CREATING VACCUM. How to create ITER test facility: reporting from the spot
Within the framework of the jointly implemented international project ITER the Russian companies and organizations are assigned to produce and deliver 25 high-tech systems for the future thermonuclear set-up. One of these systems is a port plug test tank – a utility system to be mounted in nozzles (or ports) of the reactor vacuum chamber. Test stands are designed for vacuum, thermal and functional tests of port plugs. As per Procurement agreement signed in 2011, the Russian company shall produce and deliver to ITER 4 similar stands– 2 nuclear and a non-nuclear one. Moreover, ITER requires that while testing the conditions inside the chamber shall be as close to real ones as possible. In order to tackle this goal a board of experts in Bryansk branch of the NPO GKMP applies the cutting edge and truly unique national technologies and developments. Photo shooting from the production site and comments of the lead experts are presented in press release of the ITER project Center (subdivision of State Corp. Rosatom).
Alexander Solopenko
Deputy CTO, NPO GKMP LLC
“What makes me really proud with this project is the way people cooperate, especially designers and engineers with production department. We do our best in order to be prompt at finding solutions. We never have serious conflicts. Should we have some disagreement, we solve them out promptly.
This year we will definitely finalize the first chamber out of 4 our company was assigned with. As of this moment, it’s our top priority. We do not foresee any significant difficulties while further production of the remaining 3 chambers. Our production capacities and experience shall suffice.
Technology is brand new and as for the initial plan, let’s say that technology of test chamber assembly, lifting system have undergone corrections while manufacturing. Such challenges were always welcome by our team. ITER is getting more and more emphasis and interest”.
Assembly site: general layout.
Olesya Solovyeva
Director of the ITER Project Office, NPO GKMP LLC
In terms of workmanship one shall always keep in mind that it’s about research and development activity; the idea is to come up with product never used before. This product comprises several technologies at different levels.
There is no such company that is capable to create vacuum, pressurized vessels and special radiation shielding at one single site. To gather them all in one place, i.e.to create a single technological center is a highly complicated and comprehensive task that we aim at.
Inkonickel studs (highly robust alloy) to attach port plugs
Artem Veretennikov
Quality Director, NPO GKMP LLC
- GKMP has its own competences. One of the reasons why we started working on this project is that we have a specificvacuum furnace designed and manufactured in-the-house. The vacuum annealing of stainless-steel structures is our know-how. Few companies in Russia have proper capacities for that.
- prior to proceed with non-destructive control within the framework of ITER project our experts undergo special training as per European regulation in term of quality assurance, and thus have all the necessary certificates.
- Each crucial assembly is provided with the production and inspection plan.
Every step is thoroughly documented as required by ITER. Russian agency ITER requires to stick to the regulations and monitors over very carefully.
Roman Belov
Deputy General designer, NPO GKMP LLC
We are developing a control system for ITER test facilities: from hardware to the software. In order to take part in ITER project we came up with our own standards of programming and based the entire automation system thereon. Without automation such complex system cannot be launched, it would be impossible to make it work.
- In the very beginning ITER was all new for us not only in terms of the hardware but software either, principles etc.
While working on ITER we had to explore various software products. I believe that our specialists involved in this project are one of the best in Russia.
- We had to learn a lot and with good results. We are looking forward to launch our system. The most exiting part, however, will start when we get the first practical result.
Clean room with general lifting frame
Lifting mechanism for 96 tons to move large parts of the test facility while Integration test and universal travers for 50 tons.
Samkov Yaroslav, Lead engineer-technologist NPO GKMP LLC
We work in the company that produces non-standard equipment and ITER is no exclusion. ITER is first of all about brand new cutting-edge technologiesthat we apply, new tools never used before. All this makes working process rather exiting.
- ITER has high standards applied to accuracy and workmanship. I believe that the main challenge the ITER proposes is the complexity of craftsmanship: there is a deal of intermediate milestones that require accurate positioning and thorough intermediate inspection.
- What we do for ITER project make us pioneers in many ways in Russia. And we manage to tackle the most complicated technological issues. The result proves that the technological solutions we implemented are the correct ones.
Yuri Rumyamntsev
Project manager, Private institute “ITER-center” (Rosatom)
In order to develop and set up atest facility one requires professional skills in various areas of machinery: for instance, a technique to create and continuously maintain deep vacuum up to 10-6 Pa, exposure to high temperatures up to 2500C, operating the hardware under pressure over 85 ppm.
It requires knowledge and experience in high-tech software (creating of 3D models, stress analysis of finite element models, programming and other things).
- I am glad to notice that the NPO GKMP LLC has professional skills as well asproper skills required to implement this project quite completely at its own with few activities outsourced for specific objectives.
Test vessel
