in 1979, which allows the enrichment by gas dis- semination. France is the 2nd actor in the world on the capacity of enrichment available on a mar- ket divided between 4 large actors. On going pro- ject, the replacement by the factory George Besse 2, for the enrichment based on the techno- logy of centrifugation. MELOX facility located in Marcoule for manu- This reference is a perfect example of a large and facturing of nuclear fuel components “MOX” complex control system: (mixtures of oxides). incorporating major enhancements in the moni- Reprocessing facility located in LA HAGUE: toring and control functions such as computerised, opened in 1966, following the facility of Marcou- procedures and powerful alarm management, le (1958). Pointed out: the installation of a high providing a high availability (>99,99%), Activity Oxidizes workshop for the reprocessing dealing with different safety classifications, of PWR fuel cells. Capacity of 1700 T per year, integration technologies from different suppliers. with recycling of compounds re-used in the nu- clear fuel “MOX”. Nuclear mastering CEA then ANDRA: storage of the ultimate re- sidues in surface facilities (“Centre de stockage The industrial nuclear complex organisation is de la Manche” then “CSFMA” and “CSTFA”) and mainly based on the requirements of the nuclear project of major underground geological storage. power plants for electricity generation and by the complete control of the various operations necessa- ry to support this process: treatment and enrich- ment of uranium; manufacture of nuclear “fuel components”; electricity generation in the power plants; adjustment/recycling of worn fuels; waste management. This nuclear industry operates with advanced tech- nologies covering many fields of activities. For example: instrumentation, robotics, automated sys- tems, non destructive checks, command-control systems, remote handling, mechanical engineering, welding, filters, seismic equipment, civil works, etc.

PWR fuel cells Cycle (ref.: AREVA)

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W ,7(5 3 E G I GI      This experience gathered on the nuclear fuel cycle An organized industry and waste of the nuclear reactors of fission consti- Large clients tutes a solid basis: mastering of complex physico- In the civil and energy sector, the frame of the French chemical processes with high level of safety, industri- nuclear industry is composed of the following main al approach technologies necessary for the nuclear- companies and organisations: fuel cycle of the future nuclear fusion reactors: main- “Commissariat à l’Énergie Atomique (CEA)”: ly for the deuterium component. Publicly-owned agency acting on scientific, technical and industrial matters, the CEA has the responsibility Nuclear safety to develop the implementations of the nuclear energy in the fields of science, industry and defence. The Nuclear safety organisation in France “Electricité de France (EDF)”: Publicly-owned Company, EDF is acting as project authority, indus- France set up doctrines of nuclear safety which trial architect and operator of the electro-nuclear thanks, to these high level of requirements re- power plants in France. garding to organisation, regulation and checks AREVA: created in September 2001, AREVA ap- has allowed operations on nuclear power since pears at the top level of the worldwide nuclear its creation without major accidents. The respon- groups, proposing a complete offer on the whole of sible authority for nuclear safety is the French: the activities related to this sector. “Autorité de Sûreté Nucléaire (ASN)”, it is an An extended and dynamic industrial base independent authority organisation which en- sures, on behalf of the France, the checks of nu- Beyond these large actors, French nuclear industry clear safety and the people welfare against radi- counts several hundreds of firms, from small compa- ation. A statistical comparison with the other nies with a few employees up to large industrial great sources of production of electricity sets the groups. They intervene in very many spheres of ac- nuclear energy as more safe for the people and tivity and evolve move on diversified markets, such that in which risks are the best mastered. those of the nuclear power plants, reactors of re- search, laboratories, medical equipment, nuclear fuel cycle, management of waste. The whole of these For more than 30 years, French industry has been firms constitutes a solid industrial base which is char- involved in supporting studies, manufacturing and acterised by: operations on nuclear facilities. With for this reason, its completeness which is expressed by its capacity it has an important experience in writing the safety to bring solutions on all the string of value of the files: Safety reports allowing to make the decisions nuclear operations, for building, in service start-up and nuclear opera- its structures and services diversity able to carry tions, for the nuclear facilities, covered by the French out services provider up to prime contractor for a wording of: “INB” or “INBS for defence”, correspond- full operational function, ing to the implementation in the industrial activity its maturity acquired through the mastering of the of the regulations of safety in particular, those being jobs in the nuclear activity and the associated indus- implemented to the safety critical components (so trial tools, called in French “E.I.S.” - quality decree of its dynamism in the search of innovative and oper- August 84, decree “ESPN” of December 2005, ational solutions being supported by research organ- “RCCM” regulation). isations such as the CEA agency. Industrial experts are consulted or involved in the writing of the necessary evolutions in the regulations to adapt them to the upgrade of the sizing, manufac- turing and checks methods.

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We highlight in the following list the clusters related Nuclear French Industry figures: to ITER information technology field: CEA: 16.300 people - Annual budget: 3,9 G€ € System@tic EDF: 116.000 people - Turn-over: 34 G Paris - Ile de France € AREVA: 58.000 people - Turn-over: 10,125 G Engineering and security, free software (2005) 200 companies involved Regarding the production of electricity, the nu- clear field of activity employs overall more than Minalogic 100.000 people in France. Grenoble - South East France For France: the added value created by French Systems on Chip, nano technologies nuclear industry is estimated between 20 and 28 52 companies involved billion euros a year. Secured Communicating Solutions Export activities: Mastering the whole of the South East of France (PACA) nuclear engineering, France has a worldwide Software, Telecommunications, Microelectronics leading position in this field. Its internationally 75 companies involved recognised know-how gives to the French nucle- ar industry, an important volume of export or- Aeronautics, Space & Embedded Systems ders, corresponding on average, to an income of South West of France 3 to 4,5 billion euros each year. The nuclear in- Embedded software, real-time, models, dustry became, over a period of twenty years, Man-Machine interface one of the first budget line of foreign trade of 325 companies involved France. (Données DATAR et Ministère de l’Economie, des Finances et de l’Industrie)

139 companies (cf list in final appendix) take part in the ITER Industrial Committee (C2I). This System@tic means a strong involvement of the French industry At the heart of the digital revolution, the competi- in the preparation of the industrial future in the Nu- tiveness cluster gathers about 200 industrial, aca- clear activity within the fusion scope. demic and institutional members from the Paris- Region who works in partnership on R&D projects related to five target markets: Telecoms, Security & Clusters (“pôles de compétitivité”) Defence, Automotive & Transportation, System De- dynamics sign and Development Tools and free software. System@tic cluster aims at developing the economy, France has launched in 2004 an industrial policy the companies’ competitiveness and the employ- which calls up the key factors of competitiveness, ment thanks to innovation, training and partner- with in first position the capacity of innovation, re- ships. sulting in the building of 66 poles of competitive- ness, firms association, research centres and training The key topics relevant for ITER are: organisations, letting them in a partnership (com- Software engineering: automation of the code fab- mon strategy of development), and focused to re- rication lease synergies around jointly led innovating System engineering: representation of complex projects. systems, simulation and representation of continu- These clusters federated around the markets of In- ous physical phenomena, simulation of discrete formation Technology will support the emergence phenomena, using mathematical modelling of relevant technical solutions for and around CO- Product Line Management: life cycle optimisation DAC for the ITER project. and management tools

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W ,7(5 3 E G I GI      Innovative systems and equipments for opera- France, a city whose internationally-renowned in- tional security (protection of critical infrastructures, novation ecosystem is known for its pioneering ad- etc.) vances in the creation of clusters. Grenoble has a New technologies and methods to secure infor- long tradition of fruitful alliances linking research, mation systems education, and industry. Effective, value-generating Dual use hardware and software security technol- partnerships between public and private organiza- ogies tions have made Grenoble a global hub for innova- Embedded free software such as Linux tion.

Cluster System@tic has three major goals: Focus Areas of the Cluster: To consolidate the leadership of large systems in- EmSoC Cluster: tegrators and operators in order to secure the sus- • Modeling, simulation, and validation tools and tainability of their R&D activities in the Paris- methods, Region • Software implementation tools and methods for To develop economic activity and employment on-chip multiprocessor platforms, in the Paris-Region by encouraging the creation of • Software infrastructure for embedded systems start-ups and by attracting major companies R&D • The technical building blocks for specific embed- departments ded applications, To strengthen the attractiveness of the Paris- • Multiprocessor platforms (MP-SoC). Region by developing its image on an international The Micro- and Nano-technologies Cluster: scale in the fields of designing, building and man- • Micro- and nano-electronic hardware technolo- aging complex systems gies, • Physical design (CAD) tools and libraries, Thanks to Cluster System@tic, France becomes a • Packaging techniques, including “in-package world leader at the heart of the digital revolution. system” and “package-on-package”. Solid-state electronic components. Minalogic Global competitiveness cluster Minalogic fosters Secured Communicating Solutions research-led innovation in intelligent miniaturized Focus Areas of the Cluster regarding ITER informa- products and solutions for industry. Located in Gre- tion technology: noble, France, the cluster channels gather in a single Standards to achieve convergence and interoper- physical location a range of highly-specialized skills ability for radio networks from a networking per- and resources from knowledge creation to the de- spective velopment and production of intelligent miniatur- Convergence to IP-based solutions. IPTV, VOIP ized services for industry. to name a few remarkable examples Minalogic has staked out a position as global leader Routing protocols to talk to each other on an ad in intelligent miniaturized solutions-a unique hy- hoc network, a sensor network, the Internet, private brid of micro- and nano-technologies and embed- networks... ded software-from fundamental research to technol- ogy transfer. The technologies developed at the cluster are appli- Aeronautics, Space & Embedded Systems cable to all business sectors, including more tradi- This cluster operates mainly in the south west of tional industries. The role of Minalogic is to respond France. to the business community’s need to identify new In all, this represents 1,300 establishments and value-added services that can be integrated into ex- 94,000 jobs, including 40,000 jobs with the manu- isting products in fields that include health care, facturers and main equipment suppliers and 50,000 the environment, mobility, the media, and the tex- in the subcontracting network. With these figures, tile industry. Midi-Pyrenees and Aquitaine compare very favour- Minalogic enjoys a strategic location in Grenoble, ably with European Community countries.

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W ,7(5 3 E G I GI      CODAC

Focus Areas of the Cluster regarding ITER informa- data & documentation (CAD, EDMS), tion technology: System Architecture, adapted to the required Embedded systems, function and to the necessary level of reliability and Real-time systems, safety, Models, The diversity of implemented technologies and Man Machine Interface, competences, integrated as of the design phase, Architecture and system integration. based on generic tools ensuring the links between several of these technologies and/or these compe- tences and “many fields” computer modelling in The complexity management the same system, Methods of design adapted to the constraints re- The major programs requiring an international co- lated on the system itself, often many-fields nature operation have as a common denominator to for- and many-companies of the team of design. ward the following concerns: The definition of the system environment as of Managerial context and network working: cultur- the phase of functional specification al differences, linguistic barriers, normative equiv- The taking into account of the multiple risks of alences, documentary interfaces, etc. failure and their recovery on the whole of the sys- Technical context: design of complex systems tem. composed of multiple technological parts and inter- action with “Man in the loop systems”, whose de- Lastly, the major programs on going or in operation sign and operation require different skills. have all required the development of Concept at the technologies limits, in the field of computation and The actors available in France have a long experi- software modelling, or in fast improvement technol- ence of integration for international projects in the ogies (optics, optronic, electronic, data-processing, nuclear industry: etc). Power plants design, construction and operation, Space (ARIANE, ATV) plants for enrichment, recycling and nuclear fuel Aeronautics (Concorde, AIRBUS) fabrication, dismantling, Defence (Nuclear propulsion Submarine fitted Electro-Nuclear energy production (SUPER- with Ballistic missiles systems M51,...) PHENIX), Nuclear (“Laser Megajoule (LMJ)”, experimental Nuclear research (CERN), nuclear propulsion Reactor (RES), electro-nuclear and in other industries requiring a challenging or- European pressurised Reactor -3rd generation ganisation such as: (EPR), experimental nuclear reactor Jules Horowitz Space (ARIANE 5, ATV: Automated Vehicle (RJH), etc) Transfer, Satellites), Aeronautics (AIRBUS). Development of specific components, targeted re- search programs, technological solutions derived One of the main and common points of the systems from fundamental research programs are many ways developed for these various programs remains their implemented before the development and the man- high level of reliability and safety. The French com- ufacturing in order to allow the success of these panies are mastering the design of such complex programs. systems starting from the following points: Organisational competences developed and sup- ported on precise standards (aeronautical standard- Main references s / nuclear standards), Management of project in network, within Euro- Thanks to the dynamics of the electro-nuclear pow- pean agency or holdings, implementing the most er plant programme, to the great scientific pro- powerful exchanges of information techniques for grams, such as the LMJ, and to the software poles

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W ,7(5 3 E G I GI      of excellence, the French industry has the technical The core of this experience relies on the capacity capability and a strong experience to answer the of the team to analyze the specific needs of Tokamak technical challenges of the development of the CO- operation, to study and design the suitable CODAC DAC systems. The nature of these companies, their features in close partnership with physics, to set up, skills, their industrial feedback constitutes an in- commission and operate the whole system as a full dustrial fish pond rich in technical mastering, or- integrated system within Tokamak operation. ganisational capacity, potential of innovation mak- In addition, this experience and expertise covers ing it possible to adapt to the various needs every matter related to integration within a Toka- necessary for the CODAC systems. mak environment including operability and reliabil- ity issues. The references in Information Technology, further More over, CEA participated to the very beginning detailed in the following paragraphs of the docu- to the ITER Project CODAC design (by 1997), and ment, were selected starting from their similarity to the last CODAC conceptual design review (by with the concerns of the CODAC systems: 2006 and 2007). similarity in term of performances (functional Local CEA experts in each main CODAC area are and transverse) and of constraints (environmental available to contribute to CODAC project expertise, and operational), and additional specific experts in the fields of Toka- similarity with the main servicing functions on mak engineering, physics and plasma operation can which the ITER CODAC systems will be build: be solicited if needed. • Real time acquisition and processing Control Systems is one of the skills of French excel- • Storage and processing of a large amount of data lence in the Nuclear field of activity, recognised in • Safety classified systems Europe and around the world. • Human Factor Engineering The French industry is particularly relevant to meet • Up to date control rooms the needs for ITER in IT, which must combine an • Ease of integration up to date technology and the constraints of a nu- clear environment. The design and the manufactur- 14 French companies take part in the group ing of the control systems can be carried out by “CODAC” of the C2I firms which have experience in the management of (list attached in appendix). products and the whole of the industrial tools, as well as very skilled companies in specific fields. Regarding to engineering, companies are specialised Technical capability for ITER in one or more in the following areas: The CEA is the French Atomic Energy Commission. Safety domain knowledge: Corresponding to the It is a public body established in October 1945. As requirements which the companies implement for a leader in research, development and innovation, the nuclear installations, like the hot cells in the the CEA mission statement has two main objectives: research laboratories: to become the leading technological research organ- Full implementation of the French and European ization in Europe and to ensure that the nuclear standards applicable to the nuclear facilities. deterrent remains effective in the future. Development of specialised acquisition means The CEA Information Technology division based able to cope with the environmental conditions in Cadarache has worked for more than 20 years Development of radiation hardened electronics on the Tore Supra Tokamak; hence CEA has devel- allowing to carry out tasks in a nuclear environment oped a comprehensive and deep experience in CO- (1 Mrad). DAC-like design and operation. This expertise cov- ers every main CODAC area as architecture, long pulse data management, data storage, data display, control system, plasma feedback control, timing and machine safety.

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Regarding the manufacturing and the safety quali- Avallable experiences & reference fication of equipment, companies have at their dis- Tore Supra posal powerful industrial tools, adapted to the nu- This facility located in Cadarache has been de- clear implementations. They have a perfect signed, built and is operated by the CEA. knowledge of the nuclear environment, acquired With a major radius of 2.25m (machine centre to for a long period in the French electro-nuclear pow- plasma centre) and a minor radius of 0,70m, Tore er plants and on the research sites, including on Supra is one of the largest tokamak in the world. Cadarache site which accommodates ITER. Its main features are the superconducting toroidal Some manufacturing companies are specialised by magnets which enable generation of a permanent type of knowledge, such as: mechanics, sheet met- toroidal magnetic field and its actively cooled first alwork, electricity and electronics. They offer all the wall. Tore Supra is also the only tokamak with plas- guaranties for standards implementation and work- ma facing components actively cooled. Tore Supra ing in the specific conditions required in the nuclear is specialized to the study of physics and technology environment. Integration skilled company can co- dedicated to long plasma discharge. ordinate their activities and carry out the assembly to obtain a fully operational system.

Several companies are multidisciplinary, and gather in their facilities all the means for engineering, man- ufacturing and tests. The Control systems including CODAC can keep consistency from their design to their final on site qualification. The advantage is to take benefit from the experience in information technology and nuclear environment acquired in all activity areas.

These multidisciplinary companies have in addition a great adjustment’s capacity to new and unforeseen situations. This will probably occur during the EDF N4 course of the project, in particular during the inte- The N4 Instrumentation and Control system gration of ITER on the site of Cadarache, (I&C), designed and developed by Atos Origin for In nuclear environment, measurement, being based EDF, the French electrical utility, is a major techno- on electronic technologies, is faced to the radiation logical breakthrough in the world wide power in- hardening (related to the neutron aggressions and dustry: introduction of fully computer-aided control of the associated ionising radiations, a strong level into 1450 MW nuclear power plants. of strength of the electronic junctions in the circuits ADACS, the heart of the technology, is the best an- are required to avoid the burn-out). This protection swer to such a challenge. is obtained by “shieldings”: and/or of by specific technological choices of electronic components for which the French research centres, in particular CEA (“LETI”) and the industry have developed and operate with specific manufacturing means and qualification processes.

Chooz & Civaux N4 Main Control Room

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W ,7(5 3 E G I GI      Embedded command control Large integration Projects CIO Informatique Industrielle has developed the In other industrial fields, some “CODAC” systems embedded command control on weapon system for have been developed by French industrial teams (or DCNS, a European expert in naval defence company. in European cooperation), with technical and in- The software is embedded on VME boards, in dustrial challenges equivalent to the ITER CODAC, charge of the communications between the central regarding the level of: requirements, functional in- command ship, the weapons and the various com- novation, complexity and safety. puters. Communications are performed on Ethernet or asynchronous serial lines. A few examples are: Some of the computers also use discrete IO that trig- Laser Megajoule CODAC: Nuclear fusion (ines- gers low level functions enabling the weapons. tial confinment) experimental testbed, This embedded software is build over Linux 2.6 for Airbus: Embedded Fly by wire, and flight man- PowerPC. The project is developed according to agement systems, IEEE 12207 and UML methodology ARIANE 5: European heavy launcher, ATV: Automated Transfert Vehicle - New concept Tore Supra containment of Space Transportation Vehicle to support the In- Communication & Systems has processed a study ternational Space Station (reboost, liquid and gas realized for the French Atomic Commission of ther- servicing, etc.) - first flight expected early in 2008. mal and mechanical behaviour of Tore Supra con- tainment under different loads: weight, pressure, flow radiated, Laplace forces due to Eddy currents.

Plasma turbulence Communication & Systems has processed delivered As example on ATV, many challenges have been TORRID (Linear) NOLIS (Non Linear) projects: solved during industrial development of the Development of a software allowing to better under- “CODAC”: Automated Control on board, plus a re- stand the phenomena of turbulence in plasmas, mote control from the ground during all the phases, which generate an abnormal transport of particles demonstrate the safety for flight missions of more and heat at the edge of tokamaks. Solving of a sys- than 6 months, including docking and un-docking tem of unsteady and nonlinear equations governing from ISS and cope with all the requirements mainly turbulence electrostatic discharge (Maxwell’s dis- of: turbed) with finite elements and Fourier discretiza- fully new concept of vehicle so no technical ref- tion and using a modified Adams-Bashforth scheme erences (only digital modelization and ground tests (order 2). with real time simulators),

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high level of functional complexity and safety: fail operative - fail safe control architecture, auto- mated function on board (short time controls) and manual remote control from ground control centers via real satellites, on board hard-rad electronics, se- cured radio-communications, etc.

International industrial and management organisa- tion: ATV Flight segment is an European contribu- tion (CODAC software developed by an European team), ATV is automatically docking on the Russian port of the ISS (complex interface), all flight oper- ations near the ISS checked by: NASA Safety author- ity, etc.

MOX - a benchmark project in industrial computing The MOX project aims to convert in the US surplus strategic military materials into Mixed Oxide (MOX) fuel for civil nuclear reactors. AREVA NC Inc is part of the Shaw / AREVA MOX Services LLC consortium, chosen by the US Department of Ener- gy (DOE) to run this project based on the Savannah River Site in South Carolina.

After having carried a feasibility study, EURIWARE’s role contributes to build the plant control and infor- mation system, based on expertise gain at AREVA’s own plants (MELOX and La Hague in France). The project currently employs fifty EURIWARE US and French staff, and demonstrates the company’s ability to successfully deliver and locally support complex industrial IT projects in an international environment.

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W ,7(5 3 E G I GI      Added value of the french IT industry

Without any doubt, the French Information Tech- nology industry can cope with the stringent requi- rements of ITER and has the capability to deliver. Companies could behave as prime contractors, sub- contractors or partner in consortia. Their intimate knowledge of the French Safety rules is a must for Safety systems and Interlocks.

After factory acceptance tests in Domestic agencies, the Plant Systems will need to be integrated locally in Cadarache with CODAC. This build phase will last several years and will benefit from a strong local basis, relying potentially on system integrators. Knowing that CODAC and other IT systems will be operated for more than 20 years and will require evolutions and long term maintenance nominates French companies as perfect local partners for forei- gn companies.

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Annexe: French Companies acting in the Thema group set: CODAC of the “Comité Industriel ITER” (C2I)

ADDAX ALSTOM POWER SERVICE AMESYS ASTRIUM Space Transportation ATOS ORIGIN CIO Informatique Industrielle CIRA Concept CS - COMMUNICATION & SYSTEMES EURIWARE INTESPACE SCHNEIDER ELECTRIC SIEMENS SNEF YOKOGAWA France S.A.S

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W ,7(5 3 E G I GI      CRYOGENICS

Summary

Executive Summary p30 General p30 Subject p30 Definitions and abreviations p30 Participants p30 PRA methodology description p31 Definition of criticality levels p31

Description of the project p32 Initial phase p32 Summary of the risks p33 Summary of recommendations p34 Summary of actions p34 Conclusion p35 Appendix p36 PRA table p36

Summary of tables and schemes

Table 1: participants p30 Table 2: PRA Table p31 Table 3: PRA Marguerite p32 Table 4: Description of the elements of the project p33 Table 5: Risks p33 Table 6: Recommendations p34 Table 7: summary of actions p34

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W ,7(5 3 E G I GI      Executive summary Participants

This document describes the risk analysis of the cryo- The following persons have contributed the PRA: genics projects of ITER. The study is based upon « preliminary risk analysis » methodology as presen- Sabine PORTIER ted briefly hereafter. Chargée de Mission Economie-Industrie Mission ITER/Préfecture de Région PACA Philippe OLIVIER The detailed analysis reports are attached in appen- Chargé de Mission dix. A summary is given in a synthetic table gathering Mission ITER/Préfecture de Région PACA the recommendations as well as action list resulted from the risk analysis. Isabelle NAUDE Commercial Manager 10 critical risks, including 2 maximal, are identified NORDON Cryogénie and related actions are foreseen in order to minimize the criticality. These actions ought to be followed up Arnaud ALLAIS specially. Product Manager NEXANS Alain GIRARD Head of SBT Dept. General CEA Grenoble Jean-Marie Le PONCIN Subject Commercial Manager AXIMA Réfrigération Suez This document is a preliminary risk analysis of Cryogenics ITER project. The methodology is des- Pascale DAUGUET cribed in the next chapter. Product Manager The study was done on 15/03/2007 at Air Liquide Air Liquide DTA DTA, Sassenage. Hadi MOUSSAVI Head of Cryogenics Dept Air Liquide DTA Definitions and abbreviations Emmanuel LARDEUX Risk Manager (author) PRA: Preliminary Risk Analysis Air Liquide DTA EFDA: European Fusion Development Agreement TABLE 1 EFET: European Fusion Engineering & Technology ELE: European Legal Entity

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PRA methodology description Each column contains the following data:

The PRA methodology is an inductive approach Subject: External constituent of system, identified (from particular to general or from causes to conse- at the initial phase if the « Marguerite » constitu- quences) that comprises the following steps: tion. First collection of all the elements in interaction Constraint: Constraint from the subject to the pro- with the system, represented in the shape of a mar- ject or from the project to the subject. guerite. Event: Event related to the constraint. Identification of all the threats related to each ele- ment. Cause: Possible causes of the event. Identification of the events related to each threat Consequences: Possible consequences of the event as well as the possible causes. (legal, financial, safety, image...). Analysis of the consequences of these events and the associated scenarios (financial impacts, schedule, Risk reduction means: Means available to reduce image...) the potential consequence (risk). Proposal of appropriate measures to reduce the ris- C (Criticality): Level of criticality as a combined va- ks. lue of frequency and severity. (Refer to definition Evaluation of the criticality of the residual risk blow). (taking into account the previous measures) Action: additional means to reduce the residual risk Implementation of additional means to reduce (if very important). the residual risks. Comments: Possible comments. The PRA is reported in a table as follows: Ref: Refers to the row of PRA in other tables. TABLE 2

Subject Constraint Event Causes Consequences Risk reduction means P G C Action Comment Ref

Definition of criticality levels

The level of criticality is a combination of frequency level of the cause and severity level of the consequen- ce.

In this study the criticality level is evaluated directly as per following rules. Criticality I : the residual risk is low and consi- dered « under control ». Additional means to reduce the residual risk are not necessary. Criticality II : the residual risk is not fully accep- table. Additional means to reduce the residual risk are necessary (prevention, detection, protection, etc). Criticality III : the residual risk is not acceptable at all. Additional means to reduce the residual risk are fully mandatory (the risk is endangering the pro- ject). The approach s based on a consensual agreement between the participants.

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W ,7(5 3 E G I GI      Description of the project

The project « Iter Cryo » designates the cryogenic equipment of ITER project. It is comprised of: Cryoplant (ELE contribution) for the production of cryogenic fluids, Cryogenic distribution cold boxes and transfer lines from the cryoplant to the Tokamak (Indian contribution, Current lead cold boxes (Chinese contribution + ITER Org).

The participants form the Cryogenics Thematic Group under Mission ITER control (French ITER Industrial Committee of the Ministry of Industry).

Initial Phase

The « Marguerite » methodology represents all the external elements that can interact with the project. They can be constraints to the project or consequen- ces of the project.

TABLE 3: PRA Marguerite

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The following table shows different subjects evocated in the PRA.

TABLE 4: PRA Description of the elements of the project

Summary of the risks The summary of the risks classified in the critical categories II and III is given in the following table.

33 TABLE 5: Risks

W ,7(5 3 E G I GI      Summary of Recommendations

TABLE 6: Recommandations

Summary of actions

TABLE 7: Actions

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TABLE 7: Actions

Conclusion

The analysis made it possible to identify the risks of the project « Iter Cryo ». A set of recommenda- tions as well as actions are provided to reduce the risks. 17 actions to reduce residual risks must be followed up particularity. The recommendations should be updated taking into account the evolution of the project.

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W ,7(5 3 E G I GI      Appendix: PRA tables

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W ,7(5 3 E G I GI      Annex: French Companies acting in Cryogenics

AIR LIQUIDE AXIMA Refregiration France - Suez NEXANS France NORDON Cryogenie (becomes FIVES CRYOGENIE) SDMS TECHNOR SNRI TSA and many other…

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W ,7(5 3 E G I GI      DIAGNOSTICS & OPTICS

Summary

Diagnostic components in ITER p42

Diagnostic components location p42 Diagnostic instrumentation range of technologies p42 ITER diagnostics environment p42 EU optical diagnostic procurement p42 Generic optical components p42

Skills and techniques of French companies p43

Generic knowledge and tailored services p43 Generic industrial competencies p43 Specific competencies concerning optical diagnostics p43

List of French companies considered as potential partners or competitors for optical diagnostics procurements p44

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W ,7(5 3 E G I GI      Diagnostic ITER diagnostics environment: A very high resistance of the materials components in ITER to the plasma: R&D of the optical components and mirrors, due to neutron fluxes of 14MeV, Diagnostics are the measurement systems which Heavy constraints in terms of maintenance provide information on plasma parameters and on and robustness: imaging diagnostics, processes occurring at plasma-wall interfaces. They treatment-storage and data acquisition, are foreseen for: Integration problems: electrical power supply, machine protection and basic control, distribution within the machine, robustness, advanced control and performance optimization, maintenability. performance evaluation and physics understanding. EU optical diagnostic procurement: Equatorial Visible/IR wide angle viewing system, Diagnostic components location: Thompson scattering LIDAR, inside the vacuum vessel and within the divertor Charge Exchange Resonance Spectroscopy structure, (CXRS). in the torus ports (upper, equatorial, divertor), Plasma position reflectometer, remote from the tokamak. Bolometers. Generic optical components Windows/portholes, Mirrors, Optical fibres.

Diagnostic instrumentation range of technologies: visible and far-infrared lasers, X-ray to visible spectrometers and detection systems, far-infrared, millimetre-wave and microwave sources, transmission and detection systems, mirrors and windows from VUV to microwave region, visible and infrared imaging, total radiation bolometers, optical fibres and opto-electronic technology, sophisticated control, alignment and calibration systems,

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W ,7(5 3 E G I GI      DIAGNOSTICS & OPTICS

Resistive bolometers based upon a resistance Skills and techniques bridge on a mica substrate (absorbing film substrates: of French companies Au, Pt and some variants with Pt/AlN or Pt/Al203). Infrared Imaging Video bolometers (IRVB): a thin The French companies of the Diagnostic & Optics metal foil is heated by plasma and the temperature Group, through their industrial expertise and their rises are measured by a remote infrared camera. knowledge of ITER's French context, will be the ideal Compact and high-performance integrated passive partners for foreign companies wishing to work and device. set up operations at the Cadarache site in France. Diffractive optics technology enables production of DOE (Diffractive Optical Elements). Generic knowledge Components based on Bragg gratings technology and subassemblies modules. and tailored services EUV and X ray reflectometry. Porosimetry: determination of porosity, pore size Supported by French regulations (nuclear safety, distribution, Young Modulus. norms, standards on First Mirrors, Mitigation, In situ real time analysis of coatings and surfaces. Telemanipulation...). High energy laser beam delivery. Close proximity and local support, helping Thomson spectroscopy, laser lidar. networking and advice, provided by the OPTITEC Atomic and plasma emission spectroscopy from cluster and the AFOP association, who have precise XRays to IR. knowledge of industrial competencies in terms of Laser Induced Breakdown Spectroscopy systems. optical diagnostics in France. Spectroscopic Ellipsometry, from Vacuum Ultra An overall vision of the diagnostics and of their Violet (140 nm) to Infra red (up to 30 micronmeter). integration into ITER (interface of the different Port Material evaluation & Fatigue ageing of thermal Plugs). barriers materials. Biological shieldings. Generic industrial competencies And many others... Existence of means of industrialisation. A wide offering of industrial expertise (integrators, components specialists, signal treatment). Availability of means of production and human resources. A unique entry point, with the Diagnostic & Optics Group which brings together all the competencies of French companies in this domain. Specific competencies concerning optical diagnostics

Strong skills in system engineering for complex assembly in harsh environment supported by multidisciplinary project teams. Competency in simulating optical design and phenomena within a CAD environment. Mastership of large optical parts manufacturing and coating within the highest levels of accuracy. Active and passive specialty optical fibers. World class infrared imaging cameras and systems.

43

W ,7(5 3 E G I GI      List of French companies considered as potential partners or competitors for optical diagnostics procurements.

Simulation Others Optical Spectrometry UV/VIS/IR Lasers Interferometry Bolorimetry Data (integration, components systems Processing non optical systeme)

ATIS BERTIN TECHNOLOGIES CEDIP IR SYSTEMS CILAS EGIDE EXAVISION IRELEC IVEA IXFIBER LE VERRE FLUORE LHERITIER LOVALITE MICRO CONTROLE SPECTRA PHYSICS OPA OPTICAD OPTIQUE PETER OPTIS SAGEM REOSC SAGEM DEFENSE SECURITE SDS SEDI FO SEOP SESO SHAKTIWARE SILIOS SIMTRONICS SODERN SOPRA THALES ANGENIEUX THALES LASER WINLIGHT SYSTEM

Research laboratories and other organizations considered as potential partners

AFOP (Association Française de l’Optique et de la Photonique) CEA (Scientific adviser) Cluster “Optics & Photonics” POPSUD (Contact: Guillaume Bonello: [email protected] / Katia Mirochnitchenko: [email protected]) Ecole Centrale Marseille - Institut Fresnel Laboratoire Lasers, Plasmas et Procédés Photoniques - Université de Marseille

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W ,7(5 3 E G I GI      ENGINEERING AND SERVICES

Summary

Engineering and Services for ITER - definitions p48 Where? p48 Some French companies ready to compete for ITER and to team within Europe p48 Some suggestions p49 Main challenges and stakes, as perceived by some industrialists p49 Some achievements, that may bring useful experience p50

47

W ,7(5 3 E G I GI      Engineering and Services Some French companies for ITER - definitions ready to compete for ITER

CAD, controls, costing, detailed design, design to and to team within Europe cost, PMC technical documentation, administrative documentation, expertise, facility management, inspections, ILS, RAMI analyses, PLM, integration, ABMI IT management, licensing, methods, modelisation, AKKA nuclear hardening and EMC, planning, pricing, ALTRAN project management, purchasing, sourcing, quality, APAVE radioprotection, regulatory requirements, safety, AREVA TA permitting, scheduling, simulation, standards, ASSYSTEM supply management, transportations, wages and ASTRIUM ST accounts... AVODA INGENIERIE SERVICES BUREAU VERITAS C-CON Where? COMEX NUCLEAIRE DE VIRIS/PARLYM embedded in almost each work package, EFINOR some packages are splitted in 2 parts: design ERAS and assembly on one hand, fabrication EURODOC on the other hand, IOSIS diagnostics engineering, MPH outside work packages: support to IO, F4E, other NUCLETUDES DA, AIF, prime contractors selected by the DA's, OAKRIDGE EURATOM Associations. PDCA PLANITEC Remark: the know how of tokamak design and SETEC operating is only with the scientific community; the SNSI know how of complex systems engineering and SOGETI nuclear facilities operating is mainly with industrial SUEZ world. TRACTEBEL ENGINEERING ...

...and many other, experimented in complex concur- rent projects, with highly demanding requirements, and having a good knowledge of regulations and standards, with permanent infrastructures usable for ITER and strong reactivity.

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Some suggestions Main challenges

Need of a system engineering overarching the and stakes, as perceived components. by some industrialists Identify and manage cost- and risk-drivers, bott- lenecks and key competences. Functional approach then technical and geogra- Technological, systemic, organisational, cultural phical. complexity and challenges; various practices and ter- Take profit of the strong points of ITER design minologies. and organisation and correct the weak points. Technological readiness level varies depending on Interfaces management. components, but the project is on the trail for reali- Global performances/constrains management; sation. transverse balances management: cleanliness, Necessary shift from R&D organisation to project EMC... oriented organisation, under strong time-tension. Use of integrated PLM, CAD, ILS tools. Huge number of interfaces to manage (technical Surfaces and flow management on the assembly interfaces and artificial interfaces due to the sharing). site. Necessity to use standards and shared tools and Reconciliation of standards. methods (CAD, PLM, ILS...). IT systems enabling all the partners of the project Very high volume of project datas to be managed (IO, DA's, AIF... and suppliers) to practice concurrent following stringent configuration rules. engineering during the whole lifecycle. Very high performances and availability requested Management of the "-ilities": affordability, cons- from in-vesse-remote handling, due to irradiation tructibility, availability, maintainability... levels. Breakdown and streamlining of requirements and Nuclear safety requirements, due to the thermonu- conformity evidences during the production and as- clear characteristics of the machine, induce cons- sembly cycle. traints in the optimisation and in the management; Define a "make or buy" with associations and in- not naturally compatible with the experimental cha- dustry, allowing each to work in its excellence area racter of ITER. and with acceptable risks, with clear responsibility Specific importance of instrumentation: high volu- sharing. me of data, prominent importance for the use of Commitment of industry should be a balance ITER. between attractivity of ITER as an outstanding pro- Remote utilisation and monitoring. ject, and contractual/competitive risks. Need of standardisation of components, for later Check the ABC classification of packages: from maintenance. "build to print" to "functional specification"; perhaps Very stringent time and cost constraints. some discripencies. Very high standards of reliability, safety, etc, if one wants to spare the necessary availability for experi- ments. High level of complexity and integration during the assembly phase; need of pre-assembly and inte- gration, close to the site. High complexity of procurement and strong cons- traints of synchronisation between the partners; im- portance of the quality of the specification and infor- mation gathering process, for the conformity demonstrations.

49

W ,7(5 3 E G I GI      Some achievements, that may bring useful experience

Jules Horowitz Reactor, an outstanding research reactor built under the responsibility of CEA within an international consortium

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W ,7(5 3 E G I GI      IN VESSEL COMPONENTS

Content

Introduction p54 References p54 Blanket parts manufacturing description p55 Manufacturing of a primary first wall panel p55 Manufacturing of a shield p57 IVC participants experience and know how p59 Skill and competences needed for the manufacture of the blanket p60 Machining techniques p60 Joining processes and allied techniques p62 Identification of risks and main stakes on iter IVC p63 Definition drawings p63 Industrial setup p63 Schedule p63 Specific constraints p63 Industry identified topics able to reduce the risk p64 Conclusion p64 Industries participating p64

PRIMARY FIRST WALL PANELS

53

W ,7(5 3 E G I GI      Introduction References

Manufacture of a shield prototype Among all the components to be manufactured in for primary wall Modules the ITER reactor, those located inside the vacuum Cécile Boudot (a), B. Boireau (a), A. Cottin (a), vessel are called In Vessel Components (IVC): diver- P. Lorenzetto (b), P. Bucci (c), O. Gillia (c) tor and blanket are their main parts. The technologies ISFNT 8 Heidelberg 2007 and materials involved in their fabrication are partic- ular therefore, IVC and more precisely blanket have Status of the EU R&D programme been identified as a whole topic in the frame of the on the blanket-shield modules for ITER Mission ITER France working group. This report P. Lorenzetto1, B. Boireau2, C. Boudot2, Ph. Bucci3, describes the analysis of the EU procurement in term P .E. Frayssines3, A. Furmanek4, P. Hajek5, O. Gillia5, of content, technologies, competences, risk regarding A. Peacock6, I. Ricapito7, M. Roedig8, P. Sherlock9, the blanket system mainly the Primary First Wall F. Schmalz10, S. Tähtinen11 panels and the shield block. ISFNT 8 Heidelberg 2007

Manufacture of Shield Blanket Modules for ITER P. Lorenzetto 23rd Symposium on Fusion Technology Venice, 23rd September 2004

Manufacture of two Primary First Wall Panel Prototypes with Beryllium Armor for ITER C. Boudot1, I. Bobin-Vastra1, P. Lorenzetto2, D. Conchon3, A. Cottin4, J . Jacquinot4, D. Cauvin5, M. Febvre6 22rd Symposium on Fusion Technology Helsinki, September 2002

SCHIELD BLOCK

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W ,7(5 3 E G I GI      IN VESSEL COMPONENTS

Blanket parts Manufacturing manufacturing description of a primary first wall panel The manufacture is done in 2 steps; first the heat The ITER Blanket is segmented into 440 Blanket- sink that is a Copper alloy stainless steel structure shield modules, mechanically attached to the vacu- cooled by embedded stainless steel tubes second the um vessel by four flexible radial supports. Typical beryllium cover. All the constituting parts of the dimensions of these modules are 1.5 m x 1 m x 0.5 m heat sink: SS sheets, SS tubes Copper alloy sheets and their weight does not exceed 4.5 tons. Depend- and container sheets are machined and then prop- ing upon the poloidal location, the modules have erly cleaned, etched before mounting. The parts are either 4 or 6 FW panels, with typical dimensions of placed inside a container and if the dimensional 1 m x 0.25 m x 0.07 m. They consist of a bi-metallic measurement of the assembly is conform, the con- structure made from a 20-mm thick precipitation tainer is welded. All the welds are Helium leak test- hardened Copper Chromium Zirconium (CuCrZr) ed to ensure that no leak will occur during the HIP alloy heat sink material imbedded with 10/12-mm cycle. The part is next evacuated and the evacuation diameter 316L(N)-IG SS tubes. The Cu alloy layer tubes are sealed once the required vacuum is is bonded to a 40-mm thick 316L(N)-IG SS backing achieved inside the container. plate having 12-mm diameter cooling channels. A The parts are then sent for a HIP cycle. To check 10-mm thick Beryllium (Be) layer is used as the plas- the success of the HIP, a first manual ultrasonic test ma facing material and is bonded to the Cu alloy layer is performed and when no defects are seen, the parts in the form of tiles. The FW panels are mechanically are sent for heat treatment. attached to the front surface of the Shield block using Only after the heat treatment there is the second a central key inserted in the corresponding key way machining that lead to an entire ultrasonic exami- of the Shield block and a poloidal row of studs made nation of the joints and to a machining to prepare from high strength PH13-8Mo martensitic steel. The the second HIP for joining the Beryllium tiles on FW panels are designed to sustain a peak surface heat the copper surface. flux of 0.5 MW/m2, a maximum neutron wall load of 0.8 MW/m2 and an average neutron fluence of at least 0.3 MWa/m2 (about 3 dpa in steel) for a nominal First machining before HIP number of 30,000 cycles. According to the present ITER Design Requirements, they shall also sustain a The first task is to bend the tubes, 10 tubes are limited number of 10 second transient events of up placed between the copper alloy plates and connect- to 1.4 MW/m2. ed to the stainless steel base. The acceptable toler- ances for a successful HIP are very tight. A tentative procurement sharing allocated the follow- To ensure that all the dimensional criteria are ful- ing modules to the EU: filled, a mounting test is performed and measure- FW panels: Modules BM09, BM10, BM11, BM14 ment of all the gaps is done. and BM 15. Once this step is completed, the etching and clean- According to the IT, this share corresponds to about ing of the part can be done. 30% of the total FW panels cost. Once the parts are ready for mounting, they are Shield: Modules BM14 and BM15. stored in a vinyl bag filled with inert gas. According to the IT, this share corresponds to about 10% of the total Shield cost. Assembly of the FW panels to the Shield might be under full IO responsibility.

BM 14 AND 15

55 BM 09, 10, 11

W ,7(5 3 E G I GI      Mounting of container

The manufacturing route of the container mounting is illustrated hereunder by pictures

PARTS MOUNTING FINAL MOUNTING

ALL PARTS INSIDE THE CONTAINER FINAL HE LEAK TESTS

PANEL READY FOR HIP CYCLE

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W ,7(5 3 E G I GI      IN VESSEL COMPONENTS

HIP cycle Manufacturing of a shield 1040 °C and 140 MPa for 2 hours The nomenclature used in this report is based on the location of the Shield module in the blanket and is as shown in the picture below: Heat treatment Solution annealing : 980 °C 60 Min followed by a Bottom / Top side quench Ageing 480 °C 2 h Front / Back side Lateral left / right side

Ultrasonic examination BOTTOM SIDE All joints are checked : TOP SIDE BACK SIDE Stainless Steel / Stainless Steel Copper alloy / Copper alloy Copper alloy / Stainless Steel

SS / CUCRZR AND CUCRZR / CUCRZR JOINTS LATERAL SIDE FRONT SIDE

EXAMPLE OF A UT The shield is made from a big forged stainless steel RESULTS OF CUCRZR / SS JOINT. block, that is called front part on which, a so called TUBES CAN BE rear face is hipped on the back side. The rear face DETECTED BUT NO DEFECTS ARE SEEN content a set of bended tubes inserted in powder BETWEEN THE and HIPped on the SS block. TUBES The top side and the bottom side are facetted (4), and they have an angle of respectively 52.13° and Be HIP 108.67 °. Mounting of container after cleaning and etching Be A series of holes are located between the top side tiles. He leak test, evacuation and sealing. ° and the bottom side, for the cooling water slots are HIP cycle at 580 C 120 MPa for 2 hours. machined from the front side between the holes.

Final machining and test Machining from the forged block Removing of the container by appropriate machin- Before any machining operation, the forged block ing, machining of the attachment key on the rear side needs to be roughly machined to a near final shape. of the panel and of castellation between Be tiles on To define this shape, we need to know what will be the front side the rear face design. Hydraulic tests and He leak test conclude the manu- facturing of a Primary First Wall panel. Deep drilling 283 holes are drilled between the top side and the bottom side. They are distributed as followed: 11 holes diameter 10 mm witch correspond to the end of future machined slots. 8 holes diameter 16 mm and 6 holes diameter 30 mm corresponding of the two aisles of the shield: the right and left lateral side.

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W ,7(5 3 E G I GI      6 holes diameter 22 mm are located just under Rear face design the rear face and then 9 row of 28 holes diameter The rear face design consists in the shape we will 22 mm complete the set of the top/bottom side give to the back side of the shield before the HIP. holes. The tubes will be placed into the powder and These holes are made to form a water circuit. To HIPped together to have a compact back side in complete the water circuit, water collectors are ma- witch a set of 8 tubes will be inserted. chined on the top and bottom faces and are closed with welded cover sheets. HIP There are several pieces to be HIPped: the tubes in the back side, the 2 thick plates covering the top and bottom faces. HIPping of the top and bottom faces is needed to offer the required double confine- ment of the water coolant preventing any seal weld in contact with the plasma.

Front face slots machining 11 slots will be machined from the front side, their depth vary from 100mm to 170 mm.

Water collector welding To complete the water circuit, the water collectors are machined. A thin plate of 2mm thick will be welded manually by TIG.

Tubes bending 3D bending of a set of 8 tubes (4 tubes and their symmetric)

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W ,7(5 3 E G I GI      IN VESSEL COMPONENTS

Final machining Final equipment The key corresponding to the panel location are ma- After this final machining, the connections between chined and the holes for the studs and nuts of the the inlet and outlet of the rear face cooling tubes panel attachment are drilled are done by external pipes welding. This operation The next machining stage is the machining of the completes the water circuit erection and finalise the rear keys for the shield attachment on the vacuum manufacturing of the shield. To validate the shield vessel and the machining of the hydraulic connector fabrication, reception tests as hydraulic flow and that ensure the water inlet and outlet connection pressure test are performed.

IVC participants experience and know how

Among all the industries, technical centre and re- search associations participating in the working group, a list of the skills already available for the industrialisation and manufacturing of the IVC is set up. The first objective was to dress a list of the main field needed and then do the relation between the need and the resources. Skills Design optimization and re-design the functional ITER / F4E model. industrialization of the ITER / F4E functional technical requirements which will have to take into account the technological state of the art and indus- trial abilities. Technological developments : industrialization. qualification of the HIP processes. 3D bending. surface treatment. non Destructive Testing (Ultra-sonic inspection, leak testing, mechanical characterization of the met- allurgical interfaces ).

Architecture of the Group IVC offer Prime contractor Development team • Scientist team • Industrial development • Production tools development

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W ,7(5 3 E G I GI      Sub-contractors • Elementary items production • Assembly of the parts • Machining of the HIP components

Skills matrix

HIP Material 5 axes Deep 3D pipes Be machining Surface Welding assembly HIP Heat NDT (LT, supplier machining boring bending treatment process Treatment US, ...)

ARCELOR MITTAL DP DP DP DP R&D INDUSTRY SB SB PC PC PC PC PC PC PC PC PC PC AREVA NP DB DB DB DB DB DB DB DB DB DB SB DP SB DP DP ATMOSTAT SB SB SB BODYCOTE F.B. SB DP C-CON SB SB SB SB SB CEA SP SP SP SP SP SP SP SP SP SP CETIM SP SP SP SP SP CORIMA DP MODELAGE SB SP INSTITUT SP SP SP DE SOUDURE SB MECAGEST SB REEL SB SB SB SB SAGEM D.S. SB SB SB DP DP DP SDMS SB SB SB SB SAINT-GOBAIN SB SEVA DP DP 40-30 SB

PC / Prime Contractor SB / Sub Contractor DP / Development Partner SP / Scientific Partner

Skill and competences Machining techniques needed for the General comments Cleaning degreasing of the part will be important, manufacture of the Blanket no turning has to be put in the water circuit. Surface aspect, roughness will be an acceptance cri- There are 2 kinds of competences needed for the ma- teria. nufacturing of the Blanket. Both are of equal impor- All data will come from a CATIA 3D model. tance: welding and machining. The part to manufacture are nuclear components the- refore an adapted quality, qualification, survey envi- ronment is mandatory.

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Manufacturing of shields blocks Machining of castellation on front face

Machining of key and holes on back side Manufacturing step Specific needs and remarks Machining of hydraulic collector on back side Complexity needs 5-axis machining high Rough machining of the forged block, to near net shape Hydraulic and He leak test need the final shape to be defined medium requires machining center with 1500 x 1500 capacity, preferably 5-axis Manufacturing of a primary first wall panel Machining of 4 facets on the front side

Deep drilling of 283 holes between Manufacturing step top and bottom Specific needs and remarks requires a large capacity boring machine Complexity tight tolerances in positioning long processing times Machining operations to realize the SS support high plate : external shape machining, complex milling to form water boxes Machining of water collectors medium to high on top and bottom sides Deep drilling in the length of SS support plate Machining of 11 slots (3mm width) high from the front side requires a specially adapted tool Machining of the CuCrZr alloy cover plates: medium external shape of the plates, milling of half cylindrical grooves (positioning of cooling tubes) First machining of rear face specific requirements for flatness and surface (before the placement of tubes) roughness medium 3D bending of 8 cooling tubes requires a 3D-bending machine Bending of the SS tubes for coolant channels high difficult to control the regular deformation of tube in the bending region Preparation before HIP requires very skilled workers Welding of SS tubes to the inside part high of the water boxes, and leak testing of the welds

HIP compression cycle Machining of sheets for the container requires a large HIP equipment Dimensional verifications of gaps between NDT of HIP tubes and support, tubes and cover plate requires ultrasonic equipment key issue for success of HIPping high (acceptable tolerances are very tight) medium

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W ,7(5 3 E G I GI      Before HIPping: assembly of the parts TIG (manual) welding for joining 316L stainless in the container, welding and evacuation steels plates and blocks of the container medium importance of the cleaning procedures of the parts Laser welding for joining 316L stainless steels tubes First HIP cycle high

Heat treatment (solution annealing) Laser welding for joining 316L stainless steels cover collectors and shield Ultrasonic examination Requires an interface with CAO high Preparation before HIPping of Be tiles importance of cleaning Electron beam welding for joining 316L stainless steels parts Second HIP cycle (joining by diffusion bonding) Requires an interface with CAO high Final machining : removing of the container, machining of the attachment key, castellation Diffusion bonding for beryllium tiles to copper between Be tiles support and copper to stainless steel joining security requirements for Be machining Requires a special experience high value of the almost-finished part: no error high allowed medium Powder HIP densification Requires a special experience Hydraulic tests and He leak tests high

Joining processes Allied techniques and allied techniques

General comments Allied techniques Whatever the joining process, weld and welder will Specific needs and remarks have to fulfil nuclear code (qualifications). Complexity Repair techniques have to be identified and qualified as well. Cleaning / passivation of stainless Design and utilisation of specific welding head steel tube welds after welding to improve depending on the geometry could be asked. corrosion resistance (Welding from inside tubes or in reduced areas). Complex 3D circuits to clean high Welding techniques very likely to be used for blanket manufacture Non destructive testing (ultrasonic examination or other methods) Requires very skilled NDT personnel Welding techniques high Specific needs and remarks Complexity Helium leak test high TIG (automatic or manual) welding for joining 316L stainless steels tubes medium

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Remarks • Be machining The weldability of 316L stainless steel is easy and • Cu machining without major difficulty except the prediction of The part must « be transported » from one man- deformations due to the welding. Other points to ufacturer to another to follow the complete manu- take into account are to ensure leaktightness on wa- facturing cycle. ter cooling circuits and to perform a careful and ac- A strict and accurate interface management rep- curate manufacturing. resents a strong stake in terms of: The main problem is joining copper to beryllium • Schedule, task synchronisation between manufac- and copper to stainless steel which requires a special turers; know-how. • Performance and input required for each elemen- tary tasks. Quality organisation: • Norm selection. Identification of risks and main stakes on ITER IVC Schedule Definition drawings The RFP duration (3 months) is completely in- sufficient to analyse the different proposed con- The available drawings are not definite: the def- cepts; inition reference file, applicable to the manufactur- The EFDA engineering phase is too long ing, must be complete to allow a reliable quotation; (5 years), compared to the time conceded to the Available drawings show incoherencies and phys- industrial manufacturing file; ical impossibilities (volume outputs, conflicts, in- The manufacturing phase over two years, includ- terdependences, ...); ing process and equipment definition with its real- The drawings do not sufficiently indicate the ization, is insufficient: rate of 3 per month. manufacturing limits; The limits that must be imposed to mechanical parts in order to take into account the distortions Specific constraints induced by the HIP process, are not defined ; a man- ufacturer who is not in control of the HIP process Important rejection rate: cannot anticipate the geometric modifications that • High complexity; must be induced by this process; • Large quantity of unitary items. There is a wide range of parts: the recurrent as- Health safety for disease prevention for Beryllium pect is thus limited. parts: • Dedicated workshop; • Handling; Industrial setup • Airtight packaging. Cleanness and surface area conditions to be re- On account of numerous and very specialised spected at the end of manufacturing: operations to lead, several manufacturers must take • Cleaning; part in the manufacturing of each part: • Check of surface area conditions: roughness, sur- • Manufacturing; face cleanness. • Drilling; Cleanness maintenance after manufacturing: • Welding; • Package; • HIP; • Packaging; • Bending; • Handling; • Transport.

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W ,7(5 3 E G I GI      Industry identified topics able to reduce the risk Industries participating

Risks are both on technological and organization level. Some have been identified and could be mit- AREVA NP / Chairman [email protected] igate between customer and contractors. CEA Scientific adviser Technological [email protected] A stabilized set of drawing file;(revised and val- ARCELOR RESEARCH idated by industry) A clear identification of mechanical limits defini- ATMOSTAT tion (HIP constraints); AUBERT ET DUVAL BODYCOTE Contract organisation System management; (clear definition between C-CON FRANCE ITER, “Fusion for Energy” and prime contractor) CETIM Interface management; (responsibilities of all the stakeholders) CNIM Subcontractor management (number of needed CORIMA MODELAGE subcontractors to ensure the delivery on time) GIIN Quality management; Number of QA survey, hold points, etc.. INSTITUT DE SOUDURE Schedule adjustment to balance engineering MECAGEST -AREVA tasks and manufacturing activities; REEL SAS Contract negotiation SAGEM Défense Sécurité Identification of experimented industrials. SAINT-GOBAIN SEVA Type of contract: amendment negotiation easy, cost plus fee, etc... SDMS TECHNOPLUS INDUSTRIES 40-30 Conclusion

The analysis done by the working group shows that the French industry has full know how for the man- ufacture of the Primary First Wall panels and of the shield. French industry is involved in blanket development since many years at several stages, and the special processes involved are already controlled. The techniques to be used are mastered by several highly skill companies on which the main contactor can rely on. The group identified the main contract risk and pro- posed areas where it can be reduced.

WITH EFDA COURTESY

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W ,7(5 3 E G I GI      MAGNETS SYSTEM

Summary

Presentation of the "magnets system" p69

Description of the main components of ITER p70 Description of the main components of JT60 SA project p73

Potential market for the french industry p75 ITER project p75 JT60 SA project p75

The technological and industrial challenges of the magnets system for the ITER machine p76 The technological challenges p76 The industrial challenges p76

Annex: participants to the “Magnets system” group p77

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W ,7(5 3 E G I GI      Broader Approach Executive summary The Host (Europe) and the non-Host (Japan) will each make contributions of 49 bn¥ /339 millions € ITER Tokamak (These figures are fixed at their equivalent values as th Design philosophy of the Magnets System (extract at 5 May 2005. The figure should be eventually cal- of DDD): The design philosophy refers to a set of culated by reference to the currency of the non-Host.) basic principles that have been defined as guidelines to joint broader approach activities in the territory for the designers. They are qualitative in nature and of the non-Host, on a time frame compatible with can be summarised as follows: the ITER construction phase. Arrangements The magnets will form semi permanent compo- The Host will make contributions to the Broader Ap- nents of the machine, whose removal would require proach projects in cash and in kind under the arran- a significant down-time (possibly of a period of gements between the Host and non-Host. years). They are therefore designed to be highly re- liable and include, sometimes with some cost penal- Candidate projects identified in final report of the ty, features to increase reliability and provide redun- six-Party Broader Approach workshops in January dancy. 2004 include: IFMIF (EVEDA and/or facility), The magnets will use superconductors, as the ITER research centre(s): including, power consumption of normal-conducting coils for • a computational simulation centre long plasma burns is very high and unacceptable in for fusion science a future reactor that is to generate net power. • a centre for remote experimentation Although adding complexity in the form of a Fusion power plant technology co-ordination cen- cryostat, the magnets can then operate at a constant tre, including a centre for international design activi- temperature and take advantage of a high strength ties for the demonstration reactor, of cryogenic steels, allowing simplification and a size A new plasma experimental device (Satellite Toka- reduction of the support structure. mak).

Critical elements of the magnets must have been The Magnet Group is concerned by the new experi- developed and tested within the R&D programme mental Satellite Tokamak called JT60 SA and by the in a form close to that used in the design. This im- manufacture of 18 Toroïdal Field Coils smaller than plies, among others, that the superconductors and the ITER TF Coils. cable layouts should correspond in concept to those Many thanks to all the actors of this "Magnets Sys- tested in the CS and TF model coils (minor geometric tem" group and for the active support of the teams and parameter variations are generally acceptable). of CEA and "Mission ITER".

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Presentation of the "magnets system"

ITER Magnet System

1xCS CENTRAL SOLENOÏD

18xCC CORRECTION COILS

18xCC POLOÏDAL FIELDS (stabilisation)

18xCC TOROÏDAL FIELDS (CONFINEMENT)

Broader Approach: JT60 SA Projet 18 Toroïdal Field Coils

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W ,7(5 3 E G I GI      Description of the main components of ITER ITER TF Coils Superconductor

Radial Plates

10 sets to provide, main businesses concerned: Steel Providers Machining and welding

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Double Pancakes

70 Double pancakes to provide, main business concerned: Magnet Manufacturer

Winding Pack

10 Winding Packs to provide, main business concerned: Magnet Manufacturer

71 TABLE 5: Risks

W ,7(5 3 E G I GI      Casing (Japan contribution) Insertion

10 operations to do. Main Businesses concerned: Magnet Manufacturers having urge facilities (400t crane capcity) Mechanics (welding, machining)

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ITER PF Coils Superconductor

13% of PF conductor provided by Europe 18% Russia, 69% China Main Businesses concerned: • Superconducting strand manufacturer • Cable manufacturer

Main parameters of the “European PF Coils”

Nota: the PF coils will be done at Cadarache in a building dedicted to the manufacturing of these coils.

Main Businesses concerned: •Magnet manufacturer

Description of the main components of JT60 SA

With the present knowledge, the 18 coils would be provided equally shared by France and Italy. JT60 SA TF Coils

Superconductor

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Comments: same businesses concerned as for ITER TF WP

Casing

Comment: same businesses concerned as for the ITER TF Casings

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Potential market for the french industry

ITER Project

European part (ITER WBS extract):

Potential french market forJT60 SA project

18 Toroidal Field Coils including: Superconducting cable Stainless steel casing Winding Pack and insertion

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W ,7(5 3 E G I GI      The technological and industrial challenges of the magnets system for the ITER machine The technological challenges

During the ITER EDA phase, several mock-ups have demonstrated that Industry had the knowledge of the general manufacturing processes to built ITER Magnets System: Europe (AGAN Consortium) has built a Toroidal Field Model Coil having a weight of 30 tons com- pared to the full size ITER TF Coils which will weight 300 tons. 20 years ago, Europe (Alstom) has built a super- conducting Poloidal Field Coil.

The European Industry is one of the best prepared to built ITER Magnets. However there are still big challenges to face and the main is the Coils of unprecedented size and perform- ances.

The industrial challenges

Capacity • to produce steel raw material (low temperature Stainless Steel) • to produce Radial plates (forging, machining, weld- ing, ...) • to cope with a successful oriented schedule Capability • Welding processes avoiding deformation, • Machining processes of urge components, • Assembly of very large components with high level of tolerances, • Accuracy of control of large components.

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Annex: participants to the “Magnets system” group

Chairman: CEFIVAL ALSTOM MSA Tubes inox Fabrication aimants Gérard JARIN Daniel BRESSON CIMAT AMESYS Jean Yves GASNIER Radioprotection Christian CHORDI CMW Usinage grande vitesse ARCELOR RESEARCH François WILDENBERG Aciers spéciaux Bertrand GABRIEL CNIM Mécanique lourde AREVA TA Dominique SALASCA Intégrateur aimants Thomas SALA DCNS Mécanique lourde AXON Cable SAS Jean-Luc DELAGE Joseph PUZO NEXANS BODYCOTE Câblier Process spécial pour la réalisation Arnaud ALLAIS des brins supra Louis DUMEZ Competitiveness Cluster MIPI Olivier BONNET CALLEWAERT Mécanique Réseau Provence Rhône Nucléaire Ghislain CALLEWAERT Réseau d'entreprises impliquées dans le domaine nucléaire CEA Cryomagnétisme ROBATEL Industries Pascal BAYETTI Dominique SANCHETTE C-CON France SAGEM Défense Sécurité Ingénierie Mécanique Thomas DEDERER René-Paul BENARD

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Content Recall of thematic groups objectives p82 Vacuum vessel working group composition p82 Key words p83 Technical description of vacuum vessel p83 Design p83 Materials p85 Manufacturing complexity p85 VV allocation and expected manufacturing cost p86 Identification of techniques and skills involved p87 Engineering p87 Forming p88 Welding p88 Machining p88 Tests p89 Vacuum businesses p89 Handling and transport p89 Identification of key actors p89 Collaboration with national laboratories p90 Context p90 Expertise fields and prospective support activities p90

List of figures

Figure 1 : ITER 3D view of the TOKAMAK p92 Figure 2 : ITER VACUUM VESSEL AND PORTS ASSEMBLY p92 Figure 3 : ITER VACUUM VESSEL 40° SECTOR p92 Figure 4 : ASSEMBLY OF VV POLOIDAL SEGMENTS on erection FRAME p93 Figure 5 : POLOIDAL SEGMENTS ON THEIR POLOIDAL JIGS p93 Figure 6 : VV-POLOIDAL SEGMENT MOCK'UP p93 Figure 7 : DCNS/AREVA NP MOCK-UP p93

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W ,7(5 3 E G I GI      Cornet Hervé Recall of thematic groups Spie Nucléaire objectives Crassous Nicolas CNIM Identify French Industry that could be involved Elhage François in the Vacuum Vessel procurement; SDMS Identify European and international industrial en- Gabriel Bertrand vironment; Arcelor Mittal Identify specific needs of potential level 1 manu- Gisquet Philippe facturer (make potential sub contractors in relation, Soditech cooperation strategies); Identify level 2 and more potential subcontractors, Hacq Pierre-Alain their specific needs, and information. CETIM Hugon François-Cyrille AREVA TA Hesse Jean-Paul Vacuum Vessel working Aubert et Duval group composition Lelard Lionel Cegelec CHAIRMAN Lesuffleur Gaëtan Bielak Bogdan DCNS AREVA NP Madelaine Sylvain CEA SECRETARY Parjadis Louis Portier Sabine Technip France Mission ITER PACA Peron Jean-Yves Olivier Philippe REEL Mission ITER PACA Rebillard Jean-Philippe CEGELEC MEMBERS Bénard René-Paul Aubry Aure Sagem Défense Sécurité Fédération des Industries Mécaniques (FIM) Salasca Dominique Blight John CNIM Cybernetix Vitelli Michel Bonnet Olivier Astriane Pole de Compétitivité MIPI Bontemps Alain Groupe Intersyndical de l'Industrie Nucléaire Botta Michel Mecagest Caron Didier Institut de Soudure Carrese Michel Suez

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PTC: Photo-Thermal Camera Key words TIG: Tungsten Inert Gas welding process U.T: Ultrasonic Testing ITER Vacuum Vessel Vacuum Vessel (VV) is a Torus-shaped, double wall structure, designed to provide a high quality vacuum Codes & Standards, safety and a confinement barrier for radioactive materials AFCEN: Association Française pour la Conception (figure 2). The VV inner walls are covered with blan- des Equipements Nucléaires ket modules. The VV includes ports in the outboard RCC-M: Règles de Conception et de Construction region. des matériels Mécaniques des îlots nucléaires REP - Design and construction rules for mechanical com- VV sector: The vacuum vessel is divided in nine po- ponents of PWR (Pressurized Water Reactor) Nu- loidal sectors, having each an included angle of 40° clear islands figure. RCC-MR: Règles de Conception et de Construction VV torus: The completed VV consists of 9 mentioned des matériels Mécaniques des îlots nucléaires RNR above sectors joined using poloidal field welds - Design and construction rules for mechanical equi- Inboard/outboard: Refers to the VV inner or outer pment in FBR (Fast Breeder Reactor*) Nuclear is- part of the Torus. Note that the inboard comprises lands mainly a cylindrical section. RPrS: Rapport Préliminaire de Sûreté Inner/outer shells: Refers to the VV double wall structure. The inner shell is on the plasma side. Note, "in the cylindrical portion of the inboard, the outer Organisations shell diameter is smaller than the inner shell diame- EFDA: European Fusion Development Agreement. ter". EFDA acts on behalf of the European Commission Blanket module: A block which is connected to the and is the client. Will be further replaced by ELE VV by tension/compression connections (the flexible ELE: European Legal Entity (Barcelona) housings) which are recessed into the vacuum vessel, EFET: European Fusion Engineering and Technology and two shear connections (keys). ITER: International Thermonuclear Experimental Flexible housings: Reinforcing cylindrical device Reactor between VV inner and outer shells, with a bored hole in the inner side. Blanket modules are fixed to the inner shell with 4 flexible housings. Intermodular key: Block with a cylindrical part wel- ded on the inner shell and a rectangular part that fits into a module to restrain blanket module movement parallel to the VV shell walls. Technical description Poloidal segments: Each VV sector is made of these of Vacuum Vessel parts, individually manufactured (inner shell and ribs, on a jig), and then assembled on an erection Design frame (welding between segments + outer shell facets welding). The primary functions of the Vacuum Vessel (VV) Poloidal: Oriented in a vertical plane passing by the are to provide a high quality vacuum for the plasma, poles, such as longitude for earth. as well as the first confinement barrier of radioactive Toroidal Oriented in a horizontal plane perpendicu- materials. The decay heat of all the in-vessel com- lar to polar axis, such as latitude for earth. ponents can be removed by the natural circulation Cryostat : The cylindrical vacuum tight vess which of water in the VV cooling loops. The VV is hence keeps Tokamak components (VV and magnets) un- a safety classified component and it is assumed that der vacuum against atmosphere. it will be classified as ESPN N2 according to the Welding/Examinations French "Arrêté relatif aux Equipements Sous Pres- EBW: Electron Beam Welding sion Nucléaire"). There are still on going discus- ISI: In Service Inspection LPT: Liquid Penetrant Testing sions on the classification which has to be approved MIG: Metal Inert Gas welding process by the Safety Authorities and/or Accepted Notified MMA: Manual Metal Arc welding process Body. The vessel supports in-vessel components and NDT: Non Destructive Test their loads during normal and off-normal operation.

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W ,7(5 3 E G I GI      Along with other in-vessel components, the VV pro- The general design of the VV has been proven feasi- vides adequate radiation shielding in particular for ble from the structural point of view on the basis the magnets. The VV is located inside the cryostat of the analysis mainly performed by ITER. ITER has (figure 1). been using extensively inelastic analysis due to the The main vessel is a torus-shaped, double-wall complex shape and difficulties to classify primary structure made from an austenitic stainless steel, SS and secondary stresses. The structural analysis ma- 316L(N)-ITER Grade (IG), with stiffening ribs de by ITER have not yet been reviewed and checked between the shells to give the required mechanical in detail, especially for what concerns the sound- strength. The inner and outer shells are both 60mm ness of the design margins at this project level (pre- thick plates and the stiffening ribs 40 & 60mm thick design). plates. Thick forged structures are used locally. The The design activities are to be continued to integrate VV is an all-welded structure. The space between interfaces with other systems, detailed design of the the shells will be filled with plates mainly made of in-wall shielding support system, improvement of borated stainless steel 304 to provide neutron shiel- the number and proximity of welded joints on the ding and also ferromagnetic inserts. shells, detailed design and structural analysis of the The vacuum vessel is divided toroidally into nine divertor, manifold supports and gravity support. 40° sectors (figure 3) joined by "in-situ" field welds In addition, design activities were focused on a ty- using splice plates, the sectors are fabricated in the pical VV sector, and other sectors involving more factory. Each sector includes a full set of double wall complex ports and penetrations remain to be deve- port stubs and stub extensions at the toroidal centre loped. The design of Port systems and all VV auxi- of the sector. The sector weight is about 400 T, 50% liary parts has been mainly developed by the Rus- structure and 50% shielding and typical dimensions sian federation according to ITER share. are : 13m Height * 6.6m toroidal extent * 8m radial A RCC-MR Code VV Addendum was prepared by extent. AREVA NP to provide some modifications necessa- The VV has to be designed as a box-type structure ry to make RCC-MR fully applicable to the ITER component according to Class 2 RCC-MR VV Ad- VV. It has now followed an approval procedure dendum to be finalized this year. through AFCEN groups to be published as part of The VV is a pressure vessel component operating the RCC-MR 2007 before being reviewed by the Sa- at a temperature close to 100°C and at a nominal fety Authorities together with the RPrS. The main water pressure in the interspace of 1.1 MPa. deviations to the base Code are related to the use The VV must withstand many individual and com- of Ultrasonic examination (UT) in lieu of radiogra- bined loading conditions during both normal and phic examination for outer shell stainless steel off-normal operation. Analyses done to date are tho- welds and photo thermal camera examination in se considered to be the most severe loading cases lieu of liquid penetrant testing as surface examina- which drive the basis design of the VV structure. tion. These two deviations are to be supported by Main loadings are the water pressure during baking R&D program especially on UT. In addition the operation (P=2.4 MPa, T=200°C) and the electro- double wall shell and the very limited inspection magnetic loadings acting firstly on the inner shell. possibilities on the site make the application of pres- Areas close to the VV gravity support and divertor sure vessel test and inspection requirements very support flanges are also significantly loaded. difficult. Compensatory measures for In-Service- The VV is a very complex structure due to its par- Inspection have to be developed and supported by ticular torus "D-shape" section involving in addi- R&D. tion a lot of gross structural discontinuities such as Detailed applicability of general rules is to be chec- shell to port junctions and its double-wall structure. ked for other components and penetrations also The VV involves a huge quantity (about 14 km in part of the VV confinement barrier and water pres- total) and density of welded joints far beyond pres- sure vessel. There are open points in respect of sure vessels or boiler-making standards. design, code acceptance and qualification for some A lot of components such as water cooling blankets penetrations involving more singular components manifolds will be attached to the inner shell and (non-metallic windows, bellows, different mate- the design of the attachment structure is still to be rials). developed. Huge activities are also needed for the preparation

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of Technical Specification in support of the Call for tities (order of magnitude 80t) and verify with po- Tender especially if this is intended as procurement tential suppliers (Air Liquide / SAF, BOHLER/ according to "built to print drawings". THYSSEN, ESAB) the possibility to manufacture In conclusion, the overall design of the VV sectors and to deliver in due time these products. The ten- seems viable but as industry has not been involved dency of the filler metals suppliers is to provide only into basic design analysis, uncertain issues can't be standard materials. One of the difficult requirement stated today. is the level of Delta ferrite which will lead to cost increase or risk not to get the right materials in due time. The most critical point seems to be the procu- Materials rement of coated electrodes for which no recent ex- ITER Vacuum Vessel is using Stainless Steel perience seems available. 316 L(N) Iter Grade as the main structural material. One of the potential manufacturing scheme invol- This material is an evolution of RCC-MR 316 L(N) ves the use of heavy jigs. Materials for JIG shall be used for Superphénix vessel and internals construc- either SS304 or ferritic construction steel (depen- tion, Phénix upgrading and Indian FBR construc- ding on cost incentive) with stainless steel buttering tion. where contacts with the components. Even if these The peculiarities of Iter Grade are low Cobalt con- materials are less sophisticated, the anticipated tents (< 0.05) which has a significant impact on the number of heavy jigs to be used during manufactu- cost and lower impurities contents. Iter Grade ring is important (10 sets of 4 poloidal jigs i.e about 60mm thick plates and forged parts have been re- 1200t in total). These procurements have to be con- cently produced respectively by ARCELOR and firmed and the availability in due time of these ma- AUBERT & DUVAL for VV-PSM mock-up built in terials has to be checked. This point is from minor Italy and by FANP for shield prototype procurement importance compared to structural material. (but with ordinary Cobalt content). Today's number of qualified suppliers in Europe is limited (ARCE- LOR/Industeel for plates, AUBERT et DUVAL for Manufacturing complexity forgings and bars....). The ITER Vacuum Vessel, to be constructed on site AVESTA/Polarit for plates, FOMAS for forgings and from 9 toroidal Sectors, places as-welded manufac- UGITECH for bars are other potential suppliers. turing tolerances on the surfaces (typically +/- As the materials situation worldwide is very tight, 10mm on the 60mm thick shells) several times it is important to anticipate the material procure- smaller than usual in relation to its large size, com- ment to make sure that the materials manufacturing plex shape, high weld density and stainless steel slots will be available in due time and acceptable material. AREVA NP has proposed a manufacturing price to secure the manufacturing schedule. route for the sectors construction with a view to Discussions with potential suppliers must take pla- meet the stringent tolerances which was accepted ce prior to bid to identify and minimize potential by ITER and EFDA for the manufacture of the VV risk of rejection of materials this defining the mini- Poloidal Segment Mock-up by Ansaldo (VVPSM). mum production quantities to optimize cost, qua- This sector manufacturing method, involves the joi- lity and at the end securing the schedule, in parti- ning of four, partially-constructed poloidal seg- cular for forging parts. The typical weight of forged ments together in an erection frame (figure 4). To pieces (5t) corresponds to the steelmakers capaci- limit the welding distortion, each segment, at the ties. beginning of the manufacture process, has welded The filler materials could be specific to ITER (requi- to its inner wall a jig (figure 5), (total weight per rement for a low ferrite content to avoid magnetic segment of about 135 tons) which is also used fur- effects still under discussion within ITER project). ther for supporting on the erection frame during At present time, ITER is assuming the use of RCC- final assembly. The objective of the jig is to avoid MR 16Cr-8Ni-2Mo or 19Cr-12Ni-2Mo filler mate- gross angular distortion of the shells by amplifica- rial for TIG/MIG wires and coated electrode as used tion of the local welds distortions by large bending for Fast Breeder Reactors (Superphénix and Phénix arms. The completed sector is removed from the upgrading (16-8-2 only)). It is important to define jigs only at the end of the sector assembly when the already the exact type of filler materials and quan- high stiffness of the double-wall structure should

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W ,7(5 3 E G I GI      minimize the potential effect due to residual stress chining of outer shell plates, stringent fit-up requi- relaxation. rements in case of automatic welding and need for The VV as a Nuclear Pressure Equipment (N2 as- a progressive and optimized welding of outer shell). sumption) and class 2 RCC-MR structure involves The associated difficulties on standard UT exami- full penetration welds on the shells to be inspected nation for welds without a good control of the back- at 100% by volumetric examination. side reinforcement which may bring added difficul- The welding processes were selected with a view to ties in the examination. maximize the use of existing and validated techno- Repair of welds considering no back-side access, logies for the fabrication of Nuclear mechanical hea- a lot of automatic welds and difficulties of interpre- vy components. tation of UT. EB welding was used for the assembly of small sin- VV sector high vacuum requirements (max leak gle parts (like housings and keys) on inner shell of 10-8 Pa.m3.s-1). plates. Narrow-gap TIG butt welding is extensively used for the shell welds with double side access for the inner shell and single side access for the outer VV allocation and expected shell. Manual Metal Arc or MIG can be used for full manufacturing cost penetration angle welds between ribs and shells. The ITER Vacuum Vessel cost has been estimated Heavy jigs are used for the control of the geometry by both European Industry and ITER project. The and tolerances at the different steps of sectors erec- main objective of ITER project cost estimate was to tion. Such process were used for the manufacture provide a realistic and sufficient basis for ITER par- of the VVPSM mock-up in view of its conservative ties to discuss and make their decision on the scope approach. of involvement and selecting the desirable systems Inner shell welds will be mostly controlled by radio- to manufacture. The actual price of the VV procu- graphy at the stage of segment construction. Outer rement package will result from the European shell welds as single side access welds will be ins- (ELE) Call for Tender. However the EC has provi- pected by U.T using alternative methods such as sioned a total budget consistent with the ITER and creeping waves and tandem. EFET estimates which is for sure significantly un- EFDA is developing more advanced alternative wel- derestimated. ding processes such as hybrid laser-MIG and is also considering a much more extensive use of EB wel- ITER costing figures estimated in 2001 and VV sha- ding for segments construction. ring agreed between ITER partners is as follows: Currently, the manufacturing of the next mock-up using EBW is carried out jointly by DCNS and ARE- VA NP. This mock-up involves a more advanced ap- Package Negotiation Budget Allocation proach with an extensive use of EBW. The achieve- 1.5/1A Main Vessel including Blanket Manifolds ~165 Mio€ EU = 80 % ment of the fine tolerances remains challenging and and hydraulic Connectors Korea = 20 % it will be extremely difficult to develop a tolerance recovery procedure in case the sector is out of the 1.5/1B VV Shielding ~50 Mio€ India = 100 % tolerance requirements. Other difficult manufacturing issues are related to: 1.5/2A Equatorial Ports ~32.6 Mio€ The field joint welding (currently out of the scope Russia = 24 % of the VV sectors procurement), 1.5/2B Upper Ports ~28 Mio€ Korea = 76 % High manufacturing quality components (RCC- MR class 2/ESPN N2) involving survey and inspec- 1.5/2C Lower Ports ~42.44 Mio€ tion by the Safety Authorities/Notified Body without manufacturing the true prototype. The double wall structure involving about 50% of the welds (i.e about 7 km for the full torus) as closure welds with fit-up difficulties. This will lead to time-consuming operations (sophisticated me- trology needs and numerous surveys, custom ma-

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Concerning schedule, ITER requirement of Large stainless steel components with extreme 65 months is also for sure underestimated and does tolerances (management of deformations and final not foresee the validation of the manufacturing pro- size, temperature control), gramme on a prototype or first of a kind sector. Forming of complex shape on thick stainless steel Due to the important uncertainties in the following plates, aspects, the financial and schedule risk is conside- Inspection of welds with new processes as UT red very high: tandem (creeping waves, phased-array probes), Design not yet finalized, photothermal camera..., Organization from process design to detailed de- Electron Beam welding, sign not defined, Extensive use of welding at long and complex Manufacturing contingencies not taken into ac- profiles in all positions with automatic processes, count in design, Helium leak test and hydrotest performance on Materials costs not completely evaluated, complex shape (huge structure and sealing difficul- Industrial organization not defined thus detailed ties). costs and schedule not known for subcontracting, transportation of sub-parts to a workshop to an The construction of Vacuum Vessel such as the one other, QA surveillance..., of ITER requires to implement specific and various Final assembling very tight tolerance maybe close methods covering several professions, among which to industrial limits, we have different families: Development of specific processes and associated Engineering including manufacturing engi- know-how not yet industrialized, neering and studies (detailed design, structural ana- ITER figures on cost and schedule are underesti- lysis, ..) mated and no provision is taken for third parties Forming, and Safety Authorities inspection, surveys and hold Welding, points. Machining, Tests, Vacuum skills, Heavy components Handling.

Identification of techniques Engineering and skills involved This kind of project is technically and industrially The European Industry, namely EFET with leading complex. It requires to have a strong engineering members as AREVA NP and Ansaldo (involved only because of the various topics to be dealt with and in the first mock-up manufacturing) have been the the different partners involved in the project. main contributor to the definition and performance The skills required are of different nature: of the European R&D program on VV sector assem- bly sequences, associated tolerances and feedback Design engineering: on VV sectors through numerical simulations. Con- It should first integrate interfaces 'management clusions which results from these experience are as between the different partners in order to assure the follows: cohesion of exchanged data and compatibility of The ITER Vacuum Vessel manufacturing scope co- designs in interface. As for design, the fields of skills vers all techniques used to master detailed design are as follows: and fabrication of PWR Nuclear Heavy Compo- Conception of vacuum vessels, nents. Moreover, this scope includes large part of Conception of large-sized boiled units with tight various and quite new or different to those used tolerances, currently by nuclear manufacturers as: Dimensioning calculation: static, high-vacuum, Design & Manufacturing conformity to Nuclear seismic, thermic. Code & ESPN requirements for a new component Manufacturing Engineering: with many inherent access restrictions It will be necessary to integrate, from the vessel's

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W ,7(5 3 E G I GI      conception, the particularities linked with the ma- The study for forming means (die,...) shall take into nufacturing of the different sub-assemblies. account the dimensional requirements of the fi- In terms of design, construction methods will partly nished product because the first operation result guide technical choices. This part of study is to be will affect strongly the respect for the final toleran- led in the same way than global design and dimen- ces of the sub-assemblies. The possible alignment sioning studies. defaults shall be managed from this stage.

It concerns first : Applicability of construction standards, Welding Making of manufacturing methods for the diffe- Several welding methods can be implemented ac- rent fields (welding, forming, test,..). cording to the type of item. The different sectors segments could be joined by electron beam welding. This latest point should be handled together with This method allows to reduce distortions due to hi- the industrials liable to make the works. gh-depth welding. We give more importance to the During the manufacturing ( the making) of the sub- respect of sectors' dimensional tolerances than the assemblies, it will follow the sequency of the various high cost of implementation of this technology and operations in phase of pre-manufacture (tests, qua- the construction constraints specific to this process. lifications, approval). (precise machining of edges to be weld, accurate Then, an important part will be dedicated to the fit-up, welding under vacuum, limited capacities of manufacturing follow-up and to the respect of Qua- repair, ...). lity Assurance with regard to the construction code As for other components less critical in terms of chosen. geometry, we will use conventional welding techno- In terms of design, it is a question of developing logies from MIG or TIG processes, with or without and implementing the different construction tools filler metal. (welding jig, machining and control support, ...). The whole chosen processes are subjected to speci- fic qualifications with regard to the assembly invol- Integration engineering: ved, in accordance with the construction code retai- For the integration phase, we will first materialize ned. the global phasing of sectors sub-assemblies manu- facturing in integrating the elements of other pro- curement packages (for example ports). Machining Several machining stages are to be planned in the Then to develop tools necessary to the assembling course of the sectors' construction. of the different components: The first ones will intervene at the preparation of Handling methods, the elements to be welded ( manufacturing of weld Positioning tools, edges). Preservation in position tools, Others stages will occurred after the sectors rings Access, assembly in order to give the sectors their final fra- ... me alignment for the final assembly (inter-sectors links, equipments assembly interface). This likely phasing shows that different machining Forming means could be used according to the different ca- Forming requires different techniques so as to be ses. During the preparation phases, it is quite con- in accordance with the numerous sectors' parts. The ceivable to use the means of a boilers factory whose forming of plates dedicated to sectors should requi- machining capacity is compatible with dimensions re press forming techniques. Some elements will and precision required. require the implementation of 3D forming for steel For final machining, it may be necessary to imple- plates thickness of about 60 mm. ment machining methods specifically developed for Other elements such as tapping shell shall be ma- the operation. (portable machines directed toward nufacturing by rolling or folding using more ordi- a precise referential.) nary means.

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Tests Vacuum businesses They are of different nature: The construction of a vacuum vessel requires to be Welding tests (Non Destructive Examination): very careful in terms of design, manufacturing pro- Welding tests are done by qualified people in accor- cess as well as control. A partnership with the dif- dance with construction code. ferent vacuum businesses should be set up. According to the manufacturing stage and item con- Expertise concerns: cerned, we can organize different type of control: Conception rules for the vacuum vessel manufac- VT: Visual Test, turing, LPT: Liquid Penetrant Test, Material choice and surface treatment, PT: Photothermal Camera, surfaces protection during the construction, UT: Ultrasonic Test, The surface preparation and the respect of venti- MT: Magnetic Test, lating rate, RT: Radiographic Test. Pumpage means for tests gauging. Impermeability tests In the case of sectors manufacturing, we will have Handling and transport probably to use 2 types of tightness tests: For the integration of sectors parts operations, stu- A local test at the level of each crossbeam, dies for tools and handling equipments are to be A global test of the whole sector before assembly. considered. These tests will be done according to Helium gas Sectors fitting, positioning, turning over and trans- marker method. A certain amount of tools and portation required this trade association. equipments will be required such as: Sectors manufacturing strategy has to be examined pat closing, according to a dedicated workshop on Iter location pump units, or an offshore workshop and comparing means and control systems (mass spectrometer, fitting,...). costs. Nota: The evacuation of the sectors during these tests will account for a first test under pressure (-1bar). Com- plementary tests for the pressure strength level have yet to be realized inside the double skin. Identification Geometric tests of key actors During the whole manufacturing and sectors accep- tance phases, a multitude of geometric tests will be The Table below presents the list of French, EU and necessary to guarantee the object final geometry for Korean companies considered as potential partners the assembly with the other sectors and equip- or competitors for Vacuum Vessel procurement. ments. Several technologies can be implemented : EU(France) Conventional methods: workshop equipment, AREVA NP* more adapted to small dimensions, AUBERT ET DUVAL Optical methods : Théodolite, Tracker laser, "station ARCELOR MITTAL totale", ASTRIANE Mecanical methods: stylus 3D like Faro arm, or CEGELEC MMT (three-dimensional measuring machine) CNIM Acoustic method: GPS local, DCNS* All these means will be used and adapted to a MECAGEST methodology which will fit to the precision level REEL required by the elements to be measured. SAGEM DEFENSE SECURITE

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W ,7(5 3 E G I GI      SDMS The success of the manufacture of this central part SODITECH of INB ITER is actually a major importance for the SPIE NUCLEAIRE project. ENDEL SUEZ The Euratom-CEA association has a large experi- TECHNIP FRANCE ence for more than one decade in large number of research domains and technologies of Tokamaks. Associations, Instituts, Competitiveness cluster: Among these domains, the vacuum vessel was the CEA object of a set of works for which the Association CETIM has got through to achieve an important experience FIM in the following domains: GIIN Development and\or qualification of welding Institut de Soudure process, MIPI Development and\or qualification of non destruc- tive control process for welding, EU Test for qualification and characterization of ma- ANSALDO/Finmecanica (Italy) terials to update the Codes and Standards (ASME, ANSALDO CAMOZZI (Italy) RCC-MR...), ENSA (Spain)** Test and validation of the materials strength (age- MAN DWE (Germany) ing) and welds in neutronic flux (6-14 keV), Metso/Holming (Finland) Global and local leakage test. Geldof / G & G International (Belgium) AGORIA (Belgium) In these various domains the Euratom-CEA associ- Shelde Exotech (Nederland) ation could be requested by industrials in charge of Hanover Belelli Energy (Italy) the manufacturing of the vacuum vessel who would Presmet (Poland) like to benefit from the skills acquired on an activity Probeam (Germany) support within the framework of partnerships. Rombau-Gerinox (Switzerland) Please take note that the presented domains are the main axis of the works realized on the vacuum ves- South Korea sel by the Association, but this list is not fully thor- Doosan Heavy Industry, ough and can be completed according to needs and Hyundai Heavy Industry information resulting from various partners of the project * involved in ITER VV mock-up manufacturing, Expertise fields and prospective support activities Collaboration For various support activities, the Euratom-CEA association has a large competency mapping, in with National laboratories CEA (Atomic Energy Authority) laboratories, but also in CNRS (National Centre for Scientific Re- Context search) and Academics research laboratories. The The manufacturing of the vacuum vessel of Toka- topics on which these laboratories can bring a sup- mak ITER, of which 80% are the responsibility of port for the industrials involved in the manufactur- the Europe partner of the project, is a major indus- ing of the vacuum vessel are for example: trial issue. The principal constraints related to this The welding and assembly activities where the manufacture come: CEA can propose to develop advanced solutions from the dimension of the component, (soldering laser), methodologies of simulation and of the rate of vacuum which must ensure, more generally the knowledge in the field of the of the environment of operation: strong neutron materials science and the technologies of assembly burn-up rate. themselves (brazing, Hot Isostatic Pressure).

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Actors: « Département de Modélisation des Systè- Actors: CNRS laboratories, Universities, and Acade- mes et Structures » (DM2S), “Département des Ma- mics research laboratories, in relation with the As- tériaux pour le Nucléaire (DMN)” and sociation Euratom-CEA such as CP2M ( Marseille), “Département des Technologies de l'Hydrogène” LIMHP ( Villetaneuse), the Laboratory of Enginee- (DTH). (Nb: as example the DTH has a long expe- ring of Materials (ENSAM Paris) and IUSTI ( Mar- rience in the development and the characterization of the innovative manufacturing processes for the seille) for respectively tasks in microanalysis, in ma- development of the vacuum vessel components for terials - genius of the processes and in thermal could the future thermonuclear fusion reactor ITER (blan- take part in some research skills. ket and thermal shield). In the last studies, the DTH combined: fine metallurgical study, mechanical cha- The Euratom-CEA association has a large experien- racterization and, assembly design by using the di- ce for more than twenty years of research and deve- gital simulation, technological development and if lopment on all the domains and technologies con- necessary prototype manufacturing). nected to the nuclear fusion process and to the The non destructive control process for welding. Tokamak equipment, a recognized expertise which Actors: “Département des Technologies du Capteur can be taking advantage by industrials in charge of et du Signal” (DETECS), which has a long techno- the manufacturing of the vacuum vessel for the To- logical experience in the field of the sensors and of kamak ITER. the signal processing in the sectors of the nuclear Euratom-CEA association suggests being the con- power and the industrial control. He can bring his tact for the future requests, and so far as which can expertise in physical modeling and simulation; in to help at the development of partnerships between technology of the sensors; in the acquisition and the industrials and the research laboratories in order signals processing; the associated metrology and the to contribute to the success of project ITER. experimental validation. Qualification and characterization of materials data's need to update the current Codes and Stan- dards (RCC-MR, ASME...) and validate the mate- rials strength in the time. Actors: « Département de Modélisation des Systè- mes et Structures » (DM2S) who participates to- gether with AREVA NP to working groups on codes and the standards of nuclear reactors design (RCC- MR and RCC-MX) associated with the “Département des Matériaux pour le Nucléaire (DMN)” which characterizes the properties of ma- terials (and welds) of the nuclear power, irradiated and not irradiated, to determine their performances, and to foresee, notably by modeling, their average life in operation, Validation of the safety aspect of the vacuum vessel. Actors: “Département d'Etudes des Réacteurs” (DER) which collects the skills in the domains of the evaluation of the different fields of the nuclear reactors (performances, safety, economy, waste), and more particularly on the safety of reactors and their technology. Domains with more fundamental researches, or specific.

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W ,7(5 3 E G I GI      Figure 1: ITER 3D view of the TOKAMAK

Figure 3: ITER VACUUM VESSEL 40° SECTOR (to be delivered from the factory)

Figure 2: ITER VACUUM VESSEL AND PORTS ASSEMBLY

WITH EFDA COURTESY

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Figure 4 : ASSEMBLY OF VV POLOIDAL SEGMENTS Figure 6: VV-POLOIDAL SEGMENT MOCK'UP on erection FRAME

Figure 5: POLOIDAL SEGMENTS Figure 7: DCNS/AREVA NP MOCK-UP ON THEIR POLOIDAL JIGS

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W ,7(5 3 E G I GI      Figure 8: ITER SCHEDULE

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Safety Regulations and the requirements of working Executive summary on major nuclear installations ('Installations Nu- cléaires de Base" -INB) such as ITER. Inside the Vacuum Vessel of the tokamak, "critical" The field of robotics and remote handling is very ac- components will have to be installed (assembly), to tive in France and constitutes a pole of excellence be inspected and replaced in the course of operations, not only for nuclear power, but also for other indus- thanks to access through "ports" provided on 3 levels trial sectors such as: naval, aeronautics, space. Nine around the tokamak. . clusters of competitiveness are identified and are po- As soon as plasmas exceed the threshold of power tentially significant contributors for ITER. corresponding to the activation of materials, the en- The industrial experience of French Industry covers vironment of tokamak will become highly radio- many of the functional requirements of ITER such active and will impose remote handling for all main- as: the engineering of the complex robotics systems tenance activities. The robotics and remote handling for the handling and the transfer of components, the (RH) tools will constitute a major system required remote controlled operations using manipulator top perform complex operations and processes in a arms, viewing systems and metrology, the non- confined environment to a very high level of opera- destructive inspection devices in radio-active envi- tional performance and safety. ronments. This document presents the current status of the stu- dies and design for the RH tools to be used for the French industry is well adapted to meeting ITER's following functions: needs for robotics and remote handling on ITER and Replacement of blanket modules and the divertor the 3 major challenges specific to systems for ITER: cassettes (1st internal wall of the Tokamak), Technological of handling of very heavy parts (up Transfer cask system for the tokamak components to 10 tons) in a very confined environment with dif- and the tools between the hot cell and the Tokamak, ficult access to the Tokamak vacuum vessel, for op- The initial general layout for the hotcell. erations of inspection, metrology, assembly and The RH tool designs remaining to be developed maintenance of complex and delicate components concern the maintenance functions for the Neutral including the cutting of pipes, and disassembly of Beam heating systems and "in vessel viewing and supports hidden behind the front face of the vacuum metrology". vessel walls etc Europe will provide approximately 50% of the RH Industrial challenges: the test programmes for this tools and systems, the equivalent of approximately experimental machine will lead to unforeseen situa- 76 M€ including 46 M€ to be delivered "in kind" € tions requiring considerable flexibility in performing (ELE contracts) and 30 M of contribution to the maintenance and modification of the experimental hotcell RH systems (joint funding: ILE Contracts). configuration. For each type of operation, safety will These tools and systems required by ITER for robot- be the over-riding priority. Consequently the robotics ics and remote handling constitute much more com- systems must have a very high level of reliability and plex systems than those deployed in the "fission" functional safety which must not be detrimental to nuclear facilities. These are the challenges that the requirement for considerable flexibility. French industry has the experience and capacities to Challenges of integration into the ITER system: tackle. ITER is an experimental test facility and the priority French industry has more than 30 years of experience is given to solving technical problems and optimising in the field of the nuclear power generation. It devel- solutions. However the long term and successful ex- oped, driven by large civil and military clients (CEA, ploitation of the machine is dependant on the "robot- EDF, etc) and close co-operation with the research ics and of remote handling" systems. Thus the suc- centres. This industry includes a complete pyramid cess of ITER involves the challenge of optimising the from small and medium-sized companies specialised objectives of the ITER machine with the constraints in engineering studies and the development of high- of remote handling from the start of the overall design technology equipment of high technology up to large of the ITER system. engineering contractors providing "turn-key" facili- This information note was prepared by representa- ties. All these companies are familiar with Nuclear tives of companies and research centres within the

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W ,7(5 3 E G I GI      framework of the French ITER Industrial committee resulting from the need to integrate these systems in (C2I) organised by the Mission ITER. It constitutes a very dense environment. a photograph of the current situation, and identifies These requirements will be further developed in the some of the critical requirements which must be met: 2nd stage of work and will undoubtedly demonstrate an engineering system approach, taking into, ac- the need for support in research, federation of com- count the complexity and the high level of perform- petences and knowledge, etc in order to put French ance required for the remote handling maintenance industry in the best position to win contracts in the operations, future requests for tenders which will probably be a specific effort to develop robust and reliable tech- issued by ILE and ELE in 2008. nologies capable of operating in extremely severe ra- Many thanks to all the actors of this "remote han- diation environments, dling" group and for the active support of the "Mis- the rigorous management of complex interfaces sion ITER" team.

Summary Presentation of the "Remote Handling" system on ITER p99 Principle of remote handling operations p99 The remote handling systems p99 Design features and necessary skills p101 Supply of the rh systems by the iter project partners (as of 31-05-2006) p102 General information p102 French nuclear industry: a top level technological and industrial organisation p102 The management of complexity p106 Robotics: a pole of french excellence p106 Experience of the french industry in robotics (rh) p108 Technical capability for ITER p108 Available experiences & references p109 Remote handling by manipulator arms p110 Processes tools p111 Viewing and Metrology System p111 The technological and industrial challenges of remote handling for the iter machine p111 Foreword p111 The technological challenges p112 The industrial challenges p112 The challenges of integrating remote handling equipment and component design for ITER p113

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in the Tokamak (component to be inspected includ- Presentation of the ing metrology checks using metrology instruments).

"Remote Handling" (RH) Note: 1)The operation of installation of the new component is the reverse system on ITER of the above operation. The component is loaded with the tools in the TCS in the hot cell. Inside the Vacuum Vessel of the tokamak, "critical" 2)For certain components, some positioning equipment for the RH system has to be installed in the Tokamak (TK) before introducing components will have to be installed (assembly), the RH system for removal of the component, and this positioning to be inspected and replaced in the course of oper- equipment has to be removed after the component replacement has ations, via the access ports provided for on 3 levels been performed. around the tokamak ("ports"). As soon as plasmas exceed the threshold of power RH maintenance operations have to be performed corresponding to the activation of materials, the in campaigns for several hundreds of components corresponding support operations around the toka- of the 1st wall of the Vacuum Vessel (blankets, di- mak will have to be performed in remote handling vertors, diagnoses and neutral beam heating devic- mode, including the removal of irradiated compo- es). During these operations the ITER facility is un- nents and their loading into transport containers. available for experiments. Hence the duration of these operations must be minimised.

Principle of remote For the ITER remote handling systems, essential requirements are as follows (incomplete list): handling operations Limiting the duration of the operations, Flexibility to cover multiple experimental situa- Briefly, for the replacement of components in the tions during the exploitation of ITER, vacuum vessel of the tokamak, the following main Reliability and availability, phases have to be performed: Safe operation, and in particular: avoiding any In the hotcell (HC): Preparation of the tools for blocking or jamming of the equipment in the instal- disassembling of the components and loading of lation which would produce a long term interrup- these tools into the Transfer cask system (TCS), tion of the experimental operations, and degrada- In the Tokamak building (TK): Transport of the tion of the facility and in particular the Tokamak, TCS from the hotcell towards the port of Tokamak the cryostat etc. (via a lift for the "equatorial" and "upper" ports lev- els) and docking of the TCS on the defined port of tokamak corresponding to that operation, The remote handling systems: Port of TOKAMAK (TK): Opening the door on ITER remote handling (RH) systems, designed to the port and on the TCS, installation of the tools - ensure the above operations, are as follows: operations of disassembling - removal of the com- ponent from the 1st wall (1) and recovery back into 23P1 > Blanket remote handling equipment : the TCS to allow the closing of the doors on the Complete set of complex tools consisting of: port and TCS, In vessel Rail (Mono RAIL) used as support for In the Tokamak building (TK) : Transport of the the tools of installation/removal of the blanket mod- TCS from the port in Tokamak building (via a lift ules on the 1st wall (weight of each module : around for the "equatorial" and "upper" ports levels) to the 4,5 tons - 440 modules in the Tokamak) and its as- hotcell and docking on the port of the hotcell, sociated services tools (IVT = In Vessel Tranporter) In the hotcell (HC): Unloading of the container, for installation & removal in the Tokamak of the transfer (handling) of the component to a mainte- rail. nance bay - Removal of the tools and storage in a In vessel Mobile trolley : Transport module and storage bay or to a maintenance bay - Maintenance receiver pallet, equipped with arms and special of the component including separation of the reusa- tools for the handling of a blanket module - disas- ble parts and the reusable parts (Waste) and recondi- sembling of attachment devices, cutting and reweld- tioning of the component ready for re-installation ing of tubes etc,....

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W ,7(5 3 E G I GI      Command &Control system for the RH opera- 23P3 > Transfer Cask System (TCS) tions on the blanket modules. The Transfer Cask System is designed for the trans- fer of RH equipment and components from the hot- cell up each port of tokamak (and way back). TCS is autonomous and fully operated by remote con- trol. Mobile vehicle consists of: Cask: Container of LxlxH = 8,5x2,6x3,7m3, car- rying a payload of up to approximately 40 tons): a mechanical boix structure, a containment envelope, port docking and locking system , mobile door for access in the tokamak port (PCP), Pallets (AP) - intermediate support structure which allows the TCS to separated from the ATRS after docking, 23P2 > Divertor cassettes A transport trolley using an air cushion system: remote handling equipment Air Transfer system (ATS), Set of complex tools composed of: Command control system for several TCS and Tools for transport and installation/removal of di- their deployment (e.g.: recharging the accumulators vertor cassettes (CTM: Cassette toroidal mover) of TCS). consisting of a set of rails (divertor rails), a trolley equipped with specific tools: a Multifunctions Ma- nipulator Arm (MAM), a cassette transfert module (CTM) for handling and moving the divertor cas- settes (weight of a cassette: around 10,7 tons - 54 cassettes), cutting and re-welding of pipes. Command &Control system for the RH opera- tions on the divertor cassettes.

23P4 > In vessel Viewing /metrology systems These systems are not precisely defined at this stage of the ITER project (2007). The pictures hereafter illustrate one possible principle for inspection and metrology of the complex geometry of the toka- mak; essential data for ITER.

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23P5 > Neutral beam Maintenance equipment The design presented below is currently in evolu- tion during the design review of the project. It is provided to illustrate the size and weight of compo- nents and the complexity of the maintenance oper- ations on the neutral beam heating system, which appear critical and have to be taken into account for the layout of the facilities near tokamak.

Above the hot cell, there will be a specific area for qualification of those additional remote handling operations which may need to be developed to meet the requirements of ITER during its lifetime; this facility will be used for validating the operations by "simulation" on mock-ups and for training opera- tors in the "almost real" conditions of remote han- dling operations.

Design features 23P6 > Hot cell maintenance equipment and necessary skills The design of the hot cell presented hereafter cor- responds to that at the start of the ITER project. A The remote handling systems for ITER are very new design is currently being studied by the project complex and require a multidisciplinary approach team; and should be completed by mid 2007. and a very high level of technological know-how. Without pretending to be exhaustive, a first list of Based on the main required functions, the hot cell required skills includes: will include: Complex systems Engineering: Handling & transfer equipment for the RH sys- automation, a high level of safety, operational stud- tems and components between the maintenance ies: simulation and modelling, use of virtual reality and repair bays and the bays used for loading and techniques, conceptual design, detailed design of unloading the TCS complex mechanical assemblies, automatism, com- Maintenance bays for the blankets modules mand-control, RAMS, Maintenance bays for the Divertor cassettes Detailed engineering design and build of "tailor Support & maintenance bays for the NB and tools made" machines: Facilities for loading waste into waste containers • Stable complex structures with high levels of in- Bays equipped with inspection and metrology tegration, stability, reliability,... tools for the inspection of Blanket modules • Remote controlled manipulator arms, Storage areas and handling equipment for spare • Special tools for thermal and mechanical process- parts and waste es: cutting of pipes, welding, handling, inspection, Command control systems for the RH operations metrology, control, visual inspection equipment,... in each bay or area and the overall supervision of • Automated transport vehicles the hot cell. Conception of Command-control systems (digit- al computing, high level of safety, radiation resist- ance for a nuclear environment)

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W ,7(5 3 E G I GI      System Integration and qualification: develop- slightly higher than 76 M€ (E.C. 2005). ment and design of mock-up test-beds for integra- Europe will be providing approximately half of the tion and functional tests RH systems for the ITER project. Installation, assembly and commissioning (Doc- umentation, operator training, establishing mainte- nance programmes). General information Note: Some components will be classified by the French Safety Au- thorities as being "Important for Safety" ( in french: équipement im- portant pour la sûreté : E.I.S.). The implementation of the rules of The Robotics and Remote handling (RH) require- August 1984 will be mandatory in the industrial cycle of development, manufacture, deployment for these components as will be the rules ments for ITER represent multiple challenges (tech- of the "ESPN" of December 2005. nological, risk management, organisational...). To meet these challenges and to support the ITER pro- gram, French industry is able to offer the following advantages: Supply of the RH systems A unique experience in both nuclear engineering by the ITER project and Robotics and Remote handling, partners (as of 31-05-2006) Organisational skills as required for the manage- ment of complex programs, The hotcell will be financed by "joint funding : An industrial environment for mastering the Cash" under the direct responsibility of the ITER processes of design, manufacture, integration, com- project team (ILE Organisation - Procurement pack- missioning and operational deployment. age: 23P6 estimated amount = 61,6 M€). This leading position of the French industry is The other Remote handling systems for ITER are based on the know how acquired through many provided "in kind" mainly by 3 partners which are: years of experience: Japan: Design and delivery of the entire Blanket The execution of major strategical programs , in module maintenance system - Procurement pack- particular in the field of nuclear energy, age - 23P1 estimated amount = 39,2 M€ A pole of acknowledged excellence in robotics China: Design and delivery of part of the Transfer supported by the universities, research agencies, cask system (TCS), in particular the module of and the robotic industry. transport : Transfer Cask, Procurement package - 23P3 estimated amount = 11,2 M€ (50% of 22,4M€) Europe: French nuclear industry: • Design and delivery of the complement to the Chi- a top level technological nese contribution for the Transfer cask system and industrial organisation (TCS), in particular: Pallets and motorised on air cushion: Procurement package - 23P3 estimated amount = 11,2 M¤ (50% of 22,4M€) Activities string • Design and delivery of the whole system for diver- in the nuclear industry tor cassettes maintenance: Procurement package - The French nuclear industry is one of the leading 23P2 estimated amount = 16,8 M€ industrial fields of activity in France and constitutes • Design and delivery of the whole of the modules a strategical component of the French energy policy. of in vessel viewing system (IVVS): Procurement This sector has grown continuously since the crea- package - 23P4 estimated amount = 9,8 M€ tion of the French nuclear agency "Commissariat • Design and delivery of the whole of the Neutral à l' Énergie Atomique (CEA) in 1945. The major beam heating maintenance system : Procurement nuclear energy programs, directed by the CEA, package - 23P5 estimated amount = 8,4 M€ have led to the structuring of a major industrial sec- Europe's overall contribution for RH is significant tor of activity, for the many applications of nuclear (approximately 46,2 M€ plus the contribution to engineering: medicine, energy and deterrent weap- the hotcell for approximately of about: 30 M€): on systems.

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re-processing of irradiated nuclear fuel and waste Nuclear energy in the "La Hague" center. This experience, was From 1978 to 1999, 58 electro-nuclear power- largely used to re-process the graphite sleeves at the plants with three levels of power (900, 1.300 and Vandellos 1 nuclear power plant in Spain. 1.450 MWe), built on 20 sites for an investment of 65 billion euros (value 2003), were connected to the electrical distribution network; EDF has a major programme of dismantling 78% of electric power generation capacity in its older reactors France is producted by nuclear reactors; This has led to development of a major activity The overall installed nuclear power amounts in remote handling and robotics, to 63 GWe; 9 EDF power plants stopped since 1973 and After the USA, France is the leading actor in are currently in different phases of being disman- the world in the civil nuclear field, tled, dismantling to be completed by 2025: The capital investment in the installed nuclear Bugey 1, Brennilis, Chinon A1 A2 A3, Chooz A, power plant is about 77 billion Euros (2003) Creys-Malleville, Sain(t Laurent A1 and A2, The European Pressurised reactor (EPR): This The first generation of CEA experimental re- third generation reactor was designed and devel- actors and associated nuclear facilities have been oped by AREVA NP (ex Framatome-ANP) joint dismantled. venture of AREVA and Siemens AG during years 1990 and 2000. In 2005 building of the first EPR started in Finland and in 2007 the second in France (Flamanville). The cost of the Flaman- ville EPR is approximately 3.3 Billion €.

EPR electro-nuclear power generator Brennilis: view of the chamber of the reactor and of the areas to be dismantled (Doc. Cegelec)

For more than 50 years, the CEA and its subsidiar- ies, many of which became part of AREVA, have Nuclear engineering built and commissioned approximately fifty nuclear The French nuclear industrial complex was devel- critical test beds, experimental nuclear power reac- oped to meet the requirements of nuclear power tors or naval propulsion reactors. plants and the complete nuclear cycle: treatment Associated to these different facilities, and in order and enrichment of uranium; manufacture of nuclear to support the French electro-nuclear programmes, "fuel components"; electricity generation in the many hotcells fitted with the various equipment (in- power plants; reprocessing used fuel; waste man- cluding robots) have been mainly built in the differ- agement. ent CEA research centers. The nuclear industry deploys advanced technolo- Many remote handling systems have been deployed gies in many fields of activities: instrumentation, for the dismantling nuclear installations and for the robotics, automated systems, non destructive test-

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W ,7(5 3 E G I GI      ing, command-control systems, remote handling, basis for safe mastering of complex physico- mechanical engineering, welding, filtering and ven- chemical processes with high level of safety, and for tilation, seismic equipment, civil engineering developing an industrial approach to the technolo- works, etc. gies necessary for the fuel cycle of the future nuclear fusion reactors: principally deuterium. The PWR fuel cycle The nuclear fuel cycle includes all the operations necessary to produce nuclear fuel, then to store Nuclear safety reprocess and recycle this fuel after use. France has developed all the facilities required for these The Nuclear safety organisation in France various operations: this cycle was developed in France set up doctrines of nuclear safety which France from the 1960s around the CEA, then thanks, to the high level of requirements regard- the COGEMA which became AREVA NC: ing organisation, regulation and controls, has COMURHEX factory located in Pierrelatte for avoided any major accidents since the start of manufacturing of uranium hexafluoride from nuclear power operations. The Nuclear Safety ore. Authority, called in French: "Autorité de Sûreté EURODIF facility located in Pierrelatte, Nucléaire (ASN)", is an independent authority opened in 1979, for enrichment by gas dissem- organisation which ensures, on behalf of the ination. France is the 2nd actor in the world in French Government, the control of nuclear safe- terms of enrichment capacity available on a mar- ty and radioprotection of workers and the gener- ket divided between 4 large actors. The existing al public. A statistical comparison with the other factory will be replaced the George Besse 2 fac- major sources of electricity demonstrates that tory using centrifugation for enrichment. nuclear energy is safer for people and that for MELOX factory located in Marcoule for man- which risks are the best mastered. ufacturing of mixed oxide (MOX) nuclear fuel components. For more than 30 years, French industry has been La Hague Reprocessing factory, opened in supporting nuclear facilities operators through en- 1966, following the pilot plant at Marcoule gineering studies, manufacturing and operations on (1958). Includes high activity oxide facilities for nuclear facilities. As a result French Industry has the reprocessing of PWR fuel. Capacity of 1700 considerable experience in preparing safety reports T per year, with recycling of compounds re-used for decisions concerning the building of nuclear fa- in the "MOX" nuclear fuel. cilities, for nuclear facilities commissioning and CEA then ANDRA: Storage of the ultimate res- start-up and operation: both for nuclear plant ac- idues in surface facilities ("Centre de stockage cording to the categories "INB" or "INBS for de la Manche" and "CSFMA" and "CSTFA") and defence" and for critical components related to a major project for underground geological Stor- safety (so called in French "E.I.S." - quality decree age. of August 84, decree "ESPN" of December 2005, "RCCM" regulation). Nuclear industry experts are involved in the writing of the necessary evolutions in the regulations to adapt them to the changes in size, manufacturing and inspection. As an example, several experts of group AREVA play an active role in the update of the RCCM regulations.

PWR fuel cells Cycle (ref. : AREVA) An organized industry

Large clients This experience obtained in the nuclear fuel cycle The civil nuclear energy sector is composed of fol- and nuclear reactor fission waste constitutes a solid lowing main groups:

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"Commissariat à l'Énergie Atomique (CEA)": Pub- ments an average of 3 to 4,5 billion euros each licly-owned agency working in scientific, technical year. The nuclear industry has become, over a and industrial sectors, the CEA is responsible for period of twenty years, one of the major cointrib- developing the the use of nuclear energy in the utors to the French export activity. fields of science, industry and defence. "Electricité de France (EDF)": Publicly-owned Company EDF is the industrial architect and oper- 140 companies (cf list in final appendix) take part ator of the nuclear power plants in France. in the ITER Industrial Committee (C2I) which is AREVA: created in September 2001, AREVA is a typical of the strong involvement of French industry world leader in proposing a complete offer for the in the preparation of industrial nuclear fusion. nuclear energy sector.

An extended and dynamic industrial base The dynamic activity due to the competitiveness In addition to the above major players, French nu- clusters ("pôles de compétitivité") clear industry counts several hundred companies In 2004 France launched a strategical industrial from SME with a few employees to large industrial policy to enhance the competitiveness of French groups such as Alstom, Schneider Electric or Syno- industry, and in particular its capacity for innova- dys. They work in a wide range of activity and di- tion. This resulted in establishing 66 competitive- versified markets, such those of the nuclear power ness clusters, associations of companies, research plants, research reactors, laboratories, medical centers and training organisations, working in part- equipment, nuclear fuel cycle, management of nership in a shared strategy of development, and waste. These companies constitute a solid industrial focused on developing synergies around jointly led base which is characterised by: innovative projects. its ability to provide solutions over the full range These poles in the sectors of aeronautics and space, of nuclear operations, of optics and electronic systems, software engineer- its diversified structures and services from simple ing, and manufacturing of nuclear components, are services providers up to "turn key" contractors, major "plus points" for supporting the emergence its maturity acquired through the mastering of of relevant technical solutions for and around RH the different disciplines in the nuclear industry and for the ITER project. the associated industrial tools, its dynamism in the search of innovative and op- erational solutions being supported by research or- Related to the ITER subject, the following poles of ganisations such as the CEA agency. competitiveness clusters are directly relevant: Note : French wording in this datasheet. Nuclear French Industry figures : Données DATAR et Ministère de l'Economie, des Finances et de l'Industrie CEA: 16.300 people - Annual budget: 3,9 G€ EDF: 116.000 people - Turn-over 34 G€ AREVA: 58.000 people - Turn-over 10,125 G€ Aerospace valley (2005) Toulouse Aéronautique, Espace, Systèmes embarqués Regarding the production of electricity, the nu- 75 involved companies System@tic clear field of activity employs overall more than Ile de France 100.000 people in France. Optique, Electronique et logiciel For France: the added value created by French 113 involved companies nuclear industry is estimated between 20 and Capenergies 28 billion euros a year. PACA - Corse Export activities: France is a recognised world- Energies non génératrices de gazs à effet de serre 100 involved companies wide leader in the field of nuclear engineering Microtechniques with a major volume of export orders which each Franche-Comté year are worth, in terms of the balance of pay- Micro-technologies 65 involved companies

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W ,7(5 3 E G I GI      Photonique (POPSUD) tion and to the necessary level of reliability and safety, PACA The diversity of implemented technologies and Photonique, optique, systèmes complexes skills, integrated from the start of the design phase, 75 involved companies based on generic tools ensuring the links between sev- Pôle nucléaire Bourgogne eral of these technologies and/or these skills and Bourgogne "multidisciplinary" computer modelling of the same Fabrication composants nucléaires system, 44 involved companies Methods of design adapted to the constraints related Route des lasers on the system itself, often multidisciplinary and multi- Aquitaine company design teams. Système laser, métrologie et Imagerie 44 involved companies The definition of the system environment from the TRIMATEC functional specification phase PACA, Rhône Alpes, Languedoc-Roussillon The taking into account of the multiple risks of fail- Valorisation technologies issues du nucléaire ure and their recovery on the whole of the system. 43 involved companies VIAMECA Lastly, the major programs on going or in operation Auvergne-Limousin-Rhône Alpes have all required the development of Concepts based Biens d'équipements, aéronautique, automobile on the limits of existing technologies, either in the field 43 involved companies of computing and software modelling, or in fast evolv- ing technologies (optics, optronic, electronic, data- processing, etc). Space (ARIANE, ATV) The management Aeronautics (Concorde, AIRBUS) of complexity Defence (Nuclear propulsion Submarine fitted with Ballistic missiles systems M51,...) Nuclear ("Laser Megajoule (LMJ)"), experimental The major programs with international cooperation nuclear propulsion Reactor (RES), electro-nuclear Eu- have as a common denominator the following prob- ropean pressurised Reactor -3rd generation (EPR), ex- lems: perimental nuclear reactor Jules Horowitz (RJH), etc) Managerial context and network working: cultural differences, linguistic barriers, normative equivalenc- The development of specific components, targeted re- es, documentary interfaces, etc. search programs, technological solutions derived from Technical context: design of complex systems com- fundamental research programs are often essential pre- posed of multiple technological parts and interaction liminary steps for ensuring the success of these pro- with "Man in the loop systems", whose design and op- grams. eration require different skills. Actors in France have a long experience of integration in international projects management organisations for the design of such complex systems as: Robotics: a pole of french excellence Space (ARIANE 5, ATV: Automated Vehicle Trans- fer, Satellites) Aeronautics (AIRBUS) A strong R&D activity Electro-Nuclear energy production (SUPER-PHENIX) At the French national level, in 2001-2003, CNRS Nuclear research (CERN) launched the Interdisciplinary Research Program (PIR) Robea ("robotique et entités artificielles"). The three One of the main and common points of the systems successive invitations to tender led to 32 research developed for these various programs is their high projects (on 98 submitted proposals), the last projects level of reliability and safety. The French companies finishing in 2006. Robea involved laboratories affiliat- master the design of such complex systems: ed to "CNRS", to Universities, the "INRIA", the "IN- Organisational skills developed and based on exact- SERM", the "CEMAGREF", the "CEA", the "DGA" ing standards (aeronautical standards), and the "INRETS". Network Management of projects, within European In 2006, the Robotics Research Group ("GDR CNRS") agencies or consortiums using the most powerful tech- was created with the role of leading and structuring niques for the exchanges of information, for data & of the scientific community in Robotics and establish- documentation (CAD, GED), ing and strengthening collaborations with industrial System Architecture, adapted to the required func- companies. Seven themes are concerned: medical ro-

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botics, autonomous vehicles, multi-scale handling, ro- cross obstacles, open ports, go up and down the stairs. botics methodologies, the Man in the loop systems in- They are equipped with manipulator arms, cameras, terfaces, the innovating design and the "mechatronics" light and many sensors. These robotic tools, and es- one and "Humanoid" robotics. pecially the robotic command-control electronics have The scientific community for robotics in 2006, (source been designed to operate in hard radiation environ- inquires GDR to the 10/09/2006) consisted of 400 re- ments up to 10.000 Gy (*). searchers in 60 academic research teams divided be- tween the various institutes plus 400 PhD students.

This sector of research is very active: the European "Call for interest : "Advanced Robot- ics" in December 2005, was a great success (123 for- warded projects), the "ANR" (a French national research organisation) launched the program "interactive Systems and Robot- ics ("PSIRob")" in April 2006: 43 projects involving about sixty teams, the publication of European robotics programs in the 7th PCRD.

In addition to the existence since 1999 of the network of excellence EURON (European Robotics Research Network), there has also been the recent creation of the technology EUROP which gathers together about fifty European companies, and which is coordinated by France. Lastly, it should be noted that French Robotics is placed systematically in 3rd or 4th position after the USA and Japan by the number of published papers in the most significant conferences in this field: IEEE, ICRA and IROS. Certain institutes, like "CEA" or "INRIA" are actively supporting companies through technology transfers. In the framework of the large scientific instruments, this is already happening for such projects as Laser Megajoule.

The park of robots "intra" Starting Since its creation in 1988, the Robotic Acci- dental Intervention Group (INTRA) is responsible for Robots for hostile environment DESIGN, OPERATION and MAINTENANCE The nuclear activities are not the only sectors using 24 hours a day of a fleet of robotic machines to inter- robots to intervene in hostile environments or situa- vene, in the place of man, in the event of major nuclear tions inaccessible to man. During these last years, nu- accidents, in and around the industrial facilities of its merous programs have allowed the French companies members. to develop robots to operate in varied operational The fleet is composed of mobile robotic systems and fields: machines, remotely controlled, capable of intervening Space access and exploration (satellites, Automated either inside facilities, or outside (including perform- Transfer Vehicle: ATV, and robotised arm ERA for the ing civil engineering work) and the logistics required servicing of the international space station: ISS), for full autonomy Group INTRA during operations. Underwater exploration, Inside the facilities, the robots are used where the con- Intervention in the areas of terrestrial, naval and ditions does not allow men to intervene. They can combined air-ground combat,

* 1Gy-Gray is equivalent to a deposition of 1 joule energy on 1kg of matter

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W ,7(5 3 E G I GI      These robots have a certain number of similarities Experience of the french with the robots used in the nuclear activities: industry in robotics (RH) Strong environmental constraints leading to the development of hardened technological components Due to both a dynamic nuclear power plant activity, (electronic, actuators, materials, sensors...), to the major scientific programs, such as the LMJ, Requirements for a high level in safety leading to and to the robotics pole of excellence, the French the mastering of the engineering process which takes industry has the technical capability and a necessary into account the need for safety from the initial de- experience to answer the technical challenges sign phase up to demonstrations in the qualification which represent the development of RH systems. phase, and in configuration management, The nature of the French companies, their skills, A "multi-disciplinary" skills and technologies ap- their industrial experience represent a reservoir rich proach, organised within technical and project man- in technical capabilities, organisational capacity and agement teams, often organised as a cooperation be- innovative potential allow them to meet the various tween several companies mastering different needs of RH systems. technologies, The references in robotics and remote handling, A close cooperation between the research labora- presented in the following paragraphs, were select- tories and the companies for the development of ad- ed starting for their pertinence to the needs of the vanced technologies (instrumentation, virtual reality, RH systems for ITER: decisional range, man/machine interface...). Similarity in term of performances (functional and transverse) and of constraints (environmental and operational), Similarity with the main operational require- ments for ITER RH systems : •Transfer and handling systems of components, •Remote handling by manipulator arms, •Remote handling processes, •Vision systems and metrology. 25 French companies participate in the "Robotics and Remote Handling" Group of the C2I (list at- tached in appendix).

Foot soldier Robot Technical capability for ITER Remote execution of complex operations by using Robotics, (more commonly: Remote Handling "RH"), is one of the leading skills of French Indus- try in the Nuclear field, acknowledged in Europe and around the world. Air to Ground unmanned vehicle French industry is particularly capable of meeting the needs for ITER in RH, combining robotics and the constraints of a nuclear environment. The de-

Space servicing Robot: sign and the building of RH equipment are per- automated transfert vehicle formed by companies having the required experi- ence in product management and the full range of industrial tools. They are supported by specialist companies in specific fields. As regards engineering, companies are specialised in one or more in the following areas: Management of Safety Requirements: the require- ments of ITER correspond to the requirements for other nuclear installations, like hotcells in the re- Autonomous under water Robot search laboratories:

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•during installation of the Torus, minimising the environment. Specialist companies ensure the as- cost of the intervention, ensuring the protection of sembly and integration of the different parts to ob- the handled components, and avoiding disruptions tain the complete system, coordinating the activities in the program, of the other specialist companies. •respecting environmental constraints, Some companies are multidisciplinary, and possess •protecting workers and operators including pro- all the facilities required for engineering, manufac- tecting them from possible errors of handling. turing and testing. In this case the RH equipment Full implementation of the French and European is thus managed by a single company from its initial standards and legislation applicable to nuclear facil- design up to its final acceptance testing. In this case ities. there is the advantage of using the experience in Advanced engineering, in particular in virtual im- robotics and of the nuclear environment acquired agery, necessary for the design of manipulators hav- in all activity areas in the company. For example, ing to move in limited space and a complex working welding tools, resulting from the know-how from volume, such as the ring of the vacuum vessel. metal fabrication, will be adapted by the engineer- These generate constraints for the control of umbil- ing office for remote handling, then manufactured ical of the carrier system. Virtual imagery is also in its works, and finally tested by an experienced necessary as a support for the command-control team in remote handling to validate all its functions. systems of the RH equipment above-all when direct It will be very simple in this company to make any vision is not possible, as will be the case in the Vac- final adjustments that may be necessary to ensure uum vessel on ITER. Development of specialised manufacturing proc- the perfect operation of the tools. esses adapted to the limits of remote handling, for The multidisciplinary nature of these companies example: welding processes for high performance gives them an added advantage to adapt to new and alloys and metals as will be necessary in the vacuum unforeseen situations, which will probably occur vessel for the replacement of the blankets modules. during the course of the ITER project, in particular Specific design of the machines to facilitate main- at the time of the assembly of ITER on the site at tenance, decontamination, and for a perfect reliabil- Cadarache, and which will require a management ity in their use. between numerous interfaces. In-depth research on key-aspects like the resist- In nuclear environment, inspection and monitoring ance of materials to radiation, so ensuring an sub- systems based on electronics are faced with the need stantial lifetime for the equipment in the presence for radiation hardening (subjected to neutron radi- of high dose rates as will be encountered in the vac- ation and associated ionising radiations, the junc- uum vessel of ITER. tions in electronic circuits are required to avoid Development of radiation hardened electronics burn-out). Protection is obtained by "shieldings": for performing tasks in a nuclear environment and/or of by specific technological choices of elec- (1 Mrad) and where the electronics cannot be posi- tronic components (e.g.: sensors of the robots used tioned outside the high radiation zone. "INTRA" as described in the § 2.4) for which the French research centres, in particular CEA ("LETI") As regards the building and commissioning of and industry have developed specific manufactur- equipment, French companies have at their disposal ing and qualification processes. a set of powerful industrial tools, adapted to the nuclear applications. They have a perfect knowl- edge of the nuclear environment, acquired over a long period working for the French nuclear power Available experiences plants and for the research sites, including on Ca- & references darache site where ITER will be built. Some manufacturing companies are specialised: mechanical engineering, metal fabrication, electri- Components transfer cal technology, electronics. They offer all the re- and remote handling systems quired guaranties for working to French and inter- Typical of the different current references of french national standards and meeting the specific companies for remote handling machines that have requirements for equipment to be used in a nuclear been manufactured for nuclear facilities:

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W ,7(5 3 E G I GI      the fuel handling systems for the manufacture of Of pretence are also the following handling equip- fuel and in nuclear plants (EPR programs) ment: the handling of nuclear waste (conditioning, tem- - assembly station for aircraft fuselage (AIRBUS porary storage/permanent storage, deep burial stor- program), age facilities) - handling of weapon systems on submarines and remote handling the diagnostic devices ("LMJ", surface ships (DGA program) "LIL" programs) the handling of components during the assembly of ballistic missiles (M51 program)

Weapon system handling

Experimental missile On flight test pad

Waste parcel handling equipment

Airframe structural assembly handling systems

Remote handling by manipulator arms

Nuclear matter handling The French companies have developed know-how and advanced technology in the field of system ar- chitecture for manipulator arms and associated da- ta-processing for the command-control systems used by the operators. The applications developed in this field are mainly those for the nuclear power or the offshore oil industry.

It is important to note in this field the role of the "LIST" laboratory of the CEA in Fontenay-Aux- Roses which carried out technology transfers to French companies on manipulator arms with force Waste barrel handling on (water or) air cushion transfer system feed-back (TAO environment).

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Viewing and Metrology System

The vision and metrology systems are developed from existing technologies but designed to work in constrained environments and taking into ac- count the mobility which their carrier system must have to cover the whole area to be inspected (eg LORA: long range arm Electrical arm manipulator arm). There are a number of referenc- es of systems based on arms and sensors working in strongly radiation environments.

Various technologies for the manipulator arms are characterised by architectures using multiple joints (LoRA arm) or flexibility ("LMJ" arm) in order to obtain the following capacities: Long range deployment,

Command-control device Hydraulic power arm Obstacle avoidance , for manipulator arms Stability in positioning, Payload compatibility taking into account the weight of the sensors. Processes tools

The nuclear industry uses specific tools for main- tenance, inspection, dismantling...operations. There are many references in this field of industri- ally developed special machines and tools dedicat- ed to specific processes and operations. Mechanical Process with the contact: Machining, welding, surface treatment, sample tak- ing , thermal sleeving, tapping, screwing, milling, high pressure jetting, NDT processes: Dye penetrant inspection, Ultrasonic inspection , metrology,

The specific tools are integrated onto a dedicated The technological carrier for their remote positioning in the work area (manipulator arm, mast, mobile vehicle in air or and industrial challenges under water, ...). of remote handling for the ITER machine Foreword

The managers and engineers for responsible for remote handling are confronted with 3 types of Cutting machine Welding rig in a cell Welding Machine: problem on the ITER project: for the Canopy joint for container orbital self-adapting TIG process The technological challenges resulting from the tasks to be performed and the constraints due to the environment within the machine and its aux- iliary equipment.

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W ,7(5 3 E G I GI      The industrial challenges : despite the innovative place large and heavy internal components, from the nature of the solutions to be developed, these solu- 4.5T blanket modules up to the 10T divertor cas- tions must be “industrial” as the continued operation settes. In this case the maintenance operations will of the machine in future years depends directly on be performed over several months in less severe the reliability and performance of the remote han- working conditions (slightly less than atmospheric dling equipment; pressure, temperatures up to 50°C and no magnetic The challenges involving the organisation of the field.). However access to the vacuum vessel will be studies: in particular the nedd to integrate the con- limited by the need to eliminate the risk of dispersion straints of remote handling as early as possible in the of contamination. conceptual studies of the ITER machine components The configuration of the vacuum vessel and the ge- and their assembly. The remote handling equipment ometry of the first wall are essential factors deter- interface with many of the machine components. The mining the performance of the machine. The posi- level of the ITER machine studies is not sufficiently tioning of components such as the blankets or detailed and will probably be put into question dur- divertors shall be accurate to within a few millime- ing the current design review. Equally the constraints ters - very difficult given the weight and size of the of the operation of the machine are not fully integrat- parts to be handled. Each of the vacuum vessel com- ed into the current definition of the remote handling ponents is cooled by a cooling water circuit. The equipment. replacing of parts requires delicate cutting and re- welding operations of the cooling pipes on the back faces of the parts - the limited access to the pipes The technological challenges being from the front faces. The cutting and re- welding tools are to be either deployed by the remote The Technological challenges are related to the lim- handling equipment to be used for replacing the ited access to the work zones, the tasks to be per- parts (the case of the blankets) or to be integrated formed in these work zones, and the working condi- on the remote handling equipment (the case of the tions for the equipment. divertor cassettes) or to be deployed within the pipes The access to the inside of the machine is provided themselves (also for the divertors). by a limited number of ports around the circumfer- Each of the above tasks requires the development of ence of the machine at different levels. The remote specfic remote handling equipment, calling for ded- handling equipment will be deployed from these icated equipment design and technology, mechanical ports and progress to their work areas within the ma- construction, motors, umbilical management and chine, often a considerable distance from the ports control systems associated with sensors capable of but without using the vacuum vessel components as withstanding the radioactive flux which will progres- supports. sively increase during the lifetime of the machine. Accordingly the first series of problems concern ac- cess inside the machine and deployment from the access ports. The industrial challenges Thereafter there are the tasks to be performed. The first series of tasks to be performed during the The ITER machine is a scientific test facility - as an operational phase of the machine concern the inspec- example the materials facing the plasma can be re- tion and testing of the first wall of the vacuum vessel. placed by more resistant materials. However in or- In this case the loads to be deployed are low (<50kg). der to perform this type of operation it is necessary However to minimise machine "down time" the to safely recover and replace such large components equipment must be deployed in extreme working as the blankets and the divertor cassettes. conditions : high vacuum, high radioactive flux (the Due to the unique characteristics of the ITER ma- equipment will be deployed just after the disappear- chine and the over-riding priority to avoid any de- ance of the plasma), high temperature (120°C) and terioration of the machine performances during magnetic fields up to 6 Tesla. maintenance operations, the remote handling The second series of tasks concern the preventive equipment will be designed specifically for ITER. and curative maintenance operations, programmed However they must be designed and built as indus- or otherwise. In particular it will be necessary to re- trial equipment including:

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An analysis of failure modes, their frequency and realm of the « special tailor made machine - unique criticality (FMEA studies); and a world first » applied to the installation. How- The selection of components and the design of ever to ensure an optimal operation of the machine the equipment as a function of their reliability over the years to come, and thus its maintenance, The definition and study of reduced functional it is necessary to find the correct balance in require- operating modes ments between the remote handling equipment « fall back « solutions to ensure that in any and and the components. all circumstances it is possible to recover the re- Due to its design the ITER machine is extremely mote handling equipment from the machine back complex. The organisation of the ITER Project to a rear area for maintenance and repair. Above- adds further complexity. On projects such as ITER, all it is essential to design the equipment to ensure success is dependant on a draconian management that the equipment does not stay « blocked » inside of interfaces both technical, functional and con- the machine. tractual. It appears that to-date, the processes re- quired to ensure a strict management of these in- Past experience clearly demonstrates that the terfaces have not been established for the domain FMEA studies and « fall back » mode studies have of remote handling. major decisive consequences on remote handling It is noted that the remote handling equipment equipment design. team is limited to 2 people in 2007 and that the However it appears that the studies performed to- supply of remote handling equipment is shared be- date have concentrated on the technological chal- tween 3 partners (EU, Japan, China) which reduc- lenges and not on equipment reliability and « safe es the possibilities to integrate activities as required operation ». for the optimal "co-design" of the ITER compo- Equally it should be noted that the conctraints of nents and the remote handling equipment. the nuclear environment have not been fully inte- In conclusion, despite the primordial importance grated into the remote handling equipment studies. of the remote handling equipment to ensure the Thanks to many years of experience acquired in continued operation of the ITER machine over the the design and operation of remote handling and years to come, the remote handling activities are robotic equipment in nuclear environments, there not treated with sufficient priority by the "ITER are design rules to be respected for ensuring satis- community". factory performance. However the approach The continued operation of the ITER machine is adopted to-date in using companies having little directly dependant on the reliability of the remote or no prior experience in the nuclear industry to handling equipment. A major breakdown which perform studies for ITER does not appear optimal leaves the equipment permanently blocked inside for integrating the long and difficult lessons learnt the machine will result in the end of the operational in the nuclear fission industry. life of the machine and probably the end of any further fusion research in Europe for many years.

The challenges of integrating remote Accordingly the challenges of Remote Handling are handling equipment and component major and must be treated and solved on an indus- design for ITER trial basis from the start of the assembly phase of the vacuum vessel. We are obliged to note that the priority is currently given by the ITER team to solving the major prob- Foreword: lems of component design in order to ensure the The technical and industrial illustrations of this document and ref- satisfactory performance of the Tokamak and that erences have been provided by the agencies (CEA, "ANDRA", "Mis- sion ITER"), companies (cf lists in appendix) which are acting in less priority is given to ensuring the integration of the Thema group set: Remote handling - RH" of the C2I, or included the remote handling equipment design with that after the courtesy EFDA agreement. of the components. The specific nature of the remote handling equip- ment design is due to the absence of directly appli- cable standards and the subject is closer to the

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W ,7(5 3 E G I GI      POWER SUPPLY

List of participants

A2ET ENERTRONIC / Competitiveness Cluster S2E2 ALSTOM POWER SERVICE

CEGELEC

FAUCHE

GEI2004

IST AUXITROL NUCLEAR

REYES INDUSTRIES

SCHNEIDER ELECTRIC

SERCE

SIEMENS

SNEF

SPIE Nucléaire

VINCI Energies

(only 3 meetings)

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W ,7(5 3 E G I GI      annex

MEMBRES DU C2I

40-30

A2ET ENERTRONIC / Pôle S2E2 ABMI Consulting ADDAX ADIXEN / Alcatel Vaccum Technology France AFOP (Association Française de l'Optique et de la Photonique) AIR LIQUIDE AIR LIQUIDE Gaz Industriels Services AKKA Ingénierie et Process ALSTOM ALSTOM POWER SERVICE ALTRAN AMESYS / CRESCENDO APAVE INTERNATIONAL INSPECTION ARCELOR RESEARCH ARCHIPEL AREVA NC / SGN AREVA NP AREVA TA AREVA TN International ASSYSTEM ASTRIANE ASTRIUM Space Transportation ATECHSIS ATIS ATMOSTAT ATOS ORIGIN AUBERT & DUVAL AVANTIS ENGINEERING AVODA ingénierie services AXIMA Réfrigération France AXON CABLE SAS BERTIN TECHNOLOGIES BODYCOTE FB BUREAU VERITAS CALLEWAERT C-CON France CEA CEDIP INFRARED SYSTEMS CEFIVAL CEGELEC CETIM CILAS CIMAT CIO Informatique Industrielle CIRA Concept CMW CNIM COFATHEC COMEX NUCLEAIRE CORIMA MODELAGE CS - COMMUNICATION & SYSTEMES

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W ,7(5 3 E G I GI      CYBERNETIX DAHER DCNS DE VIRIS EADS NUCLETUDES ECA Ecole Centrale Marseille - Institut Fresnel EFINOR EGIDE ERAS EURIWARE EURODOC Services EXAVISION FAUCHE FIM (Fédération des Industries Mécaniques) GIIN (Groupe Intersyndical de l'Industrie Nucléaire) GIMELEC (Groupement des industries de l'équipement électrique et du contrôle commande) GRUNDFOS IFOTEC INSTITUT DE SOUDURE INTESPACE IRELEC IST AUXITROL NUCLEAR IVEA IXFIBER KAPPA ICE LE VERRE FLUORE LHERITIER LOVALITE LP3 LABORATORY - MARSEILLE UNIVERSITY MECACHIMIE - AREVA NC MECAGEST - AREVA MICRO CONTROLE - SPECTRA PHYSICS S.A.S MPH France NEXANS France NFM Technologies NORDON CRYOGENIE SA (FIVES CRYOGENIE au 01.12.07) OAKRIDGE OPA OPTICAD OPTIQUE PETER OPTIS sas IOSIS Méditerranée PDCA Pôle de Compétitivité MIPI Pôle de Compétitivité Optique-Photonique POPSUD Pôle de compétitivité VIAMECA Pôle Route des Lasers Pôle TRIMATEC QMT Sarl REEL SAS Réseau Nucléaire Rhône-Alpes Provence REYES INDUSTRIES ROBATEL Industries SNSI Provence

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W ,7(5 3 E G I GI      SAGEM DEFENSE SECURITE SAGEM REOSC SAINT-GOBAIN SEVA SCHNEIDER-ELECTRIC SDMS SEDI FO SEOP - Sud Est Optique de Précision SERCE (Syndicat des entreprises de Génie électrique) SESO SETEC / PLANITEC SHAKTIWARE SIEMENS SILIOS SIMTRONICS SNEF SODERN / EADS SODITECH SOGETI High Tech SOPRA SA SPIE Nucléaire STMI - AREVA NC SUEZ SUEZ-TRACTEBEL ENGINEERING SYNTEC Ingénierie TECHNIP France TECHNOPLUS Industries TECHNOR SNRI et MALBRANQUE THALES THALES ANGENIEUX THALES LASER TSA VINCI Energies WINLIGHT SYSTEM YOKOGAWA France S.A.S

Many thanks to all these actors and especially, for their active support, to the CEA experts and Thematic group's leads for the redaction of this report.

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W ,7(5 3 E G I GI      Contact: [email protected] https://mioga.minefi.gouv.fr/ITER/public/SITE/

W ,7(5 3 E G I GI