Cryostat :
30 m high and 30 m diameter Outer vacuum shell of
ITER |
- Special welding techniques and weld inspection methods developed for thick welds to ensure welding across plate thicknesses ranging from 20 mm to 200 mm with a dimensional control tolerance to within 0.3% and sub-mm flatness control accuracy over 30 m size.
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| Cryolines and cryo distribution system : 4 km cryolines, 7 km warm lines and 7 cryodistribution boxes for ITER cryo-plants of capacities 75 kW at 4.5K, 1 MW at 80K & their supply |
- Multi process transfer lines capable of ensuring long distance delivery of liquid helium at specified temperatures under extreme thermal insulation developed.
- World’s largest mass-flow rate cold circulators with efficiency >70%, 3 kg/s at 4.3 k with pressure heads <0.5 bar.
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| In wall shielding : ~80 % volume between the two shells of vacuum vessel is filled with borated steel (SS304B4, SS304B7) and ferritic steel for neutron shielding and reducing toroidal field ripple. Requires ~9000 blocks from 70,000 precision cut plates. |
- High boron containing steel material developed using powder metallurgy technique. Also developed are special component machining techniques to control magnetic permeability.
- Accelerated corrosion tests carried out for reactor-like conditions
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ITER – Cooling water and Heat Rejection System :
10 cells of Cooling Tower : Avg. 510 MW : Highest heat rejection capacity – Peak ~ 1.2 GW
14 Plate type Heat Exchanger: 70 MW each: Possibly at the highest range of design
6 Air cooled Chillers: 450 kW each: First, with requirement of seismic qualification for nuclear site |
- Site constraints of buried piping required pipe in pipe design of the 20 km long piping network (SS & CS), manufactured under PED protocol – involving ~105 inch dia. welds & their volumetric examination
- 2500 spools delivered, major components- chillers (uniquely large capacity, fully made in India), cooling tower, pumps at advanced stage completion of delivery
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ICRF source system :
9 RF sources : 2.5 MW at VSWR 2.0/35-65MHz/CW OR 3.0 MW at VSWR 1.5/40-55MHz/CW |
- Tube development: Tetrode: ~1.9 MW/VSWR 1:1/300s ; Diacrode : 1 MW/VSWR 1:1/1000 s
- No unique amplifier chain able to meet ITER needs, so ITER-India developed a layout consisting of two parallel three-stage amplifier chains
- Tube qualification (R&D) demonstration done at 1.5 MW for some frequencies with mismatched load
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| Diagnostic neutral beam system : Detect He ash during D-T phase of ITER plasma and plasma diagnostics using 100 keV 20 A H neutral beam @ 20.7 m from the ion source. This requires extracting and accelerating 100 keV 60 A H- beam from the ion source at an extracted current density of 35 mA/cm2 |
- Uniquely large area plasma source for negative ion extraction: Involves making some components by only Cu- electrodeposition; multi aperture extractor and accelerator grid with aperture positioning accuracy of 50 microns, flatness control of 0.4 micron and angular accuracy of 0.011o over segment dimensions of 0.8 m width and 0.4 m height
- Deep drilling over 1.7 m with a drift control of < 500 mm; Electron beam welding of dissimilar metal joints – OFCu – OFCu, OFCu-Ni-SS, CuCrZr-CuCr, CuCrZr-Ni-SS
- UHV class 9 m long, 4.5 m diameter SS vacuum vessel with top openable lid manufactured, tested and installed at Indian test facility (INTF), first of its kind facility with beam transport length of ~ 21 m.
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Power supply (PS) system/High Voltage Power Supplies (HVPS) for DNB, ICRF and ECRF systems:
DNBPS system: Consisting of 7.2MW/96kV Acceleration Power Supply,
200kW RF Generators,
1.5MW/12kV Extraction Power Supply,
High Voltage deck and Transmission line
HVPS for ICRF: 250 kW/8-18kV for driver stage & 2.8MW/27 kV for end stage RF amplifiers
HVPS for ECRF: 6 MW/55kV, main bias power supply for Gyrotron |
- DNB: 7.2MW, 100kV Acceleration Grid Power supplies delivered to Padova Italy for ion source test bed
- Transmission line developed for INTF to support power transport of 15MW over length of 25m @100kV, also accommodates hydraulics, RF lines for Indian Test facility
- ICRH: Dual output High Voltage Power Supply developed at ITER-India (First of its kind with a unique concept)
- The technology (patented) of Switched Power Modules and cast-resin transformers was already developed by IPR. Similar high-tech power supplies are being used for other major R&D programs of DAE
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ECRH :
2 gyrotron sources : 1 MW power output at 170 GHz for 3600s pulse length |
- Gyrotron test facility under development at INTF lab
- 55kV, 110A, PSM based Main High voltage power supply for the gyrotron cathode circuit in advanced development stage
- A prototype of compact cost effective solution using solid state switch has been prepared and tested as a potential solution for the low current fast switching high voltage gyrotron body power supply
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Diagnostics: Essential to monitor plasma impurities and emission. Ports are needed to house the Diagnostic systems in position and act as shielding from neutrons.
- X-Ray Crystal Spectroscopy (XRCS) : Set of spectrometers((X-ray crystals, Detectors , Vacuum chamber)
- Electron Cyclotron Emission (ECE) : Set of Michelson Interferometers & Radiometers, Polarization splitter unit, Transmission lines
- CXRS : Optical Fibers, Detectors, Visible Spectrometers, Opto-mechanical components like filters, mounts, I&C
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- A prototype Fourier Transform Spectrometer developed to establish in vacuum attenuation calibration for a 8 m transmission length for the transmission line attenuation
- Test sources and equipment for X-Ray spectroscopy under development
- Bent-crystal spectrometers under neutron environment as well as the detection systems are a new challenge (as the components cannot be easily accessed later)
- The Port plug and its integration of diagnostics within will be another challenge
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Special material development
CuCrZr with % compositions controlled to Cr : 0.6 – 0.8%; Zr : 0.07% to 0.15% ; Cd : 0.01%; Co : 0.05% ; total impurities not to exceed 0.1% |
- Material successfully developed by ITER India under MoU with NFTDC, Hyderabad.
- Developed material is being used in ITER Beam Line components.
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