（RE-00332）ITERダイバータラングミュアプローブ付きタングステンモノブロックの認証用試作【掲載期間：2025-02-26～2025-03-17】

（RE-00332）ITERダイバータラングミュアプローブ付きタングステンモノブロックの認証用試作【掲載期間：2025-02-26～2025-03-17】 公告期間： ～ ( )に付します。 1．競争入札に付する事項RE-00332仕様書のとおり２．入札書等の提出場所等入札説明書等の交付場所及び問い合わせ先(ダイヤルイン)入札説明書等の交付方法上記２．(1)に記載の交付場所または電子メールにより交付する。 ただし、交付は土曜,日曜,祝日及び年末年始(12月29日～1月3日)を除く平日に行う。 電子メールでの交付希望の場合は、「 公告日,契約管理番号,入札件名,当機構担当者名,貴社名,住所,担当者所属,氏名,電話,FAX,E-Mail 」を記載し、上記２．(1)のｱﾄﾞﾚｽに送信。 交付の受付期限は 17:00までとする。 入札説明会の日時及び場所入札及び開札の日時並びに場所令 和 7 年 4 月 11 日松田 好広ＦＡＸ 050-3730-8549(2)件 名内 容(5)入 札 公 告 (郵便入札可)(金)茨城県那珂市向山８０１番地１管 理 部 長那珂フュージョン科学技術研究所国立研究開発法人 量子科学技術研究開発機構(月) 令和 7 年 3 月 17 日助川 辰樹国立研究開発法人 量子科学技術研究開発機構 那珂フュージョン科学技術研究所ITERダイバータラングミュアプローブ付きタングステンモノブロックの認証用試作令和7年12月22日029-210-2389履 行 場 所履 行 期 限一般競争入札14時30分製造請負令和 7 年 2 月 26 日(1)下記のとおり〒311-0193E-mail：ＴＥＬ(2)(3)(1)契約管理番号nyuusatsu_naka@qst.go.jp那珂フュージョン科学技術研究所R7.3.17(4)実 施 し な い管理部契約課管理研究棟１階 入札室(114号室) 那珂フュージョン科学技術研究所(4)R7.2.26茨城県那珂市向山８０１番地１(3)記３．競争に参加する者に必要な資格当機構から指名停止措置を受けている期間中の者でないこと。 全省庁統一競争入札参加資格を有する者であること。 当機構が別に指定する誓約書に暴力団等に該当しない旨の誓約をできること。 ４．入札保証金及び契約保証金 免除５．入札の無効入札参加に必要な資格のない者のした入札入札の条件に違反した者の入札６．契約書等作成の要否７．落札者の決定方法８．その他その他、詳細については、入札説明書によるため、必ず上記２．(2)により、 入札説明書の交付を受けること。 本入札に関しての質問書は、 15:00までに上記問い合わせ先宛てに提出すること。 なお、質問に対する回答は、 中に当機構ホームページにおいて掲載する。 本件以外にも、当機構ホームページ(調達情報)において、今後の「調達予定情報」を掲載していますのでご確認ください。 (掲載箇所URL：https://www.qst.go.jp/site/procurement/)以上 公告する。 国立研究開発法人量子科学技術研究開発機構 契約事務取扱細則第10条の規定に該当しない者であること。ただし、未成年者、被保佐人又は被補助人であって、契約締結のために必要な同意を得ている者についてはこの限りでない。 (2) 落札決定に当っては、入札書に記載した金額に当該金額の10パーセントに相当する額を加算した金額(当該金額に1円未満の端数があるときは、その端数を切り捨てた金額とする)をもって落札価格とするので、入札者は、消費税に係る課税事業者であるか免税事業者であるかを問わず、見積もった金額の110分の100に相当する金額を入札書に記載すること。 (2)(1)(2)(3)(4)(1)(4)(2)(3)前項の誓約書を提出せず、又は虚偽の誓約をし、若しくは誓約書に反することとなったときは、当該者の入札を無効とするものとする。 国立研究開発法人量子科学技術研究開発機構 契約事務取扱細則第11条第１項の規定に該当しない者であること。 (5) 本契約締結にあたっては、当機構の定める契約書(契約金額が500万円以上の場合)もしくは請書(契約金額が200万円以上500万円未満の場合)を作成するものとする。 (月) 令和7年3月10日令和7年3月5日 (水)(1)この入札に参加を希望する者は、参考見積書等の提出時に、当機構が別に指定する暴力団等に該当しない旨の誓約書を提出しなければならない。 予定価格の制限の範囲内で、最低価格をもって有効な入札を行った入札者を落札者とする。 (最低価格落札方式)(1)(5) ITERダイバータ用ラングミュアプローブ付きタングステンモノブロックの認証用試作仕 様 書国立研究開発法人量子科学技術研究開発機構那珂フュージョン科学技術研究所ITERプロジェクト部 プラズマ対向機器開発グループ1目次1. 一般仕様.. 31.1. 件名.. 31.2. 目的.. 31.3. 契約範囲.. 31.4. 実施場所.. 31.5. 納入物及び納期.. 31.6. 納入場所.. 31.7. 検査条件.. 41.8. 提出図書.. 41.8.1. 提出図書の要求事項.. 41.8.2. 提出図書の確認方法.. 41.9. 支給品.. 41.9.1. LP.. 41.9.2. 評価用LPダミー付きＷモノブロック.. 51.10. 適用法規・規格基準.. 51.11. 知的財産権等.. 51.11.1. 知的財産権等の取扱い.. 51.11.2. 技術情報の取扱い.. 51.12. グリーン購入法の促進.. 51.13. 打合せ.. 51.14. 一般責任事項.. 61.15. 協議.. 62. 技術仕様.. 72.1. LPとWモノブロックの接合に関する検討.. 72.1.1. 全般事項.. 72.1.2. 接合方法の検討.. 82.1.3. 接合方法の選定.. 82.2. LP付きWモノブロックの試作.. 132.3. LP一体型Wモノブロックの製作検討と試作.. 132.4. 提出図書作成.. 142.4.1. 検討用試験要領書.. 142.4.2. 検討用試験報告書.. 152.4.3. LP付きWモノブロックの試作要領書(Test protocol for Langmuir probe attachment with Wmonoblocks).. 152.4.4. LP 付き W モノブロックの試作報告書(Test report for Langmuir probe attachment with Wmonoblocks).. 162別紙－1：知的財産権等の取扱いについて別紙－2：ITER真空ハンドブック別紙－3：ITER計測ハンドブック31. 一般仕様1.1. 件名ITERダイバータ用ラングミュアプローブ付きタングステンモノブロックの認証用試作1.2. 目的本件は、国立研究開発法人量子科学技術研究開発機構(以下「量研」という。)が製作するITERダイバータ外側垂直ターゲット(以下「OVT」という。)のうち、ラングミュアプローブ(以下「LP」という。)付きOVTに使用されるLP付きタングステン(以下「W」という。)モノブロックの製作技術の認証を行うための試作品を製作するものである。受注者は、W に対する本作業の目的を十分に理解し、取扱方法・関係法令・規格等の基に計画を立案し、本作業を実施するものとする。なお、LP は、W ヒートシールドと W電極で構成される部品であるが、本仕様書ではWヒートシールドのみの場合をLPという。1.3. 契約範囲(1) LPとWモノブロックの接合に関する検討(2) LP付きWモノブロックの試作(3) LP一体型Wモノブロックの製作検討と試作(4) 提出図書作成1.4. 実施場所受注者事業所1.5. 納入物及び納期(1) 納入物(a) 図書(1.8節参照) 1式(b) 試験済みの評価用LPダミー付きWモノブロック 40個(c) 試験済みのLP付きWモノブロック 5個(d) LPダミー付きWモノブロック 20個(e) LP一体型Wモノブロック 5個(2) 納期令和7年12月22日(月)1.6. 納入場所茨城県那珂市向山801-1量研 那珂フュージョン科学技術研究所(以下「当研究所」という。)第1工学試験棟居室棟41.7. 検査条件1.5 項に定める納入物の納入及び本仕様書に定める作業が完了し、仕様の要求を満足すると量研が認めたことをもって合格とする。1.8. 提出図書提出図書を表1-1に示す。表1-1 提出図書名称 提出時期 確認要否検討用試験要領書 技術仕様を参照 要検討用試験報告書 技術仕様を参照 要LP付きWモノブロックの試作要領書 試作作業開始前 要LP付きWモノブロックの試作報告書 試作完了後速やかに 要打合せ議事録 打合せ後、1週間以内 要再委託承諾願(下請負等がある場合のみ提出)(量研指定様式)作業開始2週間前まで要逸脱許可申請書申請すべき事項が生じた時、直ちに要1.8.1. 提出図書の要求事項提出図書の要求を以下に記す。(1) 提出図書は電子版(CD-ROM)で提出すること。(2) 提出図書は和文または英文とすること。技術仕様で指示がある場合は指示に従う。(3) 表紙には、表題・契約件名・契約管理番号・契約年月日・契約者名を明記すること。(4) 提出図書内で使用する単位は、国際単位系(SI単位系)で記すこと。1.8.2. 提出図書の確認方法提出図書の確認方法を以下に記す。(1) 表1-1に示す提出図書の電子版(1部)を受注者から量研へ電子メール等で提出。(2) 再委託承諾願以外の提出図書は、10 暦日以内までに審査を完了し、修正を指示する場合には修正を指示する。量研の審査後、期限日を記載した確認印を押印して量研から受注者へ電子メール等で返却する。再委託承諾願は紙媒体(1部)で提出することとし、量研が確認後、書面にて回答する。(3) 全ての作業の完了後、量研の確認印が押された全ての図書(電子版)を受注者から量研に提出。1.9. 支給品1.9.1. LP支給品：LP 5個支給日：契約締結後速やかに支給場所：当研究所 第1工学試験棟付属建家5支給方法：支給品の搬出及び輸送は、受注者の責任において実施すること。1.9.2. 評価用LPダミー付きＷモノブロック支給品：評価用LPダミー付きＷモノブロック 40個支給日：契約締結後速やかに支給場所：当研究所 第1工学試験棟付属建家支給方法：支給品の搬出及び輸送は受注者の責任において実施すること。1.10. 適用法規・規格基準本件に関しては、以下の法令、規格・基準に準拠すること。詳細は量研担当者と協議の上、決定すること。(1) 労働基準法(2) 労働安全衛生法(3) 量研内諸規程等(4) その他関係する諸法令、諸規格、基準なお、技術仕様に適用される規格については、2章に記載する。1.11. 知的財産権等1.11.1. 知的財産権等の取扱い知的財産権等の取扱いについては、別紙－1「知的財産権等の取扱いについて」に定められたとおりとする。1.11.2. 技術情報の取扱い受注者は、本契約を実施することによって得た技術情報を第三者に開示しようとするときは、あらかじめ書面による量研の承認を得なければならないものとする。量研が本契約に関し、その目的を達成するため受注者の保有する技術情報を了知する必要が生じた場合は、量研担当者と受注者の協議の上、受注者は当該技術情報を無償で量研に提供するものとする。1.12. グリーン購入法の促進本仕様に定める提出図書(納入印刷物)については、グリーン購入法の基本方針に定める「紙類」の基準を満たしたものであること。1.13. 打合せ(1) 量研と受注者は、常に緊密な連絡を保ち、本仕様の解釈及び作業に万全を期すものとする。また、必要に応じて適宜打合せを行うものとし、量研又は受注者の施設等において打合せを実施する。 なお、日時については協議の上決定する。打合せの形態は、テレビ会議や電話会議も含めるものとする。6(2) 受注者は、必要に応じて、機器製作者及び作業実施者(下請など本仕様一部などを再発注した場合の契約先も含む)の技術者を打合せに出席させることができるものとする。(3) 打合せをした場合は、受注者は直ちに打合せ議事録を作成し、量研及び受注者双方の責任者の署名又は押印をする。(4) 受注者は、量研からの質問事項に対しては速やかに回答すること。回答は、打合せ議事録によることを原則とし、急を要する場合についてはあらかじめ口頭で了承を得て、後日(7暦日以内を原則とする。)正式版を提出し、確認を得ること。(5) 回答文書の提出がない場合には、量研の解釈を優先するものとする。1.14. 一般責任事項(1) 本件に係わる全ての工程に関して、充分な品質管理を行うこととする。(2) 受注者は、量研が量子科学技術の研究・開発を行う機関であるため、高い技術力及び高い信頼性を社会的に求められていることを認識し、試験検査等で当研究所の施設を使用する場合、当研究所の規程等を遵守し安全性に配慮して業務を遂行し得る能力を有する者を従事させること。1.15. 協議本仕様書に記載されている事項及び本仕様書に記載のない事項について疑義が生じた場合は、量研と協議の上、その決定に従うものとする。72. 技術仕様本技術仕様は、LP付きOVTを構成するLP付きのプラズマ対向ユニット(以下「PFU」という。)のプラズマ対向材料である LP 付き W モノブロックの製作技術の認証を行うために行う試作作業について定めたものである。受注者は、Wに対する本作業の目的を十分に理解し、受注者の責任と負担において取扱方法・関係法令・規格等を基に計画を立案し、本作業を実施するものとする。本技術仕様では、下記について定める。2.1 LPとWモノブロックの接合に関する検討2.2 LP付きWモノブロックの試作2.3 LP一体型Wモノブロックの製作検討と試作2.4 提出図書作成2.1. LPとWモノブロックの接合に関する検討2.1.1. 全般事項(1) 量研が支給するLPの図面を図 2-1に示す。(2) LP付きWモノブロックの参考図を図 2-2に示す。LP付きWモノブロックには、OVT実機に使用されるものと同仕様のWモノブロック(Type-XまたはType-A)が使用される。本契約において、受注者は、原則としてOVT実機に使用されるものと同仕様(本契約で特記する仕様を除く)のWモノブロック(Type-XまたはType-A)を調達または製作し、使用することとする。ただし、必要に応じて量研がWモノブロックを支給する。(3) LP付きWモノブロックは、別紙－2「ITER真空ハンドブック」真空分類VQC-1Aの要求を満たすこと。特に、接合に関する要求には留意すること。(4) LPの接合がろう付け接合による場合、ろう材の染み出しは支持脚付きWモノブロックの支持脚接合と同様に機械加工により取り除くこととする。(5) LPの接合に関して、ITER機構から認証を得るためには、少なくとも5個のLP付きWモノブロックにおいて、接合部の超音波探傷試験(Ultrasonic Testing。以下「UT」という。)により平底孔(Flat bottom hole。以下「FBH」という。)2mmより大きい欠陥が検出されないこと。また、プローブ軸に沿った断面のマクロ観察試験(Macroscopic Examination。以下「ME」という。)により空洞が検出されないことが必要である。(6) UTは、図 2-3のようにLPを切断した上で行うものである。UTは、LP付WモノブロックのW/W接合においてFBH 2 mmの欠陥を検出できる方法により実施すること。UTを実施するLP付きWモノブロックのLP側のW厚みは1 mmとなることに留意すること。(7) MEはUT実施後に行うものである。MEはISO 17639:2013に準拠すること。MEに関しては、エッチングの要否や観察倍率(20倍以下)を検討する。LP付きWモノブロックの試作におけるMEの条件は、検討結果を基に量研が指示する。(8) なお、OVT実機用のLP付きWモノブロックの製作では、外観検査と寸法検査のみを要し、接合部のUTや浸透探傷試験は実施しない予定である。82.1.2. 接合方法の検討(1) 受注者は、LP付きWモノブロックに関する要求を満たす接合方法を選定するため、UT・ME・せん断試験を検討し、実施すること。(2) 各試験には、量研が支給する評価用LPダミー付きWモノブロックまたは量研が認めた等価なWモノブロックを使用すること。(3) 接合方法に関して、図 2-4の参考図に示すように(a)無酸素銅拡散層なし及び(b)無酸素銅拡散層付きのLP付きWモノブロックについて検討すること。(a)については、ろう材はNiCuMn-37,NiCuMn-23及びTicuniをそれぞれ使用した場合について検討することをそれぞれ目的とする。(4) 支給品である評価用LPダミー付きWモノブロックは、上記(3)に記載された接合方法((a)無酸素銅拡散層なし、かつ、各ろう材の組み合わせ、(b)無酸素銅拡散層あり1種類につき10個を接合評価用に使用すること。その内、5 個は PFU 製作時のろう付け及び時効処理を模擬した熱処理(以下「PFU製作模擬熱処理」という。)を実施されている。評価用LPダミー付きWモノブロックは、接合方法1種類につきUTに2個・MEに2個・せん断試験に6個用い、PFU製作模擬熱処理の有無で比較すること。(5) PFU製作模擬熱処理とは下記の熱処理のことを示す。(a) 8.5℃/分で昇温し、980℃+10℃/-0℃を30分保持 → 急冷(1℃/秒)(b) 475℃±5℃を180分保持 →徐冷または急冷(6) 上記(5)において熱処理したもの及び熱処理していないものに対してUT及びMEを行い、要求事項を満たすか否かの判定を行うこと。UTは、図2-3と同様にLPダミーを厚み1mm残して切断した上で行うこと。MEは、LPダミー付きWモノブロックの3 断面(厚さ 12mmの 4 分の 1、2 分の1、4分の3の位置)に対して観察倍率20倍で実施すること。エッチングの要否は、界面の欠陥の確認のしやすさにより、事前に量研と協議の上で決めることとする。この結果を基に量研が認証用のMEの条件を決定する。(7) 上記(5)の熱処理したもの及び熱処理していないものに対し、せん断試験を行う。試験荷重方向は、LPダミー付きWモノブロックの厚さ12mmの方向とする。受注者は、せん断試験の方法を検討し、量研の承認を得た要領により試験を実施すること。このせん断試験は、LP付きWモノブロック(LP付きPFU、LP付きOVTを含む)の出荷後のハンドリングにより、LPとWモノブロックの接合が棄損する可能性を量研が調査するために行うものである。せん断試験で印加する荷重の上限は、量研との協議により決定することとする。(8) 試験済みの評価用LPダミー付きWモノブロック40個は量研に納品すること。 2.1.3. 接合方法の選定(1) LP付きモノブロックの試作は、LPダミー付きWモノブロックの2.1.2項に示す検討を完了し、検討用試験報告書の提出を受けた接合方法の中から量研が選定し、行うこととする。(2) 選定を受けた接合方法による LP ダミー付きWモノブロックを 20 個製作し、量研へ納品すること。寸法検査及び外観確認を実施すること。なお、外観確認では、受注者が不良と考えるものはモード別で選別すること。9以上の検討に関して、検討用試験要領書及び検討用試験報告書を提出すること。提出時期及び記載すべき内容は2.4節に示す。10図 2-1 LPの図面11図 2-2 LP付きWモノブロックの参考図(MB: Wモノブロック)MBMBMBLP↑平面度は目標値である。LPとWモノブロックの許容される段差の寸法公差の観点からLPの傾きを留意すること↑接触は要求ではなく目標。※上図はWモノブロックをPFUに組み付けた状態の図となっている。※LP下部に存在する突起(図 2-1には存在しないもの)は、LPに挿入された電極を示している。なお、電極は受注者が挿入するものではなく受注者の責任範囲外である。12図 2-3 超音波探傷試験(UT)の参考図図 2-4 接合方法の参考図 (a)無酸素銅拡散層なし、(b)無酸素銅拡散層あり切断UT界面UT範囲(a) 無酸素銅拡散層なし (b)無酸素銅拡散層ありNiCuMn-37,NiCuMn-23,or Ticuni無酸素銅層(厚さ1mm程度)NiCuMn-37132.2. LP付きWモノブロックの試作(1) 受注者は、2.1節で実施した検討を踏まえて、量研が支給するLP 5個を用いてLP付きWモノブロック5個を試作すること。(2) 各作業段階の状況及び条件を確認できるように、写真撮影・チャート記録(熱処理時の装置状態や物温など)を実施すること。(3) LP付きWモノブロックに使用する材料(W板、無酸素銅、ろう材)は、材料証明書を量研が承認済みのものを使用すること。(4) 試作作業の開始前には、製作・検査・試験に関して「LP付きWモノブロック試作要領書」に記載の上で量研へ提出し、確認を得ること。記載すべき内容は2.4節に示す。(5) LP付きWモノブロック5個を製作する際には、OVT実機に使用するWモノブロックと同じ非破壊検査(外観検査・浸透探傷試験・UT)を実施すること。外観検査はASME Section V, Article 9に基づき、LP 付きWモノブロックの全ての表面について実施すること。浸透探傷試験は、EN ISO3452-nn又は ISO 3452-nn又はそれと同等の規格基準に基づき、LP付きWモノブロックの全ての表面及びW材と無酸素銅緩衝層の接合面に対して行うこと。UT は、国内規格(民間規格及び社内規格を含む。)又は国際的に認知された規格に基づき、Wモノブロックと冷却管用無酸素銅(円筒)の接合部に対して行うこと。(6) 上記(5)の実施後、2.1節で検討した方法に基づいて、LP付きWモノブロックの寸法等の測定を行い、図2-1に示す要求を満たすか否かを確認すること。確認結果は、速報として直ちに量研に報告すること。(7) 上記(6)の速報を量研が確認した後、LP付きWモノブロックに対してPFU製作模擬熱処理を実施すること。(8) 上記(7)の実施後、再びLP付きWモノブロックの寸法等の測定を行い、図2-1に示す要求を満たすか否かを確認すること。確認結果は、速報として直ちに量研に報告すること。(9) 上記(8)の速報を量研が確認した後、UTを行う。要求事項を満たすか否かの判定を行うこと。確認結果は、速報として直ちに量研に報告すること。(10) 上記(9)の速報を量研が確認した後、MEを行う。要求事項を満たすか否かの判定を行うこと。確認結果は、速報として直ちに量研に報告すること。(11) 上記の作業完了後、直ちに「LP付きWモノブロック試作報告書」を提出すること。記載すべき内容は2.4節に示す。(12) 試験済みのLP付きWモノブロック5個は量研に納品すること。2.3. LP一体型Wモノブロックの製作検討と試作(1) 受注者は、図 2-1, 2-2 の参考図を基に LP 一体型Wモノブロックの製作検討を行うこと。これはLPとWモノブロックの接合に因らないLP付きWモノブロックの可能性を検討するものである。(2) 図 2-5にLP一体型Wモノブロックの参考図を示す。これは原案であり、受注者は製造可能な形状や寸法公差及び幾何公差を量研に提案すること。(3) 図 2-5のうち、0.5(+0.1/-0.05)mmのスリットはワイヤ放電加工以外の形成方法を検討すること。 これは、放電加工でWに入るクラックが最終製品に残留するのを避けるためである。14(4) 製作可能なLP一体型Wモノブロックの製作図面を作成し、量研の確認を得ること。(5) 製作図面に基づき、LP一体型Wモノブロックを5個試作すること。(6) LP一体型WモノブロックのW表面に浸透探傷試験を実施すること。(7) LP一体型Wモノブロックの外観検査を実施すること。外観は不問だが、受注者が不良と考えるものはモード別で選別すること。(8) 作業完了後、検討用試験報告書を提出すること。記載すべき内容は2.4節で示す。図 2-5 LP一体型モノブロックの参考図2.4. 提出図書作成2.4.1. 検討用試験要領書LPとWモノブロック接合に関する検討に関する内容として、以下に示す情報を含めること。原則として、作業開始前に検討用試験要領書を提出し量研の確認を得ることとするが、量研の了解の上で部分的に提出及び作業することも可とする。(1) LP付きWモノブロックの確認図(2) LPダミーの確認図(3) LPダミー付きWモノブロックの確認図(4) 寸法等の測定に使用する機器一覧(5) LPダミーとWモノブロックの接合に関する要領(a) 炉の型番、メーカー名、計測器の種類等の設備情報変更困難な寸法公差LP一体型の案15(b) 接合時の姿勢が分かるロウ付け時の設置図(治具を含む組立図)(c) 温度、真空度の計測方法(d) ロウ付け時の温度条件、真空度条件(複数条件としてもよい。)(6) LPダミー付きWモノブロックの評価に関する要領(a) UTの要領(UT試験体の図を含めること。)(b) MEの要領(c) せん断試験の要領(試験治具の図及び材質、試験機への設置図、試験条件及び手順を含めること。)(7) ろう材の材料証明書LP一体型Wモノブロックの製作検討と試作に関する内容としては、以下に示す内容を含めること。(1) LP一体型Wモノブロックの製作図面2.4.2. 検討用試験報告書LPとWモノブロック接合に関する検討に関する内容として、以下に示す情報を含めること。本報告書は遅くとも作業完了後に提出すること。ただし、全作業の完了を待って提出する必要はなく、量研の了解の上で部分的に提出することでよい。(1) LPダミー付きWモノブロックの製作及び評価結果(a) UT結果(PFU製作模擬熱処理前及び後。Cスコープ画像及び判定結果を含めること。)(b) ME結果(PFU製作模擬熱処理前及び後。MEにおけるエッチング要否を判断するために、少なくとも1つはエッチング有及び無で観察結果を比較すること。)(c) せん断試験結果(PFU 製作模擬熱処理前及び後。試験前及び後の試験体写真及び変位―荷重カーブを含めること。)(d) 上記の検査と試験に使用した機器の校正記録(2) LP ダミー付きWモノブロックの検査報告書(2.1.3 項で製作のもののみ。寸法測定結果及び外観検査結果を含めること。)LP一体型Wモノブロックの製作検討と試作に関する内容としては、以下に示す内容を含めること。本内容は試作完了後に提出すること。(1) LP一体型Wモノブロックの工程図(2) LP一体型Wモノブロックの検査報告書(浸透探傷試験、寸法測定及び外観検査の結果を含めること。)2.4.3. LP付きWモノブロックの試作要領書(Test protocol for Langmuir probe attachment with W monoblocks)LP付きWモノブロックの試作に関する要領として、以下に示す内容を含めること。試作作業開始前に提出し、量研の確認を得ること。ITER機構に提出するため、英文で作成すること。(1) LP付きWモノブロックの製作要領(Manufacturing procedure for W monoblocks with Langmuir probe)(a) 工程図16(b) LP付きWモノブロックの確認図(c) 炉の型番、メーカー名、計測器の種類等の設備情報(d) 接合時の姿勢が分かるロウ付け時の設置図(治具を含む組立図)(e) 温度、真空度の計測方法(f) ロウ付け時の温度条件、真空度条件(2) LP付きWモノブロックの非破壊検査要領(Non-destructive testing protocols of W monoblocks withLangmuir probe)LP 付きではない W モノブロックの非破壊検査要領が他の契約で承認済みであり、軽微な読み替えで適用可能な場合は、その図書番号を記載するだけでもよい。また、必要に応じて読み替え表を作成すること。(3) 寸法検査要領(Dimensional inspection procedure of W monoblocks with Langmuir probe)(a) 寸法検査で使用する計測器及び精度・計測の不確かさ・検査方法・検査場所・検査時の温度湿度条件・計測箇所(b) LP付きWモノブロックの計測ポイント図(4) LP接合の認証試験要領(Qualification procedure for Langmuir probe attachment)(a) UT試験体、ME試験体の図(b) 試験方法(条件、手順及び合否判定基準)(c) 試験装置の型番、メーカー名、計測器の種類等の設備情報(5) 認証試験に使用する材料の材料証明書(Conformity of material for qualification)(a) W板(b) 無酸素銅(c) ろう材2.4.4. LP付きWモノブロックの試作報告書(Test report for Langmuir probe attachment with W monoblocks)LP付きWモノブロックの試作に関する報告書として、以下に示す内容を含めること。試作作業完了後に提出すること。ITER機構に提出するため、英文で作成すること。(1) 非破壊検査結果(2) 寸法計測結果(3) PFU製作模擬熱処理の熱処理履歴(4) UT結果(Cスコープ画像及び判定結果を含めること。)(5) ME結果(判定結果を含めること。)以上 知的財産権特約条項(知的財産権等の定義)第１条 この特約条項において「知的財産権」とは、次の各号に掲げるものをいう。一 特許法(昭和34年法律第121号)に規定する特許権、実用新案法(昭和34年法律第123号)に規定する実用新案権、意匠法(昭和34年法律第125号)に規定する意匠権、半導体集積回路の回路配置に関する法律(昭和60年法律第43号)に規定する回路配置利用権、種苗法(平成10年法律第83号)に規定する育成者権及び外国における上記各権利に相当する権利(以下総称して「産業財産権等」という。)二 特許法に規定する特許を受ける権利、実用新案法に規定する実用新案登録を受ける権利、意匠法に規定する意匠登録を受ける権利、半導体集積回路の回路配置に関する法律に規定する回路配置利用権の設定の登録を受ける権利、種苗法に規定する品種登録を受ける地位及び外国における上記各権利に相当する権利三 著作権法(昭和45年法律第48号)に規定する著作権(著作権法第21条から第28条までに規定する全ての権利を含む。)及び外国における著作権に相当する権利(以下総称して「著作権」という。)四 前各号に掲げる権利の対象とならない技術情報のうち、秘匿することが可能なものであって、かつ、財産的価値のあるものの中から、甲乙協議の上、特に指定するもの(以下「ノウハウ」という。)を使用する権利２ この特約条項において「発明等」とは、次の各号に掲げるものをいう。一 特許権の対象となるものについてはその発明二 実用新案権の対象となるものについてはその考案三 意匠権、回路配置利用権及び著作権の対象となるものについてはその創作、育成者権の対象となるものについてはその育成並びにノウハウを使用する権利の対象となるものについてはその案出３ この契約書において知的財産権の「実施」とは、特許法第２条第３項に定める行為、実用新案法第２条第３項に定める行為、意匠法第２条第２項に定める行為、半導体集積回路の回路配置に関する法律第２条第３項に定める行為、種苗法第２条第５項に定める行為、著作権法第21条から第28条までに規定する全ての権利に基づき著作物を利用する行為、種苗法第２条第５項に定める行為及びノウハウを使用する行為をいう。(乙が単独で行った発明等の知的財産権の帰属)第２条 甲は、本契約に関して、乙が単独で発明等行ったときは、乙が次の各号のいずれの規定も遵守することを書面にて甲に届け出た場合、当該発明等に係る知的財産権を乙から譲り受けないものとする。 別紙-1 知的財産権等の取扱いについてPage 1 of 6一 乙は、本契約に係る発明等を行った場合には、次条の規定に基づいて遅滞なくその旨を甲に報告する。二 乙は、甲が国の要請に基づき公共の利益のために特に必要があるとしてその理由を明らかにして求める場合には、無償で当該知的財産権を実施する権利を国に許諾する。三 乙は、当該知的財産権を相当期間活用していないと認められ、かつ、当該知的財産権を相当期間活用していないことについて正当な理由が認められない場合において、甲が国の要請に基づき当該知的財産権の活用を促進するために特に必要があるとしてその理由を明らかにして求めるときは、当該知的財産権を実施する権利を第三者に許諾する。四 乙は、第三者に当該知的財産権の移転又は当該知的財産権についての専用実施権(仮専用実施権を含む。)若しくは専用利用権の設定その他日本国内において排他的に実施する権利の設定若しくは移転の承諾(以下「専用実施権等の設定等」という。)をするときは、合併又は分割により移転する場合及び次のイからハまでに規定する場合を除き、あらかじめ甲に届け出、甲の承認を受けなければならない。イ 子会社(会社法(平成17年法律第86号)第２条第３号に規定する子会社をいう。以下同じ。)又は親会社(会社法第２条第４号に規定する親会社をいう。以下同じ。)に当該知的財産権の移転又は専用実施権等の設定等をする場合ロ 承認ＴＬＯ(大学等における技術に関する研究成果の民間事業者への移転の促進に関する法律(平成10年法律第52号)第４条第１項の承認を受けた者(同法第５条第１項の変更の承認を受けた者を含む。))又は認定ＴＬＯ(同法第11条第１項の認定を受けた者)に当該知的財産権の移転又は専用実施権等の設定等をする場合ハ 乙が技術研究組合である場合、乙がその組合員に当該知的財産権を移転又は専用実施権等の設定等をする場合２ 乙は、前項に規定する書面を提出しない場合、甲から請求を受けたときは当該知的財産権を甲に譲り渡さなければならない。３ 乙は、第１項に規定する書面を提出したにもかかわらず、同項各号の規定のいずれかを満たしておらず、かつ、満たしていないことについて正当な理由がないと甲が認める場合において、甲から請求を受けたときは当該知的財産権を無償で甲に譲り渡さなければならない。(知的財産権の報告)第３条 前条に関して、乙は、本契約に係る産業財産権等の出願又は申請を行うときは、出願又は申請に際して提出すべき書類の写しを添えて、あらかじめ甲にその旨を通知しなければならない。２ 乙は、産業技術力強化法(平成12年法律第44号)第17条第１項に規定する特定研Page 2 of 6究開発等成果に該当するもので、かつ、前項に係る国内の特許出願、実用新案登録出願、意匠登録出願を行う場合は、特許法施行規則(昭和35年通商産業省令第10号)、実用新案法施行規則(昭和35年通商産業省令第11号)及び意匠法施行規則(昭和35年通商産業省令第12号)等を参考にし、当該出願書類に国の委託事業に係る研究の成果による出願である旨を表示しなければならない 。３ 乙は、第１項に係る産業財産権等の出願又は申請に関して設定の登録等を受けた場合には、設定の登録等の日から60日以内(ただし、外国にて設定の登録等を受けた場合は90日以内)に、甲にその旨書面により通知しなければならない。４ 乙は、本契約に係る産業財産権等を自ら実施したとき及び第三者にその実施を許諾したとき(ただし、第５条第４項に規定する場合を除く。)は、実施等した日から60日以内(ただし、外国にて実施等をした場合は90日以内)に、甲にその旨書面により通知しなければならない。５ 乙は、本契約に係る産業財産権等以外の知的財産権について、甲の求めに応じて、自己による実施及び第三者への実施許諾の状況を書面により甲に報告しなければならない。(乙が単独で行った発明等の知的財産権の移転)第４条 乙は、本契約に関して乙が単独で行った発明等に係る知的財産権を第三者に移転する場合(本契約の成果を刊行物として発表するために、当該刊行物を出版する者に著作権を移転する場合を除く。)には、第２条から第６条まで及び第12条の規定の適用に支障を与えないよう当該第三者に約させなければならない。２ 乙は、前項の移転を行う場合には、当該移転を行う前に、甲にその旨書面により通知し、あらかじめ甲の承認を受けなければならない。ただし、乙の合併又は分割により移転する場合及び第２条第１項第４号イからハまでに定める場合には、この限りでない。３ 乙は、第１項に規定する第三者が乙の子会社又は親会社(これらの会社が日本国外に存する場合に限る。)である場合には、同項の移転を行う前に、甲に事前連絡の上、必要に応じて甲乙間で調整を行うものとする。４ 乙は、第１項の移転を行ったときは、移転を行った日から60日以内(ただし、外国にて移転を行った場合は90日以内)に、甲にその旨書面により通知しなければならない。５ 乙が第１項の移転を行ったときは、当該知的財産権の移転を受けた者は、当該知的財産権について、第２条第１項各号及び第３項並びに第３条から第６条まで及び第12条の規定を遵守するものとする。(乙が単独で行った発明等の知的財産権の実施許諾)第５条 乙は、本契約に関して乙が単独で行った発明等に係る知的財産権について第三者に実施を許諾する場合には、第２条、本条及び第12条の規定の適用に支障を与えないよう当該第三者に約させなければならない。Page 3 of 6２ 乙は、本契約に関して乙が単独で行った発明等に係る知的財産権に関し、第三者に専用実施権等の設定等を行う場合には、当該設定等を行う前に、甲にその旨書面により通知し、あらかじめ甲の書面による承認を受けなければならない。ただし、乙の合併又は分割により移転する場合及び第２条第１項第４号イからハまでに定める場合は、この限りではない。３ 乙は、前項の第三者が乙の子会社又は親会社(これらの会社が日本国外に存する場合に限る。)である場合には、同項の専用実施権等の設定等を行う前に、甲に事前連絡のうえ、必要に応じて甲乙間で調整を行うものとする。４ 乙は、第２項の専用実施権等の設定等を行ったときは、設定等を行った日から60日以内(ただし、外国にて設定等を行った場合は90日以内)に、甲にその旨書面により通知しなければならない。５ 甲は、本契約に関して乙が単独で行った発明等に係る知的財産権を無償で自ら試験又は研究のために実施することができる。 甲が 甲のために第三者に製作させ、又は業務を代行する第三者に再実施権を許諾する場合は、乙の承諾を得た上で許諾するものとし、その実施条件等は甲乙協議のうえ決定する。(乙が単独で行った発明等の知的財産権の放棄)第６条 乙は、本契約に関して乙が単独で行った発明等に係る知的財産権を放棄する場合は、当該放棄を行う前に、甲にその旨書面により通知しなければならない。(甲及び乙が共同で行った発明等の知的財産権の帰属)第７条 甲及び乙は、本契約に関して甲乙共同で発明等を行ったときは、当該発明等に係る知的財産権について共同出願契約を締結し、甲乙共同で出願又は申請するものとし、当該知的財産権は甲及び乙の共有とする。ただし、乙は、次の各号のいずれの規定も遵守することを書面にて甲に届け出なければならない。一 乙は、甲が国の要請に基づき公共の利益のために特に必要があるとしてその理由を明らかにして求める場合には、無償で当該知的財産権を実施する権利を国に許諾する。二 乙は、当該知的財産権を相当期間活用していないと認められ、かつ、当該知的財産権を相当期間活用していないことについて正当な理由が認められない場合において、甲が国の要請に基づき当該知的財産権の活用を促進するために特に必要があるとしてその理由を明らかにして求めるときは、当該知的財産権を実施する権利を甲が指定する 第三者に許諾する。２ 前項の場合、出願又は申請のための費用は原則として、甲、乙の持分に比例して負担するものとする。３ 乙は、第１項に規定する書面を提出したにもかかわらず、同項各号の規定のいずれかを満たしておらず、さらに満たしていないことについて正当な理由がないと甲が認める場合において、甲から請求を受けたときは当該知的財産権のうち乙が所有する部分を無償で甲に譲り渡さなければならない。Page 4 of 6(甲及び乙が共同で行った発明等の知的財産権の移転)第８条 甲及び乙は、本契約に関して甲乙共同で行った発明等に係る共有の知的財産権のうち、自らが所有する部分を相手方以外の第三者に移転する場合には、当該移転を行う前に、その旨を相手方に書面により通知し、あらかじめ相手方の書面による同意を得なければならない。(甲及び乙が共同で行った発明等の知的財産権の実施許諾)第９条 甲及び乙は、本契約に関して甲乙共同で行った発明等に係る共有の知的財産権について第三者に実施を許諾する場合には、その許諾の前に相手方に書面によりその旨通知し、あらかじめ相手方の書面による同意を得なければならない。(甲及び乙が共同で行った発明等の知的財産権の実施)第10条 甲は、本契約に関して乙と共同で行った発明等に係る共有の知的財産権を試験又は研究以外の目的に実施しないものとする。ただし、甲は甲のために第三者に製作させ、又は業務を代行する第三者に実施許諾する場合は、無償にて当該第三者に実施許諾することができるものとする。２ 乙が本契約に関して甲と共同で行った発明等に係る共有の知的財産権について自ら商業的実施をするときは、甲が自ら商業的実施をしないことに鑑み、乙の商業的実施の計画を勘案し、事前に実施料等について甲乙協議の上、別途実施契約を締結するものとする。(甲及び乙が共同で行った発明等の知的財産権の放棄)第11条 甲及び乙は、本契約に関して甲乙共同で行った発明等に係る共有の知的財産権を放棄する場合は、当該放棄を行う前に、その旨を相手方に書面により通知し、あらかじめ相手方の書面による同意を得なければならない。(著作権の帰属)第12条 第２条第１項及び第７条第１項の規定にかかわらず、本契約の目的として作成され納入される著作物に係る著作権については、全て甲に帰属する。２ 乙は、前項に基づく甲及び甲が指定する 第三者による実施について、著作者人格権を行使しないものとする。また、乙は、当該著作物の著作者が乙以外の者であるときは、当該著作者が著作者人格権を行使しないように必要な措置を執るものとする。３ 乙は、本契約によって生じた著作物及びその二次的著作物の公表に際し、本契約による成果である旨を明示するものとする。(合併等又は買収の場合の報告等)第13条 乙は、合併若しくは分割し、又は第三者の子会社となった場合(乙の親会社が変更した場合を含む。第３項第１号において同じ。)は、甲に対しその旨速やかに報告しPage 5 of 6なければならない。２ 前項の場合において、国の要請に基づき、国民経済の健全な発展に資する観点に照らし、本契約の成果が事業活動において効率的に活用されないおそれがあると甲が判断したときは、乙は、本契約に係る知的財産権を実施する権利を甲が指定する者に許諾しなければならない。３ 乙は、本契約に係る知的財産権を第三者に移転する場合、次の各号のいずれの規定も遵守することを当該移転先に約させなければならない。一 合併若しくは分割し、又は第三者の子会社となった場合は、甲に対しその旨速やかに報告する。二 前号の場合において、国の要請に基づき、国民経済の健全な発展に資する観点に照らし本業務の成果が事業活動において効率的に活用されないおそれがあると甲が判断したときは、本契約に係る知的財産権を実施する権利を甲が指定する者に許諾する。三 移転を受けた知的財産権をさらに第三者に移転するときは、本項各号のいずれの規定も遵守することを当該移転先に約させる。(秘密の保持)第14条 甲及び乙は、第２条及び第７条の発明等の内容を出願公開等により内容が公開される日まで他に漏えいしてはならない。ただし、あらかじめ書面により出願又は申請を行った者の了解を得た場合はこの限りではない。(委任・下請負)第15条 乙は、本契約の全部又は一部を第三者に委任し、又は請け負わせた場合においては、当該第三者に対して、本特約条項の各規定を準用するものとし、乙はこのために必要な措置を講じなければならない。２ 乙は、前項の当該第三者が本特約条項に定める事項に違反した場合には、甲に対し全ての責任を負うものとする。(協議)第16条 第２条及び第７条の場合において、単独若しくは共同の区別又は共同の範囲等について疑義が生じたときは、甲乙協議して定めるものとする。(有効期間)第17条 本特約条項の有効期限は、本契約の締結の日から当該知的財産権の消滅する日までとする。 以上Page 6 of 6PDF generated on 28 May 2019DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuidelineITER Vacuum HandbookITER Vacuum HandbookUpdated to include changes reviewed under scope of mPCR 260 Change Notice "PCR-M260- Application of ITER Vacuum Handbook to standard products, clarification of requirementsand minimal update to reflect the phase of the ITER project" for "ITER Vacuum Handbook(2EZ9UM v2.3)": review and approval (SK47R3 v1.0)v2.5 is v2.3+ changes introduced through mPCR260. there is no change between v2.4 andv2.5Approval ProcessName Action AffiliationAuthor Worth L. 28 May 2019:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewers Pearce R. 28 May 2019:recommended IO/DG/COO/PED/FCED/VSApprover Lee G.- S. 28 May 2019:approved IO/DG/COODocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: EUROfusion-DEMO, AD: Auditors, AD: ITER ManagementAssessor, project administrator, RO, LG: Section Scheduling, AD: OBS - Vacuum Section (VS) - EXT, AD:OBS - VacuumIDM UID2EZ9UMVERSION CREATED ON / VERSION / STATUS28 May 2019 / 2.5 / ApprovedEXTERNAL REFERENCE / VERSION別紙ٕ2 ITER真空ハンドブックPage 1 of 382PDF generated on 28 May 2019DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogITER Vacuum Handbook (2EZ9UM)Version Latest Status Issue Date Description of Changev1.0 Signed 27 Aug 2008v1.1 Signed 28 Aug 2008v1.2 Signed 22 Oct 2008v1.3 Signed 27 Oct 2008v1.4 Signed 17 Dec 2008v2.0 Signed 10 Apr 2009v2.1 In Work 27 May 2009v2.2 Signed 28 May 2009v2.3 Approved 12 Jun 2009 VH refOriginal sentence V2.2Modified sentence V2.37.1.5 Weld Finish & RepairThe size and magnitude of weld leaks found shall be reported to theITER Vacuum RO and no weld repairs shall be carried out without prioragreementAll weld repairs shall be qualified in accordance with the relevantdesign and construction codes where applicable, and with Section 7.1.2above. Where RCCMR or ASME VIII is not applied, if a weld leak is found,the repair procedure shall be subject to specific acceptance by the ITERvacuum RO as well any other relevant approvals. 9 Confinement and Vacuum ContainmentVQC 2A components that are considered to be vulnerable shallPage 2 of 382PDF generated on 28 May 2019DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMnormally be doubly vacuum contained with a monitored interspaceconnected to the Service Vacuum SystemVQC 2A components that are considered to be vulnerable arerecommended to be doubly vacuum contained with a monitored interspaceconnected to the Service Vacuum System12 PipeworkWhere practical, for components classified as VQC 2A, water pipesforming part of the cryostat vacuum boundary shall be doubly contained. Where it is not practical to doubly contain the pipework, all welded jointsshall be full penetration butt welds subject to 100% Non-Destructive Testing(NDT)It is recommended that pipework classified as VQC 2A, water pipesforming part of the cryostat vacuum boundary, be doubly contained. Wherethe pipework is not doubly contained, all welded joints shall be fullpenetration butt welds subject to 100% Non-Destructive Testing (NDT)17.2 Design of BellowsAll vulnerable bellows for use on VQC 1 and 2 systems shall be ofdouble construction (or accepted multilayer design) with a monitoredinterspace, unless they are accessible for maintenance and fitted behind anapproved interlocked isolating valve. Where vulnerable bellows are be used on VQC 2 systems it isrecommended that they be of double construction (or accepted multilayerdesign) with a monitored interspacev2.4 RevisionRequired10 Dec 2018 Updated to include changes reviewed under scope of mPCR 260Change Notice "PCR-M260 - Application of ITER Vacuum Handbook tostandard products, clarification of requirements and minimal update toreflect the phase of the ITER project" for "ITER Vacuum Handbook(2EZ9UM v2.3)": review and approval (SK47R3 v1.0)v2.5 Approved 28 May 2019 No change from V 2.4v2.5 is v2.3 plus changes introduced by mPCR 260V2.5 is to be applied for future contracts/PAsPage 3 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 1 of 48ITER Vacuum Handbook IDM Ref :ITER_D2EZ9UMIITTEERRVVaaccuuuummHHaannddbbooookkPage 4 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 2 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM1 Background.. 62 Scope of this Handbook.. 62.1 Communications and Acceptance.. 73 Vacuum Classification System (VQC).. 73.1 Definition.. 73.2 Notification of the Vacuum Classification.. 83.3 Components without a Vacuum Classification.. 83.3.1 Supply.. 83.3.2 Connections Between Systems.. 94 Deviations and Non-Conformances.. 95 Materials for Use in Vacuum.. 95.1 Materials Accepted for Use in Vacuum.. 95.2 Adding Materials to the Accepted List for Vacuum.. 95.3 Metallic Machined Components and Fittings.. 105.3.1 Final Thickness < 5 mm.105.3.2 Final Thickness between 5 mm and 25 mm.105.3.3 Manufacture of Vacuum Flanges.105.4 Outgassing.. 115.5 Hot Isostatic Pressing.. 125.6 Castings.. 125.7 Plate Material.. 126 Cutting and Machining.. 136.1 Use of Cutting Fluids.. 136.1.1 General.136.1.2 VQC 1 and 3 Cutting Fluids.136.1.3 VQC 2 and 4 Cutting Fluids.146.2 Cleaning Prior to Joining.. 147 Permanent Joining Processes.. 147.1 Welded Joints.. 147.1.1 Joint Configuration.157.1.2 Qualification of Welding Processes.167.1.3 Selection of the Welding Process.167.1.4 Inspection and Testing of Production Welded Joints.167.1.5 Weld Finish & Repair.177.1.6 Helium Leak Testing of Production Welds.177.1.7 Helium Leak Testing after Repair of Welds.187.2 Brazed and Soldered Joints.. 187.2.1 Design of Brazed Joints.187.2.2 Qualification of Brazed joints.187.2.3 Inspection and Testing of Brazed Joints.19Page 5 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 3 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM7.3 Diffusion Bonding.. 197.4 Explosion Bonding.. 197.5 Adhesive Bonding.. 198 Surface Finish.. 198.1 Surface Roughness.. 198.2 Coatings.. 209 Confinement and Vacuum Containment.. 2110 Trapped Volumes.. 2211 Connections to the Service Vacuum System.. 2212 Pipework (Pipe & Fittings).. 2312.1 General.. 2312.2 Pipework Sizes.. 2313 Demountable Joints.. 2314 Fasteners and Fixings.. 2414.1 Tapped Holes.. 2414.2 Bolts.. 2514.2.1 Bolts for use on the Vacuum Boundary (P < 0.15 MPa).2514.2.2 Prevention of Bolt Seizing.2514.2.3 Bolt Locking.2514.3 Riveting.. 2514.4 Bearings and Sliding Joints.. 2515 Windows and Window Assemblies.. 2615.1 General.. 2615.2 Qualification of Window Assemblies.. 2615.3 Testing of Window Assemblies.. 2616 Vacuum Valves and Valve Assemblies.. 2716.1 Acceptance Testing of Vacuum Valves and Valve Assemblies.. 2717 Bellows and Flexibles.. 2817.1 General.. 2817.2 Bellows Protection.. 2817.3 Design of Bellows.. 2817.4 Qualification of Bellows.. 2917.5 Testing & Inspection of Bellows.. 2917.6 Bellows Protection.. 3018 Feedthroughs.. 3018.1 General.. 3018.2 Paschen Breakdown.. 3019 Electrical Breaks.. 3020 Cables for use in Vacuum.. 31Page 6 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 4 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM20.1 General.. 3120.2 Connectors and Terminations.. 3121 Interconnection between VQC 1 systems.. 3222 Proprietary Components.. 3223 Vacuum Instrumentation.. 3224 Cleaning and Handling.. 3324.1 Cleaning.. 3324.2 Design Rules for Cleanability.. 3324.3 Mechanical Processes on Vacuum Surfaces.. 3424.4 Pickling/passivation of Steels and Copper.. 3424.5 Post-Cleaning Handling of Vacuum Equipment.. 3424.6 Cleanliness during the Assembly of Vacuum Equipment.. 3525 Leak Testing.. 3525.1 General.. 3525.2 Maximum Acceptance Leak Rates.. 3625.3 Design Considerations for Leak Testing.. 3625.4 Scheduling of Leak Tests.. 3725.5 Methods and Procedures.. 3925.6 Acceptance Leak Testing at the Supplier’s Premises.. 4025.7 Acceptance Criteria for Leak Testing.. 4025.8 Acceptance Leak Testing at the ITER site.. 4125.9 Reporting of Leak Tests.. 4126 Baking.. 4226.1 General.. 4226.2 VQC 1 Components (non plasma-facing).. 4226.3 VQC 1 Components (plasma-facing).. 4326.4 VQC 2 Components.. 4326.5 VQC 3 Components.. 4326.6 VQC 4 Components.. 4426.7 Vacuum Conditioning of Carbon Composites.. 4426.8 Documentation to be Supplied for Vacuum Baking.. 4427 Draining and Drying.. 4427.1 Design Considerations for Draining and Drying.. 4427.2 Components Delivered to ITER.. 4528 Marking of Vacuum Equipment.. 4529 Packaging and Handling of Vacuum Equipment.. 4530 Incoming Inspection at ITER of Vacuum Equipment.. 4631 Long Term Storage of Vacuum Equipment.. 47Page 7 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 5 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM32 QA and Documentation.. 4733 Acknowledgements.. 4734 List of Attachments.. 4835 List of Appendices.. 48Page 8 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 6 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM1 BackgroundITER will include one of the largest and the most complex high vacuum systems everbuilt. Reliable vacuum is key to the success of the ITER project. A characteristic ofhigh vacuum is that the functionally of a whole system can be lost by not appreciatingand paying attention to the effect of small details. Due to the pervasive nature ofvacuum in the ITER machine, there are very few ITER systems which will not havean important vacuum interface. Orders of magnitude improvements in vacuumreliability are required compared to existing and past fusion devices to achieve theITER goals because of the scaling in the number of components and the physicalsize of ITER. There are two main vacuum systems on ITER, the Torus primary vacuum whichrequires ultra-high vacuum (UHV) conditions, and the cryostat primary vacuum whichrequires clean insulation vacuum conditions with permissible operating pressurestypically 2 orders of magnitude higher than the torus. In addition, there aresecondary vacuums and a cryogenic guard vacuum system. Details are given inAppendix 1. 2 Scope of this HandbookThis Vacuum Handbook outlines the mandatory requirements for the design,manufacturing, testing, assembly and handling of vacuum items to realise andsubsequently to maintain the various different ITER vacuum systems. In addition, thisHandbook provides significant guides and helpful information which can be used inthe production of procurement specifications for ITER components. The ITER Vacuum Handbook is issued as a high level project requirementsdocument since it is imperative that the requirements contained in this Handbook arefollowed by the International Organisation, the Domestic Agencies and Industries toensure that ITER operations are ultimately successful. This Handbook is supported by a set of Attachments and Appendices. TheAttachments are subject to the same approval process as the main handbook andcontain detailed mandatory requirements. With the exception of Appendices 3 & 4the Appendices are for guidance and provide detailed information, guides,specifications, relevant processes and lists of standard and approved components,vacuum materials, etc. Appendices 3 & 4 contain lists of materials (and associatedprocesses) which have been approved for use on, or in, the ITER vacuum systems. Only materials (or associated processes) listed in Appendices 3 & 4 shall be used in,or on ITER vacuum systems. All Appendices are working documents subject toregular update. The Appendices can be used by suppliers to aid the production of vacuumcomponents, specifications and procedures which satisfy the mandatoryrequirements of the ITER Vacuum Handbook. Page 9 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 7 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM2.1 Communications and AcceptanceTo satisfy the requirements of this handbook acceptance or accepted is called for invarious places, this acceptance is to be given by the ITER Vacuum ResponsibleOfficer (RO) or his or her nominated representative. Acceptance is to be a positiveand recorded action, either by signature or by electronic means. The ITER VacuumRO will respond in the shortest possible time from receipt of the request, normallywithin two weeks. An explanation will be provided if the proposal is rejected or ifmodification is required. Requests for Acceptance shall be sought through the submission of the Request forAcceptance (ITER_D_9AY4HD). Where the Interface compliance check list of an ITER Procurement Arrangement issigned by the ITER Vacuum Responsible officer this shall be taken as acceptance ofthese items which are detailed in the Procurement Arrangement. Where an ITERProcurement Arrangement does not provide adequate details required foracceptance of these items, then the PA can define the processes to be followedleading to acceptance in which case these processes shall be followed rather thanprocesses of the ITER Vacuum Handbook. Iterations with both the Domestic Agencies and industry are expected to benecessary to meet the requirements of this Handbook. Normal communication and approval channels set up in any specific contract forsupply should not be bypassed - rather that they should be the normal route by whichacceptance requests are made and received. A possible route of communication and acceptance would therefore be:-Supplier (Contractor) ļ Domestic Agency Contract Responsible Officer ļ ITERTechnical Responsible Officer ļ ITER Vacuum Responsible Officer. A definition of terms can be found in Appendix 21. 3 Vacuum Classification System (VQC)3.1 DefinitionEvery vacuum component is given a Vacuum Classification to denote its area ofservice on ITER. These are defined as:VQC 1X: Torus primary vacuum components or components which becomeconnected to the torus high vacuum through the opening of a valve during normaloperations. VQC 2X: Cryostat primary vacuum components or components which becomeconnected to the cryostat vacuum through the opening of a valve during normaloperations. VQC 3X: Interspaces and auxiliary vacuum systems connected to the servicevacuum system or roughing lines. Page 10 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 8 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMVQC 4X: Cryogenic guard vacuum systems or items connected to the cryogenicguard vacuum system. VQC N/A: Components not exposed to vacuum. Where:X = A denotes boundary components. X = B denotes components within vacuum but which do not form part ofthe vacuum boundary. Where a component is part of the boundary between two different vacuum classes, itshall normally meet the more demanding requirements of the higher class unless thedivision between classes is shown on the drawings. Joints which separate classesshall always be classified according to the requirements of the more demandingclass. The surface finish requirements appropriate to each class are to be applied. Surface cleaning of the less highly classified surface may be in accordance with thereduced requirements of that classification provided that the more highly classifiedsurface is not degraded in the process. Some examples of classification are:¾ In vessel divertor cassette water cooling pipe - VQC 1A. ¾ In-vessel remote handling rail - VQC 1B. ¾ Cryogenic lines within the cryostat - VQC 2A. ¾ Support within the cryostat - VQC 2B. ¾ Cryogenic transfer-line between cryo-plant and tokamak complex - VQC4A. Typical base pressures and pumping speeds for the various vacuum systems aregiven in Appendix 13.2 Notification of the Vacuum ClassificationThe VQC for a particular component shall be marked on any drawing related to andstated in any specification for that component. If this is not the case, the classificationcan be provided by the ITER Vacuum Responsible Officer (RO) upon request. 3.3 Components without a Vacuum Classification3.3.1 SupplyIn order ensure vacuum components which are intended for service on ITER and arenot classified under section 3 (such as, for e.g., mechanical displacement pumps),meet the requirements for safety and performance the IO shall approve TechnicalSpecifications for the supply of such equipment. Technical Specifications shall besubmitted to the ITER Vacuum RO for review and subsequent approval prior to thecommencement of the procurement process. Page 11 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 9 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM3.3.2 Connections Between SystemsAn item of vacuum equipment which is not classified under section 3 may beconnected to an item with a VQC, e.g. a leak detector may be connected to a valveon the cryostat or a roughing pump may be connected to the torus vacuum system. In all such cases, the use of such items and the operations for which they arerequired shall be under administrative control. A written scheme of work shall besubmitted on the appropriate form to the ITER Vacuum RO. The main criterion forapproval of such a scheme of work (other than the necessity of the work beingcarried out) shall be an assessment by the ITER Vacuum RO of the possibility ofcontamination of the system bearing the VQC. 4 Deviations and Non-ConformancesRequests for deviations from, and non-conformance with, the requirements of theITER Vacuum Handbook shall be made to the ITER IO in writing following theprocedures detailed in the ITER Quality Assurance Program (IDM Ref:ITER_D_22K4QX) and ITER Deviations and Non-Conformances (IDM Ref:ITER_D_22F53X) documents. Recommendations on the approval of the non-conformance report will be made by the ITER Vacuum RO. 5 Materials for Use in Vacuum5.1 Materials Accepted for Use in VacuumOnly materials accepted for the relevant Vacuum Classification shall be used onITER vacuum systems. All material for use in vacuum shall be clearly specified at thedesign stage and certified in accordance with EN 10204 3.1 or 3.2 before being usedin manufacturing. Materials which may be used without prior agreement on vacuum systems with theVacuum Classifications stated in the table are listed in Appendix 3. Materials listed inthis Appendix which are shown as being subject to restricted use for a particularVacuum Classification are subject to either an overall quota or to particularrestrictions on their position of use. Acceptance for any particular vacuumapplication of such a material shall be obtained by submitting the MaterialAcceptance Request Form (ITER_D_2MGWR4) to the ITER Vacuum RO. Anexample of this completed form is to be found in Appendix 35.2 Adding Materials to the Accepted List for VacuumMaterials which are not on the accepted list may be proposed for use in vacuum. Ifthe vacuum properties of the material are not sufficiently well documented for anassessment to be carried out, a programme of measurement of the relevantproperties shall be agreed between the proposer and the designated ITER VacuumRO. Details of materials to be considered for acceptance shall be submitted to the ITERVacuum RO using the Material Acceptance Request Form (ITER_D_2MGWR4). ThePage 12 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 10 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMproposer shall agree in advance with the ITER Vacuum RO a plan detailing the typeand method of testing to be used to qualify the material for use. The MaterialsAcceptance Request Form along with the test data, report and supportingdocumentation, including any supplier’s data (Certificates of Conformity, etc.), shallbe submitted for consideration. These shall be assessed by the ITER Vacuum ROwho will communicate the acceptance, refusal or restrictions on usage of the materialto the originator of the request. Materials qualified in this way may be added to Appendix 3. 5.3 Metallic Machined Components and Fittings5.3.1 Final Thickness < 5 mmAll VQC 1A components which are machined from steel, austenitic steel orsuperalloys and which are of final thickness less than 5 mm and VQC 2Acomponents which are machined from steel, austenitic steel or superalloys and whichare of final thickness less than 2 mm and are designed to contain cryogenic helium1,shall be made from cross-forged material which is Electro-Slag Remelted (ESR) orVacuum Arc Remelted (VAR). The rate of inclusions in such steels shall be checked in accordance with ASTM E-45Method D (or equivalent) to be within the following inclusion limits:¾ Inclusion Type A ” 1.0. ¾ Inclusion Type B ” 1.0. ¾ Inclusion Type C ” 1.0. ¾ Inclusion Type D ” 1.5. These requirements are synopsised in Table 5-2. 5.3.2 Final Thickness between 5 mm and 25 mmVQC 1A components which are machined and are of final thickness between 5 mmand 25 mm shall be manufactured from approved steel (listed in Appendix 3), in theform of stock which has been cross-forged (upset forged). These requirements are synopsised in Table 5-2. 5.3.3 Manufacture of Vacuum FlangesBoth halves of demountable flanges using metal seals are to be manufactured fromcross or upset forged material. 1 At the time of writing this requirement is under approval and shall be included to the next version ofthis Handbook. Page 13 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 11 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMStainless steel used for the manufacture of knife-edge sealed flanges of anythickness for all vacuum classifications shall be from cross-forged ESR gradematerial blanks. 5.4 OutgassingThe outgassing rates of materials used on ITER vacuum systems shall be consistentwith the values in Table 5-1. Appendix 17 gives details on how outgassingrequirements are derived, how they can be achieved and how they may bemeasured. Maximum Steady StateOutgassing ratePa.m3.s-1.m-2VQC+OutgastemperatureqCHydrogenisotopesImpurities Testing Guidelines1 100‡ 1 x 10-7 1 x 10-9 Appendix 172 20 1 x 10-7* Appendix 173 20 1 x 10-8 Appendix 174 20 1 x 10-7 Published data andconformity to clean workplan. For VQC 2, 3 and 4, the outgassing rate excludes the partial outgassing rates for water and hydrogen. ‡ The outgas test temperature can be reduced to 20 qC for components which normally operate atcryogenic temperatures. + For CFC refer to section 26.7* In the case of resins for magnets it is considered that this target outgassing rate will be achievable. However, a factor of 10 increase will be permitted as an acceptance criterion. Table 5-1 - Outgassing rates pertaining to VQCThese limits have been produced by taking into account the total surface areaexpected, the available pumping speed, the desired pressure and post assemblyconditioning time, with due consideration of what is reasonably achievable. Theaddition of novel high surface area components to the design requires specificacceptance and appropriate limits to be assessed. Published data and/or experimental trials shall be used to show design and processconsistency with the limits. Page 14 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 12 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMAn outgassing rate acceptance test shall be performed for all VQC 1 components toan accepted procedure such as those described in Appendix 17. Exceptions will beaccepted for components which normally operate at a pressure above 1 Pa. Outgassing acceptance tests may, with prior acceptance, be performed usingrepresentative samples which follow, and are subjected to, the completemanufacturing process. Where it is agreed that a specific vacuum component should not be subjected to aspecific outgassing rate acceptance test, compliance shall be demonstrated byconformity to a clean work and quality plan. 5.5 Hot Isostatic PressingHot Isostatic Pressing (HIP) of sintered material is allowable for use on all VQCcomponents, provided that it is demonstrated that the components meet themechanical and leak rate requirements for the proposed application and the vacuumboundary thickness is greater than 5mm. It must be demonstrated that HIP formedcomponents comply with the outgassing rates in Table 5-1. Proposals for the use ofHIP formed components, and the procedure for qualification of the components foruse as vacuum containment, shall be subject to prior acceptance at the design stage. These requirements are synopsised in Table 5-2. 5.6 CastingsFor VQC 1, 2A & 3, metallic castings shall not normally be used. Where it isconsidered that a casting technology could provide acceptable porosity and meet theoutgassing and leak rate requirements in the final application, then a vacuumproperties validation program shall be proposed for acceptance. These requirements are synopsised in Table 5-2. 5.7 Plate MaterialWhere hot or cold rolled plate material is used, it is recommended for all vacuumclasses, that a surface parallel to the direction of rolling forms the vacuum boundary. This is due to the possibility of long leak paths caused by the stratification ofinclusions. For VQC1A applications which have been assigned Remote Handling Class 3 or areNon-RH classified (ITER_D_2FMAJY) where the component becomes embedded inITER and could not in future be changed, hot or cold rolled plate material (approvedsteels from Appendix 3) produced with conventional smelting and refining processessuch as Argon-Oxygen Decarburization (AOD), Vacuum Arc decarburization (VOD))shall not be used where the transverse cross section across the vacuum boundary(wall thickness) is less than 25mm. Where for VQC1A hot or cold rolled plate material (approved Steel – Appendix 3) isused with the transverse cross section crossing the vacuum boundary (wall thicknessless than 25 mm), ESR or VAR low inclusion rate material shall be used which meetsPage 15 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 13 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMthe inclusion limits as specified in Section 5.3.1 The component shall also be provenby leak testing in an environment which conforms as closely as possible to theoperating conditions (See Section 25) with due consideration taken of the effects ofpossible leaks along laminations on the response time for the test method. These requirements are synopsised in Table 5-2. Nominalthickness(of vacuumboundary)Plate / Bar1Forging4Pipe4Pipe, 4,5(He, ч2 mm)HIP3Casting4Direction Crosses2 Parallel2RH Class3,N/A1, 2 1, 2, 3, N/A1, 2, 3,NA1, 2, 3,NA1, 2, 3,NAч 5 mm X L NR F + L NR L X A>5 mm ч 25 mm X L NR F NR NR A A> 25 mm L NR NR NR NR NR A A1VQC 1A, VQC 2A cryogenic helium pipework (pipe & fittings) < 2 mm2Transverse cross section w.r.t. vacuum boundary or parallel w.r.t vacuum boundary3All VQC4 VQC 1A,2A &3A5 Helium coolant, thickness less than 2 mm. X=Not AllowedF=Cross or Upset ForgedL= Low inclusion in compliance with 5.3.1 and ESR/VAR remeltingA=requires acceptanceNR = No requirementN/A – not applicableTable 5-2 Synopsised requirements pertaining to metallic components6 Cutting and Machining6.1 Use of Cutting Fluids6.1.1 GeneralCare must be taken in manufacturing processes so as not to introduce contaminantsinto surfaces which may be difficult to remove later and which might result indegraded vacuum performance. 6.1.2 VQC 1 and 3 Cutting FluidsCutting fluids for use on VQC 1 and 3 systems shall be water soluble, non-halogenated and phosphorus and sulphur Free. The maximum allowable content ofhalogens, phosphorus, and sulphur is 200 ppm (each)Accepted cutting fluids for use in VQC 1 and 3 vacuum applications are listed inAppendix 4. The use of other cutting fluids requires prior acceptance. Acceptance for the use of any particular non-approved cutting fluid shall be obtainedby submitting the Fluid Acceptance Request Form (ITER_D_48XLVJ) to the ITERVacuum RO. An example of this form is to be found in Appendix 4Page 16 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 14 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM6.1.3 VQC 2 and 4 Cutting FluidsFor VQC 2 & 4 vacuum applications it is recommended that cutting fluids be watersoluble, non-halogenated and phosphorus and sulphur free (< 200 ppm for each). They should be chosen from those listed in Appendix 4. Where this recommendationis not followed particular care shall be taken to ensure the appropriateness of thecleaning procedures (See section 24). 6.2 Cleaning Prior to JoiningTo minimise the risk of trapped contamination which can subsequently cause leaksor enhanced outgassing, parts and sub-components shall be degreased usingsolvents or alkaline detergents, rinsed with demineralised water, and dried prior tojoining in accordance with Section 24 below. The use of halogenated solvents isforbidden at any stage for systems of class VQC 1 and 3. Accepted fluids are listed inAppendix 4. 7 Permanent Joining ProcessesPermitted joining techniques for vacuum applications and their applicability to eachVQC are shown in Table 7-1. Proposals for joining techniques not listed here shall besubmitted for prior acceptance. 7.1 Welded JointsLack of attention to the details of vacuum sealing weld design, qualification andtesting has proved to be a significant cause of vacuum leaks on vacuum systems. All vacuum welds, except those excluded below, shall be qualified, produced andinspected in accordance with Attachment 1. The requirements of Attachment 1 aremandatory until superseded by the ITER baseline Welding Handbook. Where there is regulatory requirement to design and subsequently build a vacuumsystem to RCC-MR or ASME VIII, the requirements of these codes shall takeprecedence over the requirements of Attachment 1, while remaining in compliancewith Section 7.1.6. In other cases where vacuum sealing welds are to be qualified,produced and inspected to meet a code, and there is variation between therequirements of the code and Attachment 1, the more extensive or stringentrequirements shall be applied. Page 17 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 15 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMVQC 1 VQC 2 VQC 3 VQC 4A B A B A B A BWelded joints 3 3 3 3 3 3 3 3Brazed/soldered joints hhhh‡ 3 3 2 3Diffusionbonding 3 3 3 3 3 3 3 3HIP 3 3 3 3 3 3 3 3Compressionjoints 2 2 hh3 3 3 3Adhesivebonding 2 hhhhhhhExplosionbonding 3 3 3 3 3 3 3 33 - indicates an acceptable technique 2 - indicates an unacceptable techniqueh - application specific acceptance required‡- For soldering of super conducting joints see Section 7.2Table 7-1 Joining methods applicable to VQC7.1.1 Joint ConfigurationThe use of welds from both sides makes leak testing difficult and enhances the riskof trapped volumes forming virtual leaks or contaminant traps that are to be avoided. Thus, for all vacuum classes, vacuum sealing welds shall be either internal (i.e. facing the vacuum) or external. In VQC 2, double sided welding may be used whereunavoidable, but an NDT inspection schedule giving 100% volumetric examinationmust be used to ensure that a full-thickness melt zone has been achieved. The use of stitch welds on the vacuum facing side is prohibited. For VQC 1A, VQC 2A and VQC 3A on the boundary to air or water, full penetrationwelds are required. For VQC 4A (process to insulation vacuum) welds full penetration welds are required. It is good engineering practice to design joints to be accessible for repair ifnecessary. Butt welded joints are preferred to fillet or lap joints, since testability is improved. Fillet, corner, lap and cross joints should be avoided wherever possible on VQC 1systems. Page 18 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 16 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMWelds shall normally be made in such a way that they can be leak tested at the timeof completion. Welds that cannot be inspected (see Sections 7.1.4 & 7.1.6 ) are notpermitted for use on VQC 1 and VQC 3 and should be minimised for use on VQC 2and VQC 4. Where leak detection is not practical at the time of completion, a testplan including provision for repair of the weld must be accepted at the design stage. 7.1.2 Qualification of Welding ProcessesQualification of welding processes for use on vacuum sealing welds shall follow therequirements of Attachment 1 and section 7.1. A welding and inspection plan shall always be submitted to the ITER IO. 7.1.3 Selection of the Welding ProcessThe selected welding technique for vacuum applications (e.g. electron beam, laser orTIG welding) should produce a clean, pore free weld with minimal oxidation. Autogenous welding shall be used where practical7.1.4 Inspection and Testing of Production Welded JointsAll such inspection and testing shall be carried out using approved procedures inaccordance with Attachment 1. For all VQC 1A, VQC 2A water boundaries, vacuum boundary welds which becomeinaccessible and VQC2A cryogenic pipework connections, 100% volumetricexamination of production welds shall be performed, unless a method of pre-production proof sampling is approved. For VQC 4A (process to insulation vacuum) 100% volumetric examination ofproduction welds shall be performed, unless a method of pre-production proofsampling is approved. The range of thickness and preferred volumetric examination method to be applied isgiven in Table 7-2Wall Thickness (wt) (mm) Preferred Volumetric ExaminationMethodwt < 8 Radiography8 < wt 19 Ultrasonic or radiographyNote: For wt > 19 mm ultrasonic examination of welds is preferred only in cases where radiographicexamination would require excessive exposure times. Table 7-2 Range of wall thickness and preferred volumetric examinationmethod to be appliedFor all other vacuum boundaries, volumetric examination of 10% of production weldsshall be performed with the wall thickness limits specified in Table 7-2, unless amethod of pre-production proof sampling is agreed by the ITER IO. Page 19 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 17 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMOn welds forming the vacuum boundary the use of liquid penetrant testing (LPT) ormagnetic particle techniques shall not in general be permitted for the inspection ofwelds or in the inspection of weld preparations. This is because such substancesmay block leaks temporarily and can be difficult to remove satisfactorily. Where there is a mandatory requirement to build a component to a code then theflexibility of the code to avoid the use of LPT on welds forming the vacuum boundaryshall be a key factor in the assessment of that code for selection. The selectionprocess shall be recorded and accepted. Where a code selected for building a component requires the use of a qualifiedsurface examination method, and LPT cannot be avoided, only the ITER vacuumqualified liquid dye penetrant (see Appendix 4) may be used. If the use of LDP ispermitted, then cleaning must be performed to procedures qualified andsubsequently accepted by the ITER Vacuum RO. For VQC 1B welds which are subject to high cyclic stresses, the use of ITERqualified LDP for detection of surface defects is permitted subject to notification ofthis application to the ITER Vacuum RO. For VQC 2B and 4B the use of ITER qualified LDP is permitted. The method ofapplication and subsequent removal of LDP shall be performed to proceduresqualified and accepted by the ITER Vacuum RO7.1.5 Weld Finish & RepairProduction welds used on all vacuum systems shall be left clean and bright but thereis no vacuum requirement to machine the weld zone to match the surface finish ofthe parent material. All weld regions shall be free from scale, voids, blowholes, etc., and there shall be novisible evidence of inclusions. The size and magnitude of weld leaks found shall be reported to the ITER VacuumRO and no weld repairs shall be carried out without prior agreement. All weld repairs shall be qualified in accordance with the relevant design andconstruction codes where applicable, and with Section 7.1.2 above. Where RCCMRor ASME VIII is not applied, if a weld leak is found, the repair procedure shall besubject to specific acceptance by the ITER vacuum RO as well any other relevantapprovals. 7.1.6 Helium Leak Testing of Production WeldsAll vacuum sealing welds in each VQC shall be subject to helium leak testing inaccordance with the procedures of Section 25. Where multi-pass welding is required in the production of components of VQC 1Aand VQC 2A, it is recommended that leak testing of the root weld pass shall beperformed with only this pass completed. However, for multi-pass welding that takesplace on the ITER site, this requirement is mandatory. Page 20 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 18 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMIf it has been agreed that liquid dye penetrant may be used for testing such a weld(see Section 7.1.4), the root weld leak test shall be performed before the applicationof this liquid. Any leak which is found in the root weld to be above the minimum detectable leakrate of the equipment which has been accepted for use in the accepted proceduresfor such tests, must be repaired and re-tested before proceeding with further weldpasses. In all cases, a further leak test shall be carried out (see Section 25). 7.1.7 Helium Leak Testing after Repair of WeldsAll repaired vacuum boundary welds shall be subject to full vacuum leak testing inaccordance with the procedures of Section 25. 7.2 Brazed and Soldered JointsBrazing shall be carried out in a vacuum, hydrogen or inert gas atmosphere. Torchbrazing is not permitted except where unavoidable for VQC 2B. Where the use ofbrazing flux is unavoidable a cleaning procedure shall be qualified and submitted foracceptance to the ITER vacuum RO. Brazing materials which contain silver are subject to specific quotas for componentsfor VQC 1, 2 or 3 in systems where the irradiation environment may lead tosignificant silver transmutation to cadmium. The use of such materials is subject toprior acceptance. Brazing is not permitted for any water to vacuum joint in VQC 1, 2 or 3. Brazing is not permitted for VQC 4A where there is contact with cryogenic fluid. All brazing techniques shall be to an accepted standard or to a procedure acceptedprior to manufacture. On account of the relatively high vapour pressure of the solder, soft soldering(< 400qC with Sn, Zn, alloys of Pb, Cd, etc) shall not be permitted for VQC 1 orVQC 2A, or VQC 3A and is only allowable on VQC 2B for applications whichoperate at a temperature < 60 K. 7.2.1 Design of Brazed JointsThe design of brazed joints shall be such as to minimise the risk of trapped volumes. 7.2.2 Qualification of Brazed jointsAll brazing techniques shall be qualified to an accepted standard or to an acceptedqualification programme. Tests on pre-production samples of brazed joints shall beperformed to accepted procedures or to an accepted standard. Brazing procedurequalification shall be compliant with EN 13134:2000 (or equivalent). Page 21 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 19 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM7.2.3 Inspection and Testing of Brazed JointsBrazed joints shall be subject to qualification to ensure the vacuum integrity of thejoint. All brazed joints shall be inspected visually to ensure that the vacuum exposed brazeregions are clean, flush and free from voids, blowholes, etc., that there is no visibleevidence of inclusions and that the braze material has filled the joint withoutexcessive over-run. Where practicable, radiography of an agreed percentage sample of brazed jointsshall be carried out. Where this is not practicable, then samples shall be producedfor sectioning and microscopic examination. The use of liquid dye penetrant or magnetic particle techniques shall not be permittedfor the inspection of brazed joints or in the inspection of joint preparations. All brazed joints which form part of a vacuum boundary shall be subject to 100%helium leak testing. No braze shall be re-run for rectification of any sort without prior agreement. 7.3 Diffusion BondingDiffusion bonding of joints is acceptable for all VQC. If it is used, diffusion bondedinter-layers shall comprise materials listed in Appendix 3. Diffusion bonded jointsshall be subject to the same vacuum qualification procedures as brazed joints toensure the integrity of the joint and compliance with the requirements of thisHandbook. 7.4 Explosion BondingExplosion bonding of metals is acceptable for all VQC. Explosion bonded joints shallbe subject to the same vacuum qualification process as brazed joints to ensure theintegrity of the joint and compliance with the requirements of this Handbook. Existingqualifications of the process may be used for VQC2 applications if compliant with therequirements of this Handbook. 7.5 Adhesive BondingAdhesive bonding may only be used in limited circumstances (see Table 7-1) andusing materials listed in Appendix 3. 8 Surface Finish8.1 Surface RoughnessMetallic components for different VQC shall be supplied with the maximum averagesurface roughness listed in Table 8-1. Surface roughness is defined in accordancewith ISO 4287: 2000. Page 22 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 20 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMClassificationMaximum averageSurface RoughnessRa (Pm)Measurement TechniqueVQC 1 6.3 Electric stylusVQC 2 12.5† Electric stylusVQC 3 12.5 Electric stylusVQC 4 12.5 Electric stylus† Where to satisfy this surface roughness requirement additional machining would be required arougher surface is accepted provided the surface is easily cleanable and can be shown not tocatch fibres when wiped with a lint free cloth. Table 8-1 - Maximum permissible average surface roughness for metalsGenerally, where the base material is not produced with an acceptable surface finish,such surface finishes may be achieved using techniques including:¾ Machining. ¾ Electropolishing. ¾ Bead Blasting in a slurry in a water jet with alumina or glass beads. ¾ Surface Passivation / Pickling (see Section 24.4). All processes on vacuum surfaces shall be followed by appropriate cleaning of thesurface (see Section 24 below). 8.2 CoatingsOnly materials accepted by ITER for the relevant Vacuum Classification shall beused for coatings on ITER vacuum systems (see Section 5). Surface coatings for VQC1 shall be subject to qualification and acceptance at thedesign stage. The assessment of the coating shall include consideration of :-¾ The risk of the coating producing trapped volumes and temporary leakblocking. ¾ The method of applying the surface coating (e.g. painting, chemical,plasma spray, etc.). ¾ The chemical composition, morphology, cleaning and outgassing of thesurface coating. ¾ Conformance of the coating with the ITER outgassing requirements asdetailed in Section 5.4. ¾ The method for testing the adhesion of the surface coating to thesubstrate. Page 23 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 21 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM9 Confinement and Vacuum ContainmentConfinement is the term used for the physical enclosure of hazardous substances(e.g. tritium). “Vacuum containment” is a term used for vacuum tight boundaries which cope withdifferential pressure in either direction. Vacuum containment may also provide aconfinement function. Vulnerable components are generally considered to be those components whichhave been shown to exhibit a failure rate higher than 10-5 per year in an experimentalenvironment and typically include windows, bellows, lip seals, flexible hoses, metallicto non-metallic joints, feedthroughs, electrical breaks, thin walled material (<1.5 mm),and demountable seals. Reliability data and references can be found in Appendix 18. VQC 2 high voltage electrical breaks and high voltage feedthroughs are consideredvulnerable only if they have a specified failure rate greater than 10-5 per year or havebeen shown, in the specific design proposed, to exhibit a failure rate greater than 10-5per year. VQC 1A components that are considered to be vulnerable shall be doubly vacuumcontained with a monitored interspace connected to the Service Vacuum System(see Section 11). This requirement is necessary to achieve overall machine reliability. Lip seals which are accessible for repair in port cells are excluded from thisrequirement but shall have provision for remote leak identification. If a vulnerablecomponent is accessible for maintenance and fitted behind an approved, interlocked,isolating valve then acceptance may be sought for single vacuum containment. Demountable joints on VQC 1A shall use double seals with the interspace monitoredand connected to the Service Vacuum System. Demountable joints shall not be used for water to vacuum boundaries for anyvacuum class. Boundaries between VQC 1A and VQC 2A components that are considered to bevulnerable shall be doubly vacuum contained with a monitored interspace connectedto the Service Vacuum System. This is a requirement to avoid an undetected leak oftritium into the cryostat vacuum. VQC 2A components that are considered to be vulnerable are recommended to bedoubly vacuum contained with a monitored interspace connected to the ServiceVacuum System. Where it is considered that double vacuum containment increasesthe failure risk or failure consequences, then an alternative method to provide leaklocalisation and mitigation shall be proposed for acceptance. An analysis of the probability of air ingress is required for safety and investmentprotection for any vacuum system which contains hydrogen and can reach adeflagration pressure above the design pressure. (For a 200 KPa design pressurethe hydrogen isotope concentration limit is 1.5 mole/m3 for volumes or 0.8 mole/m3for pipes). If the probability of air ingress is greater than 10-6 per year, then theprobability shall be reduced by design. For example, measures such as doublevacuum containment with a monitored interspace may be appliedPage 24 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 22 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMThe requirements of this Handbook for VQC 1A will generally satisfy therequirements for primary tritium confinement (also see ITER Tritium HandbookITER_D_2LAJTW))5The requirements of this Handbook for VQC 3A will generally satisfy therequirements for the temporary confinement of tritium in off-normal events and oflevels expected to be permeated (also see ITER Tritium Handbook ITER_D_2LAJTW). On ITER, the secondary tritium confinement function is generally performed bybuildings, ventilation and detritation systems, and hence is not part of this Handbook. Further information on requirements for the confinement of tritium can be found in theITER Tritium Handbook (ITER_D_2LAJTW). 10 Trapped VolumesFor VQC 1 and VQC 2A, 3A and 4A, the design of any vacuum component shallavoid trapped volumes in vacuum spaces which could result in virtual leaks. For VQC 2B, 3B and 4B, care in the design of any vacuum component shall minimisetrapped volumes in vacuum spaces which could result in virtual leaks. Communicating passages should be made between any potential trapped volumeand the pumped volume. The design of welded and brazed joints shall be such as toavoid the risk of trapped volumesCare should be taken to avoid large areas of surface contact which, throughimperfect flatness, can provide a trap for gas and impurities. Such surfaces, ifrequired, should be channelled. Where relief holes are necessary, these should preferably be in the “fixed” part of thework piece, rather than relying on, for example, the use of a vented screw which maybe missed on assembly11 Connections to the Service Vacuum SystemInterspaces, e.g. between double windows, double bellows, double-sealed valves,etc., should be designed to be connected to the Service Vacuum System (SVS) witha minimum of two independent connections in every case meeting the followingrequirements:¾ Interspaces which have a total volume less than 50 L shall utilise 6 mmtube welded to 6 mm (1/4 inch) VCR male fittings. ¾ Where the interspace volume is between 50 L and 500 L, the connectionsto the SVS shall utilise 12 mm tube welded to 12 mm (1/2 inch) VCR malefittings. ¾ Interspaces with volume greater than 500 L shall be fitted with 40 mmtubes with flanges selected from those listed in Appendix 8 welded to thetubes. Page 25 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 23 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMThis requirement is valid for all interspaces except where the interspace is to bepumped to less than 5x10-1 Pa, in which case connections to the SVS shall beaccepted by the ITER Vacuum RO. 12 Pipework (Pipe & Fittings)12.1 GeneralIn all applications in VQC 1A and VQC 2A and VQC 4A (process to insulationvacuum), pipe and fittings shall be seamless. Where this is not possible, specificacceptance is required to use seamed components which shall conform to the testingrequirements of Section 7.1.4. To mitigate risk of the loss of availability associated with water leaks in the cryostat, itis recommended that single contained water pipes do not pass through the cryostat. Where practical, for components classified as VQC 2A, water pipework forming partof the cryostat vacuum boundary shall be doubly contained. Where it is not practicalto doubly contain the pipework, all welded joints shall be full penetration butt weldssubject to 100% Non-Destructive Testing (NDT). Interspaces on VQC 2A water pipework shall be brought out to the port cells or pipechase area and provision made for water detection, draining and temporary vacuumconnection for vacuum leak testing the interspaces. Where interspaces are not used as a method of water leak localization for waterpipes passing through the cryostat, an alternative accepted method shall beintegrated with the water pipe design. For VQC 1A and VQC 2A, & VQC 4A (process to insulation vacuum) pipework of wallthickness less than 2.0 mm designed to contain helium, Electro-Slag Remelted(ESR) or Vacuum Arc Remelted (VAR) material shall be used for the pre-extrudedmaterial and the inclusion limits of Section 5.3 adhered to. In the case of VQC 4 (atmosphere to insulation vacuum), there is no restriction onthe use of seamed pipe provided that it conforms to the testing requirements ofSection 7.1.4. 12.2 Pipework SizesTo comply with the ITER standard vacuum flange dimensions as specified inAppendix 8, standard pipework sizes shall be used where practical. Standard pipesizes are listed in Appendix 11. 13 Demountable JointsDemountable vacuum joints i.e. quick release couplings, compression joints,transition couplings, flange pairs, etc. for use on ITER vacuum systems shall beaccepted prior to use. Lists of standard joints are given in Appendix 8. For VQC 1 and 2 there shall be no demountable vacuum joints within the vacuum. Page 26 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 24 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMVacuum joints for use on VQC 1, 2 and 3 systems shall use all-metal seals. Inaddition, vacuum joints for use on VQC 1A shall utilise a double seal arrangement,with the interspace connected to the Service Vacuum System consistent withSection 9 (Confinement and Vacuum Containment). All demountable joints must be accessible for maintenance/testing. In all cases the fixed sealing face of the vacuum joint shall be accessible for mannedinspection and repair during periods of ITER maintenance. Seal faces must have the requisite surface finish and cutting lay or lap direction forthe seal design. Seal faces shall not be electropolished. For VQC 4, demountable vacuum joints shall normally use all-metal seals, althoughthe use of other types of seals is permitted subject to prior acceptance. For all VQC, the reuse of metal seals is permitted for system testing only. However,the final mating of demountable vacuum joints shall be made using previouslyunused metal seals. Where demountable vacuum joints are mated for testing purposes, the appliedsealing bolt loading on the test flanges shall be consistent with the final sealingoption utilised. Once the sealing flange is proven, temporary use of other sealingoptions can be permitted. When the item is in its operational position and atemporary seal is used this must be recorded using a non-conformance. All demountable vacuum joints shall be subject to 100% helium leak testing toinstallation procedures following the guidelines specified in Appendix 12. Installationprocedures shall be approved by the ITER Vacuum RO. A design guide for themanufacture of demountable joints and sealing options for use on ITER vacuumsystems is given in Appendix 814 Fasteners and Fixings14.1 Tapped HolesBlind tapped holes shall be avoided as far as possible, since in addition to being asource of virtual leaks (see Section 10), they provide a potential trap forcontaminants. Where the use of blind holes is unavoidable, holes shall be tappedwith flat bottoms and vented screws or bolts shall be used. Tapped holes shall be cut using only the approved cutting fluids listed in Appendix 4. Cutting fluids not listed in Appendix 4 may be accepted in advance by the ITERVacuum RO and submitted for inclusion in Appendix 4 using the procedure inSection 5.2. Where an insertion is used to provide a screw thread in a plain hole (e.g. Helicoil™ inserts), the material used shall be consistent with those listed inAppendix 3. Page 27 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 25 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM14.2 Bolts14.2.1 Bolts for use on the Vacuum Boundary (P < 0.15 MPa)It shall be demonstrable that bolts for use in the formation of a vacuum boundary areof satisfactory mechanical properties to provide the relevant seal force requirementsof Appendix 8. Bolts should be of rolled thread and supplied with certification inaccordance with EN 1024, 3.1. 14.2.2 Prevention of Bolt SeizingFor all VQC, threaded fixings (e.g. bolts), shall be treated to prevent seizing. Approved solid (dry) lubricants, aluminium bronze inserts or coatings are preferred. Lubricants for each class are listed in Appendix 3. The use of any other lubricant issubject to prior acceptance. Bolts for use on ITER vacuum systems but not exposedto vacuum (i.e. VQC N/A), shall be lubricated to prevent seizing with a hard coatingor, where appropriate, Molykote“. 14.2.3 Bolt LockingIt is recommended that bolts in vacuum for use on VQC 1 and VQC 2 systems shallbe locked after loading to prevent them becoming free and causing damage to otherparts of the vacuum system. Bolts may, for example, be locked using resistance spotwelded stainless steel tangs. Other suitable materials may be selected from thoselisted in Appendix 3. 14.3 RivetingRiveting is an approved technique for the joining of components in VQC 2B and 3B. Rivets shall only be formed from the materials listed in Appendix 3. Trapped volumes formed by riveting shall be eliminated at the design stage inaccordance with Section 10 above. 14.4 Bearings and Sliding JointsDesigns for in-vacuum bearings and sliding joints for VQC 1 to 3 shall be subject toprior acceptance at the design stage. These should be eliminated by designwherever practical, for example by the use of flexure pivots. Solid (dry) lubricants orcoatings are preferred, but other permitted lubricating materials are listed inAppendix 3. In VQC 2 and 4 applications, polytetrafluoroethylene (PTFE) bearings are approvedfor positions where the predicted radiation fluence over the full operational life ofITER is less than 103 Gray (up to 106 Gray for accepted cross-linked PTFE) (Gammaor Neutron dose equivalents). Page 28 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 26 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM15 Windows and Window Assemblies15.1 GeneralWindow assemblies for VQC 1 and VQC 2 shall be double, with no ’design basis’common mode failure between the two windows, or shall be fitted behind a UHVisolation valve and have direct connection through the window to a VQC 3 vacuumsystem. For windows transmitting high power (e.g. RF heating systems) the interspacepressure shall be continuously monitored and suitably interlocked with the powersystem. Window assemblies accessible from outside the vacuum systems should incorporatemechanical protection against accidental impact. For VQC 1A double window assemblies to air, the maximum diameter permitted is160 mm. An example of a specification for the design, qualification, manufacture andacceptance testing of window assemblies for use on ITER vacuum systems can befound in Appendix 615.2 Qualification of Window AssembliesPrior to manufacture, the design of window assemblies shall be qualified byperforming type tests on pre-manufacture window assemblies. The supplier shallsubmit for acceptance a qualification test plan detailing the qualification tests to beperformed in order to qualify the window for a particular application. The qualification of the window assemblies for use on a vacuum boundary shallinclude the following tests:¾ Pressure testing of window assemblies. ¾ Mechanical shock testing. ¾ Thermal shock testing. ¾ Helium leak testing. 15.3 Testing of Window AssembliesPrior to the manufacture of window assemblies the supplier shall supply foracceptance a test plan and test procedures detailing the tests to be performed onwindow assemblies before delivery to the ITER site. After the completion of allmanufacturing processes the window assemblies shall be subject to a thermal cycletest, pressure test, and helium leak test. Acceptance testing of window assemblies which operate at elevated temperaturesrequires a minimum of three thermal cycles to be performed to their maximumoperating temperature consistent with Section 25.5. Page 29 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 27 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM16 Vacuum Valves and Valve AssembliesFor VQC 1, 2 & 3, valves shall be of all-metal construction with the exception of thevalve closure seal, for which polyimide is also permitted. For VQC 2 valves, elastomers may be used on the valve closure seal only with theprior acceptance of the ITER Vacuum RO. For VQC 4, valves need not be all-metal except where they may be in contact withcryogenic fluids. For VQC 1A all actuating and actuator bellows and seals shall be of doubleconstruction with the interspaces connected to the Service Vacuum System (seeSection 11). Valves requiring compressed gas to maintain a seal shall be avoidedwhere practical and any use requires prior acceptance. Valve assemblies shall normally be installed such that the internal actuating systemfor the valve is on the side exposed to lower vacuum quality or to atmosphere andthe seal face to the higher vacuum quality side. To facilitate this, all valve assembliesshall be permanently marked on the outside with an arrow pointing towards the sealface end of the assembly. The valve position shall be positively identified by means of “open” and “closed” limitswitches and a visual position indicator shall be provided on the valve or actuatorbody. 16.1 Acceptance Testing of Vacuum Valves and Valve AssembliesPrior to shipping, valves shall be subject to an acceptance vacuum leak test. Detailedleak testing procedures shall be submitted for prior acceptance. Guidance can befound in Appendix 12. Valve testing shall include the following helium leak tests:¾ Valve body (global). ¾ Across the valve seat. ¾ Valve actuator bellows. ¾ Internal pressure element. ¾ Valve double bellows interspace. Valves for use on VQC1 systems at elevated temperature shall be baked and hotleak tested at 200 °C. An example specification for the design, manufacture and testing of valves for use onITER vacuum systems is given in Appendix 7. Page 30 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 28 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM17 Bellows and Flexibles17.1 GeneralIn general, bellows and flexibles are considered to be inherently vulnerablecomponents (see section 9) due to their method of construction and because theirapplication is typically to facilitate movement. The use of bellows or flexibles in water circuits inside vacuum systems with any VQCshall be avoided by design wherever possible, and shall only be only permitted withprior acceptance for VQC 1A and VQC 2A when the surrounding vacuum is behindan isolation valve. For such usage, consideration must be made at the design stageto proven reliable performance in similar applications. Double bellows are notrecommended for use in water circuits in vacuum. In all test situations and after installation, the bellows shall be protected against allabnormal load conditions. This may include the design of physical constraints. An example of a specification for the design, qualification, manufacture andacceptance testing of bellows assemblies for use on ITER vacuum systems can befound in Appendix 917.2 Bellows ProtectionBellows shall be protected against damage from falling objects. The bellowsprotection shall be equivalent too, or better than, that provided by a cover of schedule20 pipe. 17.3 Design of BellowsCircular bellows are to be designed to the EJMA or EN14917 or equivalent. The useof other design codes is subject to acceptance. Where design codes are notapplicable, design shall be by analysis and shall be proven by qualification. Care shall be taken to ensure that the operational loading parameters are fullyconsidered. Precautions need to be taken against rupture and other failure modeswhere there is a pressure difference in either direction between the inner and outersurfaces of the unit. Bellows for use on VQC 1 systems shall be of double construction (or acceptedmultilayer design) with a monitored interspace, unless they are accessible formaintenance and fitted behind an approved interlocked isolating valve. Where bellows are be used on VQC 2 systems it is recommended that they be ofdouble construction (or accepted multilayer design) with a monitored interspace. Multiple ply bellows are not permitted for VQC 1A components unless they areaccessible for maintenance and fitted behind an approved isolating valve. For VQC 1A and VQC 2A, where regular and significant movement is to be taken upby a double bellows, the norm shall be to design the double arrangement such thatPage 31 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 29 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMone bellows is in compression whilst the other is in expansion so as to reduce thechances of a common mode failure. The interspace between the two bellows of an assembly shall normally be filled witha suitable tracer gas and the pressure in the interspace shall be continuouslymonitored. The interspace shall be connected to the Service Vacuum System (seeSection 11). Normally accessible bellows assemblies and bellows assemblies which becomeaccessible during machine maintenance shall be supplied with mechanical protection(such as the use of metal braiding or removable cover plates) to prevent accidentaldamage and ingress of matter to the bellows edge-welds or convolutions. Non-circular bellows of non edge-welded construction are to be welded and thenformed, rather than formed in parts then joined. This does not apply to the post-forming welding of bellows sections to collars. Cross welds are to be avoided wherepossible. Hydrostatic, rolling or elastomeric formation is approved for all vacuum classes. Bellows which are of edge-welded construction shall be acceptable provided thatthey comply with Section 7.1. Cleaning of bellows shall be in accordance with the requirements of Section 24. 17.4 Qualification of BellowsBellows designed by analysis shall be subject to a qualification procedure prior tomanufacture. The design of bellows shall be qualified by performing type tests onpre-manufacture bellows assemblies. The supplier shall submit for acceptance aqualification test plan detailing the qualification tests to be performed. The qualification of the bellows assemblies shall include the following:¾ Pressure test. ¾ Fatigue life test. ¾ Mechanical shock testing. ¾ Helium leak test. 17.5 Testing & Inspection of BellowsPrior to the manufacture of bellows assemblies the supplier shall supply foracceptance a test plan and test procedure detailing the tests to be performed onbellows assemblies before delivery to the ITER site. After the completion of allmanufacturing processes the bellows assemblies shall undergo a vacuum bakingcycle to the operating temperature and a helium leak test. The supplier shall performa survey of the bellows convolutions to confirm compliance with the bellows technicalspecification. The survey results shall be supplied to ITER and any non-conformancemay lead to rejection of the bellows. Page 32 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 30 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM17.6 Bellows ProtectionBellows shall be protected against damage from falling objects. The bellowsprotection shall be equivalent too, or better than, that provided by a cover of schedule20 pipe. 18 Feedthroughs18.1 GeneralWhere for VQC 1A and 2A a feedthrough penetrating the air boundary is consideredvulnerable (see Section 9) a doubly vacuum contained electrical feedthrough withinterspace connected to the Service Vacuum System shall be used. Wherenecessary, alternative arrangements shown to ensure sufficient integrity of thefeedthrough may be accepted. The sheaths of mineral insulated cable shall not pass directly through a VQC 1A and2A feedthrough, but shall be discontinuous and sealed within feedthroughinterspaces. Where applied or induced voltages may be present on such feedthroughs, thenprotection against arcing or Paschen breakdown shall be provided. 18.2 Paschen BreakdownWhere there is a risk that Paschen breakdown may occur in an interspace of afeedthrough, it must either be continually pumped or be backfilled with a gas ofaccepted composition to a pressure appropriate to mitigate the risk of Paschenbreakdown. In both cases, the interspace pressure must be continuously monitored andinterlocked with the system controls to prevent power being applied in the event ofsingle barrier failure. 19 Electrical BreaksWhere for VQC 1A and 2A, an electrical break (i.e. providing electrical isolationbetween systems) is considered vulnerable (see Section 9), a doubly vacuumcontained electrical break with interspace connected to the Service Vacuum Systemshall be used, unless it is accessible for maintenance and fitted behind an approvedinterlocked isolating valve. If an electrical break is at risk of Paschen breakdown in an external or internal roughvacuum, suitable precautions shall be taken to ensure that the risk of breakdown iseliminated. Page 33 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 31 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM20 Cables for use in Vacuum20.1 GeneralUp to 80 km of cables are anticipated in the ITER vacuum vessel. Many kilometresare also required in the cryostat. Special care shall be taken in the choice andquality control of such cables. In-vacuum cabling shall comply with all the generalvacuum requirements for its VQC. In particular:¾ Materials shall be selected to be in accordance with Appendix 3. ¾ Outgassing shall be consistent with Table 20-1. Table 20-1 – In vacuum cabling outgassing ratesApproved cable types pertaining to each VQC are listed in Appendix 10. The use ofother cables is subject to prior acceptance. All mineral insulated cables shall be sealed at both ends, and the void volume shallbe less than 5%. The cable shall be proven to be leak tight, consistent with the levelsfor VQC 1 and VQC 2 given in Table 25-1, by helium bombing (see Appendix 12). Specification for the manufacture and qualification of in-vacuum cables shall beaccepted by the ITER Vacuum RO prior to production. A guide for the supply of in-vacuum cables can be found in Appendix 10. 20.2 Connectors and TerminationsIn-vacuum connectors shall comply with the general vacuum requirements for therelevant VQC. VQCOutgassingtemperature(qC)Maximum steady stateoutgassing rate per unitlength+ [ Pa.m3.s-1.m-1 ] Testing guidelinesHydrogenIsotopesImpurities1 100 1 x 10-9 1 x 10-11 Appendix 172‡ 20 1 x 10-9 Appendix 173 20 1 x 10-10 Appendix 174 20 1 x 10-9 Published data andconformity to clean workplan. For VQC 2, 3 & 4 the total outgassing rate excludes water and hydrogen. +Valid for cables up to Ø 5mm outer sleeve. Pro-rata values can be applied for larger cables‡ The requirements for high voltage cables in the cryostat are still being studied and hencerequirements will be specified in future. Page 34 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 32 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM21 Interconnection between VQC 1 systemsAny system which can be directly connected to the main ITER tokamak vacuum byopening a valve shall have, as a minimum, full range pressure monitoring. Residualgas analysis capability is also required for systems with volume > 1 m3. The control of the isolating valve shall be via the ITER vacuum control system. Signals for all vacuum monitoring shall be made available to the ITER vacuumcontrol system. Any necessary inhibits on valve movements required to protect the sub-system, shallbe made available to the ITER vacuum control system. 22 Proprietary ComponentsIn the context of this Handbook, proprietary components are standard products whichare listed in supplier’s catalogues and are sufficiently well documented for theirspecification to be checked for fitness for purpose. Proprietary components fully meeting the ITER specification of the item and therequirements of each VQC are permissible for useFor VQC 1, 2 and 3, proprietary components meeting the requirements of thisHandbook shall be supplied with an individual certificate of conformity, stating thatthe item conforms to the specification provided by the supplier. For VQC 4, proprietary components shall be supplied with a certificate of conformityas above, but this may be in the form of generic or type conformance certificates tothe catalogue specification. A list of standard proprietary components which are known to conform to therequirements of this Handbook and so can be recommended for use on ITERvacuum systems is to be found in the Appendix 20. Other proprietary components will be added to Appendix 20 when they are shown tomeet the requirements of this Vacuum Handbook. Proposed additions should besubmitted to the ITER Vacuum RO for consideration using the form in Appendix 2023 Vacuum InstrumentationThe requirements stated below shall be applicable to any instrumentation that directlyinterfaces with ITER vacuum spaces, and is applicable to all Vacuum Classifications. In all cases instrumentation shall be compatible with ITER operational requirementsand the ITER physical environment. This shall include among other matters:¾ Being compatible with the relevant VQC. ¾ Being compatible with operation in a hydrogen environment. ¾ Exhibiting an outgassing rate consistent with those given in Section 5.4. ¾ Being leak tight consistent with Table 25-1. Page 35 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 33 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM¾ Being resistant to neutron and gamma radiation at the instrument location. The radiation map to define these levels is defined in the ITER RoomBook. See also Appendix 3. ¾ Being able to survive any pressure within the full operational and off-normal range (from 10-9 Pa to 0.15 MPa for VQC 1 and 2). Instrumentation shall be servicing free to the maximum extent. Generally on VQC 4, wherever the operational environment permits, active sensorsmay be used. VQC 1 and 2 Instrumentation for use in the control of vacuum shall be fitted behind aUHV isolation valve or have agreed redundancy, and shall be accessible formaintenance. 24 Cleaning and Handling24.1 CleaningCleanliness is required during the whole manufacturing process and the preservationof cleanliness is good practice for any component to achieve the necessary vacuumstandards and to minimise the time required to recover from any contaminationincident. All components shall be subjected to a rigorous cleaning procedure,consistent with the Vacuum Classification of that particular component. A guide tocleaning and handling of components for use on ITER vacuum systems can be foundin Appendix 13. A detailed Clean Work Plan shall be submitted for prior acceptance to the ITERVacuum RO before any cleaning operations are undertaken at the supplier’s site. The plan shall specify how cleanliness will be maintained throughout themanufacturing process. It shall state when specific cleaning procedures will beapplied and all of the controls which will be in place to maintain cleanliness, includinghandling. Parts and sub-components shall be degreased using solvents or alkaline detergents,rinsed with demineralised water, and dried in hot gas or an oven to acceptedprocedures. The use of halogenated solvents is forbidden at any stage. Lists of accepted cleaning fluids can be found in Appendix 4. VQC 2 components incorporating cryostat vacuum-facing resins give a risk fromvolatile surface compounds which, if sticking to the reflective coatings of the tokamakthermal shields, could degrade the emissivity of the shields. As no acceptableprocedure is foreseen for cleaning volatiles from a resin surface, care shall be takennot to introduce them to the surface. 24.2 Design Rules for CleanabilityAt the design stage for a vacuum component, careful consideration shall be given tohow the item is to be cleaned. In particular, crevices, blind holes, cracks, trappedvolumes, etc., shall be avoided as these will act as dirt and solvent traps and it canPage 36 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 34 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMbe very difficult to remove contaminants from such areas. Fortunately, good vacuumpractice regarding trapped volumes will also usually result in a component which iscleanable. 24.3 Mechanical Processes on Vacuum SurfacesAbrasive techniques to clean or to attempt to improve the appearance of the surfacesof vacuum components must be kept to an absolute minimum and are preferablyavoided. For all VQC the use of files, harsh abrasives, sand, shot or dry beadblasting, polishing pastes and the like is prohibited under normal circumstances andmay not be used without prior agreement. However, for VQC 2, shot or dry beadblasting is permitted. Stainless steel wire brushes, cleaned to the standards of thishandbook, may be used only when it is considered essential to do so. If grinding is essential on VQC 1 systems, the grinding wheel shall be free of organiccomponents and shall have been manufactured in an oil-free, clean environment. The material and manufacturing process of the grinding wheel shall be accepted bythe ITER Vacuum RO before use. 24.4 Pickling/passivation of Steels and CopperIf an assembly is pickled, then final machining of vacuum sealing surfaces must beleft until after the pickling/passivation process. Pickling should always be followed by passivation. This is best carried outchemically, although native oxide layers can reform on exposure to atmosphere. Pickling and passivation must always be followed immediately by an appropriatecleaning process relevant to the VQC of the component. It should be noted that thermal outgassing from surfaces which have beenpickled/passivated may well be greater than that from a native metal surface andbaking may be required to reduce outgassing rates to acceptable levels prior toinstallation. A guide to the pickling/passivation of steels and copper can be found in Appendix 14. 24.5 Post-Cleaning Handling of Vacuum EquipmentAfter final cleaning, the handling of vacuum equipment shall be strictly controlled topreserve cleanliness. General area cleanliness requirements pertaining to VacuumClassifications are summarised in Table 24-1. The continuing suitability of any givenarea used for handling vacuum equipment should be checked on a regular basis bymonitoring the airborne particulate count, which should not exceed 5 x 106 particlesof size > 0.5 —m per m3 for VQC 1. VQC Cleanliness requirements Personnel AreaCleanlinessMonitoring1 Segregated clean area. Limited Access toauthorised personnel. Trained personnel. Protective hair nets. Clean powder freeDaily Cleaningof areaincluding floorsDaily airquality checks. Results storedPage 37 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 35 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMAuthorised equipmentoperated to approvedprocedures. Management of equipment(e.g. no vacuum pumps orother machinery exhaustinginto clean area). latex or nitrile outergloves. Clean whiteoveralls. Overshoes. Clean job specificfootwear. and surfaces. Sticky mats atarea entry. in componentdocumentpackage. Weeklycleanlinesstest of areawith resultsstored incomponentdocumentpackage. 2 Authorised equipmentoperated to approvedprocedures. Management of equipment(e.g. no vacuum pumps orother machinery exhaustinginto clean area). Trained personnel. Clean outerprotective gloves forthe handling ofclean equipment. Daily Cleaningof work areaincluding floorsand surfaces. 3&4 House Keeping. Trained personnel. Clean powder freelatex or nitrile outergloves for thehandling of cleanequipment. Daily cleaningof area. Table 24-1 – Environmental cleanliness pertaining to VQCAdditional cleanliness requirements shall be defined in the component installationprocedures. Handling cleanliness guidelines for each VQC are detailed in Appendix 2. 24.6 Cleanliness during the Assembly of Vacuum EquipmentThe mandatory requirements relating to cleanliness during assembly of vacuumequipment are detailed in Attachment 2 (ITER_D_MBXPP3). 25 Leak Testing25.1 GeneralGenerally, leak tests shall be performed:-¾ During manufacturing to confirm the soundness of joining processes andsub-components and to reduce the risk of Incorporating leaks in a systemthat are subsequently difficult to locate or to repair. ¾ As an acceptance test at the supplier’s site to show that completedassemblies meet the acceptance leak criteria. ¾ When a component arrives at the ITER site, to confirm that there has beenno damage during packaging and transport. This test, which is under thePage 38 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 36 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMcontrol and at the discretion of ITER, will be designed to be as simple andfast as possible. ¾ During installation, under the control of ITER, when testing is implementedto reduce the risk of newly made joint leaks only being detected at thecompletion of the total installation. ¾ On pumping down of the completed installation as part of the finalcommissioning. Leak testing shall be carried out by suitably trained and experienced personnel. Acceptance test methods require prior acceptance. Guidance can be found inAppendix 12Leak testing shall be performed after pressure testing (if applicable). Before leaktesting, components shall be cleaned, dried or baked in accordance with Section 27of this Handbook. Unless otherwise specified in the relevant contract or Procurement Arrangement thesupply of any vacuum component shall include all testing jigs, flange closure plates(welded or otherwise) and fittings to allow helium leak testing at the ITER site. Thesemay be the same items that were used for tests prior to delivery. Methodologies forthe subsequent removal of such features shall also be supplied. The requirement to leak test proprietary components delivered to the ITER site with asupplier’s Certificate of Compliance may be waived by ITER at the discretion of theITER Vacuum RO. 25.2 Maximum Acceptance Leak RatesMaximum acceptance leak rates for several of the ITER vacuum systems are givenin Table 25-1. Any concession to permit leak rates greater than those specified in Table 25-1 canonly be by prior acceptance. 25.3 Design Considerations for Leak TestingAll components and systems forming a vacuum boundary shall be designed so as tofacilitate leak testing using tracer gas leak detection methods during the building ofITER. Components shall also be designed to facilitate the timely localization of leaksoccurring during ITER operations. Different techniques can be considered which mayinclude the provision of small-bore tubing to allow the introduction of helium to thevicinity of potential leaks. The design of vacuum systems shall be such that leak tightness can to be provenacross all vacuum boundaries. Page 39 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 37 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM25.4 Scheduling of Leak TestsPrior to manufacture the supplier shall have an accepted leak test plan detailing thetiming and type of tests to be performed during manufacture. The plan shall includewhich tests are to be witnessed by the ITER or Domestic Agency Vacuum Specialist. The ITER Vacuum RO shall be informed a minimum of two weeks in advance of atest requiring witnessing by ITER. Scheduling of leak testing shall be in compliance with the ITER Leak Testing Policy(ITER_D_L5P5P2). Page 40 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 38 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMSystem/ Component Maximum Leak Rate (Pa.m3/s airequivalent†)VQC 1 * 1 x 10-10VQC 2* 1 x 10-9VQC 3* 1 x 10-9VQC 4* (Atmosphere to insulation Vacuum) 1 x 10-7VQC 4* (Process line to insulation Vacuum) 1 x 10-10Tokamak primary vacuum (including all in-vessel components and attachments) 2x10-7Vacuum vessel (Including ports but excludingattachments) (Total allocation of leakage intomain chamber vacuum)1x10-7Individual vessel sector (Total allocation to asector main chamber vacuum assumingenclosed)1x10-8Individual field joints (covers port and sectorfield joints) 1 x 10-8Individual port plugs (complete) 5 x 10-10Each NB/DNB injector enclosure 1x10-8Cryostat vessel (excluding contents) 5 x10-5Completed Cryostat (including all in-cryostatcomponents and attachments) ‡ 1x10-4Central solenoid assembly‡ 1x10-7Individual PF-coil assembly‡ 1x10-7Individual TF-coil assembly‡ 1x10-7Complete thermal shield assembly‡ 1x10-5Page 41 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 39 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM*Individual system or component not otherwise mentioned. † Helium equivalent Leak Rate (LR) = Air equivalent x 2.69 at the same temperature. mass atomic M 69 . 2HeliumAirAirHeliumMMLRLR‡ Values quoted refer to systems under normal operational pressures and temperatures. Conversion toroom temperature and atmospheric pressure tests can be supplied on request. Table 25-1 Maximum acceptance leak rates for various vacuum systemsGenerally it is advised that component parts should be tested before assembly, butfinal assemblies must be tested before shipping to ITER. For VQC2A in the case of aconstruction with many joints which become embedded and inaccessible in anassembly, then individual leak tests may be accepted as an acceptance test toreplace final assembly acceptance leak testing prior to shipping. Leak testing may be performed at the ITER site following transportation of vacuumcomponents prior to it being accepted by ITER for installation. Installation leak testing will be carried out to accepted procedures as part of the ITERassembly. All ITER vacuum systems will undergo final leak testing as part of theintegrated commissioning of the ITER machine. 25.5 Methods and ProceduresThe leak test procedure for acceptance tests shall be accepted in advance by theITER vacuum RO. The procedure shall describe how the leak test will be performed,and include configuration diagrams and full details of the equipment to be used. Guidance on acceptable methods of carrying out leak testing is given in Appendix 12. The acceptance leak test method shall ensure leak tightness is proven across allvacuum boundaries. Test conditions (pressure, temperature) for the acceptance leak test shall be as closeas practical to the design conditions. Testing shall be carried out with the componentat ambient temperature and as close as practical to both its maximum and minimumdesign temperatures. The direction of the pressure differential shall normally be inthe same direction as during operation exhibited by the components. Exceptions willbe considered for the larger ITER components for tests prior to the finalcommissioning tests. Where acceptance leak tests are not to be performed on cryogenic systems atcryogenic temperatures, a method of cold leak testing any welded connections shallbe accepted in advance. For an acceptance helium leak test, the helium concentration around the test pieceshall be at a minimum of 50% for the duration of the test. The helium concentrationshall be measured and recorded. The helium shall be maintained for a periodcalculated to be sufficient to identify leaks at the acceptance level. Page 42 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 40 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMAcceptance leak tests on VQC 1A or VQC 3A components which include joints ofdissimilar materials2 shall be subject to a minimum of three thermal cycles fromambient to the maximum possible operating temperature prior to leak testing. Thetime taken for any component to reach the specified bake temperature from ambientshall be less than 100 hours. A representative of the ITER Organisation may inspect the supplier’s leak testingequipment and witness a proof of procedure prior to the acceptance leak test. Acceptance leak tests shall be witnessed or, where there are many tests agreed toform the acceptance leak testing, a representative sample of the test shall bewitnessed. The ITER Vacuum RO shall nominate or approve the Vacuum Specialistto witness the acceptance leak tests. ITER may require that other key(ITER_D_L5P5P2) leak tests to be implemented as part of a manufacturing processbe witnessed. Those tests to be witnessed by ITER, including the acceptance tests,shall be defined in the Manufacturing Inspection Plan (MIP). 25.6 Acceptance Leak Testing at the Supplier’s PremisesThe supplier is responsible for the supply of all testing equipment, vacuumcomponents, all testing jigs, flange closure plates (welded or otherwise) and fittingsto allow an acceptance helium leak test to be carried out. No repair or re-work of the components (with the exception of simple tightening offlange joints or replacement of gaskets) shall be undertaken without prior agreement. Any repair or rework will require the leak test procedure to be repeated and mayinclude a repeat leak test at the operating temperature. No vacuum component which fails to meet the specified acceptance leak rate at thesupplier’s site shall be accepted for delivery to the ITER site without prioracceptance. 25.7 Acceptance Criteria for Leak TestingOn successful completion of the specified leak tests, the item under test may beaccepted provided the following conditions have been met:¾ The leak detector in the test configuration has been calibrated and itscalibration value is within the limits of ±5% of the nominal value of thestandard leak rate value, taking into account the ambient temperature andthe age of the standard leak. ¾ The background level of the leak test was below the acceptance leak ratewithout electronic correction prior to the test. ¾ The reading from the leak detector has not increased in value above themeasured background by more than the specified leak rate as defined for2 Metallic joints shall be considered to be of dissimilar materials if the difference in linear thermalexpansion coefficients over the operating temperature range of the materials comprising the joint isgreater than or equal to 20%. Joints between non-metallic materials shall be considered as dissimilar. Page 43 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 41 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMthe item under test throughout the entire duration of the leak testprocedure. ¾ The test has been performed to the agreed procedure and, wherespecified in the Quality Plan, has been witnessed by the ITER VacuumSpecialist. 25.8 Acceptance Leak Testing at the ITER siteNormally, vacuum components shall be subject to a leak test at the ITER sitefollowing transportation. The purpose of such a test is to reduce the risk of installing aleaking component and is of particular importance for components which would havea high impact to replace or repair. This test will normally be performed by ITER but asupplier may witness this test. This test may be a more limited test than thatperformed at the supplier’s site and may be performed at ambient temperature at thediscretion of the ITER Vacuum RO. 25.9 Reporting of Leak TestsFull records of the tests carried out shall be compiled in order to maintain traceabilityof the leak test history of a particular item. The records shall become part of the finaldocument package for the component concerned. Records shall include thefollowing:¾ Data records of the output of the leak detector for all the global testsspecified including the standard leak calibration and response timedetermination. These data records shall include the date and time of allthe tests as well as any other data necessary to allow a full analysis of theresults, such as the start and finish of helium gas application to the itemunder test. ¾ A record of the helium concentration during the leak test. ¾ A record of the system total pressure and temperature during atemperature cycle as it may pinpoint the time when a leak opened up andbe instrumental in the subsequent diagnosis of the leak. ¾ The make and model of the helium mass spectrometer leak detector usedin the test. ¾ The nominal value of all standard leaks used, their date of calibration,ageing and temperature characteristics, and the ambient temperature(s)experienced during the tests. ¾ Results of all tests showing whether it was a pass or fail and if a failure,the measured leak rate and the location of the leak plus the steps takenfor repair or elimination. ¾ The magnitude and location (if applicable) of all leaks identified duringtesting. This includes leaks of size lower than the acceptance criteria forwhich no remedial action may have been taken. Page 44 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 42 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM¾ A full record of any residual gas scans taken with appropriate timemarkers to identify the scans to the position in the component leak testcycle. An example template for the reporting of leak tests is provided as part of Appendix 1226 Baking26.1 GeneralVacuum components for the various classifications may require to be baked toensure satisfactory vacuum performance. Raw materials may also require bakingbefore being used in manufacture if a higher temperature is required to achievesatisfactory vacuum properties than will be possible later. Baking can be included in the component leak testing procedure (see Section 25)and/or the component cleaning procedure (see Section 24). A bake temperature andduration will normally be specified in the specification documents and/or drawings forindividual components or assemblies. If this is not the case, then the standardtemperatures listed in Table 26-1 shall be used. Normally, the time taken for anycomponent to reach the specified bake temperature from ambient shall be less than100 hours and the component shall normally be held at the baking temperature for aminimum of 24 hours. Where the supplier is unable to carry out a bake procedure, either to the standardconditions in Table 26-1 or as otherwise specified, then any variation shall be agreedwith ITER before proceeding. For all vacuum components that require baking, a detailed procedure describing thebaking process shall be submitted for acceptance before any baking is started. Theacceptable leak rate and vacuum conditions of any baking chamber shall be agreedas part of this procedure. Vacuum ovens containing heating filaments within the vacuum are not permitted forVQC 1 baking operations without full qualification of the baking process. Post bake handling of vacuum components shall be in accordance with Section 24.5. A guide to the vacuum baking of components, including baking temperatures, is to befound in Appendix 15. 26.2 VQC 1 Components (non plasma-facing)After manufacture, VQC 1 non plasma-facing components which operate at elevatedtemperature shall be baked using the guidance of Appendix 15. Baking shall be for aminimum of 24 hours at the maximum operating temperature. The bake cycle may beperformed as part of the cleaning process or, if applicable, the hot leak test. There isno vacuum requirement to bake at temperatures in excess of the design temperature. Page 45 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 43 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM26.3 VQC 1 Components (plasma-facing)To ensure vacuum cleanliness and to reduce impurity outgassing, components whichare plasma facing or operate within 0.25 m of plasma shall be conditioned aftermanufacture by vacuum baking following the guidance of the ITER VacuumHandbook Appendix 15. For VQC 1 component materials in proximity to the plasma,the normal vacuum baking temperature is given in Table 26-1. Where thetemperature is too high for a composite assembly, the component part requiringhigher temperature baking shall be baked at that temperature prior to assembly andthen the complete assembly baked at the lowest listed temperature of the componentparts. Temperature requirements for baking materials not listed shall be agreed inadvance of baking operations. For any individual component, the point in the manufacturing schedule or testingprocedure at which such bake or bakes is carried out and the maximum temperatureused shall be agreed with the ITER Vacuum RO. Post baking handling shall beminimised to preserve cleanliness and shall be in accordance with Section 24. Component Material Baking temperature (qC)1Beryllium 3502Stainless Steel (all grades) 250Carbon Composites 450 or 20003Precipitation-hardened copper alloys 250Tungsten 3501 Maximum temperature for baking complete systems may be limited by the system components2 A 250 qC baking cycle for a substantially increased duration at may be permitted on approval. 3 Section 26.7 and Appendix 16Table 26-1 Baking temperature VQC 1 materials in proximity to the plasma26.4 VQC 2 ComponentsThere is normally no vacuum requirement to bake VQC 2 components, but bakingmay be used as part of the cleaning and surface conditioning process to achieve theoutgassing requirements of Table 5-1. 26.5 VQC 3 ComponentsThere is normally no vacuum requirement to bake VQC 3 components, but bakingmay be used as part of the cleaning and surface conditioning process to achieve theoutgassing requirements of Table 5-1. Page 46 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 44 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM26.6 VQC 4 ComponentsThere is no vacuum requirement to bake VQC 4 components. 26.7 Vacuum Conditioning of Carbon CompositesIn order to remove impurities from graphite or carbon fibre composite components(CFC), it is necessary to bake components in a suitable furnace. Due to the hightemperature requirements of CFC, subcomponents shall be baked prior to systemassembly. Conditioning of CFC is dependent on the manufacturing processes involved; hencebaking procedures must be qualified and accepted prior to manufacture. After baking the total outgassing rate for Carbon Fibre Composites shall be < 1 x 10-6Pa.m3.s-1.m-3 at 200 qC (excluding the partial outgassing rates for H2, CO and CO2)The supplier shall perform a degassing cycle of components after machining to aprocedure approved by the ITER Vacuum RO in accordance with Section 26. Guidance for the conditioning of CFC can be found in Appendix 16. 26.8 Documentation to be Supplied for Vacuum BakingFor each vacuum item, the following records shall be supplied:¾ Record of the pre-baking conditioning cycle for the vacuum bakingchamber. ¾ The initial leak rate of the vacuum baking chamber. ¾ The final leak rate of the vacuum baking chamber. ¾ A record of the temperature distribution for the item and the pressurewithin the vacuum item against time for the full duration of the bakeoutprocess. ¾ A full record of any residual gas scans taken with appropriate timemarkers to identify the scans to the position in the component bakeoutcycle. ¾ Full documentation regarding any leaks or any other problems whichoccurred during the baking and any remedial action taken. 27 Draining and Drying27.1 Design Considerations for Draining and DryingIn order to perform effective vacuum leak testing systems under test must be dry. VQC 1 in-vessel systems which contain water shall be designed in such away as tofacilitate draining and drying. Systems shall be designed to be drained and dried sothat after drying for <100 hours purge gas passing through the component has awater content <4000 ppm at ambient temperature and pressure. Page 47 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 45 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMConsideration shall be given to the position of inlet and outlet water feeds to minimisethe volume of trapped water which cannot be removed without drying. 27.2 Components Delivered to ITERVacuum components delivered to the ITER site shall be dry internally and externally. Any internal volumes wetted during acceptance testing shall be drained completelyand dried by purging with dry air until the purge gas has a water content of 4000 ppm, the dryingprocess shall be repeated until this condition is met. 28 Marking of Vacuum EquipmentSurfaces which are to be exposed to vacuum shall only be marked or identified ifnecessary and shall be marked by scribing with a clean sharp point, laser scribing orelectromagnetic dot peen method. Seal faces shall not be marked in any way. ForVQC1, chemical etching shall not be used unless accepted by the ITER Vacuum RO. Only approved (appendix 4) dyes, marker pens, paints, etc. shall be used onsurfaces which will be exposed to vacuum. 29 Packaging and Handling of Vacuum EquipmentComponents shall be packed with adequate protection from thermal or mechanicalstresses which may adversely affect the operation of the component. All packingshall be sealed and marked externally with the component VQC. Handlinginstructions shall also be clearly marked on the outside of the packaging. Chemical orradiological hazards, etc., shall be identified on the packaging. All such marking shallbe in English and French. All vacuum components shall be shipped dry internally and externally, irrespective offinal acceptance testing at the supplier’s site. Aluminium foil is recommended for sealing pipe openings, and protective caps shallbe fitted to flanges before packaging and sealing. Where it is not practical to enclosethe components, e.g. due to size, all apertures must be sealed to prevent the ingressof contaminants during transit. Sealing surfaces shall be protected to preventdamage by scratching, impact, etc. The use of adhesive tape for the protection and packaging of vacuum componentsshall be restricted to prevent the risk of contamination from the tape. In particular,tape used on austenitic stainless steel shall meet leachable chloride and fluoridelimits of 15 ppm and 10 ppm, respectively. Where used, tape shall be fully removableleaving no residue, using isopropyl alcohol or acetone as the solvent to remove alltraces of the adhesive. Page 48 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 46 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UMTo prevent damage and possible contamination during transit, the packaging ofcomponents shall be done as soon as possible after acceptance testing and finalcleaning at the supplier’s premises. Cleaning and packaging operations may bewitnessed by ITER. Vacuum components shall be handled as little as possible after final cleaning. Allsubsequent operations shall be carried out in clean conditions consistent withSection 24.5. In particular persons handling VQC 1 components shall wear clean powder-free latexor nitrile gloves (over cotton or linen gloves if desired) and, as a minimum, bedressed in clean white overalls. In the cases where the component is large (e.g. avessel sector) and internal access is required, hair nets and clean overshoes overfootwear specifically provided for use in the vacuum component shall be worn. Volumes which have been pumped for leak testing shall be backfilled with drynitrogen or air (<4000 ppm H2O) at a positive pressure of 0.12 MPa and valved off. Where the equipment allows manned access, air shall always be used. Where this isnot practical, alternative conditions shall be accepted by the vacuum RO. Cryogenic volumes which have been previously filled with helium for testing shallalso follow the above or may be backfilled with dry helium (<4000 ppm H2O) at apositive pressure of 0.12 MPa and valved off. Where practical, vacuum components shall be entirely enclosed in heat sealedpolyethylene for shipping. The polyethylene enclosure shall be purged and backfilledwith dry air (<4000 ppm H2O). Where this is not practical, alternative conditions shallbe accepted by the vacuum RO. 30 Incoming Inspection at ITER of Vacuum EquipmentBefore acceptance by ITER all components delivered to the ITER site will be subjectto incoming inspection. The following inspections will normally be carried out on vacuum equipment deliveredto ITER:¾ Checking of backfilled volumes (see Section 29). ¾ Seal face inspection. ¾ Checking the integrity of packing and status of accelerometers (if fitted). ¾ Cleanliness check. ¾ Leak test. On completion of the incoming inspection any non-conformance with, or deviationfrom, the vacuum specification or this Handbook shall be raised in accordance withSection 4. Page 49 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 47 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM31 Long Term Storage of Vacuum EquipmentIn many cases vacuum components will be delivered to the ITER site in advance ofinstallation to the ITER vacuum system. Vacuum components shall be stored in sucha state as not to degrade the vacuum performance. In the case of VQC 1 components, after incoming inspection and acceptance, thecomponents, where practical, shall be entirely enclosed in heat sealed polyethylene. The polyethylene enclosure shall be purged and backfilled with dry air (<4000 ppmwater). Volumes which have been pumped for leak testing shall be backfilled with drynitrogen (<4000 ppm water) at a positive pressure of 0.12 MPa and valved off. Thecomponent shall then be re-packed into its transportation case and stored at asuitable location. After incoming inspection and acceptance VQC 2, 3 and 4 components shall bestored in clean, dry packing cases in a suitable location. 32 QA and DocumentationAll vacuum components supplied to ITER shall be subject to the ITER QualityAssurance System detailed in the ITER Procurement Quality documentation (IDMRef; ITER_D_22MFG4). Specific guidance on satisfying the vacuum requirement of such a system is outlinedin Appendix 19. 33 AcknowledgementsThe ITER Vacuum Group acknowledges the following in the preparation of the ITERVacuum Handbook:UKAEA and JET, Culham Science Centre, Oxfordshire, UKAccelerator Science and Technology Centre (ASTeC), Daresbury, UKDr. R J Reid, Dr. M Wykes and Dr. A KayeIn addition the efforts of many in extensively reviewing the Handbook areacknowledged. Page 50 of 382ITER_D_2EZ9UM v2.5ITER Vacuum HandbookRevision: Issue 2.5 Date:28th May 2019 Page 48 of 48ITER Vacuum Handbook IDM Ref :ITER_D_2EZ9UM34 List of Attachments1. Inspection and Qualification of Welded Vacuum Joints2. Cleanliness Requirements Relating to the Assembly of Vacuum Equipment(ITER_D_MBXPP3)35 List of Appendices1. Base Pressures and Expected Pumping Speeds (ITER_D_2ELEJT). 2. Environmental Cleanliness Requirements pertaining to Vacuum Classification(ITER_D_2EL9Y6)3. Accepted Materials (ITER_D_27Y4QC)4. Accepted Fluids (ITER_D_2ELN8N)5. Acceptance Checklist (ITER_D_2N4NDK)6. Guide to the Supply of Windows (ITER_D_2DXZZ3)7. Guide to the Supply of Valves (ITER_D_2EPFG4)8. Supply and Manufacture of Vacuum Flanges (ITER_D_2DJYQA)9. Guide to the Supply of Bellows (ITER_D_2E5LJA)10. Supply and Manufacture of Cables for use in Vacuum (ITER_D_2ETNLM)11. Standard Pipe Sizes (ITER_D_2E5PJK)12. Guide to Leak Testing (ITER_D_2EYZ5F)13. Guide to Cleaning and Cleanliness (ITER_D_2ELUQH)14. Guide to Passivation and Pickling (ITER_D_2F547S)15. Guide for Vacuum Baking (ITER_D_2DU65F)16. Guide for the Conditioning of Graphite and Carbon Composites(ITER_D_27YH3U)17. Guide to Outgassing Rates and their Measurement (ITER_D_2EXDST)18. Vacuum Component Reliability Data (ITER_D_2F2PYS)19. Guide Documentation and QA (ITER_D_2DMNNR)20. Standard Components (ITER_D_2F9QWX)21. Glossary of Vacuum Terms Relevant to ITER (ITER_D_2F94QX)Page 51 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 1 Base Pressures and Expected Pumping SpeedsApproval ProcessName Action AffiliationAuthor Worth L. 23 Sep 2013:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 25 Oct 2013:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2ELEJTVERSION CREATED ON / VERSION / STATUS23 Sep 2013 / 1.6 / ApprovedEXTERNAL REFERENCE / VERSIONPage 52 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 1 Base Pressures and Expected Pumping Speeds (2ELEJT)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 22 Sep 2008v1.2 In Work 13 Jan 2009v1.3 Signed 24 Mar 2009v1.4 Disapproved 02 Sep 2009 Minor changes to text for consistency with Vacuum Handbookv1.5 Approved 09 Sep 2009 Minor changes to text to clarify pumping speed(s)v1.6 Approved 23 Sep 2013 Number of TCPs updated to reflect current design (from 8 to 6)Page 53 of 382ITER Vacuum Handbook: Appendix 1Revision: 1.6 Date: September 23rd , 2013 Page 1 of 3Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPReviewed byApproved byITER ITER Vacuum Vacuum Handbook HandbookAppendix Appendix 1Base Pressures pertaining to Vacuum Classification and ExpectedVacuum System Pumping SpeedPage 54 of 382ITER Vacuum Handbook : Appendix 1Revision: 1.6 Date: September 23rd, 2013 Page 2 of 3ITER Vacuum Handbook Appendix 1 IDM Ref :ITER_2ELEJT1 ScopeThis appendix relates gives base pressures that it is expected systems with aVacuum Classification will operate. The appendix also gives the expected pumpingspeeds of ITER vacuum systems. This appendix is intended as a guide and figureswill be updated as the system design matures2 Base PressuresBase pressures pertaining to VQC are given in Table 2-1. VQC11 VQC22 VQC33 VQC43Base Pressure (Pa) 10-7 - 10-4 <10-4 10-6 -102 10-41 Before operations, the base pressure in the ITER vacuum vessel will be required to be 10-5 Pa or less for hydrogen isotopesand 10-7 Pa or less for any other individual species at 100 C after bake-out and conditioning2Pressures at ambient (with magnets cold). Lower values expected if total pressure is not helium dominated3Total pressure when pump down, some system may operate at higher pressures. Table 2-1 Base pressure pertaining to VQC3 Pumping speeds for CryopumpsThe expected pumping speeds various large ITER cryopumps are given in Table 3-1. Pumping speeds are given at the pump inlet with inlet valves fully openPumping Speed (m3·s-1) CryopumpingSystem VQCH2 D2 DT He N2TorusVacuumCryopump11A 78 55 49 52 21CryostatVacuumCryopump22A >78 >55 >49 >52 >21HeatingNeutral BeamCryopump1A 4700 3600 3255 TBD3 1380DiagnosticNeutral BeamCryopump1A 2900 2270 2035 TBD3 8601 The torus cryopumping system consists of 6 cryosorption pumps for which the individual pumping speed is given. The totalpumping speed is dependent on the operating cycle of the pumps. The conductance of the divertor duct restricts the totalpumping speed available. Modelling of the 2001 divertor duct configuration gave a maximum molecular flow pumping speed forDeuterium of 20 m3/s when using 4 ducts for the pumping. The current more open divertor duct configuration is estimated togive a molecular flow pumping speed for Deuterium of 100 m3/s when using 4 ducts and 4 pumps for the pumping2 One cryopump only, not including the cold surfaces of the magnets or the thermal shield. Pumping speed of the toruscryopump is used, but the gas conductance to the pump housing will be higher than for the torus pump. Two pumps areavailable to pump, but at times one will have to be offline for regeneration3 Pending Monte Carlo simulationsTable 3-1 Expected pumping speeds of large cryopumpsPage 55 of 382ITER Vacuum Handbook : Appendix 1Revision: 1.6 Date: September 23rd, 2013 Page 3 of 3ITER Vacuum Handbook Appendix 1 IDM Ref :ITER_2ELEJT4 Pumping speeds for roughing pumps. The design of the roughing system and the roughing lines is at an early stage andhence pumping speed cannot yet be accurately provided. The figures below outlinethe required provisional roughing pump(s) performance Torus ~1330 m3 ,105 Pa to 10 Pa in 24 Hours 1 torus cryopump, ~18 m3, max 30 KPam3† (Hydrogen isotopes), to 10 Pa in150 sec. Cryostat ~8500 m3 ,105 Pa to 10 Pa in 24 Hours 1 cryostat cryopump, ~18 m3, max 30 KPam3 (Helium + Hydrogen), to 10 Pain 150 sec NIBs ~ 171 m3 + 171 m3 + 170 m3 + 93 m3, 105 Pa to 10 Pa in 24 Hours. 1 NIB cryo-pump, ~170 m3, max 300 KPam3 (Hydrogen isotopes), to 20 Pa in650 sec PI – overnight gas transfer to TEP. Adequate pumping for Auxiliaries. †May doublePage 56 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMBaseline Report (not under Configuration Control)Appendix 2 Environmental CleanlinessThis Appendix provides guidelines relating to the cleanliness requirements for the postcleaning handling of vacuum components for installation in the various ITER Vacuumsystems. It only refers to the post final cleaning cleanliness requirements to maintain theachieved cleanlinessApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 14 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2EL9Y6VERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.4 / ApprovedEXTERNAL REFERENCE / VERSIONPage 57 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 2 Environmental Cleanliness (2EL9Y6)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 13 Jan 2009v1.3 Signed 18 Jun 2009 Updated to include new figures for airbourne contamination and minortextual changesv1.4 Approved 02 Sep 2009 Minor changes to text for consistency with Vacuum HandbookPage 58 of 382ITER_D_2EL9Y6 v1.4ITER Vacuum Handbook : Appendix 2Revision: 1.4 Date: July 29th, 2009 Page 1 of 3Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum Handbook IDM Ref :ITER_D_2EL9Y6ITER Vacuum HandbookAppendix 2Environmental CleanlinessPage 59 of 382ITER_D_2EL9Y6 v1.4ITER Vacuum Handbook : Appendix 2Revision: 1.4 Date: July 29th, 2009 Page 2 of 3ITER Vacuum Handbook Appendix 2 IDM Ref :ITER_D_2EL9Y62 Environmental Cleanliness requirements pertaining toVacuum Quality Classification2.1 ScopeThis Appendix provides guidelines relating to the cleanliness requirements for thepost cleaning handling of vacuum components for installation in the various ITERVacuum systems. It only refers to the post final cleaning cleanliness requirements tomaintain the achieved cleanliness. It is anticipated that further guidance which will not be mandatory may be provided inthe future. 2.2 Post Cleaning Handling of Vacuum ComponentsThe following details are reproduced from the ITER Vacuum Handbook (Issue 2.3),Section 24.5 and Table 24.1and are therefore mandatory. “After final cleaning, the handling of vacuum equipment shall be controlled topreserve cleanliness. General area cleanliness requirements pertaining to VacuumClassification are summarised in Table 2-1. The suitability of any given area used forhandling vacuum equipment should be assessed on a regular basis by monitoringthe airborne particulate count and should not exceed 5.0 x 106 particles of size> 0.5 μm per m3 for VQC 1. VQC Cleanliness requirements Personnel AreaCleanlinessMonitoring1 Segregated clean area. Limited Access toauthorised personnel. Authorised equipmentoperated to approvedprocedures. Management ofequipment (e.g. novacuum pumpsexhausting into cleanarea)Trainedpersonnel. Protective hairnets. Powder free latexor nitrile outergloves. Clean whiteoveralls. Overshoes. Clean job specificfootwearDailyCleaning ofareaincludingfloors andsurfaces. Sticky matsat area entryDaily airqualitychecks. Resultsstored incomponentdocumentpackage. Weeklycleanlinesstest of areawith resultsstored incomponentdocumentpackage2 Authorised equipmentoperated to approvedprocedures. Management ofequipment (e.g. novacuum pumpsTrained personnelPowder free latexor nitrile outergloves for thehandling of cleanequipmentDailyCleaning ofwork areaincludingfloors andsurfaces. Page 60 of 382ITER_D_2EL9Y6 v1.4ITER Vacuum Handbook : Appendix 2Revision: 1.4 Date: July 29th, 2009 Page 3 of 3ITER Vacuum Handbook Appendix 2 IDM Ref :ITER_D_2EL9Y6exhausting into cleanarea)3&4 House Keeping Trainedpersonnel. Powder free latexor nitrile outergloves for thehandling of cleanequipmentDailycleaning ofarea. Table 2-1 Environmental cleanliness pertaining to VQCAdditional cleanliness requirements shall be defined in the component installationprocedures.”Page 61 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 3 MaterialsApproval ProcessName Action AffiliationAuthor Vine G. 17 Jul 2017:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewers Pearce R. Worth L. 31 Aug 2017:recommended17 Jul 2017:recommendedIO/DG/COO/PED/FCED/VSIO/DG/COO/PED/FCED/VSApprover Lee G.- S. 08 Sep 2017:approved IO/DG/COO#SecureIDM#RO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: EUROfusion-DEMO, AD: Auditors, AD: ITER ManagementAssessor, project administrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG:[CCS] JACOBS,IDM UID27Y4QCVERSION CREATED ON / VERSION / STATUS17 Jul 2017 / 1.20 / ApprovedEXTERNAL REFERENCE / VERSIONPage 62 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 3 Materials (27Y4QC)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 29 Aug 2008v1.2 In Work 12 Jan 2009v1.3 In Work 14 Jan 2009v1.4 Signed 26 Jan 2009v1.5 Signed 13 May 2009v1.6 Signed 18 Jun 2009 Changed approved to accepted throughout documentv1.7 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum Handbookv1.8 Approved 26 Sep 2011 Reference to Material Approval Request form addedNew materials addedReferences to requested materials addedSimplification to material groupsChanges agreed with ITER Vacuum RO prior to Up-loadv1.9 Approved 11 Feb 2014 Added grade and standard for Aluminav1.10 Approved 11 Feb 2014 Date correctionAffiliation modificationv1.11 Signed 23 Jan 2015 Changes between v1.10 and v1.11 of 27Y4QCLinks added for,304 B7 Outgassing dataYDH 50 MARXM-19 MAROxygen Free (OF) UNS C10200Al-15 (Mirrors for EC Equatorial launcher)Tantalum sheetTiNMaterials added:-Nitronic-60 (UNS S21800)431 (UNS S43100) (1.4057)431 (UNS S43100) (1.4059)Inconel 708N-type thermocoupleSTEMET 1301 amorphous brazing alloyNicuman 23 brazing alloyNicuman 37 brazing alloySTEMET 1101 microcrystalline brazing alloySTEMET 1108 microcrystalline brazing alloyAluminium Grade 6061Tungsten Carbide Mechanical pump (sliding seal)Gold Thin leaf 100 micron (bonding agent)Silver-based braze BAg-8Titanium ASTM Grade2 T2 & 5 T5Silicon Mono-crystallineSilicon Poly –crystallineDiamond composite Sckeleton-1Glass Ceramic MACOR (MGC)Aluminum Oxide (TS-03312)Alumina Filled Cyanate Ester (MC7885-UF)Aluminium Nitride Shapal SH-15)Aluminium Nitride Shapal M-softAluminium Nitride (Circuit Board Substrate)Page 63 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMQuartz Filled Cyanate Ester (MC7883-UF or MC9883-LPM)Kalrez Non-vacuum application ( 3rd party pump)Barium Fluoride vacuum windowsMolybdenum (Tracks on surface of silicon wafer sensor)ZrO2 with TiN coating Non-vacuum application ( 3rd party pump)ZrO2 Non-vacuum application ( 3rd party pump)v1.12 Approved 23 Jan 2015 Approval corrected to restricted for:-Aluminium Nitride (Shapal SH-15, Shapal M-soft, Circuit Board Substrate)Plus previous:-Links added for,304 B7 Outgassing dataYDH 50 MARXM-19 MAROxygen Free (OF) UNS C10200Al-15 (Mirrors for EC Equatorial launcher)Tantalum sheetTiNMaterials added:-Nitronic-60 (UNS S21800)431 (UNS S43100) (1.4057)431 (UNS S43100) (1.4059)Inconel 708N-type thermocoupleSTEMET 1301 amorphous brazing alloyNicuman 23 brazing alloyNicuman 37 brazing alloySTEMET 1101 microcrystalline brazing alloySTEMET 1108 microcrystalline brazing alloyAluminium Grade 6061Tungsten Carbide Mechanical pump (sliding seal)Gold Thin leaf 100 micron (bonding agent)Silver-based braze BAg-8Titanium ASTM Grade2 T2 & 5 T5Silicon Mono-crystallineSilicon Poly –crystallineDiamond composite Sckeleton-1Glass Ceramic MACOR (MGC)Aluminum Oxide (TS-03312)Alumina Filled Cyanate Ester (MC7885-UF)Aluminium Nitride Shapal SH-15)Aluminium Nitride Shapal M-softAluminium Nitride (Circuit Board Substrate)Quartz Filled Cyanate Ester (MC7883-UF or MC9883-LPM)Kalrez Non-vacuum application ( 3rd party pump)Barium Fluoride vacuum windowsMolybdenum (Tracks on surface of silicon wafer sensor)ZrO2 with TiN coating Non-vacuum application ( 3rd party pump)ZrO2 Non-vacuum application ( 3rd party pump)v1.13 Signed 23 Feb 2015 MAR ITER_D_9K3J5P for Alumimium 6061 use in VQC 2B and 4B nowdeleted as request is unnecessary. Use of Aluminium use in all VQC (exceptVQC 1A-restricted) is already indicated in Appendix 3 Tablev1.14 Approved 25 Feb 2015 Materials:--EPDM (Ethylene-propylene), &-Nitrile rubber (Buna – N)Added with use restricted to 2nd, outer, seal gasket only ( i.e. between SVSpumped volume/Air ) in VQC 2A double sealed flanges (1st, inner seal,Page 64 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMbeing metallic) for consistency with materials noted in VH App 8, Flanges,Table 6Aluminium "and alloys" noted in grades for clarityv1.15 Approved 20 Aug 2015 Materials addedCu and Cu based alloys:-CuBe1.7CuBe2SeCuNi and Ni based alloys:-Nilo 42 ( Nickel Iron Alloy 42 material)Mineral cement:-Thermoguss 2000Glass / Ceramic:-Zirconia ZrO2v1.16 Approved 03 Nov 2015 Materials added:-Nicrobraz 10 Alloy BNi6 (Ni / P 11%)Molybdenum solid, pure (not powdered or compound)v1.17 Approved 06 Jun 2016 Materials added;-PEEK shrink tubing,Brazing Filler Material (Ni 102 / BNi2 / L-Ni2 / B-Ni82CrSiBFEDuPont 951 Green TapeShapal M-SoftNiP-11% electroless nickel brazeAluminium Nitride ( W Coated)G11 / EPGC203 epoxy glass compositeMagnesium Oxide, MgO, sinteredv1.18 Approved 12 Dec 2016 Materials added:-Polyimide-cable insulantZirconia based ceramic paste (Resbond 940)Papyex: N 998 Flexible GraphiteInconel X-750Aluminium alloy EN AW-6082-T6Boron Carbide F4CMolybdenum alloy APT-3 TZMSA-240 316Ti Stainless steelSteel 316Ti (1.4571 according to VDEh)v1.19 Signed 17 Jul 2017 Materials added:-MolybdenumMolykote D-321 R Anti-Friction CoatingSputtered MoS2Brazing matrial NIORO AuNi 82/18%Araldite RapidTicuni BrazeBrazeTec_CB10Copper Alloy (Cu-Sn-Pb)Ertalon 66SKTN-MED optical glueBPd-2 Brazev1.20 Approved 17 Jul 2017 Materials added as previous version:-Page 65 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMMolybdenumMolykote D-321 R Anti-Friction CoatingSputtered MoS2Brazing matrial NIORO AuNi 82/18%Araldite RapidTicuni BrazeBrazeTec_CB10Copper Alloy (Cu-Sn-Pb)Ertalon 66SKTN-MED optical glueBPd-2 Braze(& 1 correction-Nicrobraz 10 restored)Page 66 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 1 of 38Name AffiliationAuthor/Editor Liam Worth IO Vacuum SectionVacuum Responsible Officer Robert Pearce IO Vacuum SectionITER Vacuum HandbookAppendix 3Accepted MaterialsPage 67 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 2 of 38ITER Vacuum Handbook Appendix 3 IDM Ref :ITER_27Y4QC3 ITER Approved Materials3.1 ScopeThis appendix relates to the materials accepted for use in ITER vacuum exposed to theITER vacuum environments. The ITER Vacuum Handbook (section 5.1) states that“Only materials accepted by ITER for the relevant Vacuum Classification shall be used onITER vacuum systems. All material for use in vacuum shall be clearly specified at thedesign stage and certified in accordance with EN 10204 2.2, 3.1 or 3.2, or equivalent,before being used in manufacturing.”Pursuant to this, materials which may be used freely on vacuum systems with the VacuumClassifications stated are listed in the tables belowMaterials listed in this Appendix and shown as being subject to restricted use for aparticular Vacuum Classification are subject to either an overall quota or to particularrestrictions on their position of use. Acceptance for any particular vacuum application ofsuch a material shall be obtained by submitting the Material Approval Request Form,stored on IDM (ITER_D_2MGWR4), to the ITER Vacuum RO. An example of this formcompleted is to be found at the end of this Appendix3.2 Materials Not on the Approved ListMaterials which are not on the accepted list may be proposed for use in vacuum. If thevacuum properties of the material are not sufficiently well documented for an assessmentto be carried out, a programme of measurement of the relevant properties shall be agreedbetween the proposer and the designated ITER Vacuum RODetails of materials to be considered for acceptance shall be submitted to the ITERVacuum RO using the Material Approval Request Form. The proposer shall agree inadvance with the ITER Vacuum RO a plan detailing the type and method of testing toqualify the material for use. The Materials Approval Request Form along with the test data,report and supporting documentation, including any supplier’s data (Certificates ofConformity, etc.), shall be submitted for consideration. Materials qualified in this way may be added to the accepted list3.3 Material Selection / QualificationThe materials listed in the following tables have been considered in terms of usage(vapour pressure, outgassing etc) and in terms of the environment of intended usePage 68 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 3 of 38ITER Vacuum Handbook Appendix 3 IDM Ref :ITER_27Y4QCThe properties of materials may change either permanently or temporarily when irradiated. Such changes which can affect their suitability for use in vacuum may include - Induced radioactivity – which might necessitate the use of remote handlingtechniques to disassemble or remove a component (e.g. steels may becomeactive). Induced activity may be long-lived or short-lived Mechanical degradation – which might affect the physical integrity of a componentor a bond between components or which may generate particulates which couldspread through a vacuum system (e.g. PTFE degenerates to a powder). Suchchanges are permanent Transmutation – where a particular atomic species with good vacuum properties istransformed into one with poor vacuum properties (e.g. silver transmutes tocadmium). The products formed by transmutation can themselves transmute hencesuch changes can not be considered permanent Chemical change – where the material decomposes under the influence of radiation(e.g. Viton releases hydrochloric acid, and PTFE releases fluorine, both of whichare undesirable). Such changes are permanent Desorption – under the influence of radiation, many materials exhibit enhancedoutgassing due to induced desorption (e.g. hydrogen from steel when irradiatedwith X-rays). This stops when the source of radiation is switched offThe effect of irradiation has been considered for accepted materials, and shall beconsidered in the qualification when materials not on the list are assessed for inclusion onthe listPage 69 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 4 of 38KEY: = approved for use. = not approved for use. = restricted useTable 3-1 Accepted MaterialsVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4B316L,316LN316L(N)-IG+ Corresponding EN grades 316+ Corrsponding EN grades Austenitic stainlesssteels316Ti SA-240(NB Bellows Convolutions)MAR: ITER_D_TT37NFPage 70 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 5 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4B316Ti(Elektical and optical patch boxes)MAR: ITER_D_TLM3YP304L304LN304B4+ Corresponding EN grades 304304 B7 Outgassing data:- ITER_D_EMZ98G+ Corresponding EN grades Austenitic stainlesssteelsYDH 50MAR:- ITER_D_4CRYM8 Page 71 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 6 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BAusteniticChromium-Manganese-Nickelstainless steelsXM-19 (UNS S20910),MAR:- ITER_D_DG7SKXJJ1 AusteniticChromium-Manganese-Nickelstainless steelsNitronic-60 (UNS S21800)MAR:- ITER_D_CA3TB6Material data sheet ITER_D_CX9QCXMaterial information ITER_D_DCEREP PrecipitationHardening Iron BaseSuper-alloyGrade 660 (UNS S66286), another name A286+ Corresponding EN grades Ferritic (martensitic)stainless steel430 (UNS S43000)Eurofer, F82H, Rusfer, Page 72 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 7 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BFerritic (martensitic)stainless steel431 (UNS S43100) (1.4057)ITER roughing pump shaftMAR:- ITER_D_DCCQYEMaterials cert ITER_D_DBY4WW Ferritic (martensitic)stainless steel431 (UNS S43100) (1.4059)ITER roughing pump rotor and caseMAR:- ITER_D_DCHJDMMaterials cert ITER_D_DCEQ7B Kovar ASTM F15 KV-1~9 Nickel Nickel based AlloysNimonic 80A(UNS N070080) Page 73 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 8 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BMonel 400 Alumel (95% Ni, 2% Mn, 2%Al, 1%Si) Chromel (90%-10% Ni – Cr) Alloy 718 (UNS N07718)Alloy 625 (UNS N06625) Inconel 708Bellows sealMAR:- ITER_D_KTP2JW N-type thermocoupleMAR :- ITER_D_64J7S9 Nilo 42 ( Nickel Iron Alloy 42 material)MAR:- ITER_D_QTVQ7F Page 74 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 9 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BInconel X-750 (UNS N07750, DIN W.-Nr. 2.4669)MAR: ITER_D_S98EXMMaterial datasheet ITER_D_SM54DQ STEMET 1301 amorphous brazing alloyVacuum brazing of W-Cu joint in the DivertorDome PFUs armour (only PRPs)MAR:- ITER_D_7NTH2JOutgassing data:- ITER_D_7NSWW8Mat Cert ITER_D_7NTH2J Nickel based BrazeNicrobraz 10 Alloy BNi6 (Ni / P 11%)Brazing of stainless steel cable sheaths intostainless steel bulkheadsMAR:- ITER_D_QZW8DY Page 75 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 10 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BNi 102 Nickel-based high temp brazing pasteFor Brazing of non-vacuum boundarycomponents DNB Beam(AKA:-Ni 102, BNi2 , L-Ni2, B-Ni82CrSiBFE-970/1000, 4777F, 9500/97)MAR ITER_D_S43LCB Nickel based BrazeNickel - Phosphorus 11% vacuum braze for the6x diamagnetic coils (55.AG) under TriangularSupportMAR ITER_D_S5EHB2 Page 76 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 11 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BPure CopperOxygen Free (OF) UNS C10200Oxygen Free electronic (OFE) UNS C10100EU grades:Cu-ETP (CW004A), Cu-FRTP, (CW006A), Cu-OF (CW008A),Cu-OFE (CW009A),Cu-PHCE (CW022A) Pure CopperOxygen Free (OF) UNS C10200OF (CW008A)MAR:- ITER_D_NT9JT5 Page 77 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 12 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BCuCrZr-IG: Cr (0.6 – 0.9 %), Zr (0.07 – 0.15 %)CuCr1Zr (CW 106C)CuCrZr (UNS C18150)PQRSQ (RF grade)YZC (JA grade) CuBe1.7MAR:- ITER_D_RBENAP CuBe2MAR:- ITER_D_RB34RC Copper alloysSeCuMAR:- ITER_D_R7NEZM Page 78 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 13 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BCopper alloys-BronzeAluminum bronze: UNS C63200,(82Cu-9Al-5Ni4Fe),CuAl10Ni5Fe4 (CW307G)CW301G (CuAl6Si2Fe) Copper alloys-BronzeAluminium Bronze Casting (SO-5)(oilless bearing for in -vessel mirror motorsMAR:- ITER_D_4CT93S Copper alloys-BronzeBronze (Cu-Sn-Pb)Application is VQC N/A (approved for installationuse only)MAR: ITER_D_UG2K5VCopper alloys-Alumina DispersionStrengthenedGlidcop Al60Glidcop Al25-IGAl-15 Page 79 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 14 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BCopper alloys-Alumina DispersionStrengthenedAl-15 (Mirrors for EC Equatorial launcher)MAR:-ITER_D_4CQPLA Copper-based brazeNicuman 23 brazing alloy as a brazing alloy foruse in the divertorMAR:- ITER_D_9K83MFOutgassing data:- ITER_D_6XLFJQ Copper-based brazeNicuman 37 brazing alloy for use in VQC 1B asa brazing alloy for use in the divertorMAR :- ITER_D_9K6V2COutgassing data:- ITER_D_6XLFJQMaterials cert ITER_D_9K6V2C Page 80 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 15 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BCopper-based brazeSTEMET 1101 microcrystalline brazing alloyVacuum brazing of Cu-CuCrZr joint in the DomePFUs armourMAR:- ITER_D_7NXAUNOutgassing data:- ITER_D_7NSWW8Materials certificate ITER_D_7NSWW8 Page 81 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 16 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BCopper-based brazeSTEMET 1108 microcrystalline brazing alloyVacuum brazing of Cu-CuCrZr joint in the DomePFUs armourMAR:- ITER_D_7NSWW8Outgassing data:- ITER_D_7NSWW8Materials certificate ITER_D_7NSWW8 Beryllium S – 65C VHP, DShG-200, TGP-56FW, CN-G01 Pure or alloys AluminiumAluminium alloy EN AW-6082-T6MAR : ITER_D_S97FXRDeviation request also required for this VQC 1AapplicationPage 82 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 17 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BTungstenPure sintered W and rolled,cast W alloy, W-1%La2O3CVD Tungsten CarbideWC Cemented Carbide (Bearing Ring)MAR:-ITER_D_4CSC86Mechanical pump (sliding seal)MAR :-ITER_D_L25NLL Caesium Gold GoldThin leaf 100 micron (bonding agent)MAR:- ITER_D_QDASPX Page 83 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 18 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BGold based brazeNioro brazing materials (AuNi 82/18%)MAR: ITER_D_TVU72E Silver Silver-based brazeBAg-8 (Japanese Industrial Standard; JISZ3261)Ag as filler material for brazing on the DNBbushingMAR :- ITER_D_AJL8YXDeviation request ITER_D_4AHGK6Transmutation data ITER_D_4FJRHJ,ITER_D_7PGX7C Silver-based brazeBrazeTec_CB10MAR: ITER_D_UMF87DPage 84 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 19 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BSilver-based brazeBPd-2MAR: ITER_D_UXN7AYTantalumSheetMAR:-ITER_D_2LN64R Germanium Samarium Cobalt(Sm2Co17)R26HS Zinc Cadmium Titanium Pure or alloys Page 85 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 20 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BTitaniumTitanium ASTM Grade2 T2 & 5 T5ICH & CD antenna: Removable vacuumtransmission linesMAR:- ITER_D_6R2ZJWRelated attachments ITER_D_6R2ZJW,ITER_D_6R2ZJW, ITER_D_6R2ZJW Titanium basedbrazeTicuni BrazeMAR: ITER_D_UMFFFPQuartz SiliconMono-crystalline, 380 Vm thick boardEx-vessel magnetic sensor (55.A5/A6 MEMS)Total mass ~2.5g for all sensorsMAR:- ITER_D_DFVQ4C Page 86 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 21 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BSiliconPoly-crystalline40 Vm diameter plugs through 380 Vm thickmono-Si circuit boardEx-vessel magnetic sensor (55.A5/A6 MEMS)Total mass ~0.001g(1mg) for all sensorsMAR ITER_D_DG5JJR Silica, Fused SiO2 Composite(diamond, siliconcarbine, silicon)Sckeleton-1MAR:- ITER_D_64NG84 Diamond Pure and DLC, CVD GraphitePyrolytic (Langmuir Probe)MAR:- ITER_D_2LUWMJ Page 87 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 22 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BGR-1 (restricted to allow tracking)MAR:- ITER_D_4CRPVS (see note 1)Papyex: N 998 Flexible GraphiteMAR: ITER_D_KZWER7Technical guide ITER_D_RZM4SU Composite(Carbon FibreComposite CFC, seenote 1 )SNECMA and Dunlop: various gradesSupercarb NB 31 (3D), NIC-01Toyo Tanso:CX2002U (2D) PorcelainC221 CeramicKyocera A479 Page 88 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 23 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BDuPont 951 Green TapeFor Low-Temperature Co-fired Ceramics sensorapplied to PBS 55.AA/AB/ACMAR ITER_D_S22ME4Outgassing test reportsITER_D_QYRA8NITER_D_QYM8ZD MACOR (MGC)Small machined partsMAR:-ITER_D_LF5RDEVac data:- ITER_D_LEYH7S Glass CeramicShapal Hi-M SOFT (machinable AlN)In-vessel Magnetic Sensors (55.AA/AB/AC/AJ)applicationsOutgassing data ITER_D_C9TP4HMaterial datasheet ITER_D_C9XYVT Page 89 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 24 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BMgAl2O4 MgOMagnesium oxide as base insulation material forthe In-Vessel Coils conductor. Powder gluedand sintered in blocks, confined in the conductorjacketMAR ITER_D_STESWL Titanium dioxideTiO2 AluminaAl2O3Grade IV to ASTM D2442 Page 90 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 25 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BAlumina(Al2O3)Aluminum Oxide (TS-03312)Surface coating for slid pin, internal shield etcMAR:- ITER_D_4CQG7F Alumina cyanateesterAlumina Filled Cyanate Ester (MC7885-UF)Ex-vessel Magnetic Sensors (55.A5/A6 MEMS),Qty ~30g for all sensorsMAR:- ITER_D_DFZ4YK Aluminium NitrideShapal SH-15(Small moulded/machined parts)MAR:- ITER_D_EH72BL Page 91 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 26 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BAluminium NitrideShapal M-soft(sintered composite of Al nitrate and B nitrate)MAR:- ITER_D_C9TCXHOutgassing data:- ITER_D_C9TP4H Aluminium NitrideAluminium Nitride (Circuit Board Substrate)Ex-vessel sensor, total quantity 1.3kg maximumMAR:- ITER_D_DG7QJYOutgassing Data :- ITER_D_DG46FA Aluminium NitrideAlN (high purity sintered for IVS RF shield)MAR ITER_D_SMX5GROutgassing data ITER_D_DG46FAChemical analysis ITER_D_SLZRLQ Page 92 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 27 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BSilicon Nitride(SiN4)TSN-03 (in vacuum ball brearing)MAR:- ITER_D_4C5QZJ Caesium IodideCsITi activated Resin -Epoxy TGDDM Resin -EpoxyAraldite rapidMAR: ITER_D_UELUT4Resin -CyanateEsterQuartz Filled Cyanate Ester (MC7883-UF orMC9883-LPM)Bonding agent in sensor silicon waferEx-vessel Magnetic Sensors (55.A5/A6 MEMS),Qty ~30g for all sensorsMAR:- ITER_D_DG4HDK Page 93 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 28 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BOptical glueSKTN-MED optical glueMAR: ITER_D_76JZCPG10. Electrical insulatorMAR:- ITER_D_4E9Q2M Composite (Epoxy /(glass fibre)G11 / EPGC203. Electrical insulatorMAR ITER_D_SRSGTV Thermoguss 2000 Inorganic adhesiveThermoguss 2000MAR:- ITER_D_R69NWAPerformance as a seal on MI cable must bedemonstrated by qualification tests on actual cables Glass S 2, R- and T Page 94 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 29 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BPolyimide Vespel PolyimideERTALON 66Application is VQC N/A (approved for installationuse only)MAR: ITER_D_UG2BMPPolyimideThermopastic Polyimide (TPI), Axon CableMAR: ITER_D_RTNM3UThis sample accepted by outgassing test inMARPEEK (Polyetherether ketone)As shrink tubing for steady-state sensors55.A5/A6MAR ITER_D_RT2T5VProduct datasheet ITER_D_RMLNSM Page 95 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 30 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BEPDM (Ethylene-propylene)Use restricted to 2nd, outer, seal gasket only (i.e. between SVS pumped volume/Air ) in VQC2A double sealed flanges (1st, inner seal, beingmetallic) Nitrile rubber (Buna– N)Use restricted to 2nd, outer, seal gasket only (i.e. between SVS pumped volume/Air ) in VQC2A double sealed flanges (1st, inner seal, beingmetallic) Aluminium deposited Kapton, Mylar. Aluminiumfoil SuperinsulationAluminium deposited Polyester HalogenatedmaterialsPTFE, Fibreslip (Teflon fibre-glass weave)‡‡ PTFE bearings are approved for positionswhere the predicted radiation fluence over thefull operational life of ITER is less than 103Gray (Gamma or Neutron dose equivalents) Page 96 of 382ITER Vacuum Handbook: Appendix 3Revision: 1.19 Date: July 17th, 2017 Page 31 of 38KEY: = approved for use. = not approved for use. = restricted useVacuum Quality ClassificationMaterial / MaterialClassGrades, (or composition applicable to ITER)1A 1B 2A 2B 3A 3B 4A 4BViton KalrezNon-vacuum application ( 3rdparty pump)VQC=N/AMAR:- ITER_D_L5MK2QBromine (In Halogen lamp for CXRS Diagnosticin-situ calibration. Worth L. 31 Aug 2017:recommended17 Jul 2017:recommendedIO/DG/COO/PED/FCED/VSIO/DG/COO/PED/FCED/VSApprover Lee G.- S. 08 Sep 2017:approved IO/DG/COO#SecureIDM#RO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: EUROfusion-DEMO, AD: Auditors, AD: ITER ManagementAssessor, project administrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG:[CCS] JACOBS,IDM UID2ELN8NVERSION CREATED ON / VERSION / STATUS17 Jul 2017 / 1.14 / ApprovedEXTERNAL REFERENCE / VERSIONPage 105 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 4 Accepted Fluids (2ELN8N)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 18 Jun 2009 Name change from approved to accepted. Cutting fluid removedv1.3 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum Handbookv1.4 Approved 29 Feb 2012 New fluids addedv1.5 Approved 05 Oct 2012 Included new cutting fluid and approved liquid dye penetrant productfamilies (with restrictions)v1.6 Signed 26 Jan 2015 Fluids added:-Cutting fluidsBlasocutCastrol SYNTILO 75 EFCut1 - Carecut S cuting fluidGaria 2608 S-12Green Star SINTOL MicroJokisch Foam CutMagicutsynth-g-60QUAKER 3755 BIOHocut 2000SWISSCOOL 7722Vasco 1045Acids20% Sulphuric Acid solutionConcentrated Nitric AcidHydroflouric AcidLDPFluidLDP W divertorCouplantsBabb Co matrix UT coupling agentCGM US Paste U49OtherDemin WaterElektrolyt EH01Neutralix NG01v1.7 Signed 10 Feb 2015 Fluids added:-Cutting fluidsBlasocutCastrol SYNTILO 75 EFCut1 - Carecut S cuting fluidGaria 2608 S-12Green Star SINTOL MicroJokisch Foam CutMagicutsynth-g-60QUAKER 3755 BIOPage 106 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMHocut 2000SWISSCOOL 7722Vasco 1045Acids20% Sulphuric Acid solutionConcentrated Nitric AcidHydroflouric AcidLDPFluidLDP W divertorCouplantsBabb Co matrix UT coupling agentCGM US Paste U49OtherDemin WaterElektrolyt EH01Neutralix NG01v1.8 Approved 11 Feb 2015 Document version in header matched to IDM versionFluids added:-Cutting fluidsBlasocutCastrol SYNTILO 75 EFCut1 - Carecut S cuting fluidGaria 2608 S-12Green Star SINTOL MicroJokisch Foam CutMagicutsynth-g-60QUAKER 3755 BIOHocut 2000SWISSCOOL 7722Vasco 1045Acids20% Sulphuric Acid solutionConcentrated Nitric AcidHydroflouric AcidLDPFluidLDP W divertorCouplantsBabb Co matrix UT coupling agentCGM US Paste U49OtherDemin WaterElektrolyt EH01Neutralix NG01v1.9 Approved 19 May 2015 Fliuds and other processing media added:-Cutting fluids:-Xtreme Cut 250Page 107 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMPickling and passivation:-Avesta Passivator 601Avesta Cleaner 401Avesta picking paste BlueOne TM 130Markers:-Intrama SL.250 SL2100Abrasive media:-Cutting wheel: Abratec TIPO 42Cutting wheel: Sait “A30S” [Thk. 2 mm]Cutting wheel: Sait “XA24Q” [Thk. 3,2 mm]Cutting wheel: Sait “XA24Q” [Thk. 7 mm]Cutting wheel: Sait “XA46R” [Thk. 1,6 mm]Flapper wheel: Abratec LAMELLAREFlapper wheel: Abratec LAMELLAREFlapper wheel: Sait "SAITLAM UK 3A"Flapper wheel: S.L.F. Abrasivi LASER DISCRough Wheel: Abratec TIPO 27Rough Wheel: 3M “987C CUBITRON 2”v1.10 Approved 19 Aug 2015 Temporary fixings incorporating adhesive tape added, all VQC N/A3M™ Aluminum Foil Tape 4313M™ Preservation sealing Tape 481Delvigo DVC 48040/7 A5 weld backing stripDelvigo DVC 44040/6 A5 weld backing stripScapa 336 Aluminium adhesive tapeFor any use on higher VQC categories, verification of full cleaning processrequired on sample couponsv1.11 Approved 05 Nov 2015 Fluids added to previous version:-Metalsierra DF Cutting fluidStratomet Protective paint (for processing equipment-not vacuumcomponents)HC 1100-PassivatorCleansafe 787-Cleaning agentVK Jelly / VK Jelly – Power / VK Spray / VK Spray - 1000 -Pickling andpassivationK-2 Jelly / K-2 Jelly – Power / K-2 Spray / K-2 Paste -Pickling andpassivationUltrasonic couplant, Rock Oil 09060 -Ultra Sonic Testing (UT) couplingfluidDodecane, 297879, Sigma-Aldrich -Ultra Sonic Testing (UT) coupling fluidv1.12 Approved 07 Jun 2016 Fluids added:-Blasocut BC 935 Kombi, cutting fluidVasco 7000, cutting fluidHE 111 Electrolytic polisher,HC 1100-K3W1, passivatorHC 500, cleaning agentHE 310 Electrolytic Polisher,DR60, as LDP remover,NGL 17.40 P, ultrasonic cleaningPROSOLV HP, solventALCATUM / ALCATUM HO, cleaning agentPage 108 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMDOWCLENE 1601, cleaning agentKool Mist Formula 78, machining coolantOil Eater, degreaserRebound 7, degreaserTrim E206, machining coolantTrim Tap Heavy, cutting fluidTrim Tap Light, cutting fluidBlasocut 4000, cutting fluidv1.13 Approved 06 Dec 2016 Abrasive media added:-Klingspor KL 315 abrasive paper PMUC 100673M Roloc Disc 984F Abrasive disk3M Cloth Belts 984F. Abrasive Belt for belt grinder3M Cubitron™ II: Cut off Wheels3M Flap Disc 967A. Lukas Tungsten carbide burrsStainless steel brush3M XT-RD-Cleaning DiscCleaning agent -Surtec®089 with Surtec®132Cleaning agent -PROCIV CUPCutting Fluid -Hocut 795 HXCutting Fluid -SWISSCOOL 7722Markers-Edding 750 white, Silver and BluePickling and passivation-PROCAP 137Tape-3M 425 & 431 Aluminium Foil TapeHandling material-Kraitec Elastomer padUT coupling fluids-MR 750 Ultrasonic Coupling Agentv1.14 Approved 17 Jul 2017 Fluids / other process media added:-Paper KL361 grain 240, grain 120 and grain 80 ; Grinding tool RBAdhesive Technologies Glue Stick, Part #229Tacky tape SM 5142Cleaning fluid RBS826CitriSurf 2310Oemeta Novamet 100 CoolantSemiSyn-200 Blue CoolantS-787_Request__Fluid_AcceptanceCastrol CareCut S 600HOCUT 795 MPHocut 795 HBlasocut BC 25 MDPentagon Coolcut SBlasocut BC 35 KombiMK-SOL Soluble metal working oilSynergy 915APIEZON TMarkal paint markerEdelstahlbeize Typ 14AveryDennison HP MPI 2121Tesa 4613 – Utility grade Duct TapeSoundclear 60Soundclear 40UT Couplant for ITER CryostatPage 109 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17th July 2017 Page 1 of 42Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum Handbook Appendix 4 IDM Ref :ITER_D_2ElN8NITER Vacuum HandbookAppendix Appendix 4Accepted FluidsPage 110 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17 th July 2017 Page 2 of 42ITER Vacuum Handbook Appendix 4 IDM Ref :ITER_D_2ElN8N4 ITER Accepted Fluids4.1 ScopeThis Appendix relates to fluids accepted to be used in the preparation and processing ofmaterials and components which are exposed to the ITER vacuum environments, e.g. cutting fluids and cleaning solventsThe ITER Vacuum Handbook (Section 6.1) states that“Cutting fluids for use on VQC 1 and 3 systems shall be water soluble, non-halogenated and phosphorus and sulphur free”1“Accepted cutting fluids for use in VQC 1 and 3 vacuum applications are listed inAppendix 4. The use of other cutting fluids requires prior acceptance“Acceptance for the use of any particular non-approved cutting fluid shall beobtained by submitting the Fluid Acceptance Request Form, stored on IDM, to theITER Vacuum Responsible Officer (RO)“For VQC 2 & 4 vacuum applications it is recommended that cutting fluids be watersoluble, non-halogenated and phosphorus and sulphur free1. They should bechosen from those listed in Appendix 4. Where this recommendation is not followedparticular care shall be taken to ensure the appropriateness of the cleaningprocedures”The ITER Vacuum Handbook Section 24 states that“Lists of accepted cleaning fluids can be found in Appendix 4”Pursuant to this, materials which may be used freely for use on vacuum system items withthe Vacuum Classifications stated are listed in the tables below. 4.2 Fluids not on the Accepted ListFluids which are not on the accepted list may be proposed for use. If the vacuum relatedproperties of the fluid are not sufficiently well documented for an assessment to be carriedout, a programme of measurement of the relevant properties should be agreed betweenthe proposer and the designated ITER Vacuum RODetails of fluids to be considered for acceptance should be submitted to the ITER VacuumRO using the Fluid Acceptance Request Form. The proposer shall agree in advance withthe ITER Vacuum RO a plan detailing the type and method of testing to qualify thematerial for use. The Fluid Acceptance Request Form along with the test data, report andsupporting documentation, including any supplier’s data (Certificates of Conformity, etc.),is to be submitted for consideration. Fluids qualified in this way may be added to the accepted list1 Sulphur, phosphorus and halogen (fluoride & chloride) content below 200 ppm for eachPage 111 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17 th July 2017 Page 3 of 42ITER Vacuum Handbook Appendix 4 IDM Ref :ITER_D_2ElN8NA completed sample of the Fluid Acceptance Form is to be found at the end of thisAppendix4.3 Fluid Selection / QualificationThe fluids listed in the following tables have been considered in terms of usage for vacuumpurposesThe properties of interest for this purpose include, inter alia, Fitness for purpose, i.e. how well it does the job for which it is used Easy and complete removal from the vacuum surface No induced degradation of the vacuum properties of the surface, e.g. increasedoutgassing No significant physical change to the surface Health and safety considerationsPage 112 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 4 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyFluidsApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BIsopropyl Alcohol Ethyl Alcohol Acetone Axarel 9100 CitrinoxTM P3 AlmecoP36 or T5161 RBS 25 Cleaning fluidsRBS 35Page 113 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 5 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BRBS A350 Cleansafe 787MAR: ITER_D_RWAQR3Datasheet:- ITER_D_RWH2NT HC 500 Liquid cleaning agent(Used in electropolishing process for cryogenicpiping for the pre-production cryopump)FAR ITER_D_RZ3F5QSDS ITER_D_RZ7ZFPMDS ITER_D_RZJVUTApproved cleaning procedure ITER_D_S2FG8X NGL 17.40 PPrecision Cleaning for Ultrasonic processesFAR ITER_D_SEW4QA Page 114 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 6 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BDOWCLENE* 1601 Cleaning FluidFAR ITER_D_STQSEK Oil EaterManufacture of ITER-style vacuum flangesFAR ITER_D_Q8DUKTSDS ITER_D_SRFUYVCleaning Aqueous wash with Rebound 7followed by DI water rinse CitriSurf 2310MAR :ITER_D_UHXTT3 RBS826 Cleaning fluidMAR : ITER_D_TF3G4P Page 115 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 7 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BRebound 7Manufacture of ITER-style vacuum flanges. Aqueous wash followed by DI water rinseFAR ITER_D_QCK53ESDS ITER_D_SRF2G7 Surtec®089 with Surtec®132FAR:- ITER_D_TTWQVK PROCIV CUPFAR ITER_D_STHJGP Castrol CareCut S 125 Cutting fluidsVasco 1045 Page 116 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 8 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BVasco 7000MAR ITER_D_RFQND9MDS ITER_D_RAW9TKChemical Analysis ITER_D_RZBSEFSDS ITER_D_RF4MWR Alusol M-FXOnly approved for use for the processing of basematerial which is subject to subsequentmachining / cleaning operations utilisingaccepted water miscible fluids Hocut 2000 Hocut 795 HX Soluble Metalworking OilFAR:- ITER_D_4H3QL6Use accepted cleaning procedure Page 117 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 9 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BFluid Blasocut BC 35 Kombi SWITER_D_HY3BCT Blasocut Kombi 935MAR: ITER_D_RGD6JHChemical analysis ITER_D_RZKU4TSafety datasheet ITER_D_=RGCLWS Blasocut 4000Cleaning: Remove with water or solvent wipesFAR ITER_D_N54G6D CASTROL SYNTILO 75 EFITER_D_PVM8M6 Garia 2608 S-12https://user.iter.org/?uid=LXQXBAOnly for use on non-vacuum facing surfaces(which must be protected) and all surfacescleaned post machining. Page 118 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 10 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BGreen Star SINTOL MICROITER_D_Q3N7N7 Thread Cutting Oil Jokisch Foam CutITER_D_PNPSKN Magicutsynth-g-50ITER_D_N3Q69Y QUAKER 3755 BIOITER_D_NR4E2J Metalsierra DF Metalworking fluidFAR:- ITER_D_RMNBXQChemical analysis ITER_D_RMLNX3Product data sheet ITER_D_RKLNT9Safety data sheet ITER_D_RKLNX7 Page 119 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 11 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BSWISSCOOL 7722FAR: ITER_D_NFJ2N8Approved for the spider application only SWISSCOOL 7722FAR:- ITER_D_TTWU7XUse accepted cleaning procedure Xtreme Cut 250MAR:- https://user.iter.org/?uid=QT8QGHChemical analysis:-https://user.iter.org/?uid=QQ6LSMSubject to accepted cleaning procedure Hangsterfer’s S787 Cutting FluidMAR:ITER_D_SGMMPE Cutting fluidsCastrol CareCut S 600MAR: ITER_D_UCWFVD Page 120 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 12 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BHOCUT 795 MPMAR : ITER_D_TR7XRQ Hocut 795-HMAR : ITER_D_UDSBHL Blasocut BC 25 MDMAR : ITER_D_UFCFJC Pentagon Coolcut SMAR: ITER_D_UJ8YF4 Blasocut BC 35 KombiMAR :ITER_D_U4EZRD MK_SOL_LUBEMAR : ITER_D_U4F3YE Hocut 795MPMAR : ITER_D_UVF5MTPage 121 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 13 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BSynergy 915MAR : ITER_D_UXSKL9 Trim Tap HeavyFAR ITER_D_N9XD58SDS ITER_D_T3BGTK(manufacture of ITER-style vacuum flanges)Cleaning: Aqueous wash with Rebound 7followed by DI water rinse Page 122 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 14 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BTrim Tap LightFAR ITER_D_Q5UH9MSDS ITER_D_T3C35D(manufacture of ITER-style vacuum flanges)Cleaning: Aqueous wash with Rebound 7followed by DI water rinse Kool Mist Formula 78(manufacture of ITER-style vacuum flanges)FAR ITER_D_RCAFRLSDS ITER_D_SYC4EUCleaning: Aqueous wash with Rebound 7followed by DI water rinse Machining CoolantOemeta Novamet 100 CoolantMAR :ITER_D_U8W2E5 Page 123 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 15 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BSemiSyn-200 BlueMAR : ITER_D_UVF66V Trim E206(manufacture of ITER-style vacuum flanges)Cleaning: Aqueous wash with Rebound 7followed by DI water rinseFAR ITER_D_RZEV86SDS ITER_D_SZWMS6 Nefras S2-80/120Wiping of Dome divertor parts for degreasingafter machiningFAR ITER_D_JREV32 SolventsPROSOLV HPDegreasing of Copper & Tungsten for IVT PhaseIFAR ITER_D_ST35B5 Page 124 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 16 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BNitric acid (65%)FAR https://user.iter.org/?uid=PNAPTEhttps://user.iter.org/?uid=PNHPFUhttps://user.iter.org/?uid=PQA6AW Sulphuric Acid (20% solution)FAR https://user.iter.org/?uid=PJRKC5https://user.iter.org/?uid=PK32SYhttps://user.iter.org/?uid=PKZE6A AcidsNitric Acid ConcentratedFAR https://user.iter.org/?uid=D29SZGhttps://user.iter.org/?uid=CZMVE5https://user.iter.org/?uid=DBQPL9https://user.iter.org/?uid=DBQPL9 Page 125 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 17 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BAcidsHydrofluoric acid (in the manufacture of Divertorcomponents prior to HIP)FAR https://user.iter.org/?uid=JQH3BWhttps://user.iter.org/?uid=JQH73Thttps://user.iter.org/?uid=JQHPHU Alkaline solutionALCATUM / ALCATUM HODegreasing of Copper & Tungsten for IVT PhaseIFAR ITER_D_STLR2W Demin WaterDemin Waterhttps://user.iter.org/?uid=N3PDHF Elektrolyt EH01FAR https://user.iter.org/?uid=JEZ7DD Etch and neutraliseNeutralix NG01FAR https://user.iter.org/?uid=JF7ME6 Page 126 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 18 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BLubricantAPIEZON Medium TemperatureApproved for VQC N/A onlyMAR : ITER_D_TF84U8Avesta Passivator 601FAR:- https://user.iter.org/?uid=NVPBLQDatasheets:-https://user.iter.org/?uid=NW5VLQhttps://user.iter.org/?uid=P3WC76Subject to accepted cleaning procedure Pickling andpassivationAvesta Cleaner 401FAR:- https://user.iter.org/?uid=NSE9MNDatasheets:-https://user.iter.org/?uid=NSEMN4https://user.iter.org/?uid=NSH4DXSubject to accepted cleaning procedure Page 127 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 19 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BAvesta picking paste BlueOne TM 130FAR:- https://user.iter.org/?uid=NQ4Y7NDatasheets:-https://user.iter.org/?uid=NQTMJChttps://user.iter.org/?uid=NS77X8Subject to accepted cleaning procedure Pickling andpassivationHC 1100 Passivation solution for Stainless Steel(cryogenic piping for the pre-productioncryopump)FAR:- ITER_D_RXJZB7Datasheet :- ITER_D_RYMSKU Page 128 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 20 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BHC 1100-K3W1 Stainless steel passivator(cryogenic piping for the pre-productioncryopump)FAR ITER_D_RZ5MBEMDS ITER_D_RZ7JP4SDS ITER_D_RZK5GKCleaning procedures ITER_D_S2FG8Xto be used VK Jelly / VK Jelly – Power / VK Spray / VKSpray – 1000FAR:- https://user.iter.org/?uid=RUGXSS Edelshahlbeize Typ 14MAR : ITER_D_U7VKQS K-2 Jelly / K-2 Jelly – Power / K-2 Spray / K-2PasteFAR:- ITER_D_RVVJ9S Page 129 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 21 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BPROCAP 137FAR:- ITER_D_STGBAWUse with approved cleaning procedure Liquid DyePenetrant productfamiliesSherwin Inc. USA: NDT Europa BV:Developer: D100Cleaner: DR62Penetrant: DP51For VQC 1A/B This product is restricted andmay only be used if component / systemunder test is subsequently baked at T 200"C for a minimum of 24 hours prior to vacuumleak testing. For VCQ2A, 3A& 4A this product may only beused to accepted procedures on the prioracceptance of a deviation request from theITER Vacuum Handbook to cover theproposed area of use Page 132 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 24 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BGS CHEM Co LTDDeveloper: DA (P101017D)Cleaner: RA (P101015C)Penetrant: PA (P101016P)For VQC 1A/B This product is restricted andmay only be used if component / systemunder test is subsequently baked at T 200"C for a minimum of 24 hours prior to vacuumleak testing. For VCQ2A, 3A& 4A this product may only beused to accepted procedures on the prioracceptance of a deviation request from theITER Vacuum Handbook to cover theproposed area of use Page 133 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 25 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BEISHINKAGAKU corp. JapanDeveloper: R-1S (NT) SpecialCleaner: R-1M (NT) SpecialPenetrant: R-1A (NT) SpecialFor VQC 1A/B This product is restricted andmay only be used if component / systemunder test is subsequently baked at T 200"C for a minimum of 24 hours prior to vacuumleak testing. For VCQ2A, 3A& 4A this product may only beused to accepted procedures on the prioracceptance of a deviation request from theITER Vacuum Handbook to cover theproposed area of use Page 134 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 26 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BMAGNAFLUXDye penetrant testing of Tungsten monoblocksfor ITER IVThttps://user.iter.org/?uid=JP6EW8Penetrant: Zyglo ZL-27A, fluorescent post emulsifiablepenetrantCleaner: Zyglo ZR-10C, hydrophilic removerDeveloper: Zyglo ZP-4B, dry powder developerFluid to be removed by hot demineralised water rinsefollowed by baking. Babb Co matrix UT coupling agentFAR https://user.iter.org/?uid=PTZ2WRhttps://user.iter.org/?uid=PUW2LUPart to be cleaned to an accepted procedure after UT Ultra Sonic Testing(UT) coupling fluidsCGM US Paste U49FAR https://user.iter.org/?uid=PUXQHPhttps://user.iter.org/?uid=PVAE22Remove residues with clean cloth and acetone Page 135 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 27 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4B09060, Rock Oil,Vacuum test datahttps://user.iter.org/?uid=RRAZ87ITER_D_RMSL86 Dodecane, 297879, Sigma-AldrichVacuum test dataITER_D_RRAZ87ITER_D_RMSL86 Soundclear Grade 60MAR: ITER_D_U2WF3L(can be recommended for use as component isbaked) Ultra-Sonic Testing(UT) coupling fluidsSoundclear Grade 40MAR : ITER_D_U348TX(can be recommended for use as component isbaked) Page 136 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 28 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BPentagon Ultra 30 for use as UT couplant(approved for this application only, on basis ofpost –use surface removal by machining)MAR : ITER_D_UVC2BJMR 750 Ultrasonic Coupling AgentFAR:- ITER_D_TX5XPVCleaning as per ITER approved proceduredocument no. ITER CR-LTTS-602 Page 137 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 29 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BIntrama SL.250 SL2100MAR https://user.iter.org/?uid=QZSP86Outgassing testreport_MarkerPen_Intrama.SL.250https://user.iter.org/?uid=QXVLSUOutgassing testreport_MarkerPen_Intrama.SL.2100https://user.iter.org/?uid=QXM5QJMaterial acceptance reporthttps://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure MarkersMarkal Certified Valve Action Paint MarkerMAR : ITER_D_UBF44E(Certified for <200ppm halogen - agreed but should notbe used on thin wall boundaries with material <1.5mm.) Page 138 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 30 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BEdding 750 White, Silver & BlueFAR:- ITER_D_AFEQ97Cleaning as per approved procedure ; ITER-CR-LTTS-602 Protective paint (onmaterial processingequipment)Stratomet Protective paintFAR:- ITER_D_R7TFB7Chemical analysis:- ITER_D_R6CD9ZSafety data sheet:- ITER_D_R6CCRZ Abrasive mediaCutting wheel Abratec TIPO 42MAR:- https://user.iter.org/?uid=QZRF3EOutgassing report :-https://user.iter.org/?uid=GGREMQSubject to accepted cleaning procedure Page 139 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 31 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BCutting wheel: Sait “A30S” [Thk. 2 mm]MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Cutting wheel: Sait “XA24Q” [Thk. 3,2 mm]MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Page 140 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 32 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BCutting wheel: Sait “XA24Q” [Thk. 7 mm]MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Cutting wheel: Sait “XA46R” [Thk. 1,6 mm]MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Flapper wheel: Abratec LAMELLAREMAR:- https://user.iter.org/?uid=QZRF3EOutgassing report:-https://user.iter.org/?uid=GJ584MSubject to accepted cleaning procedure Page 141 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 33 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BFlapper wheel: Sait "SAITLAM UK 3A"MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Flapper wheel; S.L.F. Abrasivi LASER DISC –"SERIE 10-ALU DISC" MAR:-https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Rough Wheel: Abratec TIPO 27MAR:- https://user.iter.org/?uid=QZRF3EOutgassing report ;-https://user.iter.org/?uid=HD5Z3USubject to accepted cleaning procedure Page 142 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 34 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BRough Wheel: 3M “987C CUBITRON 2”MAR:- https://user.iter.org/?uid=QURJQLOutgassing report:-https://user.iter.org/?uid=HK7F54Subject to accepted cleaning procedure Klingspor KL 361 Abrasive paper. PMUC 10067FAR:- ITER_D_TXD2ZJCleaning with alcohol after usage 3M Roloc Disc 984F Abrasive DiscFAR:- ITER_D_4H8PDWArea to be cleaned with solvent after processing 3M Cloth Belts 984F Abrasive Belt for beltgrinderFAR:- ITER_D_4HBVE3Must be followed by cleaning procedure Page 143 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 35 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4B3M™ Abrasive Products, High Performance Cutoff Wheels, Depressed Center Grinding Wheels,Grind Wheels Type 27, Cubitron™ IIFAR:- ITER_D_4HD79DMust be followed by cleaning procedure 3M Flap Disc 967A Flap discFAR:- ITER_D_T79GNQArea to be cleaned with solvent after operationswith flapper 3M XT-RD-Cleaning DiscFAR:- ITER_D_4H3ZHJMust be followed by cleaning with solvent Tungsten carbide burrs Lukas Abrasive PencilFAR:- ITER_D_T8FBAG Stainless steel brushFAR:- ITER_D_T8FUKG Paper KL361 grain 240, grain 120 and grain 80 ;Grinding tool RB317 LX-R grain 80FAR: ITER_D_UAMCD5Page 144 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 36 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BTetrabor lapping paste (water/polyalcohol based)FAR:- https://user.iter.org/?uid=QF6X54Datasheets:-Safety https://user.iter.org/?uid=QED2DQhttps://user.iter.org/?uid=QEJ42Whttps://user.iter.org/?uid=QERFGWhttps://user.iter.org/?uid=QF2HJZhttps://user.iter.org/?uid=QEH9AGhttps://user.iter.org/?uid=QF7K99Subject to accepted cleaning procedure Page 145 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 37 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BHE 111 Electrolytic polisher(cryogenic piping for the pre-productioncryopump)FAR ITER_D_RN4QKVCleaning procedures ITER_D_S2FG8Xto be usedSDS ITER_D_RN6FUA HE 310 Electrolytic Polisher(cryogenic piping for the pre-productioncryopump)FAR ITER_D_RYS3HQSDS ITER_D_RYTRXGCleaning procedures ITER_D_S2FG8Xto be used Page 146 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 38 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4B3M™ Aluminum Foil Tape 431FAR:- ITER_D_R23U88For use on VQC N/A surfaces only with solventcleanBefore use on higher VQC categories, verification of fullcleaning process cleaning required on sample couponsAdhesive tapes3M™ Preservation sealing Tape 481FAR:- ITER_D_R24JEXFor use on VQC N/A surfaces only with solventcleanBefore use on higher VQC categories, verification of fullcleaning process cleaning required on sample couponsPage 147 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 39 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BDelvigo DVC 48040/7 A5 weld backing stripFAR:- ITER_D_R477ZKFor use on VQC N/A surfaces only with solventcleanBefore use on higher VQC categories, verification of fullcleaning process cleaning required on sample couponsAdhesive tapesDelvigo DVC 44040/6 A5 weld backing stripFAR:- ITER_D_R25TSTFor use on VQC N/A surfaces only with solventcleanBefore use on higher VQC categories, verification of fullcleaning process cleaning required on sample couponsPage 148 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 40 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BScapa 336 Aluminium adhesive tapeFAR:- ITER_D_R4AZFVFor use on VQC N/A surfaces only with solventcleanBefore use on higher VQC categories, verification of fullcleaning process cleaning required on sample couponsAveryDennison HP MPI 2121MAR : ITER_D_UDWANR(Recommended as component is cleaned and baked afteruse)Tesa 4613 – Utility grade Duct Tape (use ofcryostat)MAR : ITER_D_UPXQCQ(Ok for VQC 2 but avoid to use on thin walled bellows orlips <1.5 mm thick)Page 149 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17thJuly 2017 Page 41 of 42KEY: = accepted for use. = not accepted for use. =accepted for restricted use onlyApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4B3M 425 & 431 Aluminium Foil TapeFAR: ITER_D_U33P6M Handling / transportmaterialsKraitec anti-slip elastomer padsFAR:- ITER_D_4GRXXK Adhesive Technologies Glue Stick, Part 229MAR :ITER_D_UHDX7N(glue pucks for laser tracking to tie plate) AdhesivesTACKY TAPE SM5142 (vacuum bag tapesealant)MAR : ITER_D_TX66XFPage 150 of 382ITER Vacuum Handbook: Appendix 4Revision: 1.14 Date: 17th July 2017 Page 42 of 42Request for Acceptance of Fluid Ref No: fluid-01(Assigned by Vacuum RO)Fluid submitted for acceptance: Cut ace 123Proposed Use: Metal Cutting fluid1A 1B 2A 2B 3A 3B 4A 4B VQC of proposed use:Chemical Composition / suppliers datasheetYes Attached Copy (electronic if available)Agreed test plan: No Attached Copy (electronic if available)Vacuum Test data Available: Yes Attached Copy (electronic if available)Solubility in water (at ambienttemperature)Cleaning method (if applicable) Rinse in de mineralised waterVapour pressure (at 100 C) No PaSupporting information Evaporates in air leaving oily residueRequested by L.Pressure Date Submitted 29/07/08Affiliation: US DA E-Mail L.Pressure@iter.orgFluid Acceptance Status: (To be completes by ITER Vacuum Group RO)1A 1B 2A 2B 3A 3B 4A 4B Acceptance for VQC: Limits / Restrictions (Attached Doc.) Fluid to be removed by hot demineralised water rinse (Cut ace123.doc IDM Ref 15R8UI)Acceptor: H.M. Self ITER Vacuum RODate:09/08/08Grey boxes to be completed by requesting officer. Boxes in Red to be completed by ITERVacuum ROPage 151 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 5 Acceptance ChecklistApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: Section Scheduling, AD: OBS - Vacuum Section (VS) - EXT, AD: OBS - VacuumSection (VS)IDM UID2N4NDKVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 152 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 5 Acceptance Checklist (2N4NDK)Version Latest Status Issue Date Description of Changev1.0 In Work 18 Jun 2009v1.1 Signed 18 Jun 2009 Minor updatev1.2 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 153 of 382ITER_D_2N4NDK v1.2ITER Vacuum Handbook : Appendix 5Revision: 1.2 Date: July 30th , 2009 Page 1 of 16Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum Handbook IDM Ref :ITER_D_2N4NDKITER Vacuum HandbookAppendix 5Acceptance ChecklistPage 154 of 382ITER_D_2N4NDK v1.2ITER Vacuum Handbook : Appendix 5Revision: 1.2 Date: July 30th , 2009 Page 2 of 16Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum Handbook IDM Ref :ITER_D_2N4NDK5 Acceptance Checklist5.1 ScopeTo satisfy the requirements of the ITER Vacuum Handbook acceptance or acceptedis called for in various places throughout the ITER Vacuum Handbook . This appendix is intended as a tool to manage the acceptance of the requirements aslaid out in the ITER Vacuum Handbook and contains a list of all the items from theITER Vacuum Handbook where acceptance is required. An acceptance checklist can be completed for PAs by a representative of the ITERVacuum Responsible Officer. On completion of the checklist, the reviewer canindicate where further acceptance is required for the PA to be in compliance with therequirements of the ITER Vacuum Handbook . In the following table acceptances which are highlighted appear in similar form atmore than one place in the Handbook. The main occurrence for each group ishighlighted in the table in blue and subsequent occurrences are highlighted in darkyellow. A single acceptance is then valid for the whole group of acceptances. . Page 155 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note15 - Appendix 3Only materials accepted to beused on ITER VacuumsMaterials listed in Appendix 3 can be used subject to theirclassification / restriction as described in Appendix 2. Other materials may be used once qualified asacceptable. Requires acceptance of qualification plan. Mandatory for all materials not listed in Appendix 3. 25.3 - MetallicMachinedComponents andFittingsOther forms of achieving lowinclusion count material may beusedIf a supplier has a process other than ESR or VAR toproduce low inclusion material this method must beaccepted. Mandatory if ESR or VAR is not used in theproduction of low inclusion material. 35.4 - Outgassing Novel, high surface areacomponents require acceptanceThe supplier must submit for review and acceptance amethod by which components can be shown to conformto the requirements of the ITER Vacuum Handbook . Published data and /or experimental qualification may beused. Mandatory if novel high surface area components areused. Page 156 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note4VH 5.4 -outgassingOutgassing rate acceptance testto be performed on VQC 1componentsThe supplier shall submit to the ITER Vacuum RO theacceptance test procedure for review and acceptance. This acceptance may also allow for testing ofrepresentative samples of components. Proceduresshould pay due regard to Appendix 17. For specificcomponents, it may be agreed that conformity to a cleanwork and quality plan is acceptable. Mandatory for all VQC 1 components except ifoperation in vacuum above 1 Pa in which case theITER Vacuum RO will assess the use and accept thecomponent on a case by case basis. 55.5 - Hot IsostaticPressingAcceptance at the design stagefor the use of HIP formedcomponents and acceptance ofqualification procedure of suchcomponentsThe use of HIP formed material accepted at the designstage. The ITER Vacuum RO shall also review andaccept the procedure for qualification of such componentsto demonstrate that they conform to the requirements ofthe ITER Vacuum Handbook . Mandatory for components formed by Hot IsostaticPressing. 65.6 - Castings Validation programme for thequalification of castings to showthey conform to the VH shall beaccepted by the ITER VacuumROIf a casting is required for use on systems with VQC = 1,2A or 3 a qualification programme (to show that theyconform to the requirements of the ITER VacuumHandbook) shall be reviewed and accepted. Mandatory for castings with VQC =1, 2A or 3. Page 157 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note76.1.2 - VQC 1 & 3cutting fluidsCutting fluids not listed inAppendix 4 require acceptance. Cutting fluids listed in Appendix 4 can be used subject totheir classification / restriction as described in Appendix 4. Other cutting fluids may be used once qualified asacceptable. Requires acceptance of qualification plan. Mandatory for cutting fluids not listed in Appendix 4. 87 - Permanentjoining processesPermanent joining processes notlisted in Table 7.1 requireacceptanceThe supplier shall submit proposals for other permanentjoining processes not listed to be accepted. Mandatory for all permanent joining processes notlisted in table 7.1. 97.1.1 - JointConfigurationWelds for which at completionleak detection is not practicalrequire that a test plan includingprovision for repair shall beaccepted. Where welds are not leak testable the supplier mustsubmit for review and acceptance at the design stage atest plan which also details how such a weld could berepaired if it fails. Mandatory for welds which cannot be tested at thetime of manufacture. 107.1.4 - Inspectionand Testing ofProduction weldsThe selection process for codeswhich require the use of LPT forthe build of vacuum equipmentshall be recorded and accepted. If there is a mandatory requirement (such as nuclearregulator) to build a vacuum system to a code whichrequires the use of LPT to satisfy the code then theselection of that code shall be accepted. Mandatory only where there is, for example, aregulatory requirement to builda vacuum system to acode and only then if the code requires the use ofLPT without exception. Page 158 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note117.1.4 - Inspectionand Testing ofProduction weldsIf LPT is to be used then it mustbe used only according toprocedures qualified andacceptedThe supplier shall submit for acceptance a procedure forthe use of ITER qualified LDP. This shall include how theLDP is removed from the surface. Mandatory when LDP is used. 127.1.5 - Weld Finish& RepairWeld repairs shall be carried outto accepted proceduresThe supplier shall submit for review and acceptance ofweld repairs on vacuum boundary components. Only mandatory for welds not produced to a code(e.g. RCC-MR – ASME 8). 137.1.6 - HeliumLeak Testing ofProduction Welds. Procedure for helium leak testingto be accepted. The supplier shall submit for review and acceptance aprocedure detailing how the helium leak testing ofproduction welds shall be carried out and details of theequipment to be usedMandatory for all vacuum welds. Accepted with #45147.2 - Brazed andsoldered jointsBrazing flux is not normallypermittedIf brazing flux is required for use on vacuum systems aprocedure for cleaning the components shall be submittedfor review and acceptance. Only required if brazing flux is to be used. 157.2 - Brazed andsoldered jointsThe use of brazing materialscontaining silver is subject toquotasSpecific acceptance is required for use of silver bearingbraze amerials on any individual componentMandatory for all use of silver alloys in brazed jointsexcept in VQC4Page 159 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note167.2 - Brazed andsoldered jointsBrazing should be performed toan accepted standard or to anaccepted procedure. If brazing is required the supplier shall submit for reviewand acceptance either a procedure detailing how thebrazing operations are qualified and produced or aninternational brazing standard detailing the qualificationand production procedure. Mandatory for all brazing operations. 177.2.2 -Qualification ofbrazed jointsThe procedure for thequalification of brazed joints shallbe accepted. If brazing is required the qualification procedure shall beaccepted or performed to an accepted internationalstandard for brazing. Mandatory for brazing operations. Acceptance canbe granted with #16. 187.2.3 – Inspectionand testing ofbrazed jointsNo braze shall be rerun forrectification of any sort withoutprior agreementProcedure for any rerun to be agreedMandatory where rectification of a braze is required197.3 – DiffusionbondingDiffusion bonded joints shall besubject to the same qualificationprocedures as brazed jointsNote: Numbers 15-17 (inclusive) above applyMandatory for all diffusion bonded joints207.3 – ExplosionbondingExplosion bonded joints shall besubject to the same qualificationprocedures as brazed jointsNote: Numbers 15-17 (inclusive) above applyMandatory for all explosion bonded joints218.2 - Coatings VQC 1 coatings subject toqualification and acceptance. Thesupplier must provide for review and acceptance amethod for the qualification of coatings. Mandatory only for VQC1. Page 160 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note229 - Confinementand VacuumContainmentSingle containment of VQC 1Avulnerable components may beaccepted if the component isaccessible for access and fittedbehind an accepted, interlocked,isolating valve. Details of single vacuum contained VQC 1A shall besupplied for review and acceptance at the design stage. Mandatory only for VQC1A components. 239 - Confinementand VacuumContainmentSingle containment of VQC 2Acomponents. For Vulnerable VQC 2A components, which are notdoubly vacuum contained, an alternative method for leakmitigation and localisation shall be submitted for reviewand acceptance at the design stage. Mandatory only for VQC2A components. 2411 - Connectionsto the SVSAll connections to the SVS shallbe as defined in the VH with theexception of interspaces pumpedto P< 5x10-1PaThe supplier shall submit for acceptance the detaileddesign of interspaces for connection to the SVS forinterspaces where the required pressure is <5x10-1Pa. Mandatory for all SVS connections of this type. 2512.1 - PipeworkGeneralVQC 1A and VQC2A pipes andfittings shall be seamlessSpecific acceptance is required for the use of non-seamless pipes and fittings on the vacuum boundary ofVQC1 and 2 systems. Mandatory for VQC 1A and VQC 2A. 2612.1 - PipeworkGeneralWater pipes passing through thecryostat shall have interspacesfor leak localisationWhere water pipes passing through the cryostat are notinstalled with interspaces for leak localisation analternative method of localisation shall be proposed forreview and acceptance. Mandatory for all water pipes crossing the cryostat. Page 161 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note2713 - DemountableJointsAll demountable joints requireacceptanceThe supplier shall provide details of proposed type andconfiguration of demountable vacuum joints (includingseals) for use on ITER vacuum systems. Requirement is diminished if standard demountablevacuum joints are selected from Appendix 8. 2813 - DemountablejointsVQC 4 demountable vacuumjoints shall use all-metal sealsIf all metal seals are not to be used on VQC 4 systems aproposal for other types of seal shall be submitted forreview and acceptance. Requirement for VQC 4. 2913 - DemountablejointsAll demountable joints to behelium leak tested to acceptedinstallation proceduresThe supplier shall submit for review and acceptanceinstallation procedure detailing how demountable vacuumjoints are made (bolt torque, sequence etc). Thisprocedure shall include leak testing of the made joint. Mandatory for all demountable vacuumGeneral approval of leak testing techniques (only)may be made with #523014.1 – TappedholesTapped holes to be cut usingapproved cutting fluidsCutting fluids listed in Appendix 4 can be used subject totheir classification / restriction as described in Appendix 4. Other cutting fluids may be used once qualified asacceptable. Requires acceptance of qualification plan. Mandatory for cutting fluids not listed in Appendix 4. Acceptance will be granted with #7Page 162 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note3114.2.2 -Prevention of BoltSeizingDry lubricants to be selectedfrom Appendix 3If a lubricant is not listed in Appendix 3 then acceptanceto use the proposed lubricant shall be sought. Acceptance will be granted with #1. 3214.4 - Bearingsand sliding jointsDesign of bearings and slidingjoints for use on VQC 1 to 3subject to acceptanceThe supplier shall submit for review and acceptance atthe design stage proposals for the design of bearingsand/or sliding joints for use on systems with VQC 1 to 3. Excludes sliding joints used in VQC 4. 3314.4 Bearings andsliding jointsType of cross linked PTFErequires acceptanceIf Cross linked PTFE is to be used the supplier shallsubmit for review and acceptance details of the type ofcross-linked PTFE, it’s operational position and quantity. Applicable to cross-linked PTFE for use on VQC 2 or4. 3415.2 - Qualificationof WindowsQualification plan to be acceptedThe supplier shall submit for review and acceptance adetailed plan for the qualification of window assembliesfor use on a vacuum boundary. Mandatory for all window assemblies. 3515.3 - Testing ofWindowAssembliesTesting plan to be acceptedThe supplier shall submit for review and acceptance adetailed plan for the testing of window assembliesmanufactures to a procedure accepted in #29. Mandatory for all window assemblies. Page 163 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note3616 - VacuumValves and ValveAssembliesUse of elastomers for closuresealsWhere valves are to be used on VQC 2 and an elastomerclosure seal is required the supplier shall provide detailsof the type of valve and it’s operational position (etc) forreview and acceptance. Applicable to VQC 2 Valves only. 3716 - VacuumValves and ValveAssembliesUse of compressed gas tomaintain closure sealValves should not require compressed gas to maintain theclosure seal. If it is required that a valve utilisescompressed gas to maintain the closure seal, the type ofvalve, operational position, etc., shall be provided forreview and acceptance. Mandatory for all such valves. 3816.1 - Acceptancetesting of Valvesand ValveAssembliesValves to be leak tested toaccepted proceduresThe supplier shall submit for review and acceptance aleak test procedure to prove the leak integrity of valvesprior to delivery. Mandatory for all Valves, although can be waived forproprietary valves. General approval of leak testing techniques (only)may be made with #523917.1 - Bellows andFlexibles - GeneralBellows in water circuits notallowed for any VQC unless byexception. If a bellows is required for use in a water circuit and isinstalled behind an isolating valve, the supplier shallprovide for review and acceptance details of position,operational parameters, design etc. Mandatory for all bellows in water circuits insidevacuum systems. Page 164 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note4017.2 - Design ofBellowsBellows shall be designed toEJMA or equivalent. If bellows are not to be designed using the EJMA designrules then an alternative set of rules shall be submitted,with a bellows qualification plan, for review andacceptance. All non-proprietary Bellows. 4117.2 - Design ofBellowsThe use of multilayer designrequires acceptanceIf vulnerable bellows used on VQC 1&2 systems are notof double wall construction then bellows of mulitilayerconstruction may be allowable if the multilayer design isaccepted. For VQC 1& 2 Vulnerable Bellows. 4217.3 - Qualificationof bellowsProcedure for the qualification ofbellows requiredThe supplier shall submit for review and acceptance aplan detailing the tests to be performed in the qualificationof bellows assemblies. For all non –proprietary bellows. 4317.4 - Testing andInspection ofBellowsProcedure for the testing ofbellows requiredThe supplier shall submit for review and acceptance aplan detailing the tests to be performed on themanufactured bellows assemblies. For all non –proprietary bellows. 44VH 18.1 -FeedthroughsGeneralVulnerable VQC1A and 2Afeedthroughs penetrating an airboundary shall be doublyvacuum containedIf the feedthroughs are not to be doubly vacuumcontained then the supplier shall submit for review andacceptance an alternative arrangement which will ensuresufficient vacuum integrity of the component. VQC 1A&2A feedthroughs crossing an air boundary. Page 165 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note4518.2 - PaschenbreakdownChoice of backfill gas ininterspace where there is a riskof Paschen breakdown shall beacceptedThe supplier shall agree which gas shall be used tobackfill the interspace. For interspaces at risk of Paschen breakdown only. 4620.1 - Cables foruse in VacuumCables that are not listed inAppendix 10 require acceptancefor use in ITER vacuum systems. The supplier shall submit for review and acceptance atthe design stage details of proposed cables not listed inAppendix 10. Applies to all VQC. 4720.1 - Cables foruse in VacuumQualification of cablemanufacturing techniquesThe supplier shall provide for review and acceptance aprocedure for the manufacture and qualification of cablesfor use in ITER vacuum systems. Applies to all VQC. Complementary to #414824.1 - Cleaning Cleaning procedures to beagreedThe supplier shall submit for review and acceptance aclean work plan detailing the procedures and methods tobe used in the cleaning of vacuum components for use onITER. Applies to all VQC. 4924.1 - Cleaning Degreasing proceduresThe supplier shall submit for review and acceptance aplan detailing the procedures and methods to be used inthe degreasing of vacuum components for use on ITER. Applies to all VQC. Accepted with #485024.3 - MechanicalProcesses onVacuum SurfacesUse of abrasive techniques onvacuum surfacesAll such techniques require agreement before being usedIn VQC2 shot and dry bead blasting are acceptableMandatory for all VQCPage 166 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note5124.3 - MechanicalProcesses onVacuum SurfacesUse of grinding wheelsIf a grinding wheel is to be used on components withVQC 1 then the details of the grinding wheel(composition, manufacturing process, etc.) shall besubmitted for review and acceptance prior to the grindingwheel being used. For VQC 1 only. 5225.1 - Leak testingGeneralLeak testing procedures requireacceptancePrior to any acceptance leak testing the supplier shallsubmit for review and acceptance a leak testingprocedure detailing the methods , equipment to be used,etc, for acceptance leak testing. Mandatory for all acceptance leak tests, for all VQC. May be waived for proprietary components suppliedwith C of C. 5325.4 - Schedulingof Leak TestsTiming of tests Prior to manufacture the supplier shall provide a leak testplan detailing the timing and type of leak tests to beperformed. Mandatory for all acceptance leak tests, for all VQC. May be waived for proprietary components suppliedwith C of C. 5425.4 - Schedulingof Leak TestsDerogation of acceptance leaktesting of complete system. For VQC 2A components where final acceptance leaktesting of the system as a whole may be impractical thesuppler shall submit for review and acceptance aprocedure to leak test individual parts of the system andthe method of scaling of such tests to the system whole. VQC 2A components only. Accepted with #52. Page 167 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note5525.5 - Methodsand ProceduresLeak test procedures requireacceptanceFull details requiredAccepted with #525625.5 - Methodsand ProceduresCold leak testing The supplier of a vacuum system which operates atcryogenic temperatures shall submit for acceptance amethod of cold leak testing joints. For all VQC. General approval of leak testingtechniques (only) may be made with #52. 5725.6 - Acceptanceleak testing at thesuppliers PremisesRectification of detected leak If a leak is detected any rectification work (exceptremaking demountable joints) must be agreed in advanceAll VQC5825.6 - Acceptanceleak testing at thesuppliers PremisesDelivery to ITER of equipmentwhich fails the acceptance leaktestIf a component fails the acceptance leak test at thesuppliers premises then the supplier shall requestacceptance before that component can be delivered toITER. For All VQC. 5926.1 - Baking Baking proceduresThe supplier shall submit for review and acceptanceprocedures detailing the method of baking vacuumcomponents. For All VQC. 6026.7 - VacuumConditioning ofCarbonCompositesConditioning (baking) proceduresThe supplier shall submit for review and acceptanceprocedure detailing the method of vacuum conditioningcarbon composite components. For All VQC. Page 168 of 382ITER_D_2N4NDK v1.2#ITER VacuumHandbook SectionReferenceAcceptanceProc. PA Note6128 – Marking ofVacuumEquipmentChemical etching proceduresThe supplier shall submit for review and acceptancedetails of chemical etching operations to be carried out onvacuum equipment. Applies to VQC1. 6229 – Packing andHandling ofVacuumEquipmentBackfilling of volumesWhere it is not practical to backfill volumes pumped forleak testing to 0.12 MPa the supplier shall submit forreview and acceptance an alternative method. For All VQC. 6329 – Packing andHandling ofVacuumComponent packaging Where it is not practical to seal components inpolyethylene for shipping (sealed bag filled with dry air)the supplier shall propose for review and acceptancealternative methods of packing. For All VQC. Page 169 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 6 WindowsApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2DXZZ3VERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.3 / ApprovedEXTERNAL REFERENCE / VERSIONPage 170 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 6 Windows (2DXZZ3)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 22 Sep 2008v1.2 In Work 12 Jan 2009v1.3 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 171 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 1 of 9Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum ResponsibleOfficerRobert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 6Guide to the Supply of Vacuum Windows for the ITER ProjectPage 172 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 2 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ36 Requirements for the Supply of Vacuum Windows for the ITER project.36.1 Scope.36.2 Design.36.3 Materials.46.3.1 Windows.46.3.2 Window (body) Assemblies.46.4 Manufacture.46.4.1 Welding of Window Assemblies.56.4.2 Bonding of Windows.56.4.2.1 VQC 1.56.4.2.2 VQC 2.56.5 Qualification of Windows (type testing).56.5.1 Pressure testing.66.5.2 Mechanical shock.66.5.3 Thermal Shock.66.5.4 Leak Testing.66.5.5 High Power RF Transmission.76.5.6 Voltage Stand-off.76.6 Testing and Inspection of Window Assemblies.76.6.1 Leak Testing.76.7 Marking.76.8 Packaging & Delivery.86.9 Incoming inspection at the ITER Site.86.10 Documentation.8Page 173 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 3 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ36 Requirements for the Supply of Vacuum Windows for the ITERproject6.1 ScopeThis appendix is written as a guide for the manufacture and supply of vacuum windowassemblies for use on the ITER project. It is intended that the suppliers of vacuum bellows and flexibles should follow the guidancein this appendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this appendix providedthat the components manufactured comply with the requirements of ITER VacuumHandbook. “Supply” includes the design, manufacture, testing and delivery of windows as described inthe specifications, including the design, manufacture and testing of beryllium windows foruse on ITER diagnostic systems. 6.2 DesignITER IO is responsible for specifying the interface between ITER systems and the windowassemblies. The supplier is responsible for the detailed design of the window assemblies. Flanges or end fittings will be specified by ITER in accordance with The ITER VacuumHandbook Appendix 8 and the design of the window assembly must conform to the ITERremote handling requirements as detailed in the ITER Remote Handling Code of Practice. Window assemblies for use on ITER vacuum vessels forming part of the vacuumcontainment boundary for VQC1A should be bakeable to 250 °C and, to conform to theITER Vacuum Handbook Section 15, should be of a double window design (either pre-assembled or installed as separate elements) unless permanently installed behind an UltraHigh Vacuum (UHV) isolating valve. The interspace between the two windows will bebackfilled with a suitable gas (as accepted by the ITER Vacuum Responsible Officer) andconnected to the Service Vacuum System. Similarly, window assemblies for use on ITER vacuum vessels forming part of the vacuumcontainment boundary for VQC2A should be of double construction. However, there is norequirement to operate at elevated temperatures. For windows transmitting high power (e.g. RF heating systems) the interspace pressureneeds to be monitored continuously and suitably interlocked with the power system. Window assembly interspace volumes are to be manufactured with suitable connections tothe Service Vacuum System, as detailed in the ITER Vacuum Handbook Section 8. Windows used in VQC, 3 & 4 may be of a single window construction. Page 174 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 4 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ3All joining processes, bonding of the window to the ferrule and brazing or welding of themetallic components, have to be pre-qualified and production proof samples should bemade during the manufacturing process (see Attachment 1). 6.3 MaterialsAll vacuum facing materials for use in the manufacture of window assemblies shouldcomply with the ITER accepted materials list (Appendix 3). 6.3.1 WindowsCVD Diamond, natural crystal quartz, synthetic crystal quartz and sapphire are acceptedfor use in ITER window assemblies forming primary vacuum containment. Beryllium Oxideis accepted for use in vacuum windows that form part of the primary vacuum containmentafter qualification of the window in accordance Section 6.5 of this Appendix. Sodiumchloride and other hygroscopic materials are not accepted for use in VQC1 & VQC2systems. 6.3.2 Window (body) AssembliesAll tubes/pipes are to be of seamless construction and comply with the ITER VacuumHandbook Appendix 11. In accordance with the ITER Vacuum Handbook Appendix 8 flanges should bemanufactured from forged material and supplied as follows:1. Materials selection is to comply with Appendix 32. When there is a vacuum boundary across the grain of thickness <5 mm, thematerial must be Electro-Slag Remelted (ESR) or Vacuum Arc Remelted (VAR). The use of plate is prohibited. Alternative processes for achieving the requiredinclusion limits may be accepted if successfully validated. 3. The rate of inclusions in such steels should be checked in accordance withASTM E-45 Method D (or equivalent) to be within the following inclusion limits:• Inclusion Type A ≤ 1.0• Inclusion Type B ≤ 1.0• Inclusion Type C ≤ 1.0• Inclusion Type D ≤ 1.56.4 ManufactureBefore assembly commences the supplier should submit to ITER for acceptance thedocuments listed in Section 6.10. Tools used during the manufacture of the window assemblies must not contaminate thevacuum surfaces. Cutting fluids need be accepted before use and will be water based, oilfree, non-halogenated, sulphur and phosphorus free. Those listed in Appendix 4 areaccepted and, if chosen, should be specified in the quality plan and agreed in advance. Cleaning operations need to be performed to an accepted procedure in accordance withthe ITER Vacuum Handbook Appendix 13. The use of chlorine and other halogencontaining fluids (e.g. trichloroethylene) is strictly forbidden. Page 175 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 5 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ3All assemblies must be individually identified, packaged and shipped to the ITER site inaccordance with Section 22 of the ITER Vacuum Handbook . 6.4.1 Welding of Window AssembliesPrior to manufacture the supplier should submit a weld plan in accordance with the ITERVacuum Handbook Attachment 1. The weld plan is a drawing which cross referenceseach welded joint to a supporting Weld Procedure Specification (WPS). Welding procedures and the Procedure Qualification Records should be qualified inaccordance with Attachment 1Where practical, all welds shall be full penetration butt welds unless otherwise accepted. 100 % visual examination of welds should be carried out in accordance with the ITERVacuum Handbook Attachment 1Butt welds are to be 100 % radiographed in accordance with the ITER Vacuum HandbookAttachment 1Where radiography is not feasible, production proof samples must be performed inaccordance with the ITER Vacuum Handbook Attachment 1Dye-Penetrant examination of production welds is only permitted in accordance with theITER Vacuum Handbook.. 6.4.2 Bonding of WindowsAll windows should be bonded into metal ferrules. 6.4.2.1 VQC 1Windows should be bonded into the window assemblies by aluminium bonding. Otherbonding methods may be used with the advance agreement of the ITER ResponsibleOfficer after acceptance of the method. 6.4.2.2 VQC 2In addition to aluminium bonding, Sliver-Lead-Tin Eutectic may be used for windows foruse on the outer cryostat boundary. 6.5 Qualification of Windows (type testing)Prior to the manufacture of window assemblies the supplier must qualify the windowdesign. The supplier should submit for acceptance a qualification plan (as part of thequality plan) detailing the tests to be performed on window assemblies. After thecompletion of all manufacturing processes the window assemblies should undergo thefollowing qualification tests. 1. Pressure test12. Mechanical shock testing3. Thermal shock test4. Helium leak test5. High power RF transmission (where applicable)6. Voltage stand-off (including Paschen breakdown where applicable)Page 176 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 6 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ31 The pressure test should include a rapid vent “type test” in which the window is mountedin a small evacuated vessel which is then vented rapidly (simulating survival of a VacuumVessel loss of vacuum event). In each case the method of testing should be accepted before manufacture shallcommence. 6.5.1 Pressure testingPrior to leak testing it must be demonstrated that the window assemblies can withstand,and remain unaltered by, a 0.2 MPa pressure differential in either direction. Proof tests to0.3 MPa are required to qualify the window assemblies. 6.5.2 Mechanical shockType testing of the window bonded elements must show no failure at 15 g acceleration for1000 cycles. 6.5.3 Thermal ShockType testing of the window bonded elements must exhibit no change in helium leak ratewhen sprayed with water at 100o C while at the window normal operating temperature6.5.4 Leak TestingThe supplier should perform leak testing of the window assemblies in accordance with theITER Vacuum Handbook Appendix 12Window assemblies for use on VQC1 systems should be baked and hot leak tested at250 °C as follows:1. Global leak test of the window assembly2. Leak test of the water cooling circuits (if applicable)3. Leak test of the window interspace (both to vacuum and to atmosphere)The leak test procedure should include three operating cycles of the window assembly ateach test temperature before leak testing. The procedure for baking windows should be in accordance with the ITER VacuumHandbook Appendix 15 and should be submitted for acceptance before baking operationsstart. Immediately after bake-out, these tests should be repeated at room temperature. In both cases the acceptance leak rate shall be met with the background reading on theleak detector being at least one order of magnitude below the acceptance leak rate withoutelectronic correction. Leak rates for window assemblies for VQC1 (including the windowinterspace) should not exceed 1 x 10-10 Pam3s-1 at 250 °CWindow assemblies for use on VQC 2 systems should be subject to the same tests asVQC 1 but with the requirement for temperature cycling waived. Leak rates for windowassemblies for VQC2 should not exceed 1 x 10-10 Pam3s-1 at ambient temperature. Acceptance criteria for window assemblies is summarised in Table 6-1. Page 177 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 7 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ3Table 6-1 Window assembly Leak RatesVQC 11 VQC 22Max global leak rate 1 x 10-10 Pam3s-11 x 10-10 Pam3s-1Max leak rate from /to windowinterspace1 x 10-10 Pam3s-11 x 10-10 Pam3s-1 (if applicable)Max cooling channelleak rate1 x 10-10 Pam3s-11 x 10-10 Pam3s-1(if applicable)1. Acceptance criteria at 250 oC2. Acceptance criteria at ambient6.5.5 High Power RF TransmissionOn windows designed for the transmission of high power RF it must be demonstrated thatthe vacuum properties of the window remain unaltered when high power RF is applied. The supplier shall submit for acceptance a test plan detailing the method and type oftransmission tests to be performed in the qualification of the windows assemblies. 6.5.6 Voltage Stand-offThe supplier must demonstrate that windows required to stand off high voltage can do sowith no degradation of the vacuum performance of the windows. It must also bedemonstrated that the window assemblies are suitable protected from Paschen discharges(if applicable). The supplier shall submit for acceptance a test plan detailing the methodand type of tests to be performed in the qualification of the window assemblies. 6.6 Testing and Inspection of Window AssembliesPrior to the manufacture of window assemblies the supplier should provide for acceptancea test plan and test procedures detailing the tests to be performed on window assembliesbefore delivery to the ITER site. After the completion of all manufacturing processes thewindow assemblies should undergo a vacuum baking cycle to the operating temperatureand a helium leak test according to 6.6.1 below. 6.6.1 Leak TestingPrior to delivery to the ITER site, windows should be subject to helium leak testing inaccordance with Section 6.5.4. Windows will be subject to acceptance helium leak testingon delivery to the ITER site. 6.7 MarkingEach window assembly should be individually marked with a unique identification which istraceable to the window assembly document package. The use of dyes, paints, pens andother such markers that transfer marking material into any window assembly surfaceshould not be used for the marking of window assemblies. Scribing with a clean sharpPage 178 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 8 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ3point and vibro-etching are acceptable marking processes. Chemical etching is alsoacceptable, but not for use on for VQC1 vacuum facing surfaces. 6.8 Packaging & DeliveryThe packaging and delivery of window assemblies to the ITER site should be inaccordance with the ITER Vacuum Handbook. Where practical, window assemblies should be entirely enclosed in heat sealedpolyethylene and backfilled with a suitable dry gas. Nitrogen is preferred but other gassesmay be permitted with prior acceptance. All window assemblies shall be shipped dryinternally and externally irrespective of final acceptance testing at the manufacturer’s site. The use of adhesive tape for the protection and packaging of components must be limitedto prevent the risk of contamination from the tape. In particular tape used on austeniticstainless steel should meet leachable chloride and fluoride limits of 15 ppm and 10 ppm,respectively. Where used, tape must be fully removable without residue, using isopropylalcohol or acetone as the solvent if necessary. All window assemblies should be transported in rigid packing cases or containers whichare lined with waterproof material. Components must be packed with adequate protectionfrom thermal and mechanical stresses (particularly shock loads resulting from droppingand mal-handling) which may adversely affect the operation of the window. All packingcase joints should be sealed and cases marked with individual window specificidentification. Handling instructions should also be clearly marked on the outer packaging. Chemical or radiological hazards, etc., should be identified on the packaging. Allpackaging markings will be in English and French and include the Vacuum Classificationof the component(s). 6.9 Incoming inspection at the ITER SiteIn addition to the inspection detailed in this Appendix, window assemblies will be subject toan incoming inspection on delivery to the ITER site. This will include, as a minimum,dimensional inspection for compliance with the technical specification and helium leaktesting in accordance with the ITER Vacuum Handbook Appendix 12. 6.10 DocumentationThe following documents shall be accepted before pre-manufacture activities commence:¾ Weld Plan¾ Quality Plan (including test plan /schedule)¾ Welding Procedures and Welder Qualifications¾ Dimensional Drawings¾ Qualification test planThe following documents shall be accepted before manufacture commences:¾ Type testing reportOn completion of manufacturing, two sets of the following documents should be suppliedas data books:Page 179 of 382ITER_D_2DXZZ3 v1.3ITER Vacuum Handbook: Appendix 6Revision: 1.3 Date: July 28th, 2009 Page 9 of 9ITER Vacuum Handbook Appendix 6 IDM Ref :ITER_D_2DXZZ3¾ Signed-off Quality Plan¾ Welding Procedures and Welder Qualifications¾ Radiographic Reports (if applicable)¾ Production Proof Sample Reports (if applicable)¾ Material Certificates, traceable to assemblies, in accordance with EN 102042.2 ,3.1 or 3.2¾ Dimensional drawings identifying welds¾ Type testing report (s)¾ Dimensional Inspection ReportPage 180 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 7 ValvesApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2EPFG4VERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.3 / ApprovedEXTERNAL REFERENCE / VERSIONPage 181 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 7 Valves (2EPFG4)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 12 Jan 2009v1.3 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 182 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 1 of 8Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 7Guide to the Supply of All Metal Vacuum Valves for the ITER ProjectPage 183 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 2 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG47 Requirements for the Supply and Modification of All-Metal Ultra High VacuumValves for use on the ITER Project.. 37.1 Design.. 37.2 Additional requirements for the supply of standard valves with modified ends47.2.1 Materials.. 47.2.1.1 General.. 47.2.1.2 Metallic Machined Components and Fittings.. 47.2.2 Fabrication.. 47.2.2.1 Welding.. 57.3 Leak Testing.. 57.4 Marking.. 67.5 Documentation.. 67.6 Packaging & Delivery.. 67.6.1 Incoming inspection at ITER Site.. 77.7 Documentation.. 7Page 184 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 3 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG47 Requirements for the Supply and Modification of All-Metal UltraHigh Vacuum Valves for use on the ITER ProjectThis Appendix is written as a guide for the manufacture and supply and modificationof all metal ultra high vacuum vacuum valves for use on ITER vacuum systems. It isintended that the suppliers of such vacuum valves should follow the guidance in thisAppendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components manufactured comply with the requirements of theITER Vacuum Handbook. “Supply” includes the design, manufacture, testing and delivery of bellows andflexibles as described in the specifications7.1 DesignITER is responsible for specifying the interface between ITER systems and thevalves. The supplier is responsible for the detailed design of the valves including anymodifications as specified by ITER. Flanges or end fittings shall be specified by ITER and supplied in accordance withthe ITER Vacuum Handbook Appendix 8. Valves used for ITER vacuum vessel isolation (VQC1A) should be bakeable to 250°Cin the open and closed positions and, in accordance with the requirements of theITER Vacuum Handbook, should be of double bellowed design. VQC 1 valves shouldbe able to operate at 250°C and be of all metal construction (seal, body etc). Demountable valves for use on VQC 1A should utilise a metal double sealarrangement conforming with the requirements of the ITER Vacuum HandbookAppendix 8VQC 2 & 3 valves are not required to operate at elevated temperature but must be ofall metal vacuum containment. There is no requirement for VQC 4 valves to be bakeable or of all metal design. Pneumatic seals and electrical components for valves used in systems withclassification VQC1 should withstand a total radiation integrated dose of 108 Gray(TDB)Where valves require to be remotely handled as a unit rather than as part of anintegrated remotely handled assembly, they should be designed in accordance withthe requirements ITER Remote Handling Code of Practice. The design life of valves for use on ITER should be such as to limit intervention forreplacement or repair during the operational phase of the ITER Project. Typicallyvalves for ITER vacuum vessel isolation should be designed to operate for aminimum of 5000 cycles without the requirement for intervention. This requirementPage 185 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 4 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG4applies to all torus isolation valves with the exception of valve sizes larger thanDN1500 mm (e.g. Neutral Beam isolation valves)7.2 Additional requirements for the supply of standard valves with modifiedendsThe requirements of the ITER Vacuum Handbook and this Appendix should alsoapply to valves with modified ends. In addition, the following requirements will applyto the modified parts only. 7.2.1 Materials7.2.1.1 GeneralAll vacuum facing materials for use in the manufacture of bellows should comply withthe requirements of the ITER Vacuum Handbook. In particular materials should betaken from the ITER Vacuum accepted materials list (ITER Vacuum HandbookAppendix 3) and be consistent with the outgassing requirements of the ITER VacuumHandbook. 7.2.1.2 Metallic Machined Components and FittingsAll VQC 1A components which are machined from steel, austenitic steel orsuperalloys and which are of final thickness less than 5 mm, should be made fromcross-forged material which is Electro-Slag Remelted (ESR) or Vacuum ArcRemelted (VAR). The use of plate is prohibited. Alternative processes for achievingthe required inclusion limits may be accepted if successfully validated. The rate of inclusions in such steels should be checked in accordance with ASTM E-45 Method D (or equivalent) to be within the following inclusion limits:¾ Inclusion Type A ” 1.0¾ Inclusion Type B ” 1.0¾ Inclusion Type C ” 1.0¾ Inclusion Type D ” 1.5Both halves of demountable flanges using metal seals are normally to bemanufactured from cross or upset forged material. Stainless steel knife-edge sealed flanges of any thickness for all vacuumclassifications should be manufactured from cross-forged ESR grade material blanks. All VQC 1A and 2A demountable vacuum flanges should be made from cross-forgedor upset forged material. 7.2.2 FabricationBefore assembly commences the supplier shall submit to ITER for acceptance thedocuments listed in Section 7.7Tools used during the manufacture of the valves must not contaminate the vacuumsurfaces. Cutting fluids need be accepted before use and will be water based, oilfree, non-halogenated, sulphur and phosphorus free. Those listed in Appendix 4 arePage 186 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 5 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG4accepted and, if chosen, should be specified in the quality plan and agreed inadvance. Cleaning operations need to be performed to a procedure accepted by ITER inaccordance with the ITER Vacuum Handbook Appendix 13. The use of chlorine andother halogen containing fluids (e.g. trichloroethylene) is strictly forbidden. All assemblies must be individually identified, packaged and shipped to the ITER sitein accordance with Section 22 of the ITER Vacuum Handbook. 7.2.2.1 WeldingThe qualification, production and testing of welds should be in accordance with theITER Vacuum Handbook Attachment 1. In particular:1. Before fabrication can commence the supplier should prepare foracceptance a weld plan. The weld plan is a drawing which crossreferences each welded joint to a supporting Weld Procedure Specification(WPS). 2. All welds should be qualified prior to manufacture. 3. 100% visual examination of production welds should be performed. 4. 100% volumetric examination of production welds should be performed,unless a method of pre-production proof sampling is accepted. 5. Dye-Penetrant examination of production welds is only permitted inaccordance with the ITER Vacuum Handbook. 7.3 Leak TestingPrior to shipping all valves should be subject to an acceptance vacuum leak test. Detailed leak testing procedures in accordance with the ITER Vacuum HandbookAppendix 12 should be submitted for acceptance. Helium leak testing should include the following steps:Valves for use on VQC1 systems should be baked and hot leak tested at 250°C asfollows:1. Valve body2. Across the valve seat. 3. Valve actuator bellows. 4. Internal pressure element. 5. Double bellows interspace. 6. VQC 1A double seal interspace. Immediately after bake-out, the same tests must be repeated at ambienttemperature. In both cases the acceptance leak rate shall be met with thebackground reading on the leak detector being at least one order of magnitude belowthe acceptance leak rate without electronic correction. In each case, the leak testPage 187 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 6 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG4procedure should include three operating cycles of the valve at each test temperaturebefore leak testing. Leak rates for valve assemblies (including double bellowsinterspace), and across the valve seat, should not exceed 1 x 10-10 Pam3s-1 at 250 °CValves for use on VQC 2 systems are subject to the same tests as VQC 1 with therequirement for temperature cycling waived. Leak rates for valve assemblies(including double bellows interspace), and across the valve seat, should not exceed1 x 10-10 Pam3s-1It is expected that valves for use on VQC 3 & 4 systems will be delivered to ITER asproprietary items and hence be delivered with a manufacturer’s certificate ofconformity confirming leak tightness. In this case, proprietary valves may besubjected only to an ambient temperature acceptance test at the ITER site prior toinstallation. Leak rates for proprietary valve assemblies (including double bellowsinterspace), and across the valve seat, should not exceed 1 x 10-10 Pam3s-1All leak tests and test facilities may be the subject of inspection by the ITER VacuumResponsible Officer or nominated representative and hence the ITER VacuumResponsible Officer must be notified as of the final timing of tests a minimum of 4weeks prior to the tests commencing. 7.4 MarkingEach valve should be individually marked with a unique identification which istraceable to the valve document package. The use of dyes, paints, pens and othersuch markers that transfer marking material into any window assembly surface mustnot be used for the marking of window assemblies. Scribing with a clean sharp pointand vibro-etching are acceptable marking processes. Each valve shall be marked with an arrow clearly identifying the seal face direction ofthe valve. 7.5 DocumentationValve data sheets are to be supplied for all valves. A suppliers’ certificate of conformity is required confirming that the valves suppliedconform to the valve data sheet as revised and accepted by ITER. Leak test reports and / or Certificates of Conformity must be supplied in accordancewith the relevant requirements of the ITER Vacuum Handbook. 7.6 Packaging & DeliveryThe packaging and delivery of valves to the ITER site should be in accordance withITER Vacuum Handbook. Valves should be entirely enclosed in heat sealed polyethylene and backfilled with asuitable dry gas. Nitrogen is preferred but other gasses may be accepted. All valveassemblies must be shipped dry internally and externally irrespective of finalacceptance testing at the manufacturer’s site. Page 188 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 7 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG4The use of adhesive tape for the protection and packaging of components must belimited to prevent the risk of contamination from the tape. In particular tape used onaustenitic stainless steel should meet leachable chloride and fluoride limits of 15 ppmand 10 ppm, respectively. Where used, tape should be fully removable withoutresidue, using isopropyl alcohol or acetone as the solvent if necessary. All valve assemblies should be transported in rigid packing cases or containers whichare lined with waterproof material. Components should be packed with adequateprotection from thermal and mechanical stresses which may adversely affect theoperation of the valves. All packing case joints should be sealed and cases markedwith individual valve specific identification. Handling instructions should also beclearly marked on the outer packaging. Any chemical or radiological hazards, etc.,must be identified on the packaging. All packaging markings should be in English andFrench and include the VQC of the valve. 7.6.1 Incoming inspection at ITER SiteIn addition to the inspection detailed in this Appendix, window assemblies will besubject to an incoming inspection on delivery to the ITER site. This will include, as aminimum, dimensional inspection for compliance with the technical specification andhelium leak testing in accordance with the ITER Vacuum Handbook Appendix 12. 7.7 DocumentationValve data sheets should be supplied for all valves. A suppliers’ certificate of conformity is required confirming that the valves suppliedconform to the valve data sheet as revised and accepted by ITER. Leak test reports and / or Certificates of Conformity must be supplied in accordancewith the relevant requirements of the ITER Vacuum Handbook. The following documents should be accepted before pre-manufacture activitiescommence:¾ Weld Plan¾ Quality Plan (including test plan /schedule)¾ Welding Procedures and Welder Qualifications¾ Dimensional DrawingsOn completion of manufacturing, two sets of the following documents should besupplied as data books:¾ Signed-off Quality Plan¾ Welding Procedures and Welder Qualifications¾ Radiographic Reports (if applicable)¾ Production Proof Sample Reports (if applicable)¾ Material Certificates, traceable to assemblies, in accordance with EN10204 2.2 ,3.1 or 3.2Page 189 of 382ITER_D_2EPFG4 v1.3ITER Vacuum Handbook: Appendix 7Revision: 1.3 Date: July 28th, 2009 Page 8 of 8ITER Vacuum Handbook Appendix 7 IDM Ref :ITER_D_2EPFG4¾ Dimensional drawings identifying welds¾ Test reports¾ Dimensional inspection reportPage 190 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 8 FlangesApproval ProcessName Action AffiliationAuthor Worth L. 08 Jan 2015:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewers Hughes S. 09 Jan 2015:recommended (FastTrack)IO/DG/COO/PED/FCED/VSPreviousVersionsReviewsQuinn E. 28 Jan 2014:recommended v2.3 IO/DG/COO/PED/FCED/VSApprover Pearce R. 12 Jan 2015:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2DJYQAVERSION CREATED ON / VERSION / STATUS08 Jan 2015 / 2.5 / ApprovedEXTERNAL REFERENCE / VERSIONPage 191 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 8 Flanges (2DJYQA)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 18 Jun 2009 New version states development of the appendix is requiredv2.0 Approved 03 Apr 2013 Details of demountable vacuum flange sets accepted for use on the ITERprojectv2.1 Signed 20 Nov 2013 Added section on demounting flanges in-situv2.2 RevisionRequired20 Nov 2013 Updated silver coating to silver jacket for helicoflex class 1 flange setv2.3 Approved 28 Jan 2014 Revision as requested with expanded table detailing accepted flange/sealcombinationsv2.4 Signed 08 Jan 2015 Removed reference to flange classv2.5 Approved 08 Jan 2015 Header correctedPage 192 of 382ITER Vacuum Handbook: Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 1 of 9Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER ITER Vacuum Vacuum Handbook HandbookAppendix Appendix 8Demountable Vacuum Flanges for use on the ITER ProjectPage 193 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 2 of 9ITER Vacuum Handbook Appendix 8Contents8.1 Terms and acronyms.38.2 Scope.38.3 Accepted Flange Set Combinations.38.3.1 Standard Flange Set Nominal Diameter.38.3.2 Type of Flange Set.48.3.3 Flange Mounting / Demounting.68.3.4 Seal Material Type.68.3.5 Clamping Arrangement.78.4 Flange Set Manufacture.78.4.1 COTS Flange Sets.78.4.2 ITER Style Flange Set.88.5 Reference.8Page 194 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 3 of 9ITER Vacuum Handbook Appendix 88.1 Terms and acronymsThe terms and acronyms detailed in Table 1 are used throughout this documentTerm / Acronym Contextual meaningAccepted Accepted by ITER Vacuum RO through submissionfor Request for Acceptance [1]. COTS Commercial Off The Shelf (item listed in a supplierscatalogue)Flange set Demountable vacuum joint and gasket sealFlange 1 half of demountable jointGasket seal Replaceable piece which forms the vacuumcontainmentMounting Joining of a flange pair & gasket to make the flangesetRO Responsible OfficerTable 1 Terms and acronyms8.2 ScopeThe scope of this appendix is to define the vacuum demountable flange sets accepted for use on the ITERVacuum SystemsFlange sets (demountable vacuum joint and specified seal arrangements) listed herein may be used, asspecified, without further approvalDemountable vacuum joints not detailed in this appendix shall only be utilised after acceptance by the ITERvacuum RO. Acceptance of a demountable vacuum joint / seal combination not listed herein will requirequalification of the flange set. Qualification of a flange set shall be performed to an accepted procedureIn the case of the ITER style flanges the information included herein shall only be used for information. Finalised drawings, and gasket seal part numbers, will be made available on completion of the qualificationprocess8.3 Accepted Flange Set Combinations8.3.1 Standard Flange Set Nominal DiameterThe flange set nominal diameters used shall comply with Table 2DN10DN16DN25 DN40 DN50 DN63 DN100 DN150 DN200 DN250 DN300CF* ISO -KFISO-K VCR1 ITERStyle Accepted for use* CF sizes shall be in accordance with ISO 3669-2:20071 VCR from 6 to 25 mm (1/4 to 1 inch)Page 195 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 4 of 9ITER Vacuum Handbook Appendix 8Table 2 Flange SizePage 196 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th, 2015 Page 5 of 9ITER Vacuum Handbook Appendix 8 IDM Ref :ITER_D_2DJYQA8.3.2 Type of Flange SetThe type of flange set and seal combinations shall comply with Table 3VacuumClassification(VQC)Behind anAcceptedIsolatingValve(Y/N)1FlangeSetDouble SealRequired(Yes = Y / No= N /R = recommend)Range ofsize (DN)1st(Vacuum) Seal Material 2nd(Atmosphere) Seal Material1 N ITERStyleY 63 - 300 Metallic – Silver jacketed Helicoflex [2]Metallic – Silver jacketed Helicoflex [2]1 Y ITERStyleR 63 - 300 Metallic – Silver jacketed Helicoflex [2] Metallic – Silver jacketed Helicoflex [2]1 Y ISO-CF N 16 - 2502Silver coated copper gasket N/A1 Y ISO-K N 63 – 100 Aluminium edge type Table 5 [3] N/A1 Y ISO-KF N 16 - 63 Aluminium edge type Table 5 [3] N/A1 Y VCR [4] N ¼ -1 inch Silver coated gasket in carrier Table 4 N/A2 N/A ITERStyleY 63 - 300 Metallic – Silver jacketed Helicoflex [2]Metallic – Silver jacketed Helicoflex [2]2 N/A ITERStyleY 63 - 300 Metallic – Silver jacketed Helicoflex [2]Seal material from Table 62 N/A ISO-CF N 16 - 2502Silver coated copper gasket N/A2 N/A ISO-K N 63 – 100 Aluminium edge type Table 5 [3] N/A2 N/A ISO-KF N 16 - 63 Aluminium edge type Table 5 [3] N/A2 N/A VCR [4] N ¼ -1 inch Silver coated gasket in carrier Table 4 N/APage 197 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th, 2015 Page 6 of 9ITER Vacuum Handbook Appendix 8 IDM Ref :ITER_D_2DJYQA3 N/A ITERStyleY 63 - 300 Metallic – Silver jacketed Helicoflex [2]N/A3 N/A ITERStyleY 63 - 300 Metallic – Silver jacketed Helicoflex [2]N/A3 N/A ISO-CF N 16 - 2502Silver coated copper gasket N/A3 N/A ISO-K N 63 – 100 Aluminium edge type Table 5 [3] N/A3 N/A ISO-KF N 16 - 63 Aluminium edge type Table 5 [3] N/A3 N/A VCR [4] N ¼ -1 inch Silver coated gasket in carrier Table 4 N/A4 Y ISO-CF N 16 - 2502Silver coated copper gasket N/A4 Y ISO-K N 63 – 100 Aluminium edge type Table 5 [3] N/A4 Y ISO-KF N 16 - 63 Aluminium edge type Table 5 [3] N/A4 Y VCR [4] N ¼ -1 inch Silver coated gasket in carrier Table 4 N/A4 N/A ISO-K N 63 - 400 Table 6 N/A4 N/A ISO-KF N 16 - 63 Table 6 N/A1Isolates system from main VV2See section 8.4.1 for CF flange restrictionsTable 3 Accepted flange set and seal combinationPage 198 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 7 of 9ITER Vacuum Handbook Appendix 8 IDMRef :ITER_D_2DJYQA8.3.3 Flange Mounting / Demounting8.3.3.1 Design of Vacuum Flanged SystemsThe design of VQC 1 systems utilizing flanges shall be such that the system, or components of the system,can be removed from the area of service through the demounting of ITER style flange set (Table 3)8.3.3.2 Flange DemountingWhere there is a requirement to breach a VQC 1 boundary through the demounting of an accepted vacuumflange (Table 3) the breach shall only be made at an ITER style flange setIt is prohibited to demount VQC 1 flange sets other than ITER style in the area of service (e.g. in the portcell). The system, or components of the system, shall be transported to a suitably contamination controlledarea (e.g. the hot cell) prior to the demounting of a VQC 1 flange set other than ITER style8.3.3.3 Vacuum Testing100 % of vacuum flange sets shall be helium leak tested to ensure the vacuum performance of the flange setis compliant with its VQCWhere a system or component of a system has been removed from the area of service VQC 1 flange otherthan ITER style shall be helium leak tested prior to the system / component installation in the area of serviceITER style flange sets shall be helium leak tested on mounting8.3.4 Seal Material Type8.3.4.1 Metallic Seal Combinations8.3.4.1.1 ITER Style FlangesITER style flanges have been qualified with specific gasket seals. The manufacturer’s part number of sealsto be used with ITER style flanges is detailed on the manufacturing drawings (Table 8). The use of gasketseals other than those with part numbers compliant with the manufacturing drawings is prohibited unlessaccepted by the ITER Vacuum RO8.3.4.1.2 VCRVCR is a trade name of Swagelok. VCR flange sets shall utilise silver coated stainless steel gaskets with theSwagelok part numbers as listed in Table 4. VCR (inch) Product description (part number)[4]1/4316 SS VCR Face Seal Fitting, 1/4 in. Silver-PlatedGasket Retainer (SS-4-VCR-2-GR)1/2316 SS VCR Face Seal Fitting, 1/2 in. Silver-PlatedGasket Retainer Assembly (SS-8-VCR-2-GR)3/4316 SS VCR Face Seal Fitting, 3/4 in. Silver-PlatedGasket Retainer (SS-12-VCR-2-GR)1316 SS VCR Face Seal Fitting, 1 in. Silver-PlatedGasket Retainer (SS-16-VCR-2-GR)Table 4 VCR gasket product description and manufacturers part number8.3.4.1.3 CFCF type flange sets shall utilise silver coated high-purity, oxygen-free (OFHC) copper gaskets8.3.4.1.4 Aluminium Edge TypePage 199 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 8 of 9ITER Vacuum Handbook Appendix 8 IDMRef :ITER_D_2DJYQAAluminium edge type seals shall be utilised for ISO – K and ISO - KF flange setsFor reference a manufacturers part number of aluminium edge type gasket seals are provided in Table 5Manufacturers Part Number[3]Nominal Diameter (DN)ISO - K ISO - KF16 34.016001.142.116-iz125 34.016001.142.125-iz140 34.040001.142.140-iz150 34.050001.142.150-iz163 34.063001.342.10634.063001.142.163-iz180 34.080001.342.108100 34.100001.342.110Table 5 EVAC Al edge type gasket seal part numbers8.3.4.2 Non-metallic SealsNon-metal seal gasket material shall be chosen from Table 6. The seal gasket material chosen shall becompatible with the area of service. The radiation environment that the seal shall operate is defined in theITER Environmental Conditions Room Book [5]Material Temperature limit (@C)Maximum allowableaccumulated lifetimedose1 MeV equivalent(Gray)Viton 150 1 x 103EPDM (Ethylene-propylene)120 5 x 105Nitrile rubber (Buna – N) 80 1 x 104Table 6 Seal material temperature and radiation limits8.3.5 Clamping ArrangementThe flange set clamping arrangement utilised shall comply with Table 7Flange set Clamping Arrangement Flange OptionITER Style Bolt ring Fixed, rotatableConFlat Bolt arrangement Fixed, rotatableISO - KFISO - KChain clamp, ISO-K cold steeldouble clampN/ATable 7 Flange clamping arrangement8.4 Flange Set Manufacture8.4.1 COTS Flange SetsCF, VCR ISO-K and ISO-KF flange sets are commercially available items readily available in all parties’countries. It is recommended that these items be purchased from companies supplying vacuum equipmentPage 200 of 382ITER Vacuum Handbook : Appendix 8Revision: 2.5 Date: January 7th , 2015 Page 9 of 9ITER Vacuum Handbook Appendix 8 IDMRef :ITER_D_2DJYQAas part of their core business. The use of flange sets which are not purchased from a company supplyingvacuum equipment as part of its core business shall only be by prior AcceptanceTo ensure compatibility between flanges (knife edge dimensions etc.) manufacturers of CF > DN 150 shallbe accepted by the ITER Vacuum RO8.4.2 ITER Style Flange SetITER style flanges shall be manufactured according to the requirements of this Appendix and following therequirements of the ITER Vacuum Handbook8.4.2.1 Manufacturing DrawingsITER Style flanges shall be manufactured in accordance with the drawings listed in Table 8DN Drawing Reference163 ITER_D_BFGFDN v1.0100 ITER_D_BLZJ8N v1.0150 ITER_D_BLZK9E v1.0200 ITER_D_BM3LDD v1.0250 ITER_D_BM3ZRG v1.0300 ITER_D_BM43TL v1.01ITER style flange drawings issued at V1.0 are for information only. After the completion of the qualificationprogram drawings will be up-issued to version 2.0 and shall be used for manufactureTable 8 ITER Style flange drawing reference8.5 Reference[1] Request for Acceptance (ITER_D_9AY4HD v1.0). [2] http://www.techneticsgroup.com/products/sealing-solutions/metal-seals/helicoflex/[3] www.NEYCO.Fr[4] http://www.swagelok.com/products/fittings/vcr-metal-gasket-face-seal.aspx[5] Environmental Conditions Room Book (ITER_D_2UUZ23)[6] ITER Vacuum Handbook (ITER_D_2EZ9UM)Page 201 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMBaseline Report (not under Configuration Control)Appendix 9 BellowsThis Appendix is written as a guide for the manufacture and supply of vacuum bellows andflexibles for use on ITER vacuum systems. It is intended that the suppliers of vacuumbellows and flexibles should follow the guidance in this Appendix to achieve therequirements of the ITER Vacuum HandbookApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2E5LJAVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.3 / ApprovedEXTERNAL REFERENCE / VERSIONPage 202 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 9 Bellows (2E5LJA)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 12 Jan 2009v1.3 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 203 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 1 of 10Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 9Guide to the Supply of Bellows for use on ITERVacuum SystemsPage 204 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 2 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA9 Guide to the Supply of Double Wall Vacuum Bellows & flexibles for use on ITERVacuum Systems.39.1 Scope.39.2 General.39.3 Design of bellows.39.4 Materials.49.4.1 General.49.4.2 Metallic Machined Components and Fittings.49.5 Manufacture.49.5.1 General.49.5.2 Welding of bellows assemblies.49.6 Qualification of Bellows (type testing).59.6.1 Pressure testing.59.6.2 Mechanical shock testing.59.6.3 Fatigue life tests.69.6.4 Leak Testing.69.7 Testing and Inspection of Bellows.79.7.1 Dimensional inspection.79.8 Cleaning.79.8.1 Procedure for Bellows for Class VQC 1 use.79.9 Proprietary bellows.89.10 Bellows Protection.89.11 Marking.89.12 Packaging & delivery.89.13 Documentation.9Page 205 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 3 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA9 Guide to the Supply of Double Wall Vacuum Bellows for use on ITERVacuum Systems9.1 ScopeThis Appendix is written as a guide for the manufacture and supply of vacuum bellows andflexibles for use on ITER vacuum systems. It is intended that the suppliers of vacuumbellows and flexibles should follow the guidance in this Appendix to achieve therequirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendix providedthat the components manufactured comply with the requirements of the ITER VacuumHandbook. “Supply” includes the design, manufacture, testing and delivery of bellows and flexibles asdescribed in the specifications9.2 GeneralBellows are considered as inherently vulnerable components due to their method ofconstruction and because they are designed to facilitate movement. Circular bellows are to be designed to the Expansion Joint Manufacturers Association(EJMA) code or to another accepted design code. Where design codes do not apply,design shall be by analysis and proven by testing. Care shall be taken to ensure that the operational loading parameters are fully consideredincluding all design loads and combinations. Precautions need to be taken against ruptureand other failure modes where there is a pressure difference in either direction betweenthe inner and outer surfaces of the unit. In all test situations and after installation, the bellows should be protected against allabnormal load conditions. 9.3 Design of bellowsAll bellows for use on VQC 1 and 2 systems should be of double wall construction unlessthey are accessible for maintenance and fitted behind an accepted, interlocked, isolatingvalve. For VQC 1A bellows separating torus vacuum from air, double wall bellows are amandatory safety design requirement as specified in the ITER Vacuum HAndbook. ForVQC 2A where regular and significant movement is to be compensated by a bellows thatis not required to be double walled by safety rules, the use of double wall bellows is to bedetermined by considerations of reliability, maintainability, maintainability and ALARA. Bellows which are of edge-welded construction shall be accepted provided that theycomply with the ITER Vacuum Handbook Section 7.1. The interspace between the two walls of the bellows assembly will normally be filled with asuitable tracer gas and the pressure in the interspace will be monitored continuously. Theinterspace will be connected to the Service Vacuum System in accordance with the ITERVacuum Handbook Section 11. Page 206 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 4 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA9.4 Materials9.4.1 GeneralAll vacuum facing materials for use in the manufacture of bellows should comply with therequirements of the ITER Vacuum Handbook. In particular materials should be selectedfrom the ITER Vacuum Accepepted Materials list (ITER Vacuum Handbook Appendix 3)and be consistent with the outgassing requirements of the ITER Vacuum Handbooksection 5.4. 9.4.2 Metallic Machined Components and FittingsAll VQC 1A components which are machined from steel, austenitic steel or superalloysand which are of final thickness less than 5 mm, should be made from cross-forgedmaterial which is Electro-Slag Remelted (ESR) or Vacuum Arc Remelted (VAR) inaccordance with the ITER Vacuum Handbook. The use of plate is prohibited. Alternativeprocesses for achieving the required inclusion limits may be accepted if successfullyvalidated. The rate of inclusions in such steels should be checked in accordance with ASTM E-45Method D (or equivalent) to be within the following inclusion limits:¾ Inclusion Type A ” 1.0¾ Inclusion Type B ” 1.0¾ Inclusion Type C ” 1.0¾ Inclusion Type D ” 1.5Both halves of demountable flanges using metal seals are to be manufactured from crossor upset forged material. Stainless steel knife-edge sealed flanges of any thickness for all vacuum classificationsshould be manufactured from cross-forged ESR grade material blanks. All VQC 1A and 2A demountable vacuum flanges shall be made from cross-forged upsetforged material. 9.5 Manufacture9.5.1 GeneralHydrostatic, rolling or elastomeric formation of bellows is accepted for all vacuum classesNon circular bellows of non edge welded construction are to be welded then formed ratherthat formed in parts then joined. Cross welds are to be avoided. This does not necessarilyapply to the post-forming welding of bellows sections to collars where these are required. Bellows which are of edge-welded construction may be accepted provided that theycomply with the requirements of the ITER Vacuum Handbook Section 7.1. 9.5.2 Welding of bellows assembliesThe qualification, production and testing of welds should be in accordance with theVacuum Handbook Attachment 1. In particular:Page 207 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 5 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA1. Before fabrication can commence the supplier should prepare for approval aweld plan in accordance with the Vacuum Handbook Attachment 1. The weldplan is a drawing which cross references each welded joint to a supportingWeld Procedure Specification (WPS). 2. Welding procedures and the Procedure Qualification Records are to be qualifiedin accordance with Attachment 1. 3. 100% visual examination of production welds should be performed. 4. 100% volumetric examination of production welds should be performed, unlessa method of pre-production proof sampling is accepted. 5. Dye-Penetrant examination of production welds is only permitted in accordancewith the ITER Vacuum Handbook. 9.6 Qualification of Bellows (type testing)Prior to the manufacture of bellows assemblies the manufacturer should qualify thebellows design. The supplier should submit for acceptance a qualification plan (as part ofthe quality plan) detailing the tests to be performed on bellows assemblies. After thecompletion of all manufacturing processes the bellows assemblies should undergo thefollowing qualification tests. ¾ Pressure test¾ Mechanical shock test¾ Fatigue life test¾ Helium leak test¾ ITER-specific tests as prescribed in the procurement specification documentationIn each case, the method of testing should be accepted before manufacture begins.. 9.6.1 Pressure testingPrior to leak testing it should be demonstrated that with the bellows assemblies displacedaxially and radially to the maximum design values, and subjected to a 0.2 MPa pressuredifferential applied internally or externally to the assembly, that the bellows can surviveand remain unaltered when the bellows interspace is at the following pressures¾ < 10-3 MPa (evacuated interspace)¾ 0.05 MPa (interspace normal operation)¾ 0.2 MPa (Interspace over pressure)In all cases pressure testing should be followed by leak testing. 9.6.2 Mechanical shock testingType testing of the bellows assemblies should show no failures at 15 g acceleration after1000 cycles under the conditions specified in 9.6.1Page 208 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 6 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA9.6.3 Fatigue life testsThe supplier should demonstrate that the bellows assemblies will remain mechanicallyunaltered over the expected life of the ITER machine. Fatigue life tests should beperformed under load conditions similar to the ITER loading conditions. 9.6.4 Leak TestingThe supplier should perform leak testing of the bellows assemblies in accordance with theITER Vacuum Handbook. Guides to helium leak testing can be found in the ITER VacuumHandbook Appendix 12. Bellows assemblies for use on VQC1 systems should be baked and hot leak tested at themaximum operating temperature as follows:¾ Global test of bellows assembly¾ Leak test of bellows interspace (to vacuum and to atmosphere)¾ Leak test of water cooling circuits (if applicable)VQC 1A or VQC 3A components which include joints of dissimilar materials should besubjected to a minimum of three thermal cycles from ambient to the maximum possibleoperating temperature prior to leak testing. Normally, the time taken for any component toreach the specified bake temperature from ambient should be less than 100 hours. Immediately after bake-out, the above tests should be repeated at ambient temperature. Inboth cases, the acceptance leak rate should be met with the background reading on theleak detector being at least one order of magnitude below the acceptance leak rate withoutelectronic correction. In each case, the leak test procedure should include three operatingcycles of the bellows assembly at each test temperature before leak testing. Bellows for use on systems with VQC 2, & 4 should be subjected to the same leak testingrequirements as for VQC 1 & 3, but there is no requirement to test at temperatures aboveambient. Leak rates for bellows assemblies are summarised in Table 9-1. Acceptance Leak Rate (Pa.m3.s-1 air equivalent) at maximumoperating temperatureVQC1 2 3 4Global leakrate1 x 10-10 1 x 10-9 1 x 10-9 1 x 10-7Bellows interspaceto atmosphere1 x 10-10 1 x 10-9 1 x 10-9 1 x 10-7Bellows interspaceto vacuum1 x 10-10Page 209 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 7 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJACooling channels (ifapplicable)1 x 10-10Table 9-1 Maximum acceptance leak rates for bellows assemblies9.7 Testing and Inspection of BellowsPrior to the manufacture of bellows assemblies the supplier should provide for acceptancea test plan and test procedures detailing the tests to be performed on bellows assembliesbefore delivery to the ITER site. After the completion of all manufacturing processes and before delivery to the ITER sitethe bellows assemblies should undergo a vacuum baking cycle to their operatingtemperature and the following tests should then be carried out9.7.1 Leak testingThe bellows should be subject to helium leak testing in accordance with 9.6.4. 9.7.2 Dimensional inspectionThe supplier shall perform a survey of the bellows convolutions to confirm compliance withthe bellows technical specification. The survey results will be supplied to ITER and anynon-conformance may lead to rejection of the bellows. 9.8 CleaningGreat care has to be exercised when cleaning thin walled metal bellows, particularly thoseof edge-welded, nested construction. If any cleaning residues are trapped between theconvolutions, either inside or outside, these can result in corrosion which can rapidly causeleaks to develop. Similarly, if any particulates are deposited in the convolutions,mechanical puncturing can take place. Alkaline degreasing solutions such as Almeco areprone to particulate precipitation and therefore must not be used for bellows assemblies. 9.8.1 Procedure for Bellows for Class VQC 1 useThe bellows should be fixed in an extended position if at all possible. 1. Any traces of visible, loose contamination should be removed with a gentle jetof clean, dry air or nitrogen. 2. The bellows should be immersed in an ultrasonically agitated bath of isopropylalcohol (IPA) or ethyl alcohol (ethanol). 3. The bellows should be vapour washed immediately in vapour of the samesolvent. 4. The bellows, including the interspace where appropriate, should be thoroughlydried inside and out using a gentle jet of clean, dry, particulate free air ornitrogen. 5. The bellows should be placed in a dry air oven at 100 oC for at least 1 hour withthe interspace vented and open to atmosphere. Page 210 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 8 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJA6. The bellows should be baked in a clean vacuum oven at a pressure <10-4 Pa for24 hours at 250 oC with the bellows interspace pumped or open to the vacuumenvironment of the oven. 7. The bellows should be sealed under dry nitrogen in a polyethylene bag. This procedure can be used for bellows used on VQC 2, 3 & 4 systems with thevacuum bake requirement waived. 9.9 Proprietary bellowsProprietary bellows fully meeting the ITER specification of the item and the requirementsof each VQC may be allowable. For VQC 1, 2 and 3, proprietary bellows should be supplied with an individual certificate ofconformity, stating that the item is suitable for the design, operation and test conditions asstipulated in the technical specification,. For VQC 4, proprietary bellows should be supplied with a certificate of conformity asabove, but this may be in the form of generic or type conformance certificates to thecatalogue specification. 9.10 Bellows ProtectionNormally accessible bellows assemblies and bellows assemblies which becomeaccessible during machine maintenance should be supplied with mechanical protection(such as the use of metal braiding or removable cover plates) to prevent accidentaldamage and ingress of matter to the bellows convolutions. 9.11 MarkingSurfaces which are to be exposed to vacuum should only be marked or identified ifabsolutely necessary, and should be marked by scribing with a clean sharp point. Sealfaces should not be used. Chemical etching is an acceptable alternative for all VQC exceptVQC 1Dyes, marker pens, paints, etc. should not be used on surfaces which will be exposed tovacuum. Furthermore, their use should be avoided on other surfaces to eliminate thepotential for cross-contamination during subsequent cleaning operations. The use of suchsubstances may block porosity in material and result in leaks which are initiallyundetectable but may open up after some time. 9.12 Packaging & deliveryWhere practical, bellows assemblies should be entirely enclosed in heat sealedpolyethylene and backfilled with a suitable dry gas. Bellows interspaces should bebackfilled to 0.1 MPa with the connections sealed by a closed valve. Nitrogen is preferredbut other gasses may be accepted. All bellows assemblies must be shipped dry internallyand externally irrespective of final acceptance testing at the manufacturer’s site. The use of adhesive tape for the protection and packaging of components should belimited to prevent the risk of contamination from the tape. In particular tape used onPage 211 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 9 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJAaustenitic stainless steel shall meet leachable chloride and fluoride limits of 15 ppm and 10ppm, respectively. Where used tape must be fully removable, without residue, usingisopropyl alcohol or acetone as the solventWhere practical all bellows assemblies should be transported in rigid packing cases orcontainers which are lined with waterproof material. Components should be packed withadequate protection from thermal and mechanical stresses (particularly shock loadsresulting from dropping and mal-handling) which may adversely affect the operation of thebellows. All packing case joints should be sealed and cases marked with bellows specificidentification. Handling instructions should also be clearly marked on the outside of thepackaging. Any chemical or radiological hazards, etc., must be identified on the packaging. All packaging markings should be in English and French and should include the VQC ofthe bellows. 9.13 Incoming inspection at ITER SiteIn addition to the inspection detailed in this Appendix, bellows assemblies will be subject toan incoming inspection on delivery to the ITER site. This will include, as a minimum,dimensional inspection for compliance with the technical specification and helium leaktesting in accordance with the ITER Vacuum Handbook Appendix 12. 9.14 DocumentationThe following documents should be accepted before pre-manufacture activitiescommence:¾ Weld Plan¾ Quality Plan (including test plan /schedule)¾ Welding Procedures and Welder Qualifications¾ Dimensional DrawingsThe following documents should be accepted before manufacture commences:¾ Type testing reportOn completion of manufacturing, two sets of the following documents should be suppliedas data books:¾ Signed-off Quality Plan¾ Welding Procedures and Welder Qualifications¾ Radiographic Reports (if applicable)¾ Production Proof Sample Reports (if applicable)¾ Material Certificates, traceable to assemblies, in accordance with EN 102042.2, 3.1 or 3.2¾ Dimensional drawings identifying welds¾ Type testing report¾ Dimensional inspection reportPage 212 of 382ITER_D_2E5LJA v1.3ITER Vacuum Handbook: Appendix 9Revision: 1.3 Date: July 28th, 2009 Page 10 of 10ITER Vacuum Handbook Appendix 9 IDM Ref :ITER_D2E5LJAPage 213 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 10 Vacuum CablesApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2ETNLMVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 214 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 10 Vacuum Cables (2ETNLM)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 Signed 12 Jan 2009v1.2 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 215 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 1 of 6Name AffiliationAuthor/Editor B Boussier Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 10Guide to the Supply of in-Vacuum Cables for the ITER ProjectPage 216 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 2 of 6ITER Vacuum Handbook Appendix 10 IDM Ref :ITER_D_2ETNLM10 Requirements for the Supply of In-Vacuum Cables for the ITER project.. 310.1 Scope of this Appendix.. 310.2 General.. 310.3 Mineral Insulated cable (MI).. 410.4 Metal braided fibre insulated cable.. 410.5 Other cables.. 510.6 Connectors and Terminations.. 510.7 Cable Routing.. 610.8 References.. 6Page 217 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 3 of 6ITER Vacuum Handbook Appendix 10 IDM Ref :ITER_D_2ETNLM10 Requirements for the Supply of In-Vacuum Cables for theITER project10.1 Scope of this AppendixThe ITER project will include up to 80 km of in-vacuum cabling. This Appendixprovides information on the various accepted forms of cabling for use on the ITERproject for each Vacuum Quality Class, as well as general guidelines for their use. It is intended that the suppliers of in-vacuum cables should follow the guidance in thisAppendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components manufactured comply with the requirements of the ITERVacuum Handbook. 10.2 GeneralIn-vacuum cabling should comply with all the general vacuum requirements for itsVacuum Quality Class (VQC). Accepted cable types for each VQC are listed in Table10-1. Use of cable insulation containing halogens is strictly forbidden for all VQC. Fluoropolymer (Teflon, Tefzel, PTFE, PFA, FEP, ETFE,etc…), PVC and Fluorosiliconesheathed cables are therefore completely forbidden. Table 10-1 - Accepted vacuum cablingVacuum Quality ClassCable typeVQC1 VQC2 VQC3 VQC4Single Core Coaxial Solid Sleeved Mineral InsulatedCable (MI cable)33333333333Multi-core Coaxial Solid Sleeved Mineral InsulatedCable (MI cable)† 3333 33Tri-axial Mineral Insulated cable † 3333 33Metal braided Fibre insulated cable † 33 † 33Ceramic coated wire 3 3333 33Bare wire / Non insulated cablewith ceramic breads or spacers† † † †Optical fibreCeramic / metal coating33333333333Polyamide, Kapton® coated cable* 22 33 22 33Epoxy / resin insulated cable* 2 † 2 †Nylon sheathed/braided* 2 † 2 3Silicon rubber insulated wire (Fluor free)* 2 2 2 2Page 218 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 4 of 6ITER Vacuum Handbook Appendix 10 IDM Ref :ITER_D_2ETNLMPolyurethane, Polyethylene, Polypropylene,Polyester, Plastic *2 2 2 23 Cable accepted for use2 Cable prohibited from use* restriction on bakingtemperature to be considered† Restricted use conditions applyAny other cabling type and changes to Table Table 10-1 is subject to acceptanceprocedures as detailed in the ITER Vacuum HandbookSilver plated conductors should be avoided in VQC 1. 10.3 Mineral Insulated cable (MI)The procurement specifications and manufacturing control plan needs to be tightlycontrolled and should be submitted for acceptance before tender in order to mitigatethe potential of cabling adversely affecting the ITER vacuum. The procedures should include:¾ A high standard of cleaning for vacuum and of the handling of the constituentparts of the cable. ¾ Method of packing the insulant (A high and defined packing density of insulateso as to limit the void fraction ideally to <5 % this may be achieved by usingpreformed solid insulate rather than powder and specifying a hammeringoperation after each drawing operation during manufacture). In addition:¾ Cables need to be sealed and vacuum leak tested by helium “bombing”, prior toinstallation. A He leak rate of <10-10 Pa.m3/s shall be achieved. ¾ Cables should be proven to achieve outgassing rates of lower than10-9 Pa.m3/s/m for hydrogen and 10-11 Pam3/s/m for other species at 100oC(after a 48 hour 200ºC bakeout cycle for cables of <5mm diameter). ¾ The use of tri-axial MI cable will be limited and subject to specific acceptance. ¾ The use of multi-core cable will be limited and subject to specific acceptance. 10.4 Metal braided fibre insulated cableThe use of metal braided ceramic fibre insulated cable is to be limited in VQC 1 and 3systems and MI cable will be preferred for use whenever possible. Any proposed userequires specific acceptance by the ITER Vacuum Responsible Officer at the designstage. If such cable is accepted for use, the procurement specification and manufacturingcontrol plan should be submitted for acceptance by the ITER Vacuum ResponsibleOfficer. This plan should ensure that manufacturing processes are tightly controlled toensure low vacuum outgassing and should include:¾ Cleaning and air bakeout of the constituent parts of the cable prior to assembly. ¾ Vacuum outgassing testing of the constituent parts of the cable prior toassembly. Page 219 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 5 of 6ITER Vacuum Handbook Appendix 10 IDM Ref :ITER_D_2ETNLM¾ Control of cleanliness in assembly, in particular the use of dedicated drymachines. ¾ A high vacuum standard of handling component parts of the cable. In addition:¾ Cables should be proven to achieve outgassing rates of lower than10-9 Pa.m3/s/m for hydrogen and 10-11 Pam3/s/m for other species at 100o C(tested after a 48 hour 200ºC bake out cycle for cables of <5mm diameter). ¾ Possible nuclear heating of this type cable should be considered and specialcare shall be taken to avoid any detrimental effects on vacuum. 10.5 Other cablesAny cable used on VQC 1, 2 and 3 will be subjected to an acceptance criteria and to adetailed control plan. A high standard of cleaning for vacuum and of handling needs tobe applied. An outgassing test should be performed prior to acceptance. In addition toinitial vacuum compatibility of the cable, fire hazard and radiation resistance need tobe considered. ¾ There is no limitation for Bare Wire with ceramic insulator spacers from avacuum point of view if the cable is manufactured from accepted materials andif the appropriate cleanliness for its VQC has been achieved. From a practicalpoint of view, it is advisable to limit their use to short distance cabling (less than1m) and to detector internals. ¾ Polyimide and Kapton® coated cables are accepted for use on VQC 2 and 4,and are possible alternatives to MI or Fibre insulated cable for these VQC. PEEK outer weaving is accepted for cable bundles if required, but metallicwoven sheaths are preferred. ¾ Any non-listed cable should undergo qualification tests prior to acceptance. Tests should, at the minimum, include a vacuum outgassing test over the wholeoperational temperature range, residual gas analysis and radiation aging tests. ¾ Silver plated conductors are strictly limited in VQC 1, 2 and 3. 10.6 Connectors and TerminationsAll Mineral Insulated cables should be of the vacuum-tight termination type (bothends), and should not be perforated. Leak tightness will be proven by helium“bombing” of the cable, followed by leak detection. A leak rate of <10-10 Pa.m3/s is tobe obtained. If the cables are part of a feedthrough assembly, the full feedthroughassembly should be leak tight to <10-10 Pa.m3/s. Cable terminations made after crossing a boundary for VQC 1 and VQC 2 systemsshould be within a suitable termination vacuum enclosure connected to the SVS. Thisspace can be within a feedthrough interspace and is to be connected to the SVS by 2connections (½ inch VCR™ couplings are envisaged). In-vacuum connectors should be designed for vacuum compatibility and are to complywith the general vacuum requirements for the relevant VQC. This includes, amongother factors: design, materials, manufacturing process, cleaning and outgassing. Page 220 of 382ITER_D_2ETNLM v1.2ITER Vacuum Handbook: Appendix 10Revision: 1.2 Date: July 28th , 2009 Page 6 of 6ITER Vacuum Handbook Appendix 10 IDM Ref :ITER_D_2ETNLM10.7 Cable RoutingIt is not permitted for cables to pass across a pressure boundary to atmosphere. The following considerations should also be taken into account when routing thecables. ¾ The routing scheme should offer good protection against damage to cables. Loops should be properly designed to permit adequate gas pumping, whilstprotecting the cables from external contamination. ¾ The routing should offer appropriate thermal contact of the cable with cooledcomponents to avoid any overheating of the cables that might affect vacuumperformance or cable integrity. ¾ Thermal expansion and contraction of cabling shall be considered in the design. ¾ High voltage cables and signal cables shall be separated where possible. 10.8 References[1] ITER D 22H4HUv1.0, FDR01-DDD18 31 Vacuum Pumping and Fuelling. [2] R.J.H. Pearce and Al. Fusion Engineering and Design 82 (2007) 1294–1300 –“ITER relevant outgassing and leakage from different types of in-vessel cabling”[3] G.Vayakis and Al., ITER IT, JAERI NAKA, N 55 RI 37 04-02-19 W 0.1[4] R. Pearce and Al., UKAEA, TW3-TPDS-DIADEV, ITER D222N5N[5] G 55 MD 32 98-06-02 F 1, “Table 2.4.1-2 - cable specifications”[6] G 55 MD 37 98-06-03 W 0.1, “Table 2.4.4-1 - cable for use in-vessel”[7] G 55 MD 5 96-12-11 W 0.1,DIAGNOSTIC ENGINEERING NOTE 19Page 221 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 11 Standard Pipe and Pipe Fitting DimensionsDimensions of standrad pipe and pipe fittings for use on ITER vacuum systems. Includesweld bevel for weld preparationApproval ProcessName Action AffiliationAuthor Worth L. 26 Jul 2017:signed IO/DG/COO/PED/FCED/VSCo-Authors Bansal G. 19 Jul 2017:signed IO/DG/COO/PED/FCED/VSReviewers Pearce R. Woods N. 31 Aug 2017:recommended31 Jul 2017:recommendedIO/DG/COO/PED/FCED/VSIO/DG/COO/PED/FEIDApprover Lee G.- S. 08 Sep 2017:approved IO/DG/COO#SecureIDM#RO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: EUROfusion-DEMO, AD: Auditors, AD: ITER ManagementAssessor, project administrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG:[CCS] JACOBS,IDM UID2E5PJKVERSION CREATED ON / VERSION / STATUS19 Jul 2017 / 3.0 / ApprovedEXTERNAL REFERENCE / VERSIONPage 222 of 382PDF generated on 08 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 11 Standard Pipe and Pipe Fitting Dimensions (2E5PJK)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v2.0 Approved 16 Jul 2015 Data loaded to documentv3.0 Approved 19 Jul 2017 Tables 4, 4-a & 4-b addedReference [4] addedText modified appropriatelyPage 223 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th , 2017 Page 1 of 9Name AffiliationAuthor/Editor Liam Worth PED/ VSCo-author Gourab Bansal PED/ VSVacuum Responsible Officer Robert Pearce PED/ VSReviewed by Nick Woods PED/ VSApproved by G S Lee IO/DG/COOITER Vacuum HandbookAppendix 11Standard Vacuum Pipe and Pipe Fitting Dimensions for the ITER ProjectPage 224 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th , 2017 Page 2 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJK11 IntroductionThe IO vacuum pipework systems are designed and constructed to the ASME B31.3(2010) designated for fluid cat. (M) and NF EN13480 codesPipe and pipefittings (tees, elbows etc.) for use on the IO vacuum systems shall meet thetechnical requirements as specified in the Technical Specifications [1]11.1 ScopeThe scope of this document is to detail the dimensions for standard pipe and pipefittings(tees, elbows etc.) for use on the IO vacuum systems and to define the weld preparation tobe used in fabrication of IO vacuum pipework systemsThe use of pipe and/or pipefittings with dimensions not listed in this document requiresacceptance [2]11.2 Dimensions11.2.1 Standard PipeStandard pipe dimensions for use on IO vacuum systems that comply with dimensions asspecified in [3] are synopsized in Tables 1, 2, 3. Standard pipe dimensions for use on IO vacuum systems that comply with dimensions asspecified in [4] are synopsized in Table 4 with “Outer Diameter Tolerances” and “WallThickness Tolerances” specified in Tables 4-a and 4-b11.2.2 Standard Pipe FittingsStandard pipe fittings (tees, elbows etc.), for pipe dimensions as specified in [3], for use onIO vacuum systems shall comply with dimensions as specified in [5]11.3 Weld PreparationThe dimensions weld bevels for pipe and pipe fittings shall comply with ASME B16.9 “PlainBevel” as described in Figure 1Page 225 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th , 2017 Page 3 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJKFigure 1 ASME B16.9 Plain bevelGeneral Notes:a. Dimensions in parenthesis are in inchesb. Other dimensions are in millimetresNote (1) See ASME B16.9 for transition contours11.4 Bibliography[1] Supply of Seamless Stainless Steel Pipework and Pipework Components to the ITERIO (ITER_D_R22L3M). [2] ITER Vacuum Handbook (ITER_D_2EZ9UM). [3] ASME B36.10M, 2004. [4] NF EN ISO 1127, 1996. [5] ASME B16.9M, 2012. Page 226 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 4 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJKTable 1 Pipe Dimensions Schedule 10sPermissible variation in wallthickness(% from nominal), mmPermissible variation in outerdiameter (mm)DN SchNominalWallthickness(mm)Over UnderOuterdiameter,(mm)Over Under16#152.11 (20.0), 0.42 (12.5), 0.26 21.30 0.4 0.840 2.77 (20.0), 0.55 (12.5), 0.35 48.30 0.4 0.863*653.6 3.05(20.0), 0.72(20.0), 0.61(12.5), 0.45(12.5), 0.3871.0673.000.8 0.8100 3.05 (22.5), 0.69 (12.5), 0.38 114.30 0.8 0.8160**1503.0 3.4(22.5), 0.67(22.5), 0.76(12.5), 0.37(12.5), 0.43159.00168.301.6 0.8200 3.76 (22.5), 0.85 (12.5), 0.47 219.10 1.6 0.8250 4.19 (22.5), 0.94 (12.5), 0.52 273.00 2.4 0.8300 4.57 (22.5), 1.02 (12.5), 0.57 323.80 2.4 0.832010sAs DN 300#Where specified in the design that DN 16 pipe is required the dimension of said pipe and/or fittings shall be that of DN15*Where specified in the design that DN 63 pipe is required the dimension of said pipe and/or fittings shall be that of DN65**Where specified in the design that DN 160 pipe is required the dimension of said and/or fittings pipe shall be that of DN150Page 227 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 5 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJKTable 2 Pipe Dimensions Schedule 20sPermissible variation in wallthickness(% from nominal), mmPermissible variation in outerdiameter (mm)DN SchNominalWallthickness(mm)Over UnderOuterdiameter,(mm)Over Under16#152.11 (20.0), 0.42 (12.5), 0.26 21.30 0.4 0.840 2.77 (20.0), 0.55 (12.5),0.35 48.30 0.4 0.863*653.05 (20.0), 0.61 (12.5), 0.3871.0673.000.8 0.8100 6.35 (15.0), (12.5), 114.30 0.8 0.8160**1506.35(22.5), 1.42(22.5), 1.42(12.5), 0.79(12.5), 0.79159.00168.301.6 0.8200 6.35 (22.5), 1.42 (12.5), 0.79 219.10 1.6 0.8250 6.35 (22.5), 1.42 (12.5), 0.79 273.00 2.4 0.8300 6.35 (22.5), 1.42 (12.5), 0.79 323.80 2.4 0.832020sAs DN 300# Where specified in the design that DN 16 pipe is required the dimension of said pipe and/or fittings shall be that of DN15* Where specified in the design that DN 63 pipe is required the dimension of said pipe and/or fittings shall be that of DN65Page 228 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 6 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJK** Where specified in the design that DN 160 pipe is required the dimension of said pipe and/or fittings shall be that of DN150Table 3 Pipe Dimensions Schedule 40sPermissible variation in wallthickness(% from nominal), mmPermissible variation in outerdiameter (mm)DN SchNominalWallthickness(mm)Over UnderOuterdiameter,(mm)Over Under16#152.769 21.30 0.4 0.840 3.68 (20), 0.74 (12.5), 0.46 48.30 0.4 0.863*653.6 5.16(20), 0.72(20), 1.03(12.5), 0.45(12.5), 0.6571.0673.000.8 0.8100 6.02 (15.0), 0.9 (12.5), 0.75 114.30 0.8 0.8160**1503.0 7.11(22.5), 0.67(22.5), 1.59(12.5), 0.37(12.5), 0.88159168.301.6 0.8200 8.18 (22.5), 1.84 (12.5), 1.02 219.10 1.6 0.8250 9.27 (22.5), 2.09 (12.5), 1.16 273.00 2.4 0.8300 10.31 (22.5), 2.32 (12.5), 1.29 323.80 2.4 0.832040sAs DN 300Where specified in the design that DN 16 pipe is required the dimension of said pipe and/or fittings shall be that of DN15Page 229 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 7 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJK*Where specified in the design that DN 63 pipe is required the dimension of said pipe and/or fittings shall be that of DN65**Where specified in the design that DN 160 pipe is required the dimension of said pipe and/or fittings shall be that of DN150Table 4 Pipe DimensionsWall Thickness (mm) Outside Diameter(mm)1.0 1.2 1.6 2.0 2.6 3.26YY----8YY----10YY----12 Y - Y Y - -14 Y - Y Y - -16YYYY--18 Y - Y Y - -20YYYY--22 Y - - Y - -25YYYYY-30 - - Y Y - -32 - Y - Y - -35 - Y - Y - -Page 230 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 8 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJK38-YYYYY40-YY-Y-Y indicates availabilityNOTE: Pipes of wall thickness less than 2.0 mm designed to contain cryogenic helium, Electro-Slag Remelted (ESR) or Vacuum Arc Remelted (VAR) material (or equivalentprocess demonstrated to achieve similar inclusion size and number) shall be used for the pre-extruded material with inclusion limits as specified in [2]Table 4-a Outer Diameter Tolerances applicable to Pipe Dimensions presented in Table 4Tolerance Class Tolerance on Outside DiameterD1 ±1.5% with ±0.75 mm minD2 ±1.0% with ±0.50 mm minD3 ±0.75% with ±0.30 mm minD4 ±0.5% with ±0.10 mm minTable 4-b Wall Thickness Tolerances applicable to Pipe Dimensions presented in Table 4Tolerance Class Tolerance on Wall ThicknessT1 ±15% with ±0.60 mm minT2 ±12.5% with ±0.40 mm minT3 ±10.0% with ±0.20 mm minT4 ±7.5% with ±0.15 mm minT5 ±5.0% with ±0.10 mm minPage 231 of 382ITER Vacuum Handbook: Appendix 11Revision: 3.0 Date: July 19th, 2017 Page 9 of 9ITER Vacuum Handbook Appendix 11 IDM Ref :ITER_D_2E5PJKPage 232 of 382PDF generated on 23 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 12 Leak TestingApproval ProcessName Action AffiliationAuthor Worth L. 16 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 16 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2EYZ5FVERSION CREATED ON / VERSION / STATUS16 Sep 2009 / 1.4 / ApprovedEXTERNAL REFERENCE / VERSIONPage 233 of 382PDF generated on 23 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 12 Leak Testing (2EYZ5F)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 22 Sep 2008v1.2 In Work 12 Jan 2009v1.3 Approved 18 Jun 2009 Changed approved to acceptedv1.4 Approved 16 Sep 2009 Maximum detectable leak rate changed from 0.1Mpa.m3.s-1 to 100Pa.m3.s-1Page 234 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 1 of 16Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 12Guide to Leak Testing of Components for the ITERProjectPage 235 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 2 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F12 Vacuum Leak Tightness and Testing.. 412.1 Scope and Status.. 412.2 General.. 412.3 Leak testing Methodologies.. 512.3.1 Over Pressure Methods.. 512.3.1.1 Mass Spectrometer Sniffing Probe.. 512.3.1.2 Probe leak testing (vacuum box or suction cup method).. 512.3.1.3 Pressurisation – evacuation (“bombing”) test.. 612.3.2 Vacuum Leak Detection Methods.. 612.3.2.1 Pressure Rise test.. 612.3.2.2 Helium Leak Detectors.. 612.4 Procedure for Helium Leak Tightness and Testing.. 712.4.1 Equipment.. 712.4.2 Pumping System.. 712.4.2.1 Detection System.. 812.4.2.2 Miscellaneous.. 912.4.3 Preliminaries.. 912.4.3.1 Initial Checks on the Leak Detection System.. 912.4.3.2 Pump-down.. 912.4.3.3 Background Determination.. 1012.4.4 Leak Detector Calibration.. 1012.4.4.1 Response and Cleanup Time Measurement.. 1012.4.5 Cold Leak Tests.. 1112.4.5.1 Global Leak Check.. 1112.4.5.2 Probe Tests.. 1212.4.5.3 Acceptance Criteria.. 1312.4.6 Hot Leak Check.. 1312.4.6.1 Test Conditions.. 1312.4.6.2 Global Leak Check with the Component under test Hot.. 1412.4.6.3 Probe Test.. 1412.4.6.4 Final Cold Acceptance Check.. 15Page 236 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 3 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F12.4.6.5 Acceptance Criteria.. 1512.5 Responsibilities.. 1512.6 Reporting.. 16Page 237 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 4 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F12 Vacuum Leak Tightness and Testing12.1 Scope and StatusAs an Appendix to the ITER Vacuum Handbook, the status of this document is advisoryand not mandatory on the supplier of any component. Nevertheless, it is stronglyadvised that the requirements of this document are adhered to for the supply of vacuumcomponents to ITER. Where it is not envisaged that leak tests will be performed at cryogenic temperatures onvacuum components which are for use on cryogenic systems, a method of “thermalshocking” of welded connections shall be agreed in advance. The supplier is responsible for all jigs, seals and equipment to allow the leak tightness tobe proven across all vacuum boundaries, unless otherwise stated in the contract. Wherepressure testing is required, this must always be performed prior to final vacuum leaktesting. Acceptance tests shall wherever possible use the same type of seal which shallbe used after installation of the component. The supplier is responsible for the supply of tooling and methodologies for thesubsequent removal of jigs, seals, temporary closure plates, etc., which have been fittedto components to facilitate the leak testing of such components. The leak test method shall be agreed in advance with ITER. This will involve thesubmission for approval of a procedure as part of an external supply contract. Theprocedure should describe how the leak test will be performed, and include configurationdiagrams and full details of the equipment to be used etc. The ITER Vacuum Responsible Officer (RO) will nominate a Vacuum Specialist towitness the acceptance leak tests and any other leak test deemed necessary as part ofa manufacturing process. Page 238 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 5 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5FIn no circumstance shall any vacuum equipment be installed without an accepted pre-installation leak check being performed at the ITER site, without the express permissionof the ITER Vacuum Responsible Officer. This applies to all Vacuum QualityClassifications. 12.3 Leak testing MethodologiesThis Appendix describes recommended procedures for carrying out the most widelyused methods of helium leak testing; it does not consider all available methods. Othermethods may be used, but only with the prior approval of the ITER Vacuum RO12.3.1 Over Pressure MethodsOver-pressure methods enable thin-walled vacuum chambers to be leak tested whichmight otherwise collapse under vacuum. This method is also useful when the equipmentto be tested is already filled with a gas which can be used as the test gas. However thetest gas which flows out through any leaks always mixes with contaminants present inthe air, and this might reduce sensitivity. 12.3.1.1 Mass Spectrometer Sniffing ProbeHelium, or some other suitable gas, is used to slightly pressurise the component to betested and a sampling probe “sniffs” for leaks. Helium passing through the leak issampled from the surrounding atmosphere through a long narrow flexible tube which isconnected to a mechanical pump to give a drop in pressure from atmosphere to about10-2 Pa at the ion source of a mass spectrometer detector. Traces of helium or halogenin the environment can also be detected, which may lead to errors in the measured leakrate. The helium content of atmospheric air limits the sensitivity of the sampling probe, andthe detection limit is typically ~1 x 10-7 Pam3s-1 if the volume is filled with pure helium (orthe tracer gas appropriate for the detector used such as argon). The sampling tube should be as short as possible to reduce the response time of thegas flow of the air-helium mixture from the entrance of the tube to the detector. The flowrate may also be limited by the available pumping throughput. 12.3.1.2 Probe Leak Testing (vacuum box or suction cup method)Open objects can be tested using the vacuum box or suction cup method. A partialenclosure which can be evacuated by a leak detector is tightly pressed against the wallof the component being tested. The enclosure is evacuated and helium tracer gasapplied to the opposite surface of the wall by a spray gun or other means. Heliumleaking through the wall can pass to the detector via the vacuum box. This method ofleak detection is widely used for the testing of welds on incomplete enclosures. Thesensitivity is usually limited by diffusion of helium through the seal between theevacuated enclosure and the component wall. Page 239 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 6 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F12.3.1.3 Pressurisation – Evacuation (“bombing”) TestHermetically sealed objects which cannot be pumped out can be leak tested using theso-called “bombing” method. The component to be tested is subjected to a highpressure of tracer gas, usually helium, to force gas into the component through anyleaks present. After flushing to remove adsorbed tracer gas from the surface of thecomponent, it is placed in a vacuum chamber which is connected to a leak detector. This can then detect any tracer gas passing out of the sealed volume through the leaks. This method is usually employed as a “go/no go” test since it is very difficult to locate theposition of any leaks on such components. 12.3.2 Vacuum Leak Detection Methods12.3.2.1 Pressure Rise TestA pressure rise test is a useful way of determining the overall magnitude of any leakspresent in a component. A vessel to be tested of volume V is evacuated and sealed off. The pressure rise ΔP ismeasured over a time interval Δt and the leak rate qL (at constant temperature) isevaluated from:tPV qLΔΔ⋅ =This calculated leak rate also includes contributions from any other gas sources such asvirtual leak and outgassing. Real leaks may be distinguished from other sources of pressure rise since a real leakgives a pressure rise which is strictly proportional to time, while virtual leaks andoutgassing result in an initially rapid pressure rise which tends to level off after sometime12.3.2.2 Helium Leak DetectorsThese are based on a mass spectrometer, usually a small magnetic sector device. Leakdetection can begin only when high vacuum conditions are obtained in the massspectrometer. Due to its high sensitivity this method is the most frequently used methodof leak detection for vacuum applications. The inlet pressure at the entrance to the leakdetector depends on the design of the unit, but can range from atmosphere down toabout 10-4 Pa. Helium is usually used as the tracer gas, but other gases such as argon, neon, krypton,hydrogen and mixed gases may be used with the mass analyser suitably tuned. Modernhelium leak detectors are usually supplied with the capability of detecting H2, He3, andHe4. To increase the helium detection sensitivity and improve detector stability, the massanalyser in helium leak detection systems is often de-tuned to give lower massresolution. This can lead to a contribution to the measured mass 4 intensity from mass 2Page 240 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 7 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5Fand mass 3, thus giving a higher leak detector background signal at mass 4. For largecomponent leak testing at high sensitivity, it may be necessary to reduce the partialpressure of hydrogen at the analyser by selectively pumping it with a getter in serieswith the leak detector input. It may also be necessary to selectively pump condensablegasses at the leak detector inlet. This can be achieved by the addition of a cold (e.g. liquid nitrogen) trap in series with the inlet. 12.4 Procedure for Helium Leak Tightness and Testing12.4.1 EquipmentPirani+ PenningGaugeG1Vessel or SystemUnder TestV1V2V3V4LeakDetectorTurbo-Molecular PumpRoughing PumpStandard LeakPirani+PenningGaugeG2PiraniGaugeFigure 12-1 Typical Leak Detection Equipment12.4.2 Pumping SystemAn indication of the basic elements of a pumping system, which could be used for leakdetection, is illustrated in Figure 12-1. In this form it consists of the following items: -1. A turbo-molecular pump isolated by a valve V1 and backed by a roughing pump viaa valve V2, of enough pumping capacity to pump the system under test down to asuitable pressure at the inlet of the leak detector. Ideally all fittings and seals (atleast those on the high vacuum side) should be all-metal to alleviate the problem ofhelium permeation. 2. A Pirani gauge to measure the pressure in the backing line of the turbo-molecularpump and a pressure gauge system (G1) on the high vacuum side of the turbo-molecular pump (but below valve V1) capable of measuring in the range 0.1 MPato 10-7 Pa. Page 241 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 8 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5FPossible additional options to this pumping system could include a quadrupole or othertype of mass spectrometer to measure the residual gas spectrum. This is essential ifsystem cleanliness is to be assessed. A hydrogen getter and liquid nitrogen trap may beused to lower the detector background signal. A vent valve on the vessel side of V1 is also advisable for venting the item under test toa clean dry gas such as nitrogen to retain cleanliness. 12.4.2.1 Detection SystemThis is the system used to detect any vacuum leaks which may be present, thus it is thecentral part of the system and normally consists of the following items:1. A helium mass spectrometer leak detector installed such that it can be connectedinto the backing line of the turbo-molecular pump through valve V3. For maximumleak detection sensitivity, it should provide the necessary backing pressure for theturbo-molecular pump. It therefore should have its own pumping systemcomprising a turbo-molecular and backing pump combination. It must be able todetect leaks at least one order of magnitude smaller than that required by thespecification of the item under test, and up to at least 100 Pam3s-1. It should be noted that with modern leak detectors, it is possible to suppress thebackground and gain up to 2 orders of magnitude in sensitivity. Although this modeis useful in localising leaks, it shall not be used for the purpose of acceptancetesting without prior approval by the ITER Vacuum RO. An alternative when the item under test is of relatively small volume of less than1 m3, and when only a simple cold leak test is required, is to use the massspectrometer leak detector on its own. In this case the leak detector is connecteddirectly to the item under test. The separate turbo-molecular and roughing pumpsystem is not required. If there is a large leak on the item to be tested or where the pumping system isincapable of pumping the item under test to a sufficiently low pressure for the leakdetector to be connected directly to the backing line of the turbo molecular pump,valve V2 may be left open and valve V3 partially opened so that the leak detectorsamples part of the gas stream to the backing pump. This configuration may beused to locate, but not size, any leaks. 2. A pressure gauge system (G2) on the vessel under test, capable of measuring inthe range 0.1 MPa to 10-7 Pa. 3. A calibrated helium standard leak of value commensurate with the magnitude ofleak rate required by the specification of the item under test, mounted on thesystem under test, and isolated by valve V4. Traceable calibration certificates shallbe kept for this item and these should be readily available. 4. A helium bag or other enclosure fashioned in such a way that the test gas cansurround all parts of the item under test with a concentration preferably exceeding50% in air. Page 242 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 9 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F5. A system for continuous recording of the leak test process. This can be achievedby using an analogue recording device such as a paper strip chart recorderconnected to the output of the helium mass spectrometer leak detector or bycontinuous logging (and display) of data on a computer or dedicated data logger. 12.4.2.2 MiscellaneousThe following equipment is optional but experience has shown the items to be of use inhelium leak tests. 1. A standard vacuum cleaner to pump the helium enclosure out if it is a sealedcollapsible type such as a plastic bag before inflating it with helium, to ensuremaximum concentration of the helium in the enclosure. 2. A helium-in-air concentration monitor to ascertain the percentage of helium in thebag or other enclosure during the test. 3. A triggered helium spray gun for subsequent probe testing of the item to localiseany leaks found during the global leak test. 12.4.3 Preliminaries12.4.3.1 Initial Checks on the Leak Detection System1. With valve V2 open and valves V1 and V3 closed, the roughing pump is started. When the pressure falls to a suitable level, the turbomolecular pump is started andleft until the pressure on gauge G1 stabilises. 2. The leak detector is switched on and when it is ready, an internal calibration iscarried out as per the manufacturer’s instructions. 3. The backing line Pirani gauge pressure reading is noted and valve V3 is carefullyopened so that the leak detector does not trip out. (Most modern leak detectorscan cope with this.)4. The roughing pump valve V2 is closed. 5. When a relatively stable reading has been obtained on the leak detector, a leakcheck is carried out, by using a helium gun to probe with helium gas all joints andwelds up to and including the pumped sides of V1 and V3. 6. If any leaks are found of magnitude greater than one decade smaller than themaximum leak rate called for in the specification of the item under test, then theseshall be rectified and this sequence repeated until no such leaks are found. 12.4.3.2 Pump-downBefore the leak test can be undertaken, the item under test must be pumped down tothe requisite pressure. In the case of the system shown in Figure 12-1 which uses aturbo-molecular and roughing pump set, the following actions shall be performed. 1. The roughing pump is started and valves V1 and V2 are opened. Page 243 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 10 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F2. When the system Pirani pressure reaches the level given in the manufacturersinstructions the turbo-molecular pump is started. 3. The system is ready for initial tests when the pressure reaches 10-3 Pa or lower onG1, or such other pressure specified as suitable by the manufacturer of the leakdetector. If it does not reach this pressure then there may be a large leak presentwhich must be located and rectified. It should be located using either anoverpressure technique as described in Section 12.3.1.1 or the procedures ofSection 12.4.5.2 but with valve V3 only partially opened so that the pressure at theinlet of the leak detector remains below the upper pressure limit specified by themanufacturer with the gas flowing to the roughing pump being sampled into theleak detector. 12.4.3.3 Background DeterminationAfter a stable pressure reading has been obtained on gauge G2 with valves V1 and V2open and the turbomolecular pump set running normally, with the leak detector fullyfunctioning and the data logging device connected and operating, then the roughingvalve V2 is closed and the leak detector valve V3 opened. The leak detector reading is monitored until it has stabilised, without any electroniccorrection. This should take around 10 minutes, but the time can be longer dependingon the size of the system under test. This reading is recorded as the background level. Any reading above this value duringthe overall test constitutes a positive indication of a leak. 12.4.4 Leak Detector CalibrationWith the system in the state as above for background determination, leak detectorcalibration shall be performed. Valve V4 is carefully opened and the reading on the leak detector monitored until it isstable. This should correspond to the value of the standard leak to within ±5% aftersuitable corrections for the age of the standard leak and its temperature have beenapplied. If a response time measurement is not required, then V4 is closed and the readingshould then return to the background level. 12.4.4.1 Response and Cleanup Time MeasurementThis should be done for a large system or where there is a long path length involvingsmall bore tubes. This ensures that the duration of the overall test will be valid. 1. With the standard leak open to the system and the leak indication stable at thevalue of the standard leak, suitably corrected for age and temperature, valve V4 isclosed. Page 244 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 11 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F2. The time taken for the reading on the leak detector to return to the backgroundlevel is recorded. This is the cleanup time for the system and will depend on theapplied pumping speed for helium and the configuration of the system under test. 3. When the background level has been attained, valve V4 is opened and the timetaken to return to the level of the standard leak indication, suitably corrected, isrecorded. This is the response time for the system. 4. Valve V4 is closed and the system is allowed to return to the background level. 5. This concludes the initial set-up tests and the overall leak test may then beundertaken. 12.4.5 Cold Leak Tests12.4.5.1 Global Leak CheckIf all the preceding conditions have been met with all equipment functioning and readyfor use, a global cold leak test may be carried out according to the following procedure. 1. The data recording system is connected to the output of the leak detector andstarted and the date and time are recorded. 2. Valves V1 and V3 are opened and valves V2 and V4 are closed. 3. When the background reading is stable and is at a level consistent with the leakspecification of the item under test, which will be for most purposes at least anorder of magnitude lower than the specified maximum leak rate of the componentunder test and without electronic correction, the global leak check may be started. 4. The component under test is surrounded by a suitable helium enclosure. If thehelium enclosure is a flexible type, it should have as small a volume as possible. The enclosure is filled with helium to a concentration of at least 50% in air and thetime is recorded in the data log5. Helium should remain in contact with the item under test for at least 10 minutes orlonger, depending on the size of the object and the response time previouslymeasured, or for the time specified in the test specification for the componentunder test, whichever is longer. In the case of components where there might be possible low conductance leakpaths, for example porosity, the time required for a sensible test may besignificantly longer than the response time measured for the system using thetechniques of Section 12.4.4.1. Details of the method and time of duration ofhelium application shall be included in the leak testing procedure to be accepted bythe ITER Vacuum Responsible Officer. 6. Where the helium enclosure is not completely sealed, then suitable precautionsshall be taken to ensure that helium cannot back-diffuse through the roughingpumps and/or the leak detector pumps into the mass spectrometer detector. In thePage 245 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 12 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5Fcase of long-duration global tests, it may be advisable to house these items in aseparate enclosure held at a small positive pressure above atmosphere. 7. After the appropriate time interval, the helium supply is closed off (whereappropriate), and the enclosure vented to atmospheric air and removed. The timeis recorded in the data log. 8. If the leak rate indication on the leak detector has not risen by more than thespecified maximum leak rate at any time during this test procedure, the item undertest shall be deemed to have passed, subject to the requirements of Section12.4.5.3. 9. It may be advisable to recheck the background reading and leak detectorcalibration if the global test has been of significant duration. When that has beendone according to the procedures of 12.4.3.3 and 12.4.4, then the global leak testis complete. 10. Valves V1 and V3 are closed and valve V2 opened. 11. The item is vented, or left under vacuum for further work as required. 12. If the leak rate reading during the test has at any time exceeded the specificationvalue, then the item has failed the test, and the leaks shall be located using theprocedures of Section 12.4.5.2. 12.4.5.2 Probe TestsThese are necessary to locate any leaks greater than the value in the specification ofthe component being tested which may have been indicated during the global test. Theymay be required not only at this stage, but may be needed also after the hot global testand the final cold global test, if those two tests are required as part of the contract orother instruction. The following procedure shall be used, although others are possible and may be usedafter prior agreement. 1. Any helium enclosure or other covering or obstruction is removed from the itemunder test wherever possible. 2. If the component under test is at cryogenic temperatures, it may have to bewarmed to ambient temperature before probe tests can be carried out. 3. Valves V1 and V3 should be open and valves V2 and V4 should be closed. 4. In the case of a large item, the data logging system shall continuously record theleak detector signal so that any longer term variations in leak rate may be observed. 5. Using a helium gun, helium gas is sprayed over or into all suspect locations andunder any non-removable coverings, starting at the top of the item under test andworking down as required. The helium spray should be introduced to the areaunder test for a time period consistent with the response time of the systemmeasured in accordance with Section 12.4.4.1Page 246 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 13 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F6. If a leak indication is found, then the point of maximum reading shall be localised. For subsequent testing to localise any other leaks, it is advisable to blanket thatpoint with a physical barrier such as a polythene bag or sheet or with a stream ofanother gas whilst checking the remainder of the system. 7. When all detectable leaks have been located, then the leak detector is isolated byclosing valve V3. Valve V1 is closed and the item under test shall be vented to drynitrogen or clean dry air admitted through the vent valve. The ITER VacuumResponsible Officer shall be contacted to agree a procedure to rectify the leak orleaks. 8. When any agreed repair has been successfully accomplished, the process startingfrom stage 12.4.3.2 and to point 10 at the end of stage 12.4.5.1 is repeated untilthe item is proved to meet the relevant specification. 12.4.5.3 Acceptance CriteriaIf all the stages above have been successfully completed then the item under test maybe accepted by the ITER Vacuum Specialist as having met the relevant specificationprovided that the following conditions have been met. 1. The leak detector has been correctly calibrated and its calibration value is within±5% of the standard leak rate value as corrected for the ambient temperature andthe age of that item and that standard leak rate value is commensurate with thevalue of the maximum leak rate specified for the item under test. 2. The leak test has been performed by suitably qualified and experienced personnelto the accepted procedure, with no significant deviation from that procedure andhas been witnessed by the ITER Vacuum Specialist. 3. The leak rate value as measured by the leak detector has not increased in valueabove the measured background to a value greater than the specified leak rateduring the entire duration of the global leak test. The location and magnitude of all identified leaks shall be recorded. Normally, allpracticable efforts shall be made by means agreed with the ITER Vacuum ResponsibleOfficer to reduce any leak discovered during the manufacturing phase to a level lowerthan the limit of detection of the leak detection method used for the tests. 12.4.6 Hot Leak Check12.4.6.1 Test ConditionsIf it is required as part of the contract or other instruction to perform a hot leak test on anitem which during its life may be subject to increased temperature usage, then thefollowing procedure shall be carried out. 1. Before commencing any part of this leak test procedure, the item under test musthave completed one or more temperature cycles as specified and be at that pointon the cycle where it is specified that the hot leak test shall take place. Page 247 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 14 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F2. The leak detector shall be set up using the procedures of Sections 12.4.3.3 and12.4.4. If the response time of the system has already been determined, or is notrequired, it need not be re-measured. 3. If the background is elevated when the item under test is at temperature (as mayoften be found), then the conditions stipulated in 12.4.5.1 Point 3 may not be met. However with judicious choice of scale it may be possible to do a perfectly validleak check at a raised background level. It may also be necessary to selectivelypump hydrogenic species from the leak detector input gas stream. This can bedone by the correct choice of getter installed in series with the leak detector inlet. The applicable conditions for this test must be agreed with the ITER VacuumResponsible Officer. 4. The helium enclosure used for these tests must be capable of toleratingtemperatures above ambient since the increased thermal conductivity of helium willraise the temperature of this item above the level it would reach with onlyatmospheric air in the enclosure. 12.4.6.2 Global Leak Check with the Component under test HotEssentially, this is a repeat of the cold global leak test described in Section 12.4.5.1except that, if a leak indication is observed, the item may need to be cooled down beforeprobe tests can be performed. The temperature at which the hot leak test is performedshall be recorded and shall be within the limits as specified in the leak testing procedure. If, with the component at the specified hot temperature, no leak rate of size greater thanthat specified for the component has been observed, then provided that the conditions ofSection 12.4.5.3 have been met, the component will be deemed to have satisfied the hotleak test requirement. If, however, with the component at the specified hot temperature, a leak rate of sizegreater than that specified for the component has been observed, then a probe test tolocalise any leaks present must be undertaken. The supplier should be aware that under some conditions, a leak may be observed attemperature but may disappear when the component is cooled to ambient temperature. If this is the case, then it may be necessary to implement an agreed procedure for leaklocation at elevated temperature. 12.4.6.3 Probe Test1. This method of probe leak testing baked components is the essentially the sameprocedure as detailed in 12.4.5.2., but with additional steps as noted below:2. If the probe test cannot be carried out at the hot temperature, the component shallbe cooled to ambient temperature3. Steps 1 – 7 of section 12.4.5.2 shall be carried out. Page 248 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 15 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5F4. If, after probe testing at ambient temperature, no leak has been identified, then, asagreed with the ITER Vacuum Responsible Officer, a further temperature cycleshall be completed as specified up to the point on the cycle where it is specifiedthat the hot leak test shall take place. 5. Then eithera. an agreed procedure for leak location at this elevated temperature shall becarried outorb. the component shall be cooled and step 2 of this Section shall be carried out inthe hope that the hot leak may have opened up further and now may bedetectable at or close to ambient temperature. 6. Step 5 shall be repeated until no leaks which have not been localised are evidentat the hot temperature. 7. When all detectable leaks have been located and the component is close toambient temperature, then the leak detector is isolated by closing valve V3. ValveV1 is closed and the item under test shall be vented to dry nitrogen or clean dry airadmitted through the vent valve. The ITER Vacuum Responsible Officer shall becontacted to agree a procedure to rectify the leak or leaks. 8. When any agreed repair has been successfully accomplished, the global hot leaktest procedure of this Section is repeated. 12.4.6.4 Final Cold Acceptance CheckThis test shall be carried out following a satisfactory global hot leak test procedure whenthe item under test has cooled down to a temperature in the range 60°C to 80°C, sinceexperience has shown that small leaks can be blocked by water vapour below thistemperature. It shall follow the procedures of Section 12.4.5.1. 12.4.6.5 Acceptance CriteriaThese shall be the same as those specified in Section 12.4.5.312.5 ResponsibilitiesIt shall be the responsibility of the supplier to ensure that all vacuum leak tests carriedout off-site and of the ITER Vacuum Responsible Officer when such tests are carried outon-site that they be performed in accordance with the contract or other specification. Alldeviations from such specification or agreed variation thereof shall require a non-conformance to be raised covering each specific case. In the case of any particularcomponent, a nominated ITER Vacuum Specialist may witness the tests. Page 249 of 382ITER_D_2EYZ5F v1.4ITER Vacuum Handbook : Appendix 12Revision: 1.4 Date: September 16th , 2009 Page 16 of 16ITER Vacuum Handbook Appendix 12 IDM Ref :ITER_2EYZ5FAll records as detailed in the following section shall be completed and shall become partof the final document package for the component concerned. 12.6 ReportingFull records of the tests carried out on any component shall be completed in order tomaintain traceability of the leak test history of a particular item. The records shall consistof the following. 1. Data records of the output of the leak detector for all the global tests specifiedincluding the standard leak calibration and response time determination. Thesedata records shall include the date and time of all tests as well as anything else ofrelevance, such as the start and finish time of helium gas application to the itemunder test. 2. A record of the helium concentration during the leak test where that is required. Inthe case of a simple cold leak test this will be on request of the ITER VacuumResponsible Officer, but in the case of a full cycle of leak testing involvingtemperature variation it will be required. 3. A record of the system total pressure throughout a temperature cycle since it maypinpoint the time when a leak opened up and be instrumental in the subsequentdiagnosis of the leak. 4. The make, model and date of manufacture of the helium mass spectrometer leakdetector used in the tests. 5. The nominal value of all standard leaks used, their date of calibration, ageing andtemperature characteristics, and the ambient temperature(s) experienced duringthe tests. 6. The results of all tests showing whether it was a pass or fail, and, if a failure, themeasured leak rate and the location of the leak, together with the steps taken forany repair or elimination. The magnitude and location (if applicable) of all leaks identified during testing shallbe recorded. This includes leaks of magnitude lower than the acceptance criteriafor which no remedial action may have been taken. Page 250 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMBaseline Report (not under Configuration Control)Appendix 13 Cleaning and CleanlinessThis Appendix specifies typical processes which conform to the requirements of the ITERVacuum Handbook for the cleaning of vacuum vessels, components and assemblies whichare required for the ITER Project. This covers vacuum vessels and any item which will be ina vacuum environment, whether individually or made up into assemblies containing a numberof such itemsApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2ELUQHVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 251 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 13 Cleaning and Cleanliness (2ELUQH)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 252 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 1 of 14Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 13Guide to Cleaning and Cleanliness for the ITER ProjectPage 253 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 2 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH13 Guide for Cleaning and the Cleanliness of ITER Vacuum Components.. 313.1 Scope.. 313.2 General Cleaning Requirements.. 313.3 Health and Safety.. 313.4 Proprietary Items and Trademarks.. 413.5 Design Rules for Cleanability.. 413.6 Initial Inspection and Preparation.. 413.7 Mechanical Processes on Vacuum Surfaces.. 513.8 Use of acids.. 513.9 Treatment of Weld Burn.. 513.10 Electropolishing for VQC1 Applications.. 613.11 Handling and Packing.. 613.12 Spray washing.. 713.13 Standard Cleaning Procedure for Stainless Steel Components.. 713.13.1 Preclean.. 713.13.2 Wash.. 713.14 Chemical Clean for Stainless Steel, or similar Items, for VQC 1application.. 713.15 Chemical Clean for Stainless Steel or similar Items for use on VQC 2, 3 &4 components.. 813.16 Chemical Clean for Copper and Copper Alloys.. 813.17 Cleaning Ceramics.. 913.18 Cleaning of Aluminium.. 913.19 Air Baking.. 913.20 “Snow” Cleaning.. 1013.21 Cleaning Procedures for Vacuum Bellows.. 1013.21.1 General.. 1013.21.2 Procedure for Bellows for Class VQC 1 use.. 1013.22 Cleanliness.. 1113.22.1 Wipe Test for Cleanliness.. 1113.22.1.1 Dry test.. 1113.22.1.2 “Wet” test.. 1113.22.2 General Test for Cleanliness.. 1113.23 Definition of Terms.. 12Page 254 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 3 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH13 Guide for Cleaning and the Cleanliness of ITER VacuumComponents13.1 ScopeAs specified in the ITER Vacuum Handbook all vacuum components to be suppliedto ITER are subject to the provision of a “clean work plan” and cleaning procedures. This requirement is waived for proprietary components which are compliant with themandatory requirements of the ITER Vacuum Handbook and are supplied to ITERwith Certification of Conformity. This Appendix specifies typical processes which conform to the requirements of theITER Vacuum Handbook for the cleaning of vacuum vessels, components andassemblies which are required for the ITER Project. This covers vacuum vessels andany item which will be in a vacuum environment, whether individually or made up intoassemblies containing a number of such items. This guide is intended to assist the supplier of vacuum components to ITER in thepreparation of a clean work plan and cleaning procedures for submission to ITER foracceptance. Following the guidance in this Appendix should help suppliers to achievethe requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components manufactured comply with the requirements of theITER Vacuum Handbook. 13.2 General Cleaning RequirementsIn general, all components classified as VQC1 will need cleaning to Ultra HighVacuum standards. Those components classified as VQC2, VCQ3 and VCQ4 willgenerally be operated in less stringent vacuum environments and will therefore notrequire cleaning to such rigorous standards. However, it is the responsibility of the supplier to satisfy themselves that theyunderstand fully the implications of cleaning to the requisite standard. Any proposed deviation from the procedures and processes described in thisAppendix need to be accepted in writing by ITER. This is particularly important wherethe use of any chemical product (solvent, etchant, detergent, etc.) other than thosespecified is proposed. 13.3 Health and SafetySome of the chemicals or equipment used in cleaning processes may be classifiedas hazardous. It is the responsibility of the supplier to satisfy themselves that any cleaningprocedure complies fully with local legislative and regulatory standards regardinghealth and safety of any or all processes used and that all operatives have receivedthe necessary training. Page 255 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 4 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHThe supplier shall have the responsibility of ensuring that all staff fully understand allhealth and safety information issued by the manufacturer or supplier of any chemicalor equipment to be used. Neither ITER nor any of its agents shall be held responsiblefor any consequences arising from the application of any cleaning process describedin this handbook unless it is under their direct control. 13.4 Proprietary Items and TrademarksWhere propriety items from particular manufacturers or suppliers are mentioned inthis specification any or all trademarks are duly acknowledged. Manufacturers orcontractors are free to suggest alternative items from other manufacturers orsuppliers provided that they are chemically identical. Any such substitutions need tobe accepted in writing by ITER. 13.5 Design Rules for CleanabilityAt the design stage for a vacuum item, careful consideration should be given as tohow the item is to be cleaned. In particular, crevices, blind holes, cracks, trappedvolumes, etc., should be avoided as these will act as dirt and liquid traps and it canbe very difficult to remove both dirt and cleaning materials such as solvents fromsuch areas. Fortunately, good vacuum practice regarding trapped volumes will alsoresult in a component which is cleanable. 13.6 Initial Inspection and PreparationPrior to cleaning any item, the following inspection should take place:1. All vacuum flanges or covers should be removed and the item strippeddown as much as is permissible, ideally to single components. 2. All items should be clearly identified by scribing a suitable identificationmark on an external surface (never a vacuum surface). This identifier willoften be a drawing number with component identifier or some such whichis carefully recorded. Alternatively, for items which are either small and areto be exposed to a vacuum, a suitable metal label, preferably of the samematerial as the component and bearing a scribed identifier may be tiedwith clean bare wire to the component. If none of this is possible, the itemsshould be stored in a suitable container which is marked with an identifierbefore and after the cleaning process. After cleaning, these items shouldbe packed in such a way that they will not be re-contaminated by thecontainer. 3. The item should be inspected visually to identify any possible traps, etc. (see 13.5 above) which could affect the vacuum performance of the item,taking into account the specified cleaning process and vacuum regime inwhich the item is to be used. 4. All vacuum sealing faces should be inspected to ensure that there is nodamage to the seal area such as scratches, pitting or other defects. If theseal is of the knife edge type, the knife edge should be carefully examinedfor damage which could affect the sealing properties. Page 256 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 5 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH5. Any adhesive tape attached to surfaces of the item whether or not they areto be exposed to vacuum must be removed and any adhesive residuecarefully removed with the solvent isopropyl alcohol or ethanol. 6. Any marker pen or paint or similar on any surfaces of the item whether ornot they are to be exposed to vacuum should be carefully removed byscraping if necessary followed by washing with the solvent isopropylalcohol or ethanol and rinsing in demineralised water. 7. Any threaded holes, etc., whether or not they are to be exposed tovacuum, should be examined to see if there are traces of lubricants,cutting fluids or swarf left inside. Any such should be removed carefullyusing brushing or blowing out with clean compressed air or nitrogen and/orwashing with a suitable solvent followed by rinsing with demineralisedwater, taking care that no residue is transferred to a vacuum surface. 13.7 Mechanical Processes on Vacuum SurfacesAbrasive techniques to clean or to attempt to improve the appearance of the surfacesof vacuum components should be kept to an absolute minimum and are preferablyavoided. The use of grinding wheels, wire brushes, files, harsh abrasives, sand, shotor dry bead blasting, polishing pastes and the like is prohibited under normalcircumstances and certainly without prior acceptance by ITER. Accepted techniques are slurry blasting with alumina or glass beads in a water jet;gentle hand use of a dry fine stone or a fine stone lubricated with isopropyl alcohol orethanol; hand polishing using fine mesh alumina in an isopropyl alcohol or ethanolcarrier on a lint free cloth; hand polishing with ScotchBrite™ (Alumina loaded,Grade A). If any such surface finish technique is employed, care must be taken that any powderor other residues are removed by copious washing in hot water. Any other such operations may be carried out only with prior acceptance. 13.8 Use of acidsAcid treatment of any sort is to be avoided wherever possible and may only becarried out with specific prior acceptance by the ITER Vacuum RO. Most acidtreatments are for cosmetic purposes only and may result in degradation of vacuumperformance. Where the use of acids is accepted, then exposure of the component must be kept toa minimum and must be followed by copious washing in hot demineralised water. 13.9 Treatment of Weld BurnOne particular use of acid pastes is in the removal of weld burn. In general suchburns do not affect vacuum performance and are best left alone. Any scaling (i.e. loose oxides) should be removed using the techniques of Section 13.7. If it is desired to remove burns, then slurry blasting with alumina in water or handburnishing with alumina powder is a satisfactory alternative. Heavy abrading, grindingPage 257 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 6 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHor wire brushing is prohibited. Hand finishing with ScotchBrite™ or a dry stone is alsoacceptable. 13.10 Electropolishing for VQC1 ApplicationsElectropolishing should only be carried out where it is necessary to produce asmooth surface for reasons of electrical discharge or field emission minimisation,emissivity or similar purposes. It is usually unnecessary from a pure vacuum point ofview and indeed can be detrimental to vacuum performance. Electropolishing should be carried out in clean polishing tanks, using freshelectrolyte. Local electropolishing can be carried out with tampons. Fresh clean pads dipped inclean electrolyte should be used and excessive pressure should be avoided. After electropolishing, the item should be washed with copious quantities of hotdemineralised water. If required, vacuum Items for use in Class VQC 1 may be baked to 450 oC for at least24 hours to remove the residual hydrogen and other contaminants introduced into thesurface layers by the electropolishing process. 13.11 Handling and PackingHandling and packaging of components should be in accordance with therequirements specified in the ITER Vacuum Handbook . Specifically:1. Once components have completed initial rough cleaning care should betaken that vacuum surfaces are never touched by bare skin. Powder freelatex or nitrile gloves (over cotton or linen if desirable) should always beused when handling components. Coloured gloves are not acceptable. 2. Once components have started the cleaning process they shouldcomplete the cycle without a break. If it is unavoidable that a delay occursbetween stages, then care must be exercised that the component isthoroughly dry before storage, and all seal faces and ports must beprotected as below. There must never be a break between any chemicalcleaning stage and a subsequent water washing stage. 3. After the component has been cleaned and is completely dry, it should bepacked carefully to ensure that it remains clean and free from damage. Allvacuum sealing faces should be protected with a clean metal plate or ahardboard or similar fibre free board covered with clean aluminium foilheld in place by a number of bolts through the fastener holes. Knife edgesshould be protected with clean metal gaskets (which may have been usedpreviously, but they should be completely free from loose oxide scale). Allports should be covered with strong clean new aluminium foil and plasticcovers. Small items should be wrapped in clean aluminium foil and sealedin a polyethylene bag, under dry nitrogen if possible. Clean conditions for the handling of vacuum components are also defined in theITER Vacuum Handbook. Page 258 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 7 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH13.12 Spray washingWhere an item is cleaned by spray washing, it should be ensured that all hoses,lances, spray heads, etc are thoroughly cleaned out with clean hot water before thecleaning process starts. Washing should start at the top of the item and the spray should be worked down tothe bottom, ensuring good run-off. 13.13 Standard Cleaning Procedure for Stainless Steel Components13.13.1 PrecleanAll debris, such as swarf, should be removed by physical means such as blowing outwith a high pressure air line, observing normal safety precautions. Grosscontamination, e.g. greases or cutting oils, etc., should be removed by washing,swabbing and rinsing with any non halogenated general purpose solvent. Scrubbing,wire brushing, grinding, filing or other mechanically abrasive methods may not beused (see 13.7 above). 13.13.2 Wash1. The item should be washed down using a high pressure jet of hot townwater (at approx. 80oC), using a simple mild alkaline detergent. Thedetergent should then be switched off and the item rinsed thoroughly withhot water until all visible traces of detergent have been eliminated. 2. If necessary, any scaling or deposited surface films should be removed bystripping with alumina or glass beads in a water jet in a slurry blaster. 3. The item should be washed down with a high pressure hot demineralisedwater jet (at approx. 80oC), with no detergent, ensuring that any residualbeads are washed away. Particular attention should be paid to anytrapped areas or crevices. 4. The item should be dried using an air blower with clean dry air, hot ifpossible. 13.14 Chemical Clean for Stainless Steel, or similar Items, for VQC 1application. With the addition of the relevant safety precautions, the cleaning process below canalso be applied to beryllium,1. Where possible, the item should be immersed completely in anultrasonically agitated bath of hot clean liquid solvent for at least 15minutes, or until the item has reached the temperature of the bath,whichever is longer. The temperature should be the maximum specified bythe supplier of the solvent. 2. Halogenated solvents are not permitted. Page 259 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 8 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH3. Suitable solvents need to be accepted by ITER before use. IsopropylAlcohol, Ethyl Alcohol, Acetone, Axarel 9100™, CitrinoxTM, P3 Almeco™P36 or T5161 are accepted for this purpose. 4. Where technically feasible, after the liquid immersion stage, the itemshould be immersed in the vapour of the solvent used for at least 15minutes, or until the item has reached the temperature of the hot vapour,whichever is longer. 5. It must be ensured that all liquid residues have been drained off, payingparticular attention to any trapped areas, blind holes etc. 6. The item is then be washed down with a high pressure hot (approx. 80oC)water jet, using clean demineralised water. Detergent must not be used atthis stage. 7. The item is dried in an air oven at approx 100oC or with an air blower usingclean, dry, hot air. 8. If the item is too large to be cleaned by immersion the item may becleaned by washing it down with a high pressure jet of P3 Almeco™ P36or T5161. 9. The item is cooled to room temperature in a dry, dust free area conformingclean conditions as defined in ITER Vacuum Handbook . 10. The item is inspected for signs of contamination, faulty cleaning ordamage. 11. The item is baked to a temperature of 300oC or whatever othertemperature has been specified for a minimum period of 24 hours attemperature in accordance with the ITER Vacuum Handbook Appendix 1512. The item is packed and protected as in 13.11 above. 13.15 Chemical Clean for Stainless Steel or similar Items for use on VQC 2, 3& 4 componentsAll items may be cleaned to the specification for items in Class VQC 1It is also be permissible to use halogenated hydrocarbon solvents for cleaning itemsin these classes by analogy with 13.13 and 13.14. For items for Class VQC 2, 3 and 4, baking will not normally be necessary with theexception of items specifically listed in the Vacuum Handbook. 13.16 Chemical Clean for Copper and Copper AlloysItems manufactured from copper or copper alloys may be cleaned using theprocedures for stainless steel, except that in this case Almeco P3-36™ is notacceptable. Copper surfaces may alternatively be cleaned using a light chromic acid or citric acidetch, followed by thorough washing in hot, clean demineralised water. Page 260 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 9 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH13.17 Cleaning CeramicsCeramics such as alumina and beryllium oxide may be cleaned using the processdescribed here. Other ceramics may not be able to withstand the high temperatureair bake, so manufacturers specifications’ must be checked. Beryllium oxide must in no circumstances be ground or scraped except in specialistfacilities. 1. Any surface contamination is removed by wet slurry blasting with aluminapowder, or by hand polishing with fine-mesh alumina or diamond powderin an acetone, ethanol or isopropyl alcohol carrier. 2. Components are baked at 1000oC in atmosphere for 24 hours inaccordance with Appendix 15. The maximum baking temperature may belimited by the system component materials. 3. Items are wrapped in clean aluminium foil and sealed under dry nitrogen ina sealed polyethylene bag13.18 Cleaning of Aluminium1. Components are sprayed with high pressure jets at 60 oC with a 2%solution of Almeco 29™ (an alkaline detergent). 2. This is be repeated with a 2 % solution of Amklene D Forte™. 3. Components are rinsed thoroughly with a jet of hot demineralised water. 4. Components are dried with hot air at 80 oC. Alternatively,5. Components are immersed in Sodium Hydroxide (45 g l-1 of solution) at 45oC for 1 - 2 minutes. 6. Components are rinsed thoroughly in hot demineralised water. 7. Components are immersed in an acid bath containing Nitric acid (50% v/v)and Hydrofluoric acid (3% v/v). 8. Components are rinsed thoroughly in hot demineralised water. 9. Components are dried in warm air. 13.19 Air BakingItems manufactured from stainless steel and the like may be air baked to provide alow hydrogen outgassing surface. Note that this procedure is not suitable for materials that form a loose oxide, e.g. copper. Items should be chemically cleaned using the procedures of 13.13 aboveItems should then be heated in air at a temperature of 450 oC for a period of 24 hoursin accordance with Appendix 15. Page 261 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 10 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQH13.20 “Snow” CleaningA final clean after assembly of components into a large vacuum system may beachieved by the use of “snow” cleaning. Snow cleaning uses a high velocity stream of soft microscopic particles of solid CO2to wash the surface and is effective for removing particulates and some organiccontamination from surfaces. Operatives undertaking this procedure must wear suitable protective clothing andpersonal safety equipmentThe procedures used will be as specified by the suppliers of the equipment. Snow cleaning will normally only be used for items to Class VQC 1, but may be usedon all vacuum components. 13.21 Cleaning Procedures for Vacuum Bellows13.21.1 GeneralGreat care has to be exercised when cleaning thin walled metal bellows, particularlythose of edge-welded, nested construction. If any cleaning residues are trappedbetween the convolutions, either inside or outside, these can result in corrosionwhich can rapidly cause leaks to develop. Similarly, if any particulates are depositedin the convolutions, mechanical puncturing can take place. Alkaline degreasingsolutions such as Almeco are prone to particulate precipitation and therefore mustnot be used for bellows assemblies. 13.21.2 Procedure for Bellows for Class VQC 1 useThe bellows must be fixed in an extended position if possible. 1. Any traces of visible, loose contamination are removed with a gentle jet ofclean, dry air or nitrogen. 2. The bellows are immersed in an ultrasonically agitated bath of isopropylalcohol (IPA) or ethyl alcohol (ethanol). 3. The bellows should be vapour washed immediately in isopropyl alcohol orethanol vapour. 4. The bellows, including the interspace where appropriate, must bethoroughly dried inside and out using a gentle jet of clean, dry, particulatefree air or nitrogen. 5. The bellows should be placed in a dry air oven at 100 oC for at least 1hour. 6. The bellows should be baked in a vacuum oven, for 24 hours at 250 oCwith the bellows interspace pumped. 7. The bellows should be sealed under dry nitrogen in a polyethylene bag. Page 262 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 11 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHThis procedure can be used for bellows used on VQC 2, 3 & 4 systems with thevacuum bake requirement waived. 13.22 Cleanliness13.22.1 Wipe Test for CleanlinessGross contamination of a vacuum component may be assessed by means of a wipetest. This may be carried out “dry” or “wet”. Gross contamination may also manifest itself as an “oily” or “solvent-like” smell. Note that these tests are of a somewhat subjective nature and may not be conclusiveand therefore should only be used as a guide to cleanliness and as a marker forsubsequent cleaning operations should the tests result in a failure of cleanliness. 13.22.1.1 Dry testThe surface of the component is wiped gently with a clean lint free cloth. If there is any evidence of a deposit on the cloth (i.e. a stain or a change in colour)then the item should be regarded as unclean. Similarly if the surface of the component which has been wiped shows any evidenceof a change in colour or reflectivity of light, then the item should be regarded asunclean. 13.22.1.2 “Wet” testThis uses a clean lint free cloth dipped in a solvent which evaporates at roomtemperature, such as isopropanol, ethanol or acetone. Appropriate safety precautions against fire hazard, breathing in of solvent fumes, eyeand skin protection must be taken. 1. The cloth is dipped in the solvent which is then be allowed to evaporate ina safe manner. There should be no change in the appearance of thesurface of the dry cloth. 2. The cloth is dipped in the solvent and the surface of the component iswiped gently while the cloth is still wet. 3. The solvent is allowed to evaporate from the cloth and the surface of thecomponent until they are dry. 4. If there is any evidence of a deposit on the cloth (i.e. a stain or a change incolour) then the item should be regarded as unclean. 5. Similarly if the surface of the component which has been wiped shows anyevidence of a change in colour or reflectivity of light, then the item shouldbe regarded as unclean. If required, the deposit on the cloth may be analysed by a suitable means todetermine the chemical nature of the contamination. 13.22.2 General Test for CleanlinessAn item shall be deemed to be clean for the purposes of this Appendix provided thatit meets the following criteria. Page 263 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 12 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHCleanliness is defined to mean that the concentrations of “contaminants” (i.e. unwanted gas species) in the residual gas spectrum of the item are less than thespecified values. The concentration of a species is defined as the fractional intensity of its measuredpartial pressure components related to that species defined in a particular way to thetotal pressure in the system expressed as a percentage. The partial pressures of species in the vacuum system or related to the componentbeing measured should be obtained using the equipment and procedures defined inAppendix 17 of the Vacuum Handbook. The residual gas spectrum will have been recorded over 1 –200 amuThe spectrum will have been corrected for sampling error, mass discrimination andspecies relative sensitivities. The definition of “general contaminants” is the sum of the partial pressures of allpeaks present in the residual gas spectrum of mass to charge ratio (amu) equal to39, 41-43 and 45 and above (excluding any above 45 specifically listed in the tablebelow). Also to be excluded from this summation are any peaks related to the raregases xenon (i.e. 132, 129, 131) and krypton (i.e. 84, 86, 83)Table 13-1 Allowed concentrations of contaminants pertaining to VQCVacuumClassGeneralContaminantsPerfluoropolyphenylethersSum of (peak at 69 and 77amu)Chorinatedspecies(Sum ofpeaks at35 and 37amu)CommentVQC 4 5 1 1VQC 3 2 0.5 0.5Excluding water(sum of 17 and 18amu) from the totalpressureVQC 2 1 0.1 0.1 If unbaked,excluding water asaboveVQC 1 0.1 0.01 0.01 After bakeThis general test for cleanliness can be carried out as part of the verification ofcomponent outgassing in accordance with Appendix 1713.23 Definition of TermsFor the purposes of this specification, the words or terms listed in Table 13-2 beloware taken to have the stated meanings. Page 264 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 13 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHTable 13-2 Definitions of terms usedTerm DefinitionContaminant Any unwanted substance present on a surfaceBrushing Using a fibre glass or wire brush to gently remove looselyadhered matter (e.g. dust) from a surfaceSwabbing Vigorous rubbing with a lint free cloth or ragWiping Gentle rubbing with a lint free cloth or rag, either dry orsoaked in a liquidWashing Cleaning an item by total immersion in a liquid or by pouringor spraying a liquid over itDipping Immersing an item in a liquid and removing it relativelyquicklyRinsing Using copious quantities of a liquid to remove traces of acontaminant or other material from an item, usually byrepeated dipping or pouring the liquid over the itemScraping Using a hand tool of a material harder that the item beingscraped to gently remove a thin layer from a surfaceGrinding Using a wheel or stone to remove a substantial amount ofmaterial from a surfaceScribing Marking a surface with a clean metal point, vibratingengraver or laser engraving device, usually for identificationor marking out purposesSand or shot blasting Using a stream of abrasive particles e.g. silica or alumina toremove a surface layer. The medium may be a gas or aliquid. Polishing or burnishing Using a paste of fine particles, e.g. diamond or alumina, ora dry tool to produce a smooth surfaceSolvent A material which removes a contaminant from an item bydissolving it to form a solutionDetergent A material which removes a contaminant from an item byacting as a surfactant i.e. by hydrophobic or hydrophilicaction. Often used interchangeably (but incorrectly) with theterm soap. Etching Removing a surface layer by chemical actionPickling Stripping of the oxide layer from a surface by use of acidsPassivation Modifying a surface so that it is left in an inactive state,usually by leaving a uniform oxide film on the surfaceElectropolishing Removal of the surface layers of a metal by immersing thesurface in a buffered acid solution and applying an electricalpotential. Ultrasonic cleaning Immersion of a component in a bath of liquid with ultrasonicagitationPage 265 of 382ITER_D_2ELUQH v1.2ITER Vacuum Handbook: Appendix 13Revision: 1.2 Date: July 28th, 2009 Page 14 of 14ITER Vacuum Handbook Appendix 13 IDM Ref :ITER_D_2ELUQHVapour washing Immersion of a component in a hot vapour such that thevapour condenses on the item and runs off by gravitation,carrying any contaminant in solution or suspensionGlow discharge An electrical discharge set up in a low pressure gas. Discharges may use dc or radio frequency potential(voltage) sourcesClean surface A surface with the desired properties e.g. outgassing. Page 266 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 14 Passivation and PicklingApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2F457SVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 267 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 14 Passivation and Pickling (2F457S)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 Signed 12 Jan 2009v1.2 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 268 of 382ITER_D_2F457S v1.2ITER Vacuum Handbook: Appendix 14Revision: 1.2 Date: July 28th, 2009 Page 1 of 5Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 14Guide to Passivation & Pickling for the ITER ProjectPage 269 of 382ITER_D_2F457S v1.2ITER Vacuum Handbook: Appendix 14Revision: 1.2 Date: July 28th, 2009 Page 2 of 5ITER Vacuum Handbook Appendix 14 IDM Ref :ITER_D_2F457S14 Guide for the Pickling/passivation of Steels and Copper for the ITER Project.. 31.1 Scope of this Appendix.. 31.2 General Comments.. 31.3 Pickling and Passivation of Steels.. 31.4 Pickling and Passivation of Copper and Copper Alloys.. 51.5 Standards.. 5Page 270 of 382ITER_D_2F457S v1.2ITER Vacuum Handbook: Appendix 14Revision: 1.2 Date: July 28th, 2009 Page 3 of 5ITER Vacuum Handbook Appendix 14 IDM Ref :ITER_D_2F457S14 Guide for the Pickling/passivation of Steels and Copperfor the ITER Project1.1 Scope of this AppendixThis Appendix specifies typical procedures and processes to be used when materialsused for vacuum components for the ITER project need to be passivated. It is intended that the suppliers using such processes should follow the guidance inthis Appendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components supplied comply with the requirements of the ITERVacuum Handbook. 1.2 General CommentsPickling is most frequently used to remove heavy scale from steels or a heavy, looseoxide layer from copper (or aluminium). Pickling is rarely specified for vacuum components, normally only for those to be usedin rough vacuum, since the process attacks the metal surface and the oxide layer,tending to leave residues which are difficult to remove. Heavy scale on steel is best avoided by specifying that the plate produced in a rollingmill or a hot-forged blank is stripped with an air knife while still hot. Light scale on steel may be removed with a wire brush. Loose oxide on a coppersurface can also be brushed off. Pickling often leaves the surface in an etched state with a matt finish, which may ormay not be desirable. Dimensional stability cannot be guaranteed during the pickling process, so it shouldnormally be carried out on the material before manufacture. If a vessel assembly is pickled, then final machining of vacuum sealing surfaces mustbe left until after the pickling/passivation process. Pickling and passivation must always be followed immediately by an appropriatecleaning process, relevant to the Vacuum Classification of the component. (Refer toAppendix 13)Pickling should always be followed by passivation. This is best carried out chemically,although native oxide layers can reform on exposure to atmosphere. It should be noted that thermal outgassing from surfaces which have beenpickled/passivated may well be greater than that from a native metal surface and mayrequire additional baking to achieve the outgassing requirements of the ITER VacuumHandbook. 1.3 Pickling and Passivation of Steels. Steel manufacturers/suppliers will often have their own preferred method ofpickling/passivation and may be unwilling to use any other method. Expert advice fromPage 271 of 382ITER_D_2F457S v1.2ITER Vacuum Handbook: Appendix 14Revision: 1.2 Date: July 28th, 2009 Page 4 of 5ITER Vacuum Handbook Appendix 14 IDM Ref :ITER_D_2F457Sboth a metallurgical and vacuum point of view shall be sought in this case. Thevacuum person in this case will be the ITER Vacuum RO. In no case, however, shall the use of glue in the pickling solution be permitted. Note that the chemicals used in these processes are hazardous and all appropriatesafety procedures must be followedTable 14-1 below lists some of the acceptable pickling solutions for steels. Material Solution ConcentrationTemperature (oC)CommentSulphuric acid (SG 1.84) 10%solution50-80 Until ScalevisuallyremovedIron and steelHydrochloric acid (SG1.19)10-20%solution50-80 As aboveNitric acid (SG 1.4)Hydrofluoric acid (52%)200gl-140gl-155-65 As aboveSulphuric acid (SG 1.84)Hydrofluoric acid (52%)Chromic acid - 6060gl-160gl-160gl-1Room As aboveStainless steelHydrochloric acid (SG1.19)Nitric acid (SG 1.4)250gl-122gl-160-70 Bright FinishTable 14-1 – Pickling solutions for steelsUnless the pickling/passivation process is carried out on the raw material as part of theproduction process at the steel mill, the process to be used will typically be as follows -¾ Gross contamination is removed by washing the material in a jet of hot (80oC)water. ¾ The material is allowed to dry. ¾ The material is thoroughly degreased using one of the methods specified inAppendix 13 of the ITER Vacuum Handbook¾ The pickling baths should be checked visually to ensure that there are novisible signs of contamination, e.g. oils or greases floating on the surface. Ideally, clean pickling solutions in clean baths should be used. ¾ The material is lowered into the pickling solution for the specified time or untilthe process is complete. ¾ The material is washed in a jet of hot (80oC) water. ¾ The surface of the material is then passivated by lowering into a bath of dilutenitric or citric acid. Page 272 of 382ITER_D_2F457S v1.2ITER Vacuum Handbook: Appendix 14Revision: 1.2 Date: July 28th, 2009 Page 5 of 5ITER Vacuum Handbook Appendix 14 IDM Ref :ITER_D_2F457S¾ The material is washed in a jet of hot (80oC) water and allowed to dry. Note that there are alternative methods of pickling and passivation using spray and geltechniques. The use of such techniques is not prohibited but should only be usedfollowing acceptance of the proposal by the ITER Vacuum RO1.4 Pickling and Passivation of Copper and Copper AlloysThe generalities and procedures of Section 1.3 above apply except where notedotherwise. Pickling solutions for copper and copper alloys are given in Table 14-2 belowMaterial Solution Concentration Temperature(oC)CommentSulphuric acid (SG 1.84) 20% aqueoussolution65-75Sulphuric acid (SG 1.84). . Sodium dichromate20% aqueoussolution75gl-120-75Copper andcopper alloysCitric acid 1% aqueoussolutionAmbient Alsopassivatesthe surfaceTable 14-2 – Pickling solutions for copperFollowing pickling, copper parts must be passivated immediately by dipping in a 1%aqueous solution of citric acid. 1.5 StandardsThe following standard procedures may be used to inform the processes described inthis AppendixEN 2516:1997 – Passivation of corrosion resistant steels and decontamination ofnickel bas alloysASTMA380 – Practice for Cleaning, Descaling and Passivation of Stainless SteelParts, Equipment and SystemsASTM A967 – Specification for Chemical Passivation Treatments for Stainless SteelPartsPage 273 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 15 Vacuum BakingApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2DU65FVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.3 / ApprovedEXTERNAL REFERENCE / VERSIONPage 274 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 15 Vacuum Baking (2DU65F)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 12 Jan 2009v1.2 In Work 12 Jan 2009v1.3 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 275 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 1 of 8Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 15Guide to the Vacuum Baking of Components for the ITER ProjectPage 276 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 2 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65F15 Guide for Vacuum Baking.. 315.1 Scope.. 315.2 General Comments.. 315.3 General Procedures for Baking of Vacuum Items.. 415.3.1 Preliminary.. 415.3.2 Vacuum Pumps and Gauges.. 415.3.3 Temperature Monitoring and Control.. 515.3.4 Completing the Bake Process.. 515.4 Control of the Bake Process.. 515.5 Types of Bake Procedure.. 615.5.1 Total Immersion Bake.. 615.5.2 Oven Bake.. 615.5.3 “Tape” Bake.. 715.5.4 Air Bake.. 715.6 Documentation to be Supplied. .. 8Page 277 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 3 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65F15 Guide for Vacuum Baking15.1 ScopeThis Appendix specifies typical procedures and processes which may be used whenvacuum components and materials used for vacuum components for the ITERproject are required to be baked. It is intended that the suppliers using such processes should follow the guidance inthis Appendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components supplied comply with the requirements of the ITERVacuum Handbook. 15.2 General CommentsVacuum components for the various classifications may require to be baked toensure satisfactory vacuum performance. Baking can be included as in thecomponent leak testing procedure (Appendix 12) and/or the component cleaningprocedure (Appendix 13). A bake temperature and duration will normally be specifiedin the specification documents and/or drawings for individual components orassemblies. If this is not the case, then the standard temperatures and durationslisted in Table 15-1 should be used. Vacuum baking has three functions, viz., (a) the removal of contaminants which canbreak down to volatile components under the application of temperature (b) reducingthe outgassing rate of the surface by accelerating the thermal desorption ofmolecular species (most often water) and (c) opening up incipient leaks, particularlyporosity, where the leak path has been blocked by, for example, a carbon inclusion. In order that the objectives of this Appendix are achieved, the times andtemperatures specified for vacuum bakes have been based on considerableexperience of using the processes. In the following sections, the term “vacuum item” shall be taken to refer to anindividual vacuum component, a sub-assembly or complete assembly as appropriate. It may also refer to material, e.g. steel sheet, being processed prior to manufacture. Where the temperature is too high for a composite assembly the component partrequiring higher temperature baking should be baked at that temperature prior toassembly and then the complete assembly baked at the lowest listed temperature ofthe component parts. Temperature requirements for baking materials not listedshould be accepted in advance of baking operations. Where the manufacturer is unable to carry out a bake procedure, either to thestandard conditions in Table 15-1 or as otherwise specified, then any variation shallbe accepted by ITER before proceeding. Page 278 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 4 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65FTable 15-1Standard Temperatures and Durations for Vacuum BakingVacuum Classification Temperature(oC)Time(hr)CommentVQC 1 240 24VQC 1* 350 24 Stainless steel and beryllium450 - 2000 24 Carbon composites (see Appendix16)250 24 Precipitation-hardened copper alloys350 24 Tungsten* For vacuum items in line vicinity of plasma15.3 General Procedures for Baking of Vacuum Items15.3.1 PreliminaryPrior to baking, the vacuum item will have been thoroughly cleaned in accordancewith the procedure of Appendix 13 of the ITER Vacuum Handbook. If the vacuum item is not capable of being vacuum sealed and pumped down (e.g. itmay be a batch of material or a part-finished vessel), then the vacuum item should besubjected to a total immersion bake (see 15.5.1 below)All vacuum flanges should be sealed with a blank flange of material and thicknesssimilar to that on the main vacuum item, using gaskets of the type to be used whenthe vacuum item is in service and fasteners of the appropriate strength. Where a copper gasket is to be used and the bake temperature is greater than100oC, then the gasket should be silver plated to avoid the formation of a loose oxideon the atmospheric side of the joint. The vacuum item should be placed in or on a suitable bakeout stand which cansafely support the vacuum item at the maximum temperature of the bake procedure. Any fixings should take into account the thermal expansion of the vacuum item andstand. The vacuum item should be pumped down to an appropriate vacuum level andthoroughly leak tested to the appropriate specification in accordance with Appendix12 of the ITER Vacuum Handbook prior to starting any baking process. 15.3.2 Vacuum Pumps and GaugesVacuum Pumps of the appropriate pumping speed and base pressure specificationshould be used in these processes. Vacuum pumps used for these processes should be inherently clean (e.g. turbomolecular pumps with magnetic or greased bearings, dry backing/roughingpumps, cryosorption pumps or sputter ion pumps). Otherwise, the supplier needs tosatisfy ITER that a suitable failsafe trapping system has been implemented to protectagainst back-streaming and/or pump failure. Page 279 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 5 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65FVacuum gauges (total and partial) with suitable measurement ranges and withappropriate calibration certificates should be fitted as required to monitorsatisfactorily the progress of the bakeout process. The manufacturer should provide ITER with complete details of all such equipment(including manufacturer, age, calibration certificates and history). No bake procedure should be started before ITER has accepted the use of thisequipment. ITER will have the right to request documentary proof of the performance of thepumping equipment in the form of blank pump down characteristics and/or residualgas scans of the pumping equipment. 15.3.3 Temperature Monitoring and ControlThe manufacturer should implement a suitable system to monitor, control and recordthe temperature of the baked vacuum item throughout the procedure. It is important that the rate of rise and fall of temperature is controlled to within theaccepted specification as detailed in the accepted baking procedure. Full details of this system should be supplied to ITER. No bake procedure may be started before ITER has accepted the use of thisequipment. 15.3.4 Completing the Bake ProcessWhen the temperature of the vacuum item has fallen to room temperature, thevacuum item should be leak tested thoroughly to the appropriate specification inaccordance with Appendix 12 of the ITER Vacuum Handbook. The vacuum item should be vented to dry nitrogen (dew point –50 °C), removed fromthe bakeout stand and suitably packed and protected for transport or storage. 15.4 Control of the Bake ProcessTo avoid undue stress on the vacuum item being baked, the temperature should becontrolled such that it is uniform to within ±20 °C at all points on the surface of thevacuum item, unless otherwise accepted by ITER. The temperature differential across a metal sealed vacuum flange pair of greater that200 mm diameter should be less than 10 °C at all times. The rate of rise and fall of the temperature of the vacuum item should be held withinspecified limits and, unless otherwise accepted by ITER, should be no greater than10 °C per hour. When the temperature is falling, it is normally permissible to switch off thetemperature control when the temperature falls below 50 °C and let the vacuum itemcool naturally to room temperature. Thus for a 200 °C bake, the rise time will normally be 18 hours, the dwell time 24hours and the fall time 15 hours plus the natural final cooling time. Page 280 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 6 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65FAt no time during the bake process should the pressure within the vacuum item beingbaked exceed 10-3 Pa. If it should approach this level, the temperature must be helduntil the pressure falls again as the outgassing rate decreases. The use of a residual gas analyser to monitor the bake process is strongly advised. This can indicate possible leaks opening up during the process. It can also be usedfor “end point” detection – e.g. when the water peak falls to below a specified partialpressure. 15.5 Types of Bake Procedure15.5.1 Total Immersion BakeIn this procedure, the vacuum item is totally immersed in the vacuum environment ofa vacuum furnace which is capable of reaching the required temperature andmaintaining a pressure less than 10-3 Pa at the maximum temperature used. The manufacturer should, before the start of any baking process, demonstrate toITER, by the provision of residual gas analysis spectra of the furnace during a blankrun at the temperature to be used for the bake procedure, that the vacuum level andthe cleanliness of the furnace at the temperature at which the bake is to beperformed is satisfactory for the purpose . This requirement may be waived byagreement with ITER where the furnace has not been used for any other purposebetween two successive bake processes for the ITER organisation. Any vacuum joints on the vacuum item to be baked shall be left open. The vacuum item is placed in the furnace, which is sealed and pumped down to thestarting pressure with equipment conforming to the requirements of Section 15.3.2above. The furnace is checked for leaks. The appropriate time/temperature bake cycle is carried out. 15.5.2 Oven BakeThe vacuum item, which will be a sealed vacuum vessel or assembly, is placedinside a suitable insulated enclosure and connected by a suitable pumping manifoldto a vacuum pumping system conforming to the requirements of Section 15.3.2above. The arrangement shall be accepted by ITER before use. Wherever possible, a suitable vacuum gauge or gauges capable of being operated atthe maximum temperature of the bake cycle should be attached directly to the vesselor assembly being baked. Pressure readings on these gauges should be scaled toroom temperature values by the appropriate temperature correction factor. The insulated enclosure may be heated by convection heaters, radiant heaters or hotgas. It is recommended that some form of circulation of the air inside the enclosurebe used to assist temperature uniformity. A suitable number of temperature monitors should be fixed to the vacuum item sothat the temperature distribution may be adequately monitored to ensure that theappropriate limits are not exceeded (15.4 above). Page 281 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 7 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65FIf any glass or similar viewports or accessories are fitted, they should be covered intriple thickness aluminium foil for thermal protection and fitted with suitablemechanical protection against impact or implosion. The assembly should be leak tested to the appropriate specification. The appropriate time/temperature bake cycle is carried out15.5.3 “Tape” BakeIn this procedure, the sealed vacuum item is wrapped with heater tapes. Rodheaters, heater plates or flange band heaters may also be used. A suitable number of temperature monitors is fixed to the vacuum item so that thetemperature distribution may be adequately monitored to ensure that the appropriatelimits are not exceeded (15.4 above). In this case, it is very important to monitor thetemperature on each side of every large (i.e. greater than 200mm diameter) flangepair. Temperature measurement sensors will normally be located close to the heatingdevice (i.e. in the location of highest expected temperature)Wherever possible a suitable vacuum gauge or gauges capable of being operated atthe maximum temperature of the bake cycle are attached directly to the vessel orassembly being baked. Pressure readings on these gauges should be scaled to roomtemperature values by the appropriate temperature correction factor. The vacuum item is connected by a suitable pumping manifold to a vacuum pumpingsystem conforming to the requirements of Section 15.3.2 above. The assembly shall be leak tested to the appropriate specification in accordance withAppendix 12 of the ITER Vacuum Handbook. The vacuum item may then be wrapped in aluminium foil to assist in uniformity of thetemperature distribution, taking care around electrical connections. If there are glass or similar viewports or accessories fitted, they must be covered intriple thickness aluminium foil for thermal protection and fitted with suitablemechanical protection against impact or implosion. The vacuum item is then covered with suitable thermal insulation, preferably aceramic fibre filled flexible jacket or blanket. The appropriate time/temperature bake cycle is carried out. 15.5.4 Air BakeWhere an air bake is specified for any item, the general procedures are as specifiedin this Appendix for the particular type of bake (Immersion, Oven or Tape) except thatin this case all sections referring to pumping are ignored and all surfaces (interior andexterior) of the item shall be exposed to normal atmospheric air during the bakeprocess. Vacuum equipment conforming to the above requirements may still be requiredwhere a leak test and/or outgassing test has been specified as part of the bakeprocess either before or after such a process. Page 282 of 382ITER_D_2DU65F v1.3ITER Vacuum Handbook: Appendix 15Revision: 1.3 Date: July 28th, 2009 Page 8 of 8ITER Vacuum Handbook Appendix 15 IDM Ref :ITER_D_2DU65F15.6 Documentation to be SuppliedFor each vacuum item, the following certificates and records will normally besupplied:¾ If requested by ITER a record of the performance of the pumping equipment¾ A certificate of the initial leak rate¾ A certificate of the final leak rate¾ A record of the temperature distribution for the item and pressure within thevacuum item against time for the full duration of the bakeout process¾ If agreed between the manufacturer and ITER, a full record of any residualgas scans taken with appropriate time markers which identify the scans to theposition on the component bakeout cycle¾ Full documentation regarding any leaks or other problems which occurredduring the tests and any remedial action takenPage 283 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 16 Conditioning of Carbon CompositesApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID27YH3UVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 284 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 16 Conditioning of Carbon Composites (27YH3U)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 13 Jan 2009v1.2 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 285 of 382ITER_D_27YH3U v1.2ITER Vacuum Handbook: Appendix 16Revision: 1.2 Date: July 28th, 2009 Page 1 of 4Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 16Guide to the Conditioning Carbon Composites for the ITER ProjectPage 286 of 382ITER_D_27YH3U v1.2ITER Vacuum Handbook: Appendix 16Revision: 1.2 Date: July 28th, 2009 Page 2 of 4ITER Vacuum Handbook Appendix 16 IDM Ref :ITER_D_27YH3U16 Vacuum Conditioning of Graphite and Carbon Composites.. 316.1 Scope.. 316.2 Procedures.. 316.2.1 Procedure for high temperature baking.. 316.2.2 Procedure for lower temperature baking.. 4Page 287 of 382ITER_D_27YH3U v1.2ITER Vacuum Handbook: Appendix 16Revision: 1.2 Date: July 28th, 2009 Page 3 of 4ITER Vacuum Handbook Appendix 16 IDM Ref :ITER_D_27YH3U16 Vacuum Conditioning of Graphite and CarbonComposites16.1 ScopeIn order to remove absorbed impurities from graphite or carbon fibre compositematerials it may be necessary to vacuum bake the raw material in a suitable vacuumfurnace. This Appendix outlines a process which may be used when graphite and carboncomposites which are used on the ITER project are required to be baked. It is intended that the suppliers using such processes should follow the guidance inthis Appendix to achieve the requirements of the ITER Vacuum Handbook. The supplier is at liberty to utilise other techniques not described in this Appendixprovided that the components supplied comply with the requirements of the ITERVacuum Handbook. 16.2 ProceduresThe supplier shall perform a degassing cycle on components after machining to aprocedure accepted by the ITER Vacuum Responsible Officer in accordance withAppendix 15 of the ITER Vacuum Handbook . The temperature of the bakeout cycle will depend on the base pressure achievable inthe vacuum furnace. Leak tests of the vacuum furnace should be carried out in accordance with the ITERVacuum Handbook. 16.2.1 Procedure for high temperature bakingThe preferred outline procedure is as follows. 1. Condition the furnace. 2. Load the component parts. 3. Achieve a vacuum pressure of < 10 Pa. 4. Perform a leak test of the furnace. The acceptance leak rate will normallybe < 10-6 Pa.m3.s-15. Increase the temperature of the furnace to 2000 °C, maintaining thepressure at < 10 Pa6. Hold at 2000 °C for 24 hours maintaining the pressure at < 10 Pa. 7. Cool under vacuum to 400 °C. 8. Back fill the furnace with pure (UHP grade) Nitrogen to ~30 kPa. 9. Cool to room temperature. 10. Vent the furnace to atmospheric pressure with Nitrogen (zero grade). 11. Package the parts in accepted packaging and atmosphere. Page 288 of 382ITER_D_27YH3U v1.2ITER Vacuum Handbook: Appendix 16Revision: 1.2 Date: July 28th, 2009 Page 4 of 4ITER Vacuum Handbook Appendix 16 IDM Ref :ITER_D_27YH3U16.2.2 Procedure for lower temperature bakingIn order to maintain the furnace base pressure < 10-3 Pa the baking temperature maybe lowered as follows:1. Condition the furnace. 2. Load the component parts. 3. Achieve a vacuum of < 10-3 Pa. 4. Perform a leak test of the furnace. The acceptance leak rate will normallybe < 10-6 Pa.m3.s-15. Increase the temperature of the furnace to 450 °C, maintaining thepressure < 10-3 Pa. 6. Hold at 450 °C for 24 hours maintaining the pressure at < 10-3 Pa. 7. Cool under vacuum to 400 °C. 8. Back fill the furnace with pure (UHP grade) Nitrogen to ~30 kPa. 9. Cool to room temperature. 10. Vent the furnace to atmospheric pressure with Nitrogen (zero grade). 11. Package the parts in accepted packaging and atmosphere. Page 289 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 17 Guide to Outgassing Rates and theirMeasurmentApproval ProcessName Action AffiliationAuthor Worth L. 08 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 08 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2EXDSTVERSION CREATED ON / VERSION / STATUS08 Sep 2009 / 2.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 290 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 17 Guide to Outgassing Rates and their Measurment (2EXDST)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 15 Jan 2009v1.2 In Work 15 Jan 2009v2.0 Signed 17 Feb 2009v2.1 Signed 02 Sep 2009 Minor textual changes for consistency with Vacuum Handbook. Refferenceadded. Corrections to outgassing rate tablesv2.2 Approved 08 Sep 2009 Correction to cryostat outgassing figuresPage 291 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 1 of 28Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 17Guide to Outgassing Rates and their MeasurementPage 292 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 2 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST17.1 Scope.417.2 Limitations.417.3 Specific Outgassing Rate.417.4 Generic Methods of Measuring Outgassing Rates.517.4.1 Rate of Rise of Pressure Method.517.4.2 Dynamic Flow (Conductance) Method.617.4.3 Variant Dynamic Flow Methods.717.4.4 Weight Loss Method.717.5 Sources of Errors in Measuring Outgassing.717.5.1 System Effects.717.5.1.1 Vacuum Vessels and Conductance’s.717.5.1.2 Vacuum Gauges.817.5.1.3 Vacuum Pumps.817.5.1.4 Temperature.817.5.2 Gas Sources and Sinks.817.5.2.1 General Types of Gas Source or Sink.817.5.2.2 Surfaces as Sources.917.5.2.3 Surfaces as Sinks.917.5.2.4 Joints.1017.5.2.5 Leaks.1017.5.2.6 Moving items.1017.5.2.7 Gauges as Sources.1017.5.2.8 Gauges as Pumps.1017.5.3 Some Practical Considerations.1117.5.3.1 Minimising Errors.1117.5.3.2 Time Zero for outgassing.1217.5.4 Stating Outgassing Requirements.1317.5.4.1 Vessel or Component Acceptance Tests as normally used in a Vacuum Quality AssuranceSeries of Procedures.1317.5.4.2 Testing items, materials or procedures for acceptability for more general use.1317.6 Procedures.1417.6.1 General.1417.6.1.1 Start Time.1417.6.1.2 Pump Set Conditioning.1417.6.1.3 Vacuum Vessel Outgassing Measurements.1417.6.1.4 Vacuum Component or Sample Outgassing Measurements.1417.6.2 Rate of Pressure Rise Method.1517.6.2.1 Equipment.1517.6.2.2 Procedure.1517.6.3 Dynamic Flow Method.1617.6.3.1 Equipment.1617.6.3.2 Procedures.1617.6.3.2.1 Outgassing measurements on a vessel.1617.6.3.2.2 Outgassing measurements on coupon samples.1717.7 Presentation of Results.1817.8 Derivation of the ITER Outgassing Rate Requirements.1817.8.1 Vacuum Vessel.1917.8.2 Cryostat.20Page 293 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 3 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST17.9 Outgassing Rates Review.2317.9.1 Material thermal outgassing.2317.9.2 Unbaked Stainless Steel.2417.9.3 Baked Stainless Steel.2417.9.4 Organic Material.2517.10 Outgassing Rates - Published Data.2517.10.1 Stainless Steel.2517.10.2 Epoxies.2617.11 References.28Page 294 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 4 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.1 ScopeThis Appendix is intended as a guide to the measurement of the total and partial thermaloutgassing rates of materials, vacuum vessels, components and assemblies for therequirements of the ITER Project. It is intended that the guide be used to assist suppliersin producing outgassing test procedures to comply with the mandatory requirements of theITER Vacuum Handbook. It also gives details on how the outgassing requirements forITER systems have been derived. It is envisaged that outgassing tests will normally be performed on components, parts ofthe component or “coupons” which have been subjected to the complete manufacturingprocess. Manufacturing operations which have been applied, including baking andcleaning operations, should be recorded and traceable to the coupon (where used) or tothe manufactured component. 17.2 LimitationsThis Appendix describes a set of procedures for the measurement of thermal outgassingfrom a vacuum item when used as part of the vacuum quality assurance procedures forthe ITER Project. This Appendix describes the recommended procedures of the mostwidely used methods of measuring the outgassing rates; it does not consider all availablemethods. Despite this limitation, the techniques are more widely applicable and form abasis for more general good practice. The supplier is at liberty to propose other methods of thermal outgassing measurementnot described in this Appendix. When this set of procedures is used to measure the outgassing from a component orcoupon placed within a vacuum chamber, the outgassing of the chamber walls cannotusually be neglected and must be subtracted from the measured value to obtain that fromthe coupon. For this, an independent measurement of the wall outgassing from the emptychamber will be required – often referred to as a blank run. Unless otherwise specifically indicated, outgassing measurements using these procedureswill be carried out with the component under test at 100 °CIn these procedures the term outgassing shall be taken to mean thermal outgassingunless otherwise indicated. The methods of measuring outgassing rates described in these procedures yield anaverage value of the outgassing rate for each surface exposed to the vacuummeasurement system. 17.3 Specific Outgassing RateOutgassing is described in terms of the rate of desorption of gas from a vacuum surface. The measured (or net) outgassing rate is the difference between the intrinsic outgassingrate (of the component) and the rate of re-adsorption on the surfaces of the test chamber. The specific outgassing rate defined as the total gas load generated per unit time due togas desorbing from a vacuum surface due to the temperature of the surface per unit areaof desorbing surface. It is represented here by qth. Units are Pam3s-1m-2Page 295 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 5 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Clearly,A q Q th th⋅ =Where:Qth is the total outgassing rate (Pa.m3.s-1)A is the area of the desorbing surface (m2)17.4 Generic Methods of Measuring Outgassing Rates17.4.1 Rate of Rise of Pressure MethodThis method of measuring outgassing rates is in principle very simple, but there are anumber of considerations that need to be taken into account if the measurements are tobe meaningful. The principle of the method is that if one has a volume evacuated to a given pressure p0and then isolated from the vacuum pump, the specific thermal outgassing rate qth is givenbyqVA(p p )t tht0=⋅−where V is the containing vessel volumeA is the total internal surface area of the desorbing surfacep t is the pressure after a time interval tprovided that the outgassing rate is reasonably constant with both pressure (over therange ptĺp0) and the time interval t and that the temperature of the outgassing surfaces isconstant. Partial (i.e. species dependent) outgassing rates may be determined by using a calibratedgas analyser to measure the rate of rise of the partial pressure of a particular species. What is actually measured using the rate of rise technique when the pressure remains inthe high vacuum region or below, is the increase in number density of gas moleculesentering the measurement volume of the “pressure” sensor. This increase can be affectedby various processes, which can be classified as being either gas sources or gas sinks. Agas source is something which releases gas molecules into the interior of the vessel, andhence eventually into the measurement volume. A gas sink is something which adsorbs orabsorbs a gas molecule which strikes it, i.e. it acts as a pump. This is further discussedlater. This method is quite simple to implement and requires the minimum of equipment. Since,during the measurement time the vacuum pump is valved off, there is no need to know thepumping speed (especially where the speed may be species dependent). Only onevacuum gauge is required. For absolute measurements, the gauge needs to be calibratedPage 296 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 6 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST for the outgassing species. Where only relative measurements of outgassing are required(e.g. before and after a process such as baking), provided the gauge is known to bereasonably stable in sensitivity, calibration may not be required. No vacuum parameters of the system need to be calculated or measured, apart from thepressure. This method works best for relatively low outgassing rates, where measurements can betake over a long time period. For high outgassing rates, the rise in pressure can be quiterapid, making time and/or pressure dependent measurements difficult. The volume of the vessel (and all appendages) needs to be measured or calculated to areasonable degree of accuracy. This method is more suitable for the measurement of outgassing from vessels orassemblies rather than coupon samples, unless either the intrinsic outgassing rate of thecoupon is very much higher than that of the containing vessel or the surface area of thesample is much higher than that of the vessel or both. 17.4.2 Dynamic Flow (Conductance) MethodIn this method, the item being measured is pumped through a known conductance andthe pressure difference across this conductance is measured. The specific thermaloutgassing rate qth is then given byApC qthΔ⋅ =where:C is the conductanceǻp is the pressure difference across the conductanceA is the area of the desorbing surfacePartial (i.e. species dependent) outgassing rates may be determined by using calibratedgas analysers to measure the differences in partial pressure of the particular species. The method is suitable for all but the lowest values of outgassing, since the value of theconductance can be chosen to give a sensible pressure difference. Variation in outgassingrate with time can readily be measured even when the outgassing rate is quite high or isvarying relatively rapidly and the volume of the vessel is not required. The method requires two vacuum gauges which must both be calibrated for the desorbingspecies for the most accurate results. Both must remain stable across the full range ofmeasurement for the duration of the test. If partial outgassing rates are required, then twocalibrated residual gas analysers (RGAs) should be fitted. It requires the use of a pump whose speed is much larger than the conductance for all gasspecies. The conductance, which is gas species dependent, must be measured or calculated to areasonable degree of accuracy. Page 297 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 7 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST When measuring outgassing from coupon samples, the outgassing rate of thecontainment vessel must remain sufficiently stable for a blank run to yield a meaningfulcorrection. 17.4.3 Variant Dynamic Flow MethodsOne variant of this method assumes that the pressure on the pump side of theconductance is very much less than that on the sample side and so can be ignored. In thiscase only one calibrated gauge and one RGA is required, both situated upstream of theconductance. Good practice would require a total pressure gauge also to be fitteddownstream of the conductance to ensure that the pressure conditions were being met,but this gauge need not be calibrated. A second variant uses an arrangement of valves so that a single calibrated gauge canalternatively be exposed to either side of the conductance. This requires good linearity inthe gauge and an outgassing rate which is stable over the time of measurement. 17.4.4 Weight Loss MethodThe method of weight loss measurement can be used to measure outgassing rates frommaterials with high outgassing rates, for example organic materials. The test consists of measuring the weight loss of a sample which has been subject to adefined thermal cycle under vacuum. The sample is placed in an effusion cell and heated. The outgassing flux is condensed on temperature controlled collectors which are placed infront of the sample. From the mass deposit on the collector the total mass loss (TML) andhence outgassing rate are derived, as function of time, and is usually expressed as %TMLThe setup and procedure are described in the ASTM E595-93 standard and are widelyused in characterisation of materials for use in space applications. 17.5 Sources of Errors in Measuring OutgassingAll methods of measuring outgassing are susceptible to errors which may yield misleadingresults. Detailed consideration should always be given to this. 17.5.1 System Effects17.5.1.1 Vacuum Vessels and Conductance’sEither the internal volume of the outgassing measurement chamber, or the conductancebetween this and the pump, must be known to a reasonable degree of accuracy,dependent on the technique employed. Volumes are notoriously difficult to measure orcalculate to high accuracies and are temperature dependent. In some cases (e.g. wherebellows are present) they may also be dependent on the atmospheric pressure in thelaboratory. Volumes will change if there are movable items present, e.g. vacuum valves. The value of a conductance element is also temperature dependent and, moreimportantly, dependent on the mass of the gas species traversing the conductance. Tosome extent the transmission probability of gas molecules through a conductance isdependent on the size and shape of the vacuum chamber at each end. Page 298 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 8 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST It is usually assumed that in measuring outgassing, free molecular flow conditions prevail. This may or may not be the case and needs to be checked. In the dynamic flow method, it is assumed that outgassing of the vacuum systemdownstream of the conductance does not influence what is happening in themeasurement chamber upstream of the conductance. 17.5.1.2 Vacuum GaugesThe calibration of both total pressure and partial pressure gauges is non trivial and thestability of many gauges is not good. Clearly this may introduce significant measurementerrors, especially in the two-gauge dynamic flow method. 17.5.1.3 Vacuum PumpsPumping speeds of vacuum pumps vary with the species being pumped, so for thedynamic flow method it is important to ensure that a sufficiently high pumping speed (i.e. compared to the conductance for the particular gas species) is maintained at all times. 17.5.1.4 TemperatureSome of the effects of temperature have been discussed above. However, outgassing isitself strongly dependent on temperature, so it is important that for the most accuratemeasurements, the entire apparatus is maintained at a constant temperature during theperiod in which measurements are being taken. 17.5.2 Gas Sources and SinksErrors in measured outgassing rates may be affected by sources of gas other than trueoutgassing entering the measuring volume of the gauge or gauges used. In this case anenhanced value will be measured. Likewise any pumping in the vessel for whichoutgassing is being measured will lead to an apparent value being measured which islower than the true value. In extreme cases, negative values of apparent outgassing maybe measured. 17.5.2.1 General Types of Gas Source or SinkPossible sources of gas include:¾ any surfaces exposed to the vacuum which release molecules by desorption otherthan thermal desorption or by permeation¾ all joints, which tend to be areas of increased permeation¾ leaks, real or virtual¾ any gauge¾ gas bursts from items moving in the vacuum systemPossible sinks for gas include:Page 299 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 9 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST ¾ any surfaces exposed to the vacuum which can exhibit wall pumping, particularly“active” surfaces found in capture pumps even when switched off¾ any gauge which can act as a pump17.5.2.2 Surfaces as SourcesThe point of the measurement is to measure thermal desorption from the surface ofinterest, i.e. gas molecules released by the absorption of phonons, so it is important thatextraneous forms of desorption are minimised. Details are not discussed here, but itshould be noted that the surfaces under investigation should not be exposed to significantfluxes of photons of wavelengths shorter than the short-wavelength end of visible or toelectrons of energy greater than a few eV. It is also important that the temperature of thesurfaces under test is kept constant as thermal desorption is an exponential function oftemperature. For metals at room temperature, permeation is only significant for hydrogen and even thatwould normally be very low unless very thin walls are present or when measuring very lowoutgassing rates. However it should be remembered that hydrogen is by far the dominantspecies in such cases and there is some debate as to whether hydrogen permeation is infact the rate limiting step in outgassing from metals. The source of the hydrogen may beeither dissolution from the bulk metal or passing from atmosphere on one side of the wallto the other. In practice, both will happen. Glasses, plastics and elastomers may have quite large permeabilities for hydrogen, heliumor water. Care must therefore be exercised when these are exposed to both atmosphereand vacuum. A special case of thermal outgassing is evaporation or sublimation of the wall material(vapour pressure). For most normal vacuum materials, this is only a problem whenmeasuring extremely low outgassing rates. 17.5.2.3 Surfaces as SinksWhen gas molecules strike a surface, in general they stick. They may stick for a short timebefore being re-emitted or they may stick for a long time. Here, the former process isignored although it is important for the thermodynamics of the system. However, the latterprocess gives rise to the phenomenon known as wall pumping. In some cases thisprocess can be enhanced by preparing a surface which is chemically active anddeliberately used as a pump in, for example, a Titanium Sublimation Pump (TSP) or aNon-Evaporable Getter (NEG). A similar effect is seen when a surface is cooled tocryogenic temperatures. In normal circumstances the walls of a vacuum system aresufficiently inert that wall pumping is insignificant. However there are circumstances wherethis may not be the case. A surface which has been glow discharged will have had itschemistry altered somewhat and until a passivation film, usually an oxide, is formed mayexhibit wall pumping. Similarly a surface where the gas concentration has been reducedby photon desorption, electron or ion desorption or high temperature thermal desorptionmay be sufficiently far from equilibrium to exhibit wall pumping. It is very difficult to estimate what wall pumping speeds might be in such circumstances. Page 300 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 10 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.5.2.4 JointsVacuum joints can be regions of enhanced permeability, especially demountable jointsusing elastomer gaskets. However, welds and brazes may also be suspect. If componentshave been hydrogen brazed, then enhanced hydrogen outgassing may be experiencedfrom all surfaces. Joints which have been welded using the Tungsten Inert Gas (TIG)process may exhibit enhanced outgassing of (usually) argon. 17.5.2.5 LeaksNaturally, the presence of leaks can vitiate any sensible measurement of outgassing andso thorough leak checking of the test system is a necessity. 17.5.2.6 Moving itemsWhen items move in a vacuum, gas molecules can be desorbed. The most commonmoving item in an outgassing measurement system will be a vacuum valve. These cangenerate significant gas bursts when moving. This can be minimised by operating themslowly and by thorough outgassing. In practice, this is not usually very important in measuring outgassing rates. In the case ofrate-of-rise measurements, the system is sealed and static. Any gas generated when thevalve is closed at the start of measurement forms part of the base pressure. In the twogauge dynamic flow technique, valve states do not change during the measurement. Inthe variant of this technique where a single gauge is exposed successively to either sideof the conductance to eliminate gauge errors, some care has to be exercised to minimiseany such effects. 17.5.2.7 Gauges as SourcesHot filament gauges are clearly potentially major sources of error in measurements of thistype, since they not only run at high temperatures but will also cause local heating of thevacuum system. Enhanced outgassing will be experienced from the gauge and walls. Cold cathode gauges are better than hot filament gauges in this respect since theyoperate at room temperature. Ionisation gauges, hot or cold cathode, are also sources of x-rays, ions and electrons ofsufficient energy to cause desorption when they strike surfaces. Cold cathode gauges mayalso generate energetic neutrals which may themselves cause desorption. 17.5.2.8 Gauges as PumpsAll ionisation gauges will act as pumps. Hot filament Bayard-Alpert Gauges typicallyexhibit pumping speeds of around 0.1 l.sec-1 but this will normally be swamped by theoutgassing. Cold cathode gauges of the Penning or magnetron (whether inverted or not) type may wellexhibit (net) pumping speeds of up to 1 l.sec-1. Page 301 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 11 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.5.3 Some Practical Considerations17.5.3.1 Minimising ErrorsClearly if one wishes to measure an outgassing rate, all of the above effects may play apart in introducing errors. Good vacuum practice will help in many cases to vitiate theworst of these. Leak testing should be carried out with a sensitivity of at least an order ofmagnitude better than the measured total outgassing rate. Permeation (but not of coursebulk dissolution) can be reduced by surrounding the measurement chamber with a guardvacuum. Wall pumping may be reduced by waiting or by saturating the surface with aninert gas. This may of course make nonsense of what one is trying to do!In practice, the bulk of the errors will come from the gauge. A hot cathode gauge shouldbe mounted on a water-cooled side arm, preferably with a cooled baffle in the gaugethroat. It should be well-degassed, and any pressure difference between the gauge andthe measurement chamber carefully evaluated. If possible a cold cathode gauge shouldbe used or a gauge specially designed to minimise outgassing. The gauge head must be mounted out of line of sight of the surfaces being tested andtubulation to the gauge head should have as large a conductance as possible. As is sooften the case, such requirements are to some extent contradictory so some compromiseis necessary. There is not a lot one can do to eliminate the effects of gauge pumping. Recent developments using stable field ion emitters as the electron source for a Bayard-Alpert gauge may offer a good compromise for measuring low outgassing rates. Thetemperature effect is eliminated and gauge pumping is relatively low. Energetic electronsand X-rays are still produced however. The most troublesome effect is gauge pumping. In many cases it is relatively easy toguess what the minimum outgassing rate to be expected from a sample might be. Thesurface area of the sample should then be such that the expected gas load generated issignificantly greater than the gas load pumped by the measuring gauge. If this is not thecase, then the measurement is not meaningful. In some cases, where the measured pressures are within it’s operating range, a suitablegauge is the spinning rotor gauge. Outgassing form this type of gauge is simply that of itsrather small internal surface area and there is no pumping effect. It is best suited to rate ofrise measurements. Because not all sources of error can be eliminated, rate-of-rise measurements, forexample, can only set a lower bound for the outgassing rate. It may be possible toestimate an upper bound by guessing the gauge pumping speed. If these two values arereasonably close, then the result may be meaningful. This assessment cannot be doneunless a real effect, i.e. a measurable pressure rise, is obtained. It will be apparent that in the rate of rise method, sufficient time must be allowed for thepressure to rise significantly. Initially after isolating the main pump, there will be a periodwhen the system is not in a steady state as the various gas sources and sinks settle down,but in a well-behaved and well designed experiment, this should be relatively short and fora constant outgassing rate a log-log plot of pressure against time should yield a straightline of positive slope. For outgassing rates close to the pumping speed of the systemsensible measurement times may well be of the order of hours, not minutes. Page 302 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 12 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.5.3.2 Time Zero for outgassingAs noted earlier, the outgassing rate measured is a function of the time that a surface hasbeen exposed to vacuum (i.e. has been pumped), and an idealised characteristic is shownin Figure 17.5.3-1 (Note that no great significance should be attached to the actual valuesof outgassing rate shown in the figure.) It is clear that the measured value of outgassingwill depend on when the measurement is made. 1.00E-111.00E-101.00E-091.00E-081.00E-070.1 1 10 100 1000Time (hr)Outgassing Rate (Pa.m3.s-1)Figure 17.5.3-1 Idealised outgassing rate of a surface as a function of exposure time to vacuumBecause of the above, in order to achieve some sort of comparability, outgassing ratesare often quoted as either 1 hour, 10 hour, 100 hour or “long term” rates. These are ratesmeasured at these time intervals after time = 0. One matter of particular difficulty isdetermining just when time = 0 actually is. In a pump down, for example, when is thepressure determined by outgassing rather than removal of gas from the volume?Since this set of procedures is intended for use in a quality assurance environment, thisdifficulty can be circumvented by careful specification of what should be done in individualcases. Page 303 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 13 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.5.4 Stating Outgassing Requirements17.5.4.1 Vessel or Component Acceptance Tests as normally used in a VacuumQuality Assurance Series of ProceduresIn the specification for the vacuum item, if an outgassing test is required, then thespecification should state the requirement in one of three alternative forms. These are asfollows:“x hours after the end of the procedure y, the specific outgassing rate shall be less than avalue of z Pa.m3.sec-1.m-2 using the measurement techniques described in the ITERVacuum Handbook Appendix 17.”or“m hours after the end of the procedure n, the total outgassing rate shall be less than avalue of r Pa.m3.sec-1 using the measurement techniques described in the ITER VacuumHandbook Appendix 17.”or“k hours after the end of procedure g, the steady state specific outgassing rate shall beless than a value of s Pa.m3.sec-1.m-2 using the measurement techniques described in theITER Vacuum Handbook Appendix 17”. The steady state outgassing rate is defined at as the outgassing rate at the time when therate of change of measured outgassing rate is less that 5 % over an elapsed time of 120minutes. That is to say:05 . 0) 120 () 120 (≤−++tt tqq qWhere q(t) = specific outgassing rate at time t (minutes). Procedures y, n and g will have been defined earlier in the specification and, unless thereare good reasons otherwise, x and m will normally be 10 hours. 17.5.4.2 Testing items, materials or procedures for acceptability for more generaluseSuch tests are of a more generic nature and so some standardisation of results isnecessary. There are two particular cases to be considered (a) where there is no form ofprocessing and (b) where there is a processing stage included e.g. a bake. Where no processing is involved outgassing measurements should be taken at intervals of1 hour, 10 hours and (optionally) 100 hours after the start of pump down of the vacuumitem. It should be noted that such results may be influenced by the pumping speedapplied, so this should always be quoted. Following a process stage, outgassing measurements should be taken at intervals of 1hour, 10 hours and (optionally) 100 hours after the end of the process. In the case of aPage 304 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 14 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST bakeout, the end of the process may be defined as when the system returns to roomtemperature, unless a particular specification states otherwise. It should be noted thatresults may be influenced by the pumping speed applied, so this should always be quoted. 17.6 Procedures17.6.1 General17.6.1.1 Start TimeIn the following procedures, it is assumed that the appropriate starting time formeasurements has been set according to the considerations discussed earlier. This isreferred to below simply as the start time. 17.6.1.2 Pump Set ConditioningBefore the start time, all pump sets will have been conditioned and proved to be leak tightand clean. 17.6.1.3 Vacuum Vessel Outgassing MeasurementsThe vessel should be assembled into the appropriate apparatus using flanges andgaskets appropriate to the vacuum regime for which the vessel is designed. In the case of the measurement of outgassing of a vacuum chamber whilst being pumpedfrom atmospheric pressure, a preliminary pump down should be made and the vessel andits appendages proved leak tight. Following this leak test, the vessel should be vented toeither clean dry nitrogen (dew point < -50oC) or normal atmosphere as specified in the testdocumentation. If nothing is so specified, then clean dry nitrogen is recommended. In the (usually rare) circumstances of an outgassing measurement being required for avessel in “as received” condition, then leak tests should be carried prior to the completionof the outgassing measurements to ensure that the results are not dominated by any leakbeing present. Clearly, great care must be taken during assembly to minimise thepossibility of such leaks. If such a leak is detected, the originator of the request for testmust be consulted before any further work is carried out. 17.6.1.4 Vacuum Component or Sample Outgassing MeasurementsThe component or sample should be inserted into a vacuum chamber for which theoutgassing characteristics have been established in a blank run immediately prior to thetests. For a meaningful measurement of outgassing, the expected outgassing load of thecomponent or sample must be at least 10 times greater than that of the empty chamber. The procedure to be followed will be the same as that for a vessel as specified in therequest for test. Page 305 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 15 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.6.2 Rate of Pressure Rise Method17.6.2.1 EquipmentThe equipment used will typically take the form shown in Figure 17.6.2-1. Figure 17.6.2-1 of outgassing - pressure rise technique. The choice of pumping set and the type of total pressure gauge to be used will depend onthe maximum total pressure expected during the measurements. The gauge is shown as acold cathode device, but need not be. There are distinct advantages to using a SpinningRotor Gauge if the pressures measured lie within its range of operation. The use of a partial pressure gauge will normally mean that the total pressure should notnormally rise above about 10-3 Pa during measurements unless some sort of samplingstage is used. The pump set should be chosen so that the volume may be evacuatedthrough the valve to a reasonable pressure in a reasonable time. What “reasonable”means must be assessed on a case-by-case basis, but must be short compared to thetime at which the first outgassing result is required. 17.6.2.2 ProcedureWith the pump set under vacuum at or close to its ultimate, the vacuum valve is openedcarefully and the volume evacuated to its base pressure or for the time at which anoutgassing measurement is required, whichever is less. Any processes specified (e.g. a bake cycle) are completed. If the pressure achieved is below about 10-6 Pa, then any hot filament measuring devicesshould be thoroughly outgassed and the outgassing products pumped away. The vacuum valve is closed and the pressure or partial pressure of the species of interestrecorded at frequent intervals until a pressure rise of at least one decade is obtained. Thetimes of recording each pressure should be noted. The use of a continuous record as on achart recorder or a data logger is to be preferred. Page 306 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 16 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST If outgassing measurements are required at a number of values of pumping time, then thevalve should be opened and the process repeated at the appropriate time. The outgassing rate(s) are then calculated using the above formula. 17.6.3 Dynamic Flow MethodNote that only the two-gauge method is described here. 17.6.3.1 EquipmentThe equipment used will typically take either of the forms shown in Figure 17.6.3-1. Thaton the left is more suited to measurements on vessels or assemblies, that on the right tocoupon samples. Figure 17.6.3-1 Equipment for the measurement of outgassing - dynamic flow technique. The choice of pumping set and the types of total pressure gauges to be used will dependon the maximum total pressure expected during the measurements. The gauges shownare cold cathode devices, but need not be. The use of partial pressure gauges willnormally mean that the total pressure should not normally rise above about 10-3 Pa at thegauge during measurements, unless some sort of sampling stage is used. The pump setshould be chosen so that the volume may be evacuated to a reasonable pressure in areasonable time. What “reasonable” means must be assessed on a case-by-case basis,but must be short compared to the time at which the first outgassing result is required. The value of the conductance should be chosen so that a reasonable pressure differentialis obtained. 17.6.3.2 Procedures17.6.3.2.1 Outgassing measurements on a vesselHere, the equipment shown on the left of Figure 17.6.3-1is the more suitable. Page 307 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 17 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST With the pump set under vacuum at or near its ultimate, vacuum valves V1 and V2 areopened carefully and the volume evacuated to its base pressure or for the time at whichan outgassing measurement is required, whichever is less. Any processes specified (e.g. a bake cycle) are completed. If the pressure achieved is below about 10-6 Pa, then any hot filament measuring devicesshould be thoroughly outgassed and the outgassing products pumped away. The vacuum valve V1 is closed and the pressures on either side of the conductancemonitored until the values have stabilised over a period of about 15 minutes. If quasi-continuous measurements of outgassing as a function of time are required, thensets of readings shall be taken at appropriate time intervals. If outgassing measurements are required at a number of discrete values of pumping time,then the valve V1 is opened after a set of readings is complete and closed shortly beforethe next set is due, allowing sufficient time for the system to stabilise before each set ofreadings. The outgassing rate(s) are then be calculated using the formula above. 17.6.3.2.2 Outgassing measurements on coupon samplesIn this case, the equipment shown on the right of Figure 17.6.3-1 is the more suitable. To be meaningful, the following procedure should be carried out first with the upper (test)chamber empty, then vented to clean, dry (dew point <-50oC) nitrogen and the sampleinserted. The sequence is then repeated, the sample removed and, ideally, a finalsequence carried out on the empty system. The two blank (i.e. empty chamber) runsshould give consistent results. The measured pressure in the upper chamber with thesample inserted must be significantly higher than the blank runs if a meaningful value ofoutgassing is to be calculated. With the pump set under vacuum at or near its ultimate, the valve to the pumping set (notshown) and the by-pass valve are opened and the volume evacuated to its base pressureor for the time at which an outgassing measurement is required, whichever is less. The by-pass valve should be of sufficient size that adequate pumping speed is achieved abovethe conductance. Any processes specified (e.g. a bake cycle) are completed. If the pressure achieved is below about 10-6 Pa, then any hot filament measuring devicesshould be thoroughly outgassed and the outgassing products pumped away. The by-pass valve should be closed and the pressures on either side of the conductancemonitored until the values have stabilised over a period of about 15 minutes. If quasi-continuous measurements of outgassing as a function of time are required, thensets of readings should be taken at appropriate time intervals. If outgassing measurements are required at a number of discrete values of pumping time,then the by-pass valve should be opened after a set of readings is complete and closedshortly before the next set is due, allowing sufficient time for the system to stabilise beforeeach set of readings. Page 308 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 18 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST The outgassing rate(s) are then calculated using the formula above. 17.7 Presentation of ResultsOn completion of outgassing tests a report should be issued recording:¾ full details of the apparatus used (including volumes where appropriate)¾ copies of calibration certificates for all gauges used¾ details of the calculation of the value of the conductance (where appropriate)¾ results of system leak tests¾ proof of cleanliness of the pump set¾ tabulated measurements of pressure with times at which readings were taken orcopies of recorder traces as appropriate¾ tabulated values of calculated total and partial outgassing rates as appropriate17.8 Derivation of the ITER Outgassing Rate RequirementsThe limits of outgassing rates for materials for use in ITER vacuum systems are givenTable 17.8-1, which is Table 5-1 of the ITER Vacuum Handbook and the values aretherefore mandatory. These limits have been produced by taking into account the total surface area expected,available pumping speed, the desired pressure, and post assembly conditioning time, withdue consideration of what is reasonably achievable. Page 309 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 19 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Maximum steady stateOutgassing ratePa.m3.s-1.m-2VQC+Outgastemperature°CHydrogenisotopesImpurities Testing Guidelines1 100‡ 1 x 10-7 1 x 10-9 Appendix 172 20 1 x 10-7* Appendix 173 20 1 x 10-8 Appendix 174 20 1 x 10-7 Published data and conformityto clean work plan. For VQC 2, 3 and 4, the outgassing rate excludes the partial outgassing rate for water and hydrogen. ‡ The outgassing test temperature can be reduced to 20 °C for components which normally operate atcryogenic temperatures. + For CFC, refer to the ITER Vacuum Handbook Section 26.7* In the case of resins for magnets, it is considered that this target outgassing rate will be achievable. However a factor 10 increase will be permitted as an acceptance criterion. Table 17.8-1 – Outgassing rates pertaining to VQC17.8.1 Vacuum VesselIn calculating the maximum outgassing rates specified for the Vacuum Vessel (VQC 1) thefollowing assumptions and calculations have been used. The approximate total surface area of vacuum vessel is 20000 m2 and is calculated as thesum of the following:¾ vacuum vessel+ports ≈ 3000 m2¾ port plugs ≈ 4000 m2¾ blankets ≈ 5000 m2¾ divertor ≈ 2000 m2¾ piping ≈ 1000 m2¾ in-vessel cabling ≈ 2500 m2¾ fixtures and fittings ≈ 2500 m2The ITER Project Integration Document (PID) specifies the vacuum vessel base pressureto be < 10-5 Pa for hydrogen and <10-7 Pa for impurities prior to ITER operations at theoperating temperature of 100 °C. Page 310 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 20 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Using a conservative estimate of the vacuum vessel pumping speed of 20 m3.s-1 yields aderived maximum hydrogen throughput of 2 x 10-4 Pa.m3.s-1Thus, the maximum allowable outgassing rate of hydrogen prior to pulsing is calculatedas,2 - 1 - 3 84m . s . Pa.m 10 12000010 0 . 2 −−= = = xxAQqIt is expected that a factor 10 decrease in the outgassing rate for hydrogen can beachieved by baking the vessel to 200 °C and hence the maximum outgassing rates forVQC 1 components has been defined in Table 17.8-1 as:¾ 1x10-7 Pa.m3.s-1.m-2 for hydrogen at 100 °C¾ 1x10-9 Pa.m3.s-1.m-2 for impurities at 100 °C17.8.2 CryostatThe outgassing requirement for VQC2 is derived from the need to manage three areas:-1) To be able to pump down the cryostat initially in a reasonable time with limitedpumping and conditioning capacity and to achieve a level of vacuum suitable for aninsulation vacuum. 2) To avoid poisoning of the activated charcoal in the reference cryostat cryo-pumpswith heavy hydrocarbons. 3) To ensure that over time, the build up impurities on the cold thermal shields doesnot adversely affect their emissivity and hence the heat load on thesuperconducting coils and the cryo-plant. The specified outgasing limit for VQC 2 excludes water because it is considered that it willnot be possible during the cryostat construction to avoid surfaces becoming watercontaminated. It is the case that for item 3 above water ice is likely to be the dominant issue. Howeverother gasses which are condensable at 80K can also present a similar problem and thesecan be more difficult to condition once the cryostat is complete. To quantify an acceptableoutgassing rate, water is used below, as there is a better database available for therelevant emissivity change. In calculating the maximum outgassing rates specified for the ITER cryostat (VQC 2) thefollowing assumptions and calculations have been used. Page 311 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 21 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Source[27] A (m2)[27] qH2O(Pa.m3.s-1.m-2)+QH2Otot(Pa.m3.s-1)Pressure in cryostat(H20,Pa)‡Metallic surface 2.5 x 104 1 x 10-7 2.5 x 10-3 5.0 x10-5Vacuum facing epoxy 1.3 x 103 1 x 10-5 1.3 x 10-2 2.6 x 10-4‡Assumes 50 m3s-1 H2O cryostat pumping speed.[27]+Values from Table 17.8-1 & equation Section 17.8.1 after 100 hours. Table 17.8-2- Assumed cryostat areas and calculated H2O outgassing ratesUsing the figures from Table 17.8-1 the calculated partial pressure of water vapour in thecryostat prior to the cool down of the magnets is approximately 2.6 x 10-4 Pa. The 2007 ITER PID value for partial pressure of H2O before cool-down is quoted as ” 2 x10-7 Pa. This figure is considered to be unachievable and the basis can not be found. Assuming the cryostat thermal shield does not cool uniformly, residual water will initiallycondense on cold spots covering an estimated 10% of the thermal shield surface areawith an equivalent thickness of 0.02 monolayers. After baking the vacuum vessel and cooling the magnet structures and thermal shields,the remaining source of condensable water will be from the cryostat walls and internalcomponents which are at ambient (or elevated) temperature, having an estimated totalsurface area of 3000 m2. Assuming a steady state outgassing rate of 1 x 10-7 (H2O) Pa.m3.s-1.m-2, the load to thethermal shield remains unchanged for 3 years. Over approximately 8 years a coverage ofH2O of 2000 monolayers (1μ thickness) will form on the cryostat-facing thermal shield. Thechange in emissivity of the thermal shield due to formation of this water layer results in acalculated increase in heat load to the cryo-plant of approximately 50% [28]. The ice crystal size significantly affects the infra-red absorption and consequently theemissivity of a panel: the larger the crystals, the higher is the emissivity; therefore themorphology of the ice formation significantly effects the change in emissivity. In this estimation, it is assumed that the water forms a uniform layer of ice over thethermal shield with the coverage rate constant over the time period considered. If thecoverage rate is not constant, and it is assumed water condenses on the thermal shield inbatches as “snow”, the time taken for a similar change in emissivity decreases toapproximately 3 years. The effect on emissivity due to the build up of ice can be seen in Figure 17.8.2-1[28] andthe effect on the additional load to the cryo-plant due to water condensing on thecryostat-facing thermal shield is shown in Figure 17.8.2-2[28]. Page 312 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 22 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Figure 17.8.2-1 Effect on emissivity due to ice layer formationIt is considered that the effect on the emissivity of the cryostat thermal shields will begreater due the condensation of hydrocarbons outgassing from the cryostat internalcomponents. Hence the maximum outgassing rate from cryostat vacuum-facing surfacesis defined in Table 17.8-1 to be1 x 10-7 Pa.m3.s-1.m-2 (excluding water and hydrogen) atambient temperatureIn order to reduce the steady state outgassing rate of water from the cryostat internalsurfaces, a method of purging the cryostat with dry nitrogen prior to cool down of themagnet structures and thermal shields is being studied. The order in which the cryostatcryogenic surfaces are cooled, and the resulting effect on the emissivity of the cryostatcold surfaces due to condensed gas, is also to be studied. (See [28] for furtherrecommendations)Page 313 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 23 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST Figure 17.8.2-2 Additional power load on thermal shield coolant due to H2O Outgassing17.9 Outgassing Rates ReviewThe purpose of this section of the Appendix is to outline the methodology used in theassessment of outgassing rates from published data and to establish the relationshipbetween common parameters which influence material outgassing rates17.9.1 Material thermal outgassingThermal outgassing from material surfaces is time and temperature dependant and it canbe shown that the measured outgassing rate from a metallic surface will increase by factorof about 10 by increasing the sample temperature from ambient to 100 ºC, and increasesby a further decade by raising the sample temperature from100 to 250 ºC.[5]The medium term (1 to 100h) outgassing from a surface can be described by a power lawof the form:α − = t Q Q . 0Where, Į (the outgassing decay index) is typically near unity for metallic surfaces and 0.5for epoxies and t is the time in hours [21]. Page 314 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 24 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST The outgassing rate of a surface is also dependant on the surface condition. Factorsaffecting the outgassing rate include:¾ chemical composition¾ the presence of oxide layer’s¾ surface finishing¾ cleaning and other processesReferences to published data, listing outgassing rates for materials after varying surfacetreatments, are to be found in Section 17.10. While a large record of outgassing rates can be found in literature for vacuum compatiblematerials comparisons of the reported data are difficult as, in many cases, for the samematerial differing surface treatments and measurement techniques are reported, someimportant factors may not be reported at all. 17.9.2 Unbaked Stainless SteelThe rate of outgassing from unbaked stainless steel is dependant of the process to whichthe stainless steel surface has been subjected. Outgassing rates gathered from literature(see Section 17.10) for Stainless steel after surface treatments are summarised in Table17.9-1. SST treatment qtot (Pa.m3.s-1.m-2) at 1h, 20ºCAs received/fresh 1x10-4Degreased 2x10-6Surface finished (machined) 2x10-7Table 17.9-1 Outgassing rates of stainless steel after surface processingGenerally water is the dominant species outgassed from unbaked stainless steel and willevolve at a rate dependant on the elapsed pumping time of the surface. Generally, forunbaked stainless steel surfaces, water will remain the dominant outgassing species atpumping times in excess of 100 h. 17.9.3 Baked Stainless SteelBaking at 150 ºC for a minimum of 24 h can reduce the total outgassing rate by a factor of100 as water is desorbed from the metal surface. After this time the predominantoutgassing species from clean stainless steel is hydrogen [5]. A reduction in the hydrogenoutgassing rate can be achieved by vacuum firing or air baking the material. After baking, stainless steel will generally exhibit outgassing rates between 10-9 and 10-10Pa.m3.s-1.m-2 (see Section 17.10.1)Page 315 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 25 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.9.4 Organic MaterialFor organic materials (epoxies etc), the method of weight loss measurement is usuallyused for the determination of outgassing rates with the outgassing rate quoted as apercentage of total weight loss, or gram/s. Using the formula below the outgassing rate can be calculated from the total mass lossmeasurement3 10 ⋅ ⋅ =MRTdtdM qwhere:q is the outgassing rate in Pa.m3.s-1.m-2R is the universal gas constant (83.14 mbar.l.mol-1.K-1)dM/dt is the mass loss per unit time (g.s-1)T is the sample temperature (K)M is the molecular mass of the outgassing speciesUsing the above formula it can be shown that for water outgassing from a surface at a rateof 1μg.s-1 the specific outgassing rate near room temperature will be approximately 1Pa.m3.s-1.m-2. The outgassing rate of organic materials is also dependent on the fabrication process(curing temperature, chemical hardener, vacuum, inert gas process, etc.). There is a lackof published data on outgassing rates for material of the same composition which hasundergone different fabrication processes, making comparisons difficult. Hencequalification of new organic materials for use on ITER will have to be performed usingexperimental data. An analysis of weight loss measurements on epoxies shows that the ratio of wateroutgassing to impurity outgassing is approximately 100 to 1, so, assuming a wellcontrolled fabrication process, a low outgassing epoxy should outgas at a rate in the rangeof 10-7 Pa.m3.s-1.m-2 (excluding water) after 100 h baking (see Section 17.10.2). 17.10 Outgassing Rates - Published DataOutgassing rates quoted in referenced publications are summarized in the tables below. 17.10.1 Stainless SteelPublished data on the outgassing rates of stainless steel following various surfacetreatments is given in Table 17.10-1Page 316 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 26 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST TreatmentTotal outgassing rate(Pa.m3.s-1.m-2)Time meas. (hours)ReferenceNone 2x10-4 1h 2None 2x10-5 10h 2Polished & vapor degreased 1.4x10-6 10h 2None 1.1x10-7 100h 2Degrease + water rinse 4.0x10-8 40h 2Degrease + water rinse, baked invacuum 150ºC for 12h4.0x10-9 5h after bakeout 2Baked 24h @ 200°C 9.3x10-10 100h 2Unbaked 2x10-7 10h 1Baked (150º C,24h) 2x10-9 1Std cleaning 10-6 1h 3Baked 10-8 1h 3Untreated 7x10-5 4Degreased 1x10-6 4Baked 3x10-10 4unbaked 9x10-7 20h 5Electrochemical buffing 5x10-8 50h 8Electrochemical buffing followed bybaking(215 °C,23h) and air(10days)1x10-8 50h 8Electropolished, baked, airoxidation1x10-11 9Air exposure/baking cycles 1x10-10 10UT cleaning + bake 250C,24h 3x10-10 12Various treatments 2x10-6 100h 13Annealing+bake 2x10-11 14Air firing 3x10-11 15Pre-baking+baking 4x10-10 164x10-9 17 Chemical cleaning1x10-6 1h 188x10-72x10-919 CleanedWith bakeout2x10-6 4h 20Table 17.10-1 Outgassing rates for stainless steel – published data17.10.2 EpoxiesPublished data on the outgassing rates of various epoxies and resins is given in Table17.10-2MaterialOutgassing rate(Pa.m3.s-1.m-2)Outgassing rate% Total Mass Loss (TML)ReferencePage 317 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 27 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST MaterialOutgassing rate(Pa.m3.s-1.m-2)Outgassing rate% Total Mass Loss (TML)ReferenceRF4000 EV Roberts(baked)5x10-6 (10h)ERL4221 union carbide(baked)1x10-5(10h)CY179 Ciba Geigy(baked)3x10-6(10h)1138 Ciba-Geigy(baked)2x10-6(10h)828 Shell chemical(baked)1x10-5(10h)22DGEBA, +  materials 10-3 -10-4(10h) 23Stycast 4x10-5 (72h) 0.87 24Redux 312UL 7x10-6(72h) 0.40 25Ablebond Ablestik0.2ESAdatabaseAraldite resin 10-3-10-4(10h) 1Polymers 10-5(10h) 26Table 17.10-2 Outgassing rates for epoxies and resins – published dataPage 318 of 382ITER_D_2EXDST v2.2ITER Vacuum Handbook: Appendix 17Revision: 2.2 Date: July 29th , 2009 Page 28 of 28ITER Vacuum Handbook – Appendix 17 ITER Ref: ITER_D_2EXDST 17.11 References>@3&KLJJLDWR2XWJDVVLQJ&$6>@0:RQJUHYLHZRIRXWJDVVLQJUDWHV0DUKWWSKRPHIQDOJRYaPOZRQJRXWJDVBUHYKWPFOHDQ>@30RQQHDX6'06/HGpJD]DJH'HF>@9$5,$18+9FRXUVH>@-+&UDLJ-967$YRO$SU>@+@06XHPLWVX-967$YRO0D\>@@.2NDGD9DFXXPYRO>@.2NDGD-967$YRO2FW>@-3%DFKHU&(51-967$YRO-DQ>@-'+HUEHUW-967$YRO-XO>@+)'\OOD-967$YRO6HS>@@9%ULVVRQ9DFXXP>@@.-0LGGOHPDQ9DFXXP>@$5RWKYDFXXPWHFKQRORJ\WKLUGHGLWLRQ>@-0/DIIHUW\YDFXXPVFLHQFHDQGWHFKQRORJ\>@1+DUULVPRGHUQYDFXXPSUDFWLFH>@0/LDQG+)'\OOD-679$YRO-XO$XJ>@65RVHQEOXP-679$YRO-DQ)HE>@60XUDOLWKDU7ULXPSKUHSRUW'HF>@26,UHSRUW1RY>@26,UHSRUW2FW>@$%HUPDQYDFXXPFDOFXODWLRQV>@0:\NHVHWDOµ'HVLJQ6WDWXVRIWKH,7(5FU\RVWDW+LJK9DFXXP3XPSLQJ6\VWHPµ3URFHHGLQJV62)7>@$$QWLSHQNRY0HPR´7KHUPRVKLHOG,FLQJµ,'05HI(<&Page 319 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 18 Vacuum Reliability DataSource document for referenceApproval ProcessName Action AffiliationAuthor Worth L. 07 Feb 2011:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewers Pearce R. 29 Mar 2011:recommended IO/DG/COO/PED/FCED/VSApprover Kim Y.- H. 05 May 2011:approvedDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2F2PYSVERSION CREATED ON / VERSION / STATUS07 Feb 2011 / 2.0 / ApprovedEXTERNAL REFERENCE / VERSIONPage 320 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 18 Vacuum Reliability Data (2F2PYS)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 13 Dec 2010 New document createdv2.0 Approved 07 Feb 2011 New data addedPage 321 of 382ITER Vacuum Handbook : Appendix 18Revision: 2.0 Date: February 2011 Page 1 of 8Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER ITER Vacuum Vacuum Handbook HandbookAppendix Appendix 18Vacuum component reliability dataPage 322 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSCONTENTS18 Vacuum component reliability data.318.1 Scope.318.2 Source data.318.3 Failure rates for major vacuum components.418.4 Failure rates for bellows.618.5 Failure rates for metallic tubing and pipework.718.6 Other References.8Page 323 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYS18 Vacuum component reliability data18.1 ScopeThis document is a summary compilation of reliability data of vacuum componentsculled from a variety of sources (See Section 18.2). All failure rate data quoted isaverage value and is presented as frequency per annum. All mtbf (mean time beforefailure) values are in yearsBy the very nature of such data this summary cannot be fully comprehensive, giventhe large variety of vacuum components and materials which are available from adiverse number of manufacturers. In addition, although there is a vast quantity ofcomponents in use around the world, there is little systematic gathering of data onfailure modes and failure rates. One assumes that individual manufacturers collectsuch data for their own components (and maybe that of their competitors) but little ispublished and the remainder is generally inaccessible to usersAnecdotal data, based mainly on experience in the world of accelerators, suggeststhat an ordered listing of vacuum component failures causing leaks would looksomething like (worst to best): - damaged or improperly made demountable vacuum seals edge-welded bellows leaks valve seat leaks ceramic or glass component shock damage ceramic or glass to metal seal failure (corrosion or otherwise) brazed coolant feedthrough seal corrosion hydroformed or rolled bellows failure weld leaks metal porosityIt is difficult to draw systematic conclusions from the data presented, perhaps castingsome doubt on its statistical significance. It is important when making anyassessment of such data to ensure that one is comparing like for like. All data quotedin this appendix is believed to be inherently comparable, coming from the fusion andaccelerator communities, where the vacuum atmosphere is relatively non-aggressive,as opposed to the semiconductor industry for example, where chemical corrosion is amajor problem18.2 Source dataTitle Author Date Reference CitedasVacuum System OperatingExperience Review for FusionApplicationsL.CCadwallader1994 EGG-FSP-11037ITER/US/93/TE/SA-18LCC-1In-Vessel ITER Tubing FailureRates for Selected Materialsand CoolantsT DMarshalland L C1994 EGG-FSP-10928 TDMPage 324 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSCadwalladerSelected Component Failurerate values from Fusion SafetyAssessment TasksL.CCadwallader1998 INEEL/EXT-98-00892 LCC-2Fusion Component FailureRate DatabaseT. Pinna 2001 FUS-TN-SA-SE-R-43http://spx595.frascatienea.it:8080/homepage.nsf*TP-1Collection and analysis of datarelated to fusion machinesT. Pinna etal2005 Fusion Engineeringand Design 75-79(2005) 1199TP-2Failure Rate Estimate forStainless Steel Piping used inITER Vacuum SystemL.CCadwallader2010 LCC-3Vacuum Bellows. VacuumPiping, Cryogenic Break andCopper Joint Failure RateEstimates for ITER DesignUseL.CCadwallader2010 INL/EXT-10-18973 LCC-4* Page unavailable in Sept 2010In reality, the information in the paper by Pinna (TP-1) – which is a description of thedatabase rather than digested information contained therein – is very limited andrepeats that in LCC-2 so is of little additional value in this context. As noted above,the actual database is no longer accessible at the url cited (or indeed the alternativecited in Fusion Engineering and Design, 51-52, November 2000, 579-585)The data listed in LCC-1 and LCC-2 is derived from a range of operating facilities –fusion machines, accelerators, space simulators and industrial vacuum furnaces. Thedata in TP-2 derives from experience at JET and TLK. Note that this paper does notcite error factorsLCC-4 is an attempt to draw together as much relevant data as is available in orderto provide a reasonable estimate of the likely reliability of the ITER vacuum system18.3 Failure rates for major vacuum componentsThe following sections provide a digest of the failure rates for major types of vacuumcomponents from the sources cited. The figures will be averages and need to betreated with some care – one would expect there to be some variance betweenspecific models of each type of component, especially when these are available fromdifferent manufacturers. This is probably the reason why there is considerablevariability in the figures quoted – there is insufficient information cited to clarify thisaspectFor simplicity, values are quoted in two different formats – in terms of failure rates peryear and MTBF (mean time before failure) in years. The quoted error factor is ameasure of the reliability of the data – the lower the better. This will be related ofcourse in some way to both the number of data points available and their spread. It isnot clear how this figure is derived and it is not available for some of the dataPage 325 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSIt should be noted that the figures quoted are derived on the assumption thatdistribution of failures in time follows the “bathtub” curve and that these lie on the partof the curve where failure rates are nearly constant18.3.1 Failure rates for vacuum pumpsType of Pump Failure modeFailurerate peryearMTBF(yr)ErrorfactorSourceRough Pumps Failure to operate 0.13 7.6 1.2 LCC-2External leak 5.0X10-3 200.0 10 LCC-2Turbo Pump Bearing failure 7.9X10-2 12.7 3 LCC-1Housing Leak 5.0X10-3 200.0 10 LCC-1Cryosorption pump Housing Leak 5.0X10-3 200.0 10 LCC-1Cryopumps Failure to operate 1.8X10-2 57.1 10 LCC-2Leak into vacuumchamber0.18 5.7 1.7 LCC-2TSP Filament o/c 1.8X10-2 57.1 1.7 LCC-1Feedthrough leak 0.65 1.5 1.4 LCC-1Housing Leak 3.0X10-5 33333.3 10 LCC-1NEG (Cartridge) Failure to operate 7.9X10-3 126.8 LCC-1Housing Leak 3.0X10-5 33333.3 10 LCC-1Ion Pump Failure to operate 0.18 5.7 3 LCC-1Housing Leak 3.0X10-5 33333.3 10 LCC-1Feedthrough leak 13 0.8 1.4 LCC-118.3.2 Failure rates for vacuum gaugesType of gauge Failure modeFailurerate peryearMTBF(yr)ErrorfactorSourceRough Vacuum Gauges Failure to operate 0.88 1.1 10 LCC-2Leak 1.0X10-3 1000.0 3 LCC-2Pirani gauge Failure to operate 0.26 3.8 10 LCC-1Leak 6.0X10-3 166.7 2.2 LCC-1High Vacuum Gauges All modes 6.0X10-3 166.7 2.2 LCC-2Penning gauge All modes 6.0X10-3 166.7 LCC-1BAG All modes 6.0X10-3 166.7 2.2 LCC-1Not specified Leak 2.5X10-2 39.4 TP-218.3.3 Failure rates for vacuum gate valvesType(where known)Failure modeFailurerate peryearMTBF(yr)ErrorfactorSourceFailure to operate 0.88 1.1 2 LCC-1Failure to operate 4.4X10+2 0.0 2 LCC-2Failure to operate 9.6X10-4 1037.8 TP-2Spurious open or close 2.6X10-2 38.1 10 LCC-2Motorised Spurious open or close 4.4X10-4 2283.1 10 LCC-1Pneumatic Spurious open or close 2.6X10-2 38.1 10 LCC-1Solenoid Spurious open or close 4.4X10-3 228.3 10 LCC-1Housing Leak 1.8X10-3 570.8 10 LCC-1Housing Leak 1.8X10-3 570.8 10 LCC-2Housing Leak 6.6X10-3 152.2 TP-2Seat leak 2.6X10-2 38.1 30 LCC-1Seat leak 2.6X10-2 38.1 30 LCC-2Seat leak 4.6X10-2 21.5 TP-2Page 326 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSVacuum gate valves can have one of two distinct types of actuator for the sealmechanism. The first uses a shaft sliding through a sealing bush or gland. In thesecond type, the motion is accommodated by means of a bellows, normally an edgewelded bellows. Although it is not clear to which type the data in the table refers, it ismost likely to be the latter which are more reliable. Bellows leaks are not specificallyidentified in the data but probably dominate the statistics quoted for housing leaks18.3.4 Failure rates for standard fittingsGroup Type Failure modeFailurerate peryearMTBF(yr)ErrorfactorSourceMetal gasketflange160-215mm Leak 1.0X10-3 1000.0 3 LCC-1295-360mm Leak 6.0X10-2 16.7 3 LCC-1>1m Leak 0.5 2.0 10 LCC-1Bolt 1.8X10-4 5707.8 10 LCC-1Window Leak 1.2X10-2 81.5 1.8 LCC-118.4 Failure rates for bellowsVacuum bellows are used in vacuum systems to facilitate motion, to take upexpansion and contraction and to compensate for construction inaccuracies. Thereare two major families, edge welded bellows which are fabricated from stacks of thinannuli welded alternately on the outer and inner diameters, and formed bellowswhich are rolled or moulded from thin seam welded sheet or thin wall drawn tube. However, because of the different characteristics of these two types of bellows, it ismuch more likely that edge welded bellows will be used in motion actuators ratherthan in the relatively static applications for which formed bellows are more suitable. Lifetimes for edge welded bellows will therefore tend to be dominated by duty cyclerather than mtbf. It may be noted that for edge welded stainless steel bellows,manufacturers will typically quote lifetimes of 10,000 cycles. LCC-4 provides an extensive discussion of bellows failures based almost entirely ondata from LEP at CERN, as is that in LCC-1. The TP-2 data derives from JET. TheLCC-1 data is derived from 3 bellows failures during a vacuum bake in the earlyconditioning phase of LEP and are included in the early service leak data in LCC-4. The values of failure rates from CERN are based on assumptions about the time inservice of bellows units which do not appear to take into account duty cycles. Thishowever, would not explain the discrepancies in the values. Failure data is summarised in the table belowType Failure modeFailurerate peryearMTBF(yr)ErrorfactorSourceMetalBellowsLeak 70.1 0.14 1.6 LCC-1Leak 1.66x10-2 60.1 TP-2Page 327 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSEarly service leak 7.01x10-2 14.3 LCC-4Small leak (10-8 Pam3s-1)7.0X10-4 1430 LCC-4Large leak 8.8X10-5 11400 LCC-4Based on the derived operational data from LEP, LCC-4 calculates anticipatedlifetimes for the double bellows configuration anticipated for ITER. The values are, forsmall leaks, a failure rate of 7x10-6 per annum (mtbf 1.4x105 yrs) and for large leaks,8.8x10-7 and 1.1x106 respectively18.5 Failure rates for metallic tubing and pipeworkDetermining failure rates for metallic tubing and pipework is a very complex businesssince there are many variables to be taken into account. TDM, LCC-3 and LCC-4 gointo this in considerable detail for many of the potential situations relevant for ITER. For the purposes of the Appendix, we shall note that there are three distinctcategories of pipe and tubing – those forming a boundary between atmosphere orother gas and vacuum; those immersed in vacuum and containing water as acoolant; those immersed in vacuum and carrying a cryogenic fluid. In all cases, theinherent reliability of the system will most likely be dominated by joints rather than themetal itself. The data in TDM, LCC-3 and LCC-4 is derived mainly from fission reactor data withpipes carrying liquid coolant, so will be particularly relevant to water coolant lines inITER. Values for stainless steel pipe type 304L when scaled to ITER conditions aregiven below. The reliability of vacuum lines will be dominated by joints – seam welds,joining welds/brazes, etc., and should be comparable to any other vacuum envelopeFailure rate per year per mSchedule 20pipe1.2x10-7Schedule 10pipe2.4x10-7It may be of interest to note that the failure rates quoted above for vacuum pumphousings for ion pumps, TSPs and NEG pumps which are basically simple stainlesssteel vacuum vessels of characteristic dimension somewhat less than 1 m, are abouttwo orders of magnitude higher. Whilst it is true that the wall thickness will be lessthan schedule 10, it is difficult to account for this difference if it is statisticallysignificantTDM lists data for a number of different materials. It shows copper water cooingtubing to have failure rates rather more than two orders of magnitude worse than forstainless steel type 316L. It may be relevant to comment here that acceleratorexperience shows enhanced corrosion rates for copper in the presence of X-ray flux18.6 Other ReferencesL.C. Cadwallader and T. Pinna, Progress Toward a Component Failure Rate DataBank for Magnetic Fusion SafetyL.C. Cadwallader, Failure Rate Data Analysis for High Technology Components,INL/CON-07-12265Page 328 of 382ITER Vacuum Handbook Appendix 18 IDM Ref :ITER_D_2F2PYSThese references discuss methodology rather than providing dataPage 329 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 19 Documentation and QAApproval ProcessName Action AffiliationAuthor Worth L. 02 Sep 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 09 Sep 2009:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2DMNNRVERSION CREATED ON / VERSION / STATUS02 Sep 2009 / 1.4 / ApprovedEXTERNAL REFERENCE / VERSIONPage 330 of 382PDF generated on 24 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix 19 Documentation and QA (2DMNNR)Version Latest Status Issue Date Description of Changev1.0 In Work 27 Aug 2008v1.1 In Work 10 Sep 2008v1.2 In Work 13 Jan 2009v1.3 In Work 13 Jan 2009v1.4 Approved 02 Sep 2009 Minor textual changes for consistency with Vacuum HandbookPage 331 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 1 of 7Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPITER Vacuum HandbookAppendix 19Guide to Documentation and QA for Vacuumcomponents for use on the ITER ProjectPage 332 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 2 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR19 Documentation and Vacuum Quality Assurance.. 319.1 Scope of this Appendix.. 319.2 Areas to which Vacuum QA Applies.. 319.3 Supplier’s QA System.. 319.4 Certificates.. 319.5 Materials Used.. 419.5.1 Information Normally Required Prior to Manufacture.. 419.5.2 Normal Post Manufacture Certification.. 419.6 Cleaning and Processing.. 419.6.1 Information Normally Required Prior to Manufacture.. 419.6.2 Normal Post Manufacture Certification:.. 419.7 Assessment of Cleanliness.. 519.7.1 Information Normally Required Prior to Manufacture.. 519.7.2 Normal Post Manufacture Certification.. 519.8 Leak Tightness.. 519.8.1 Information Normally Required Prior to Manufacture.. 519.8.2 Normal Post Manufacture Certification.. 519.9 Outgassing Performance.. 619.9.1 Information Normally Required Prior to Manufacture.. 619.9.2 Normal Post Manufacture Certification.. 619.10 Baking.. 619.10.1 Information Normally Required Prior to Manufacture.. 619.10.2 Normal Post Manufacture Certification.. 6Page 333 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 3 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR19 Documentation and Vacuum Quality Assurance19.1 Scope of this AppendixThis Appendix describes typical documentation which should normally be producedto assure adherence to the Quality Assessment (QA) system for vacuum items foruse in the ITER Project. Suppliers who follow the guidelines contained in this Appendix will provide suitabledocumentation which will meet the requirements of the ITER Vacuum Handbook. Other forms of documentation which satisfy these requirements may be accepted. This Appendix does not specify a Quality Control System for vacuum items for theITER Project. This will be specified elsewhere to conform to the necessaryinternational standards. This document does not specify the technical requirements for, or specifications of,any individual vacuum item. Such information will be found in general form elsewherein the ITER Vacuum Handbook and in detail in the specification and/or drawingsissued by ITER for any particular tender or contract. In any dispute over QA related to vacuum procedures applied to or vacuumperformance of any item, the decision of the ITER Vacuum Responsible Officer (RO)will normally be taken as authoratative. 19.2 Areas to which Vacuum QA Applies¾ Materials¾ Satisfactory procedures for cleaning and processing¾ Assessment of cleanliness¾ Leak tightness¾ Outgassing performance¾ Baking19.3 Supplier’s QA SystemIt is to be expected that the supplier will have experience in operating a qualityassurance system to the relevant national or international standards, e.g. ISO 9001or equivalent. Evidence of this would normally be supplied with the tender orquotation process. 19.4 CertificatesExcept where the ITER Project has issued a specific pro-forma certificate pertainingto any requirement, the supplier should use a suitable certificate of the supplier’sdevising. Draft versions of such certificates should be submitted as part of the tenderor quotation process to be accepted before use. Certification should conform toEN 10204 2.2, 3.1 or 3.2Page 334 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 4 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR19.5 Materials Used19.5.1 Information Normally Required Prior to Manufacture¾ The supplier should supply typical certificates of chemical analysis for eachbatch of material called in the specifications and/or drawings, based on thesupplier’s previous experience of such materials. If the supplier has noprevious experience of using such materials, a statement of this fact should besupplied. ¾ The supplier should normally supply certificates and/or samples of capabilityof carrying out welding or other jointing techniques called in the specificationsand/or drawings for the materials to be used. 19.5.2 Normal Post Manufacture Certification¾ The supplier should issue a certificate that all materials used conform to thespecification and/or drawings, drawing attention to any discrepancies. ¾ Unless otherwise specified, certificates of chemical analysis of each batch ofmaterial used (e.g. ladle or ingot samples) are normally required. ¾ Forged stainless steels for use on VQC 1A components should be suppliedwith certificates of inclusion counts conforming to ASTM E-45 method D orequivalent. 19.6 Cleaning and Processing19.6.1 Information Normally Required Prior to Manufacture¾ The supplier should provide details of the cleaning processes to be used in theform of a job flow check sheet or diagram, together with a list of the chemicalsused. ¾ The supplier should provide details of all equipment to be used for cleaning orprocessing, including sizes, supplier and approximate date of manufacture. Details of all vacuum pumps and gauges which may be used in any processare to be included. Where any equipment cannot meet the requirements ofthe specification this must be clearly indicated. ¾ The supplier should provide details of any subcontractor to be used forcleaning and/or processing. 19.6.2 Normal Post Manufacture Certification:¾ The supplier should deliver a certificate for each item supplied showingcompliance with the appropriate specification. This will clearly identify the itemand record all significant parameters (e.g. time and temperature) of the majorstages of the processes applied and all equipment used. ¾ A non-conformance report should be provided for each item where anydeviation from the accepted procedures has occurred. Page 335 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 5 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR19.7 Assessment of Cleanliness19.7.1 Information Normally Required Prior to Manufacture¾ The supplier should provide details of the method or methods to be used toassess cleanliness of the items. ¾ The supplier should provide full details of all equipment to be used forassessing cleanliness including specification, supplier and approximate dateof manufacture. Details of all vacuum pumps and gauges to be used in anytesting are to be included. Where any equipment cannot meet therequirements of the specification this must be clearly indicated. ¾ The supplier should provide details of any subcontractor to be used forassessing cleanliness. 19.7.2 Normal Post Manufacture Certification¾ The supplier should deliver a certificate for each item supplied showingcompliance with the appropriate specification. This will clearly identify the itemand all equipment used. Included will be a record of all significant parametersof the major stages of the procedures used to carry out these tests andcalibration certificates for vacuum gauges and gas analysers used. Results ofany chemical analyses or residual gas spectra will be supplied in full. ¾ A non-conformance report should be provided for each item where anydeviation from the performance specification has occurred. 19.8 Leak Tightness19.8.1 Information Normally Required Prior to Manufacture¾ The supplier should provide details of the method or methods to be used toleak test the items in accordance with the ITER Vacuum Handbook. ¾ The supplier should provide full details of all equipment to be used for leaktesting including specification, supplier and approximate date of manufacture. Details of all vacuum pumps and gauges, including dates of calibration, to beused are to be included. Where any equipment cannot meet the requirementsof the specification this must be clearly indicated. ¾ The supplier should provide details of any subcontractor to be used for leaktesting19.8.2 Normal Post Manufacture Certification¾ The supplier should deliver a certificate for each item supplied showingcompliance with the appropriate specification. This will clearly identify the itemand all equipment used in these tests. Included will be a record of allsignificant parameters of the major stages of the procedures used andcalibration certificates for leak detection equipment and standard leaks used. ¾ A non-conformance report should be provided for each item where anydeviation from the performance specification has occurred. Page 336 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 6 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR¾ The supplier should report details of all leaks found during the manufacturingphase and details of remedial action taken to minimise the size of anyidentified leaks. 19.9 Outgassing Performance19.9.1 Information Normally Required Prior to Manufacture¾ The supplier should provide details of the method or methods to be used formeasuring outgassing in accordance with the ITER Vacuum handbookAppendix 17, where this is called for in the specification and/or drawings¾ The supplier should provide full details of all equipment to be used formeasuring outgassing including specification, supplier and approximate dateof manufacture. Details of all vacuum pumps and gauges, including dates ofcalibration, to be used are to be included. Where any equipment cannot meetthe requirements of the specification this must be clearly indicated. ¾ The supplier should provide details of any subcontractor to be used formeasuring outgassing. 19.9.2 Normal Post Manufacture Certification¾ The supplier should deliver a certificate for each item supplied showingcompliance with the appropriate specification. This will clearly identify the itemand all equipment used for these measurements. Included will be a record ofall significant parameters of the major stages of the procedures used andcalibration certificates for vacuum gauges and gas analysers used. ¾ A non-conformance report should be provided for each item where anydeviation from the performance specification has occurred. 19.10 Baking19.10.1 Information Normally Required Prior to Manufacture¾ The supplier should provide details of the method or methods to be used forBaking in accordance with the ITER Vacuum Handbook where this is calledfor in the specification and/or drawings¾ The supplier should provide full details of all equipment to be used for bakingincluding specification, supplier and approximate date of manufacture. Detailsof all vacuum pumps and gauges, including dates of calibration, to be usedare to be included. Where any equipment cannot meet the requirements of thespecification this must be clearly indicated. ¾ The supplier should provide details of any subcontractor to be used for baking. 19.10.2 Normal Post Manufacture Certification¾ The supplier should deliver a certificate for each item supplied showingcompliance with the appropriate specification. This will clearly identify the itemand all equipment used for these measurements. Included will be a record ofall significant parameters of the major stages of the procedures used andcalibration certificates for vacuum gauges and gas analysers used. Page 337 of 382ITER_D_2DMNNR v1.4ITER Vacuum Handbook: Appendix 19Revision: 1.4 Date: July 29th , 2009 Page 7 of 7ITER Vacuum Handbook Appendix 19 IDM Ref :ITER_D_2DMNNR¾ A non-conformance report should be provided for each item where anydeviation from the performance specification has occurred. Page 338 of 382PDF generated on 23 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMGuideline (not under Configuration Control)Appendix 20 Standard ComponentsApproval ProcessName Action AffiliationAuthor Pearce R. IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApproverDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: [CCS] CCS-All for Ext AM, LG: [CCS] CCS-Section Leaders, LG: [CCS] JACOBS,LG: [CCS] CCS-Doc CoIDM UID2F9QWXVERSION CREATED ON / VERSION / STATUS27 Aug 2008 / 1.0 / In WorkEXTERNAL REFERENCE / VERSIONPage 339 of 382ITER Vacuum Handbook: Appendix 21Revision: 1stDraft Date: August 26th, 2008 Page 1 of 5KEY: = approved for use. = not approved for use. = restricted useStandard Components TBDApplicable to Vacuum Quality ClassificationType Name / type1A 1B 2A 2B 3A 3B 4A 4BDouble bellows VAT series 10 VCR, all sizes ValvesVacuum FittingsPage 340 of 382ITER Vacuum Handbook: Appendix 21Revision: 1stDraft Date: August 26th, 2008 Page 2 of 5KEY: = approved for use. = not approved for use. = restricted useType Name / typeApplicable to Vacuum Quality Classification1A 1B 2A 2B 3A 3B 4A 4BPage 341 of 382ITER Vacuum Handbook: Appendix 21Revision: 1stDraft Date: August 26th, 2008 Page 3 of 5KEY: = approved for use. = not approved for use. = restricted useType Name / typeApplicable to Vacuum Quality Classification1A 1B 2A 2B 3A 3B 4A 4BPage 342 of 382ITER Vacuum Handbook: Appendix 21Revision: 1stDraft Date: August 26th, 2008 Page 4 of 5KEY: = approved for use. = not approved for use. = restricted useType Name / typeApplicable to Vacuum Quality Classification1A 1B 2A 2B 3A 3B 4A 4BPage 343 of 382ITER Vacuum Handbook: Appendix 21Revision: 1stDraft Date: August 26th, 2008 Page 5 of 5KEY: = approved for use. = not approved for use. = restricted useType Name / typeApplicable to Vacuum Quality Classification1A 1B 2A 2B 3A 3B 4A 4BPage 344 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMBaseline Report (not under Configuration Control)Appendix_21_Glossary_2F94QXGlossary of vacuum terms relevant to ITERApproval ProcessName Action AffiliationAuthor Worth L. 18 Mar 2011:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewersApprover Pearce R. 29 Mar 2011:approved IO/DG/COO/PED/FCED/VSDocument Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: Section Scheduling, AD: OBS - Vacuum Section (VS) - EXT, AD: OBS - VacuumSection (VS)IDM UID2F94QXVERSION CREATED ON / VERSION / STATUS18 Mar 2011 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 345 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAppendix_21_Glossary_2F94QX (2F94QX)Version Latest Status Issue Date Description of Changev1.0 In Work 09 Dec 2008v1.1 Approved 13 Jan 2009v1.2 Approved 18 Mar 2011 definition of seamless addedPage 346 of 382ITER Vacuum Handbook : Appendix 21Revision: 1.1 Date: December 9th , 2008 Page 1 of 6Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPReviewed byApproved byITER ITER Vacuum Vacuum Handbook HandbookAppendix Appendix 21Glossary of vacuum terms relevant to ITERPage 347 of 382ITER Vacuum Handbook Appendix 21 IDMRef :ITER_D_2F94QXNote that common standard vacuum terms related to gas flow, vacuum pumps orpressure measurement are not included as they may be found in any standardtextbook on the subjectBack-filling Raising the pressure of a vacuum space by admission of adefined gasBaking orbakeoutHeating of a vacuum component to remove adsorbed gas(usually water) from the surfaceBellows(incorrectlybellow)A section of a vacuum envelope which permits movement of onepart of the vacuum envelope with respect to another partBlow hole A surface hole in a material which has solidified from a liquid andwhich may join onto a void within the material, especially in aweld melt zone or in a braze fillBonding In this context, the joining of two materials or vacuum items toform a permanent, leak tight jointBrazing A technique for joining two items by filling the interspace betweenthem with another material, usually an alloy, which melts at atemperature lower than that of the items and which wets thesurface of each of the items, filling gaps between workpieces bycapillary actionClean A vacuum item is clean when it is in a state such that it emits noundesirable species into the vacuum space or does not adverselyaffect any desired process in the vacuumClean work plan A documented set of procedures by means of which a vacuumitem shall be transformed into a clean state and by means ofwhich it shall be maintained in that state during all subsequentoperations or proceduresCleaning The process of transforming a vacuum item from a contaminatedstate to a clean stateCoating Covering the surface of a material with a conformal layer ofanother materialCold welding A process by which two clean metal surfaces held in physicalcontact become permanently bonded without the action of heatComponent See Vacuum componentContaminant A substance on the surface or in the bulk of a vacuum item whichcan interfere with any process intended to be carried out on thatitem or which can desorb to give an undesirable species in theresidual gas of the vacuumCrosscontaminationWhere a contaminant present on the surface or in the bulk of onevacuum item is transferred onto or into another vacuum itemPage 348 of 382ITER Vacuum Handbook Appendix 21 IDMRef :ITER_D_2F94QXCryopumping Removal of a gas from the vacuum space by condensing it onto acold surfaceCryosorption Removal of a gas from the vacuum space by adsorbing it onto acold porous material e.g. charcoal or zeoliteCutting fluid A fluid used for cooling and/or lubricating a cutting device, e.g. amilling headCVD (Chemicalvapourdeposition)Deposition of a coating onto a substrate by chemical reaction inor from the gas phase, usually at an elevated temperatureDA Domestic AgencyDegassing Removal of gas dissolved in a material, usually by heating thematerial to a high temperature in a vacuumDesorption The release of a substance from a surface into the vacuumspace. (Note: the related verb form is desorb)Diffusion In this context, the transmission of gas atoms or molecules fromone side of a vacuum barrier to the other by direct migrationthrough the solid or glassy phase or along the grain boundaries ofthe materialDiffusion bonding A technique for joining two items by filling the interspace betweenthem with a material or materials which can diffuse into thesurface layers of the host material of each item under the actionof heat and/or pressure thereby forming a bond between themDry lubricant In this context, a solid state material which when depositedbetween two surfaces in vacuum reduces the coefficient offriction significantly or prevents cold weldingExamples would be MoS2, WS2 or WSe2Edge weldedbellowsBellows which are formed from a number of thin annuli bywelding around the circumference of alternately the inner andouter diameters of the annuli. Such bellows can provide greatflexibility longitudinally and significant flexibility in the transversedirectionElectrical break A device which permits two parts of the envelope of a vacuumsystem to operate at different electrical potentials whilstmaintaining gas flow continuity between the two parts of thevacuum envelopeExplosionbondingA technique for joining two items, usually in the form of sheetmetal, by generating a high pressure at the interface by means ofan explosion. There will not normally be any filler materialbetween the itemsFeedthrough A device by means of which electrical potential or current cancross the boundary of a vacuum space or by means of which apipe carrying a fluid can cross the boundary of a vacuum spacePage 349 of 382ITER Vacuum Handbook Appendix 21 IDMRef :ITER_D_2F94QXFormed bellows Bellows formed from a thin sheet or cylinder of metal in whichconvolutions are manufactured by rolling or by hydrostaticpressing against a former. Such bellows allow limited flexibility inany directionFriction bonding A technique for joining two dissimilar materials by using frictionheating to liquefy the interfaceFull penetrationweldingWelding where the heat is applied to one side of a prepared jointsuch that the melt zone extends through the whole thickness ofthe materialGasket A mechanical seal that fills the space between two objectsGetter A material which acts as a vacuum pump by trapping residual gasatoms by chemically bonding them to the atoms of the gettermaterial or by dissolving themHelium bombing A technique by which a nominally hermetically sealed componentis subjected to an overpressure of helium so that, on subsequentexposure of the component to a vacuum, helium desorption intothat vacuum indicates that a leak or porosity may be presentwhich allowed helium to enter the component. The energy transfer may be effected by an electron beam or byions generated in the gas phase by a gas discharge for exampleSupplier Any legal entity providing items or services in accordance with acontractual document. An all-inclusive term used in place of anyof the following third parties DA’s, vendor, seller, contractor,subcontractor, fabricator, consultant, and their sub-tier levels)Trapped volume In this context either(i) a void within a material with a small passage opening to thevacuum space (the passage will have a transverse dimensionsmaller than that of the void.)(ii) a space between two surfaces in contact which is not wellvented to the vacuum spaceUltrahigh vacuum(UHV)Pressures < 10-7 PaUndetectableleaksLeaks with a value below the sensitivity (minimal detectable leakrate) of the equipment being used to try to find themVacuum arc A vacuum discharge which carries sufficient current to melt thesurface of the material into which it comes into contactPage 351 of 382ITER Vacuum Handbook Appendix 21 IDMRef :ITER_D_2F94QXVacuum baking Baking a vacuum item which is totally immersed in a vacuumVacuum barrier A boundary between a vacuum space and another space. Vacuumcomponent oritemAny item with one or more surfaces exposed to vacuum. Theterm includes individual components (like a fixing screw forexample), a sub assembly (like a pumping port) or a completeassembly (like the whole vacuum vessel)VacuumdischargeA mechanism whereby the residual gas inside a vacuum systembecomes ionised and hence electrically conductingVacuum flange A demountable vacuum joint, normally used in pairsVacuum seal In this context, a gasket trapped between two vacuum flanges tocreate a leak tight jointVacuum space A bounded system held at sub-atmospheric pressureVacuumSpecialistA person nominated by the ITER Vacuum Responsible Officer asan expert in a particular field of vacuum science or technologyVacuum system Any assemblage of vacuum items forming a discrete,independent vacuum space, comprising at the minimum avacuum envelope, pumping and pressure measurementVacuum valve A mechanical device which can be used to isolate or link twoindividual vacuum spaces, depending on its state. Venting Opening a vacuum space to another spaceWelding A technique for joining two items by melting the interface region,with or without the use of a filler materialStandardsEN 10204 Metallic products. Types of inspection documentsPage 352 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMBaseline Report (not under Configuration Control)Attachment 1 WeldingThis Attachment relates to welding of vacuum boundaries and outlines the procedures fordocumentation, qualification, approval and testingApproval ProcessName Action AffiliationAuthor Pearce R. 14 Apr 2009:signed IO/DG/COO/PED/FCED/VSCo-AuthorsReviewers Kim Y.- HSands D. 13 Jun 2009:recommended15 Jun 2009:recommended ITER Organization (IO)Approver Holtkamp N. 16 Jun 2009:approved SLAC - National Accelerator Laboratory (US)Document Security: Internal UseRO: Chiocchio StefanoRead Access GG: MAC Members and Experts, GG: STAC Members & Experts, AD: ITER, AD: External Collaborators,AD: IO_Director-General, AD: EMAB, AD: Auditors, AD: ITER Management Assessor, projectadministrator, RO, LG: Section Scheduling, AD: OBS - Vacuum Section (VS) - EXT, AD: OBS - VacuumSection (VS)IDM UID2FMM4BVERSION CREATED ON / VERSION / STATUS10 Apr 2009 / 1.2 / ApprovedEXTERNAL REFERENCE / VERSIONPage 353 of 382PDF generated on 22 Feb 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogAttachment 1 Welding (2FMM4B)Version Latest Status Issue Date Description of Changev1.0 Signed 17 Dec 2008v1.1 Signed 26 Jan 2009v1.2 Approved 10 Apr 2009Page 354 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 1 of 14Name AffiliationAuthor/Editor Liam Worth Vacuum Group - CEPVacuum Responsible Officer Robert Pearce Vacuum Group - CEPReviewed by D SandsY-H KimMQP Working GroupDDG - CEPApproved by N Holtkamp PDDGITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2828YLITER Vacuum HandbookAttachment 1Inspection and Qualification of Welded JointsPage 355 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 2 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL1 Scope.. 32 The Welding and Inspection Plan.. 33 Welder and operator Qualification.. 34 Applicable Standards.. 35 Welding Procedure Specification.. 46 Welding Procedure Qualification Record.. 66.1 Qualification of the Welding Procedure Specification.. 66.2 Extent of Approval.. 66.2.1 Material Groups.. 66.2.2 Base Materials.. 66.2.3 Thickness Range.. 76.2.3.1 Thickness Range for Welds Excluding Fillet and Branch.. 76.2.3.2 Thickness Range for Fillet Welds.. 76.2.3.3 Thickness Range for Branch Pipes (Diameter Range).. 86.2.4 Range of Approval of Welded Joints.. 86.2.5 Range of Approval Welding Consumables.. 86.2.6 Welding Processes.. 86.2.7 Welding Position.. 86.3 Non –Destructive Examination.. 96.3.1 Examination.. 96.3.2 Acceptance Criteria.. 106.4 Destructive Tests.. 116.4.1 Test Specimens.. 116.4.2 Test Results.. 116.4.3 Qualification for Welds Under Stressed Applications.. 127 Production Welds.. 127.1 Inspection of Fusion Welded Joints.. 127.2 Production proof samples.. 137.3 Helium Leak Testing of Production Welds.. 147.4 Repair by welding of production welds.. 148 Documentation.. 14Page 356 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 3 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL1 ScopeThis Attachment relates to welding of vacuum boundaries and outlines theprocedures for documentation, qualification, approval and testing. Whilst this Attachment is based on the international standards ISO 9606, EN 287-1,ISO 15614 and ISO 15609, additional requirements are specified to achieve the highintegrity and reliability of the vacuum systems to ensure the required ITER machinereliability. Specifically this Attachment is more stringent in places than the standardsin the range of approval for joint types, mechanical testing and acceptance criteria. The requirements are designed to complement codes which may be used. Whererequirements differ in general the more stringent standard should be applied oradvice sort from ITER. 2 The Welding and Inspection PlanBefore fabrication can commence the supplier shall prepare for approval a weld plan. The weld plan is a drawing which cross references each welded joint to a supportingWelding Procedure Specification (WPS). 3 Welder and operator QualificationThe welder qualification is intended to show the competence of the welder/operatorfor implementing the specified WPS. Welder qualification shall be in accordance with EN 287-1, ISO 9606 or equivalentstandards agreed in advance. For welding operators ISO 1418 shall be used. Other standards may be approved by ITER on submission of documentation detailingthe equivalence between the proposed standards and the standards quoted herein. All standards and documentation pertaining to equivalence shall be submitted inEnglish and must be agreed in advance of welding operations. The supplier shall establish and maintain a list of qualified welders and operators. This list shall include their individual identification and range of welds for which theyare qualified. 4 Applicable StandardsThe latest revisions of the standards listed in Table 4-1 shall be applied in theprocedure, qualification, and acceptance testing etc. of any welding process andform, where applicable, part of this attachment. Alternative national standards maybe submitted for approval but they must meet the minimum technical requirements ofthis Attachment. Alternatives must be formally accepted through writtencommunication before welding can commence. Where this attachment is more stringent than the standards, this document takesprecedence. Where specified in this document, additional requirements to orrequirements differing from the quoted international standards have been highlightedin bold italics. Page 357 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 4 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLISO 15607 Specification for the qualification of welding procedures formetallic materials – general rulesISO 15614 – 1, 2,5 ,6, 8, 11:2004Specification and qualification of welding procedures formetallic materials-welding procedure testISO 15609 Specification and qualification of welding procedures formetallic materials – Welding procedure specificationEN 970, ISO17637Non-destructive examination of fusion welds. Visualexamination. ISO 4063 Welding and allied processes – Nomenclature of processes andreference numbers. EN 571 ,ISO 3452 Non destructive testing. Penetrant testing. EN 1290, ISO9934Non-destructive examination of welds. Magnetic particleexamination of weldsEN 1435, ISO17636Non-destructive examination of welds. Radiographicexamination of welds. EN 1714, ISO17640Non-destructive examination of welds. Ultrasonic Examination. EN 287-1 Qualification test of welders – Fusion welding – Part 1: steels. ISO 9606 Qualification test of welders – Fusion welding – Part 2:aluminium and aluminium alloys. ISO 14344 Welding and allied processes – Flux and gas shielded electricalwelding processes – Procurement guidelines for consumables. ISO 5817 Fusion welded joints in steel, nickel, titanium and their alloys(beam welding excluded) – Quality levels for imperfections. ISO 1418 Welding personnel. Approval testing of welding operatorsEN 473 , ISO 9712 Non-destructive testing - Qualification and certification of NDTpersonnel - General principlesISO 22825 Non-destructive testing of welds - Ultrasonic testing - Testing ofwelds in austenitic steels and nickel-based alloysISO 10380 Corrugated metal hoses and hose assembliesTable 4-1 Standards relating to welding5 Welding Procedure SpecificationThe Welding Procedure Specification (WPS) is a document which details all thevariables which must be defined to produce a weld of acceptable quality. Thequalification of the WPS shall be performed in accordance with this Attachment. Each WPS shall detail each type of weld and shall include, but not be limited to, thefollowing in accordance with ISO 15609:¾ Identification of equipment manufacturer¾ Equipment calibration records¾ Examiner or test body¾ WPS numberPage 358 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 5 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL¾ Parent material(s), defining which joint element is comprised of a givenmaterial¾ Filler material(s): classification, type, trade name, flux, diameter ofelectrode, rod, or wire¾ Joint sketch and weld run sequence¾ Range of qualified thicknesses and/or diameters¾ Welding position¾ Welding process (in accordance with ISO 4063)¾ Welding technique (single, multipass etc)¾ Groove or edge preparations (cleaning, degreasing, jigging etc)¾ Shielding and backing gas (composition and flow rates)¾ Welding equipment parameters which may include:-ƒ AC or DCƒ Polarityƒ Current rangeƒ Voltage rangeƒ Pulsed welding parametersƒ Tungsten electrode diameter and typeƒ Nozzle diameter¾ Backing: method and type, materials and dimensions¾ Back gouging: method¾ Heating: pre-heat temperature, interpass temperature, post weldtemperature¾ Drying and preservation temperatures for covered electrodes (ifapplicable)Additional Parameters for automatic welding may include:ƒ Welding equipment specificationƒ Tool and programme numbers (where applicable)ƒ Travel speed rangeƒ Wire feed speed rangeƒ Arc Voltage Control parametersFor special processes (remote welding etc) additional information may be required. Page 359 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 6 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL6 Welding Procedure Qualification RecordThe Welding Procedure Qualification Record (WPQR) is used to record all therelevant data from the welding of test pieces in the qualification of the WPS. ¾ The qualification of the WPS provides proof that the defined weldingprocess, will achieve a weld of acceptable quality. The welding andtesting of this must be witnessed by an ITER recognised IndependentInspection Authority. All welding data and results from the required non-destructive and destructive testingshall be documented using a Welding Procedure Qualification Record (WPQR). Itcan also be called Welding Procedure Approval Record (WPAR). 6.1 Qualification of the Welding Procedure Specification. An existing Welding Procedure Qualification Record (WPQR or WPAR) is acceptableif the following conditions are met:¾ The test must have been performed in the same environment asproposed for production, using the same welding technique, process,joint configuration and welding equipment (for mechanised welds)¾ The allowable ranges are the same with regard to essential variables. ¾ The related Preliminary Welding Procedure Specification (pWPS) hasbeen qualified in accordance with ISO 15614¾ The test must have been witnessed by an ITER recognisedIndependent Inspection AuthorityWeld produced for qualification must be performed by suitably qualified welders. The supplier must also demonstrate that the welding equipment and plant use forqualification is properly maintained and calibrated in accordance with the relevantoperation and maintenance schedules. 6.2 Extent of Approval6.2.1 Material GroupsFor differing grades of stainless steel (304, 304L, 316, 316L and 316LN-IG), crossqualification can be accepted for manual welds when 316L filler is used. Crossqualification is not acceptable for automatic welds. Transition welds joining dissimilarmaterials other than those listed above must have specific qualification testsperformed. 6.2.2 Base MaterialsQualification on the production heat number is mandatory for special weldingprocesses (e.g. electron beam welding, orbital, TIG etc). If this is not possible thenPage 360 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 7 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLthe welding of a production proof sample (PPS) is required during productionwelding. 6.2.3 Thickness Range6.2.3.1 Thickness Range for Welds Excluding Fillet and BranchThe qualification of a welding procedure test on thickness t shall include qualificationfor thickness in the ranges given in Table 6-1 in accordance with ISO 15614. Range of approval1,2 (Dimensions in mm) Thickness of test piece t(mm)(where t is the thicknessof the thinner material)For single run orsingle run fromboth sidesMulti-runt ≤ 33 1000.7t to 1.3t0.5 (3 min) t to 1.3 t0.5 t to 1.1tNot applicable0.7 t to 2 t3 mm to 2 t0.5 t to 2 t50 mm to 1.5 t1) when impact requirements are specified the upper limit of qualification is 12 mm unless impacttesting has been performed2) The range of approval may have to be reduced in order to avoid hydrogen crackingTable 6-1 Range of Approval for material thickness and weld depositthickness– all welds6.2.3.2 Thickness Range for Fillet WeldsThe qualification of a welding procedure test on thickness t shall include qualificationfor thickness in the ranges given in Table 6-2 in accordance with ISO 15614. Range of approval (Dimensions in mm)Throat thicknessThickness of test piece t(mm)Material thicknessSingle run Multi-runt ≤ 33 < t < 30t ≥ 300.7t to 2 t0.5t (3 min) t to 1.2 t≥ 50.75 a to 1.5 a0.75 a to 1.5 a†No restrictionNo restrictionNo restrictionNote 1a is the throat thickness of the test pieceNote 2 Fillet welds cannot be qualified by Butt welds† For special applications only. Each throat thickness has to be proofed separately by a weldingprocedure testTable 6-2 Range of qualification for material thickness and throat thickness offillet weldsPage 361 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 8 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL6.2.3.3 Thickness Range for Branch Pipes (Diameter Range)The qualification of a welding procedure test on diameter D shall include qualificationfor diameters in the following ranges give in Table 6-3 in accordance with ISO 15614. Diameter of test piece D1,2 (in mm) Range of approvalD ≤ 25 0.5 D to 2 DD > 25 ≥ 0.5 D up to plates (25 mm min)1) D is the outside diameter of the pipe or the outside diameter of the set-on branch pipe2) Approval given for plates also covers pipes when outside diameter is > 500 mmTable 6-3 Range of approval for pipe and branch connections6.2.4 Range of Approval of Welded JointsLip weld and Automatic socket welds shall be qualified on actual size within nominalmaterial specification tolerances. Pre-weld /socket/spigot gap shall be adequate topreclude post-weld abutment contact and minimise weld stress. The range ofapproval for other types of joint is given in Table 6-4. 6.2.5 Range of Approval Welding ConsumablesAll consumables shall be certified to a standard acceptable to the ITER IO (e.g. ISO14344). In the case of manual welding processes the approval range of fillermaterials covers other filler metals as long as they are in the same range andchemical composition. In the case of automatic and semi automatic welding processes the weldingconsumables used for qualification shall be the same batch as those used forproduction welds. Following any change during production, weld samples shall bewelded and examined prior to the continuation of production with the new batch ofconsumables. Qualification using filler does not qualify autogenous (fusion weldingwith out filler material) welds or vice versa. 6.2.6 Welding ProcessesIn all cases, any change in the welding process will require a requalification of theprocess. In addition, in the case of automatic welding any change to the weldingequipment will require requalification. 6.2.7 Welding PositionWelds for qualification shall be done in local conditions similar to the local conditionswhere the production weld will be made. Local access to the test piece (in terms ofwelder access) and the orientation of the test piece (relative to the welder) shall besimilar to those for the production weld for which they qualify. Page 362 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 9 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLRange of ApprovalButt welds on plate T Butt welds on plate Butt welds on pipe Branch welds onpipeWelded from one side Welded from bothsidesWeldedfromone sideWeldedfrombothsidesFilletweldonplateWelded from one sideFilletweldonpipeSetonSetthroughType of Joint in Approval TestPieceWithbackingNobackingWithgougingNogougingWithbackingNobackingWithBacking 3 2 Δ Δ 2 2 2 2 2 2 2 2Weldedfrom onesideNoBackingΔ 3 Δ Δ 2 2 2 2 2 2 2 2Withgouging 2 2 3 Δ 2 2 2 2 2 2 2 2Buttweld onplateWeldedfrombothsides Nogouging 2 2 2 3 2 2 2 2 2 2 2 2WithbackingΔ 2 Δ Δ 2 Δ 2 3 2 2 2 2Buttweld onpipeWeldedfrom onesideNobackingΔ Δ Δ Δ Δ Δ 2 Δ 3 2 2 2Weldedfrom oneside2 2 2 2 2 Δ 2 2 2 2 2 2T Buttweld onplateWeldedfrombothsides2 2 2 2 2 3 2 2 2 2 2 2Plate2 2 2 2 2 2 3 2 2 2 2 2FilletweldPipe2 2 2 2 2 2 Δ 2 2 3 2 2Set on2 2 2 2 2 2 2 2 2 2 3 2Branchweld inpipeSetthrough2 2 2 2 2 2 2 2 2 2 3Key:3Indicates the weld for which the WPS is approved in the approval testΔ Indicates those welds for which the WPS is also approved2 Indicates those welds for which the WPS in not approvedTable 6-4 Range of approval for type of joint6.3 Non –Destructive ExaminationSupplier’s inspectors shall be competent in accordance with ISO 9712. 6.3.1 ExaminationAfter post weld heat treatment and prior to destructive testing, test pieces shall beexamined by the following:¾ Visual examination (in accordance with ISO 17637)¾ Dye Penetrant testing (in accordance with ISO 3452) or Magneticparticle testing (in accordance with ISO 9934)Inspection using Photothermal camera is permitted in the case wherethe manufacturer has qualified the method/acceptance criteria prior tothe weld qualification¾ Radiographic examination (in accordance with ISO 17636)and/or¾ Ultrasonic examination (in accordance with ISO 17640 and ISO 22825for austenitic steels and nickel alloys)For a pipe or plate of 2 mm (or less) wall thickness, the method of examination shallbe agreed prior to examination. Page 363 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 10 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BL6.3.2 Acceptance CriteriaDefects which are detected by the relevant non-destructive examination method shallbe assessed in accordance with ISO 5817 level B. In particular acceptance criteriaare detailed in Table 6-5. Table 6-5 is in accordance with ISO 5817 howevercontains additional requirements for production vacuum boundary welds. Defect Type Permitted maximumPlanar DefectsCracks or lamellar tearsLack of root fusionLack of side fusionLack of inter-run fusionLack of root penetrationNot permittedSlag inclusions - individual 20% of t or 2 mm, which ever issmallerSlag inclusions - Group Aggregate length not to exceed t in alength of 12 t, except when thedistance between successiveindications exceeds 6L where L is thelongest indication in the groupSolid inclusionsInclusions – Tungsten orCopperNot permittedIsolated pores - round Diameter 3 mm or 10% for t < 3mm. Under cut to blend smoothlywith the parent material. Incompletely filled groove,sagging. Root concavity, shrinkagegroove0.05 t or 0.5 mm, which ever issmaller. Weld thickness shall not beless than the parent plate thicknessExcess penetration - pipe Not greater than 5% of the pipeinternal diameter up to 2 mm max. Profile defectsExcess penetration – plate t = 0.5 to 3 mm: , h ”1 mm+10% bt > 3mm: h ”1 mm+20% b max 3mm. h=height of excess penetration onbackside of plate and b the widthExcess weld material Not greater than 10% weld widthMisalignment Not greater than 10% of the parentmaterial thicknessPage 364 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 11 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLFillet leg length (asymmetry) Unequal leg length should not exceed20% of the fillet throat thicknessBurn through Not permittedOther Root oxidation Not permitted where a backing purgegas is specified in the WPSTable 6-5 Acceptance levels6.4 Destructive Tests6.4.1 Test SpecimensThe number of test specimens that shall be subjected to destructive testing is givenin Table 6-6 in accordance with ISO 15614. TEST SPECIMEN No of TestsBUTT WELDTransverse Tensile (room temp.) 2Root Bend (for t <12mm) 2Face Bend (for t 12mm) 4Transverse Tensile (design temp. if required by tech. spec.) 1Impact test (for t ≥12 mm one set from weld metal and one set fromHAZ if required by tech. spec). 2Macro-examination (with photo) 1Micro-examination x 200 (if required by tech spec.) 1Hardness test surveyBurst test†11FILLET WELDFracture Test 1Macro-examination (with photos) 4Micro-examination x 200 (if required by tech. spec.) 2Hardness Survey 2T-BUTT/BRANCH CONNECTIONMacro-examination (with photos) 4Micro-examination x 200 (if required by tech. spec.) 2Hardness Survey 2SOCKET/LIP WELD+Macro-examination (with photos) 4Micro examination x 200 (if required by tech. spec.) 2Hardness Survey 2† Longitudinal butt weld on bellows (or flexible) tube to ISO 10380Table 6-6 Number of destructive test specimens6.4.2 Test ResultsUnless specified differently in Table 6-7 destructive testing and test results shallcomply with ISO 15614. Page 365 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 12 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLBend test (stainlesssteel and nickel alloyonly)The bend angle shall be 180° round a former ofdiameter 2t, where t is the thickness of the specimen. The bend test specimen shall have no open defectsexceeding 2 mm measured in any direction on theconvex surface after bending. Micro - Examination In general micro-examination shall only be requiredfor welds which form part of the vacuum boundary orare in contact with cryogenic liquids. If required micro-examination tests shall be specified in the technicalspecification. Macro Examination For lip welds, penetration shall be 0.7t where t is thethickness of the thinner material. Table 6-7 Acceptable test results6.4.3 Qualification for Welds Under Stressed Applications. Additional destructive tests to those listed in Table 6-6 to qualify welds understressed applications may be required as defined in the technical specification. 7 Production WeldsProduction welds shall be performed to qualified procedures by qualified welders. The WPS shall be available for reference by welders or welding operators, by theresponsible welding engineer and by the authorised inspector. The contractor must also demonstrate that the welding equipment and plant isproperly maintained and calibrated in accordance with the relevant operation andmaintenance schedules. 7.1 Inspection of Fusion Welded JointsAfter post weld heat treatment welds shall be subject to the following tests:¾ Visual examination (in accordance with ISO 17637)¾ Dye Penetrant testing (in accordance with ISO 3452) if permitted†. (Inspection using Photothermal camera is permitted in the case wherethe manufacturer has qualified the method/acceptance criteria prior tothe weld)¾ Radiographic examination (in accordance with ISO 17636)and / or¾ Ultrasonic examination (in accordance with ISO 17640 and ISO 22825for austenitic steels and nickel alloys)† See ITER Vacuum Handbook Section 7.1.4. Page 366 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 13 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLThe range of wall thickness and preferred volumetric examination method is given inTable 7-1 . Defects which are detected by the relevant non-destructive examination method shallbe assessed in accordance with Table 6-5. For all VQC 1A, VQC 2A water boundaries and vacuum boundary welds whichbecome inaccessible, 100% volumetric examination of production welds shall beperformed, unless a method of pre-production proof sampling is approved. For all other vacuum boundaries, volumetric examination of 10% of production weldsshall be performed unless a method of pre-production proof sampling is approved. Inthe event of failures, this shall be increased to 100% examination of the batch,defined as same welder/same WPS/ same weld. ……. Acceptance criteria arespecified in Table 6-5On welds where it is specified that volumetric examination be performed andradiography or ultrasonic inspection is not possible, Production Proof Sampling isrequired. Wall Thickness Preferred Volumetric ExaminationMethodWt wt 19 mm UltrasonicTable 7-1 Range of wall thickness and preferred volumetric examinationmethod7.2 Production proof samplesWelds where radiography or Ultrasonic testing is impractical (e.g. welds that are notfull penetration butt welds) must be covered by Production Proof Sampling (PPS). Each PPS will only represent a specific type of weld and must use the samematerials, thickness and set-up as the production weld. For VQC 1 and 2 vacuum boundary welds a PPS must be welded during the sameshift as the production welds and by the same welder using the same equipment tobe representative of the production welding. If more than one welder welds the production welds, each must perform a PPS. PPS’s are required each shift production welding is being performed to represent thewelds performed on that shift. For VQC 3 and 4 vacuum boundary welds a PPS shall be welded for each welderperforming the production welds. PPS’s should be sectioned and macro examined in four places (including onestop/start area). Photographs of the macros giving the date the PPS was welded, thePage 367 of 382ITER_D_2FMM4B v1.2ITER Vacuum Handbook: Attachment 1Revision: Issue 1.2 Date: January 26th, 2009 Page 14 of 14ITER Vacuum Handbook – Attachment 1 IDM Ref :ITER_D_2FMM4BLwelder’s identity and identifying the production welds it is covering must be includedin the final documentation package. An ITER representative will normally witness PPS welding and all PPS macros shallbe reviewed. Operations with witness and hold points to facilitate this must beincorporated in the Work Schedule. As the PPS is a representative sample, rejection of the macro will result in rejectionof all welds covered by this PPS. 7.3 Helium Leak Testing of Production Welds100% of vacuum sealing welds (VQC 1A, 2A, 3A, 4A) shall be subject to helium leaktesting in accordance with the requirements and procedures of the ITER VacuumHandbook. 7.4 Repair by welding of production weldsNo weld repair shall be performed with out qualification of the welding procedure. Welding procedures used for welding repair shall be qualified in accordance with thisdocument. 8 DocumentationAll quality assurance documentation required by this procedure shall form part of thedelivery to ITER, and shall include:¾ Weld plans¾ WPS’s¾ WPQR’s and test reports¾ Welder qualification’s and test reports¾ PPS test reports¾ Production weld test reports¾ Reports on weld repairs¾ Non-Conformance ReportsPage 368 of 382PDF generated on 16 Apr 2014DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMReportITER Vacuum Handbook Attachment 2 - CleanlinessRequirements Relating to the Assembly of VacuumEquipmentThis Attachment sets out the requirements which must be satisfied when performingassembly work on, or in, the ITER vacuum systems.It coverspreliminary assembly work inassembly areas final assembly and integration work inside and outside the vacuum vesselsApproval ProcessName Action AffiliationAuthor Worth L. 13 Mar 2014:signed IO/DG/DIP/PSE/FCED/VSCo-AuthorsReviewers Blackler K. Pearce R. Sands D. Shaw R. 14 Apr 2014:recommended01 Apr 2014:recommended17 Mar 2014:recommended14 Apr 2014:recommendedIO/DG/DIP/PCA/AOPIO/DG/DIP/PSE/FCED/VSIO/DG/SQS/QAIO/DG/DIP/PCA/AOP/MAIApprover Haange R. 16 Apr 2014:approved IO/DG/DIPDocument Security: level 1 (IO unclassified)RO: Pearce RobertRead Access RO, project administrator, AD: ITER, AD: External Collaborators, AD: IO_Director-General, AD:IC_OMPE_WG, AD: Section - Vacuum - EXT, AD: Section - Vacuum, AD: Auditors, AD: ITERManagement AssessorIDM UIDMBXPP3VERSION CREATED ON / VERSION / STATUS13 Mar 2014 / 1.7 / ApprovedEXTERNAL REFERENCEPage 369 of 382PDF generated on 16 Apr 2014DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogTitle (Uid) VersionLatest Status Issue Date Description of ChangeITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_7)v1.7 Approved 13 Mar2014Construction Volume 13: Health, Safety andEnvironmental Management Plan(ITER_D_EC8ALD) removed and replaced with"ITER Health & Safety & Environmentmanagement plan" with out referenceUpdated version numbers and dateITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_6)v1.6 Signed 13 Mar2014version number!ITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_5)v1.5 Signed 13 Mar2014Reference list updateITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_4)v1.4 Signed 13 Mar2014Corrected the version numberAll comments from reviews of the document havebeen taken into account in this final version. Thisversion is ready for final review by the ITERVacuum RO and subsequent approvalITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_3)v1.3 Signed 13 Mar2014Removed reference to "Construction Volume 13:Health, Safety and Environmental ManagementPlan "ITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_2)v1.2 Signed 06 Feb2014All comments from all reviewers addressedITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tov1.1 Signed 04 Feb2014All comments received addressed. Track changesincluded in attachmentPage 370 of 382PDF generated on 16 Apr 2014DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMthe Assembly of VacuumEquipment(MBXPP3_v1_1) Requirements for atmospheric air includedITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v1_0)v1.0 Signed 20 Dec2013Version 1.0ITER VacuumHandbook Attachment 2- CleanlinessRequirements Relating tothe Assembly of VacuumEquipment(MBXPP3_v0_0)v0.0 In Work 20 Dec2013Page 371 of 382ITER VacuumHandbook – Attachment 2 IDMRef :ITER_D_MBXPP3ITER Vacuum Handbook: Attachment 2Revision: 1.7 Date: 13th March2014 Page 1 of 11ITER Vacuum HandbookAttachment 2Cleanliness Requirements Relating to theAssembly of Vacuum EquipmentName AffiliationAuthor/Editor Liam Worth IOVacuumResponsible Officer Robert Pearce IOPage 372 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3Contents1 Terminology.42 Scope.43 Purpose.44 General Requirements.54.1 Management of Work.54.1.1 Risk Assessment.54.1.2 Work Instruction.54.1.3 Personnel.54.2 Area Designation.54.3 Operator Attire.54.3.1 Personnel Protective Equipment.54.3.2 Ex-vessel work.64.3.3 In-vessel work.64.4 Tools.64.4.1 General.64.4.2 Tools for use in-vessel.64.5 Materials.74.5.1 Marking.74.5.2 Adhesive Tape and plastic coverings.84.5.3 Grinding and Cutting Wheels.84.5.4 Products for Ultrasonic Testing (UT).84.5.5 Products for Liquid Penetrant Examination.84.5.6 Machining Fluids.84.5.7 Unacceptable Materials.85 Performance of Work.85.1 In-Vessel Dressing Working Procedures.85.2 Cutting, Drilling, Grinding, Filing and Polishing.95.3 Welding, Brazing &Soldering.95.4 Mechanical Joining.105.5 Marking.106 Specific Requirements.106.1 Assembly and Integration.106.1.1 VQC 1 and 2 Demountable Joints.106.1.2 Ex-Vessel.106.2 In-vessel.116.2.1 General.116.2.2 VQC 1.116.2.3 Ventilation.116.3 Work Areas in the Vicinity of VQC 1 and 2 Systems.11Page 373 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP37 References.12Page 374 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP31 TerminologyThe following terms and acronyms listed in are used throughout this AttachmentTerm/acronym Contextual meaningAccepted Accepted for use by the ITER Vacuum Responsible OfficerALARA As Low As Reasonably AchievableEx-vessel work Work for which the operator(s) remains physically outside thevacuum system (e.g. assembly of a vacuum pipework run)In-vessel work Work for which the operator(s) must enter the vacuum system toperform (e.g. assembly in the main VV or cryostat)Operator(s) Person(s) performing the workRA Risk AssessmentUT Ultrasonic TestingVV ITER main Vacuum VesselVQC Vacuum ClassificationWRO Work Responsible Officer – Responsible for preparation of the RAand WI. The WRO is also responsible for ensuring that the work isperformed to the WI and any safety requirements are satisfiedWI Work Instruction – as part of the documentation package includeswritten procedures such as method statementsTable 1 Terms and acronyms with meaning in context of this document2 ScopeThis Attachment sets out the requirements which must be satisfied when performingassembly work on, or in, the ITER systems which have been assigned a VQC [1].Thisdocument is applicable for work performed at the ITER site. It covers preliminary assembly work in assembly areas final assembly and integration work inside and outside the vacuum equipment3 PurposeThe purpose of the requirements described herein are to ensure that the overallcontamination levels in the various vacuum equipment of the ITER machine when it isbrought into operation are commensurate with the Vacuum Classification (VQC) of thepertinent vacuum equipmentAll procedures and processes used during assembly and testing work of ITER vacuumsystems equipment shall comply with the requirements of the ITER Vacuum Handbook[1]4 General RequirementsThese requirements are applicable to all assembly work for all items with a VQC. Subsequent sections detail VQC specific requirements. Page 375 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP34.1 Management of WorkAll work shall be performed in compliance with the ITER Health & Safety & Environmentmanagement plan which concerns the safety of work on the IO site. The basicrequirements of the referenced document which must be satisfied are outlined below4.1.1 Risk AssessmentThe risks associated with assembly and test of vacuum equipment shall be assessedprior to work commencing. The risk assessment shall be performed by a competentperson and approved by the IO. Prior to work commencing all controls identified to lowerthe risks to a level commensurate with the principles of ALARA shall be in place4.1.2 Work InstructionAll assembly and test operations shall be performed to a Work Instruction (WI). The WImay take the form of, for example, a written procedure or method statement. The WI shallbe approved by the IO and supported by a relevant Risk Assessment (RA)The requirements for cleanliness and cleanliness control as described in this Attachmentshall be stated in the WI as shall the processes to achieve the requirements as statedherein4.1.2.1 Deviations from the WIDuring the execution of the tasks as defined in the WI it may be necessary to deviatefrom the WI. All deviations from the WI shall be agreed with the WRO prior to execution. The WRO shall update the WI accordingly to account for the deviation. Any unauthoriseddeviation from the WI shall be reported to the WRO4.1.3 PersonnelNo work shall be performed except by competent personnel trained to perform the workto be carried out4.2 Area DesignationThe area in which the work shall be performed shall be designated according to the VQCof the system being worked upon. All general and any specific requirements pertaining tothe work being performed in the area shall be clearly displayed in the working areapreferably with the WI and RA. 4.3 Operator AttireAll operators performing work on vacuum equipment with any VQC where there is a riskof the operator coming into physical contact with the vacuum facing surfaces shall wearsuitable attire. The exact nature of the attire to be adorned shall be specified in the WIand displayed on the area designation (section 4.2)4.3.1 Personnel Protective EquipmentThe operators shall adorn PPE as defined as a result of the Risk Assessment. All PPEshall be clean and free from surface contamination such as grease and oil4.3.2 Ex-vessel workAs a minimum and in addition to the requirements of 4.3.1 the operator shall wear thefollowing when assembling vacuum equipment ex-vessel; Clean powder free latex or nitrile outer gloves Clean lint free overalls4.3.3 In-vessel workIn addition to the requirements of 4.3.2 the operator shall also adorn the followingPage 376 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3garments when performing work in-vessel; Clean plastic overshoes Hair nets or caps and beard covers where appropriate Clean plastic helmet cover4.4 Tools4.4.1 GeneralAll tools shall be fit for purpose and shall be specified in the WI. Prior to use all tools shall be cleaned by wiping with a clean lint free cloth dampened withisopropyl alcohol (IPA) or laboratory grade ethanol4.4.2 Tools for use in-vesselAll tools for use in-vessel shall come from a dedicated set of tools which are new or haveonly been used for in-vessel workTools shall be logged into and out of the working areaAfter each assembly stage a check shall be made to ensure all tools have been removedfrom the work area. 4.4.2.1 Hand ToolsHand tools shall be stored in a clean tool container which may be transported into theworking area. The tool container shall also include an inventory list of tools containedtherein. Prior to removal from the work area the inventory of tools shall be checkedagainst the inventory list. Any discrepancy between the tools in the container and theinventory list shall be reported to the Work Responsible Officer (WRO). 4.4.2.2 Power ToolsThe use of power tools in-vessel shall be specified in the WIPrior to the use of power tools adjacent parts of the work area shall be screened off bythe use of clean polyethylene sheeting, aluminium foil or the like to catch swarf, debris,etc. and to minimise its spread to other parts of the jobFollowing each stage of such work, swarf, debris, etc., shall be cleaned up by vacuumingand surfaces wiped down with clean lint-free rags dampened with IPA or laboratory gradeethanol4.4.2.3 Welding/ Brazing EquipmentWelding and/ or brazing equipment shall be used only as specified in the WI. Alloperations of this type shall be supported by the relevant paper work (such as hot workpermit) which shall be attached to the WI. Prior to starting any such operation, surfaces to be worked on shall be cleaned byswabbing with an IPA or laboratory grade ethanol on clean lint-free ragsAdjacent parts of the work piece shall be screened off by the use of clean polythethylenesheeting, aluminium foil or the like to catch weld spatter etcPPE such as welding screens shall be clean and new, or clean and dedicated for in-vessel work. 4.4.2.4 Tools Containing FluidsThe use of tools containing fluids, such as hydraulic jacks, shall be avoided wherepossible. Where the use of a tool containing fluid cannot be avoided then the followingrequirements must be satisfiedPage 377 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3The working fluid shall normally be air or glycol basedThe use of hydraulic tools containing oils as the working fluid is prohibited unlessaccepted by the ITER Vacuum Responsible OfficerThe area surrounding to tool shall be protected, with plastic sheeting, from the possiblerelease of the fluidAs far as is practical the tool shall be wrapped in plastic sheet to prevent the possiblespread of contamination from leaking fluidThe WI shall include measures which must be taken in the event of loss of fluid from thetool into the work area4.4.2.5 Equipment, trolleys, jigs, slings, etcAll such equipment, etc., shall be maintained in a fully serviceable mannerAll such items shall be operated in a manner such that no oils, greases, etc., can betransferred to surfaces in the clean area or that debris including particulates can be shedfrom the items4.4.2.6 Vacuum PumpsAll vacuum pumps for use in-vessel shall be dry (oil free) type4.4.2.7 Specialised ToolsThe use of specialised equipment shall be by prior agreement with the WRO and only tothe procedures as specified in the WI4.5 Materials4.5.1 MarkingIndelible inks and paint used for temporary mark shall only be accepted for use under thefollowing conditions:The marking can be completely removed without residueAll markers shall not contain any contaminates as described below: Ferrite steel Chlorine content greater 0,25% Sulphur and sulphur compounds Products which may release elements: Pb, Hg, P, Zn, Cd, Sn, Sb, Bi, As, Cu, rareearth elements4.5.2 Adhesive Tape and plastic coveringsAdhesive tapes, peel-off preservative varnishes and temporary plastic coverings, used foraustenitic stainless steels shall meet the following requirements: halogen or sulphur content shall be less than 0,10% in weight less than 15 ppm of chloride and 10 ppm of fluoride shall be released throughlixiviation4.5.3 Grinding and Cutting WheelsGrinding and cutting wheels for use on vacuum equipment shall be alumina based andonly used for austenitic stainless steel. Cutting wheels for use in vessel shall be acceptedfor use by the IO4.5.4 Products for Ultrasonic Testing (UT)Only ITER approved [2] coupling fluids required for UT are accepted for use on vacuumPage 378 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3equipment. Requirements pertaining to coupling fluids are detailed in the ITER VacuumHandbook [1]4.5.5 Products for Liquid Penetrant ExaminationOnly ITER approved liquid penetrant product families are accepted for use on vacuumequipment [2]. 4.5.6 Machining FluidsOnly machining fluids accepted by the IO are acceptable for use on vacuum equipment[2]4.5.7 Unacceptable MaterialsIt is prohibited for the materials listed in Table 2 to become in contact with the surface ofvacuum equipmentMetals PlasticsCarbon steel PVCZincLeadTable 2 Prohibited materials5 Performance of Work5.1 In-Vessel Dressing Working ProceduresThe following general clean area procedures shall be followed and combined with goodjudgment in order to produce and maintain vacuum1. Controlled clean dressing area at entrance and exit of vacuum vessel will be setup with appropriate notices posted2. No food, drink, chewing gum or ablutions allowed within the vacuum vessel3. Clean protective clothing must be worn when working in-vessel. Cleanoveralls/coats, gloves and overshoes will be put on when entering the vacuumvessel and taken off upon exit4. Hands should be washed before wearing clean gloves. This must be doneespecially if any lotions or creams have been used5. Change clean gloves if contamination is suspected6. Cover hair and arms if there is any possibility of them contacting a clean vacuumsurface7. Equipment brought into the clean dressing area for entry into vacuum vessel mustbe clean. Carts, stands, tools and other equipment must not be oily or greasy andmust be wiped down with appropriate cleaning solutions immediately prior toentering the clean area. Note that wheels on carts must also be cleaned8. Tools that are cleaned for in-vessel use must not leave the clean area until end ofjob9. Expendable tools (saw blades, files, cutters, stainless steel wire brushes, grindingwheels, etc.) used shall be new and cleaned to minimize the potential forcontamination5.2 Cutting, Drilling, Grinding, Filing and PolishingSuch operations shall only be carried out when specified in the work instructionsPage 379 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3Cutting fluids, lubricants, polishing materials, etc., may only be selected from those whichhave been accepted by IO for the relevant VQCPrior to starting any such operation, surfaces to be worked on shall be cleaned byswabbing with IPA or laboratory grade ethanol on lint-free ragsAdjacent parts of the work piece shall be screened off by the use of clean polyethylenesheeting, aluminium foil or the like to catch swarf, debris, etc. and minimise its spread toother parts of the jobFollowing each stage of such work, swarf, debris, etc., shall be cleaned up with a vacuumcleaner and surfaces wiped down with an IPA or laboratory grade ethanol using clean lintfree ragsIf grinding is essential, the grinding wheel shall be free of organic components and shallhave been manufactured in an oil-free, clean environment. Grinding wheels shall beaccepted by IO prior to use5.3 Welding, Brazing &SolderingAll welding shall be to the requirements of the ITER Vacuum Handbook Attachment 1 [3]Such operations shall only be carried out when specified in the WIOnly accepted weld fillers, brazing materials, solders and fluxes may be usedFollowing each stage of such work, surfaces once cooled shall be wiped down with IPAor ethanol using clean lint-free rags and all traces of flux, etc., removed5.4 Mechanical JoiningSurfaces to be joined shall be cleaned by swabbing with IPA or laboratory grade ethanolon lint-free ragsOnly fasteners of the type specified in the WI and fabricated from accepted materialsshall be usedUnless specified in the WI, no lubricants, greases, thermal compounds, etc., shall beused on joints or fasteners5.5 MarkingMarking of any surface shall normally be carried out by scribing. The use of marker pens,ink, dyes, paint, etc., shall only be as specified in the WI. Only IO accepted marker pens,ink, dyes, paint, etc. shall be used6 Specific RequirementsTo preserve cleanliness of the components and the area in which the components areassembled and/or integrated the requirements as specified in the following sections shallbe satisfied. The requirements pertain to vacuum equipment after final cleaning6.1 Assembly and Integration6.1.1 VQC 1 and 2 Demountable JointsThe making of demountable joints of flange class 1 [4] for use on VQC 1 equipment shallbe under the supervision of the IO Vacuum Section. This requirement shall be stated inthe WI. The ITER Vacuum Responsible Officer will nominate a representative of the IOVacuum Section to supervise this activity6.1.2 Ex-VesselIn the case where assembly operations are to be performed on a piece of vacuumequipment with exposed surfaces of different VQC (for e.g. VV sector) the more stringentPage 380 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3requirements for cleanliness shall apply to the whole piece6.1.2.1 VQC 1Areas for the assembly of VQC 1 equipment shall be physically segregated from otherwork areas in the vicinity unless those work areas are of the same cleanliness (i.e. theroom in which the clean area is to be established meets the cleanliness requirements perse)The suitability of the clean area shall be checked on a regular basis (daily) by monitoringthe airborne particulate count, which should not exceed 5 x 106 Particles of size > 0.5 —mper m3. Should the daily air check return a particle count not in compliance with theselimits specified herein the WRO shall be informed as soon as possible6.1.2.2 VQC 2Areas for the assembly of VQC 2 equipment shall be maintained clean by daily cleaningof the working areas, including the floors and surfaces6.1.2.3 VQC 3 and 4Areas for the assembly of VQC 3 and 4 equipment shall be kept clean by daily cleaningof the general area. 6.2 In-vessel6.2.1 GeneralPersonnel entering the inner area shall wear clean room clothing, comprising clean whiteoveralls; overshoes or clean job specific footwear; protective hair nets or caps and beardcovers where appropriate; powder free latex or nitrile outer gloves as specified in Section4.3Personnel entry shall be through a controlled temporary vestibule with curtains screeningthe vessel entry aperture and the outer access from general areas. This vestibule shall beconstructed so that it can be maintained in a clean and controlled manner. The vestibuleshall be divided into two areas with a step over barrier between them. Each area will havesticky mats on the floor. The outer area will be for changing into clean room clothingDedicated clean tools and equipment shall be stored in the inner area. Positive air flowshall be maintained from the inner to the outer areaOnly authorised personnel shall be permitted to enter the inner areaNo work shall be carried out by personnel who have not been trained for such workWhere possible when working in the vessel, personnel shall stand on suitably supportedtemporary flooring manufactured from stainless steel or aluminium sheet covered withclean aluminium foil. Such foil shall be replaced at frequent intervals6.2.2 VQC 1The requirements for cleanliness pertaining to in-vessel VQC 1 work areas shall becompliant with section 6.1.2 of this Attachment with the exception that the vacuumcontainment boundary may be considered a barrier for work area segregation6.2.3 Ventilation6.2.3.1 VQC 1 & 2 ventilation air flow rateVacuum enclosures shall be ventilated with atmospheric air at a flow rate sufficient toprovide at least 10 air changes per hour. The flow rate shall be determined on a case bycase basis depending on the volume to be ventilated. 6.2.3.2 VQC 1 and 2 ventilation air humidityPage 381 of 382ITER Vacuum Handbook – Attachment 2 IDM Ref: ITER_D_MBXPP3Air for the ventilation of VQC 1 and vacuum enclosures shall have a relative humidity notexceeding 70%6.2.3.3 Particulate countAir for ventilation of VQC 1 enclosures shall have a maximum particulate count whichshall not exceed 5 x 106 Particles of size > 0.5 —m per m3measured at the vessel air inlet6.3 Work Areas in the Vicinity of VQC 1 and 2 SystemsAll vessel apertures open to VQC 1 and / or 2 vacuum areas which are not directlyinvolved in the work being undertaken shall where practical be covered by cleanpolyethylene sheeting or clean aluminium foilThe region of the machine being worked on shall be screened by a polythene tent orsimilar. All surfaces inside this area shall be cleaned off before and after the process byvacuuming and swabbing with IPA or laboratory grade ethanol using clean lint-free ragsAll equipment shall be protected in such a way that no contamination can be transferredto vacuum surfacesCare shall be taken to ensure that no oils or greases (including finger grease) are rubbedinto any surface which forms a vacuum boundary7 References[1] ITER Vacuum Handbook (ITER_D_2EZ9UM). [2] Appendix 4 Accepted Fluids (ITER_D_2ELN8N). [3] Attachment 1. Inspection and Qualification of Welded Joints (ITER_D_ 2FMM4B). [4] ITER Vacuum Handbook Appendix 8 Flanges (ITER_D_2DJYQA). Page 382 of 382PDF generated on 27-Jun-2012DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMUser ManualITER Dimensional Metrology HandbookThis Metrology Handbook outlines the mandatory requirements for dimensional control ofthe components, assemblies and systems for the ITER machine. In addition this handbookprovides significant guidance and helpful information on best practise for large volumemetrology applications which can be used in the production of procurement specifications. The handbook also provides information on the ITER metrology infrastructure and theprovision of alignment and metrology services during assembly ofApproval ProcessName Action AffiliationAuthor Wilson D. 08-Mar-2012:signed IO/DG/DIP/CIE/AOP/MAICoAuthorReviewers Higuchi M. 08-Mar-2012:recommended IO/DG/SQS/QAPreviousVersionsReviewsBlackler K. Kondoh M. Shaw R. 31-Jan-2012:recommended v2.007-Mar-2012:recommended v2.031-Jan-2012:recommended v2.0IO/DG/DIP/CIE/AOPIO/DG/DIP/CIEIO/DG/DIP/CIE/AOP/MAIApprover Haange R. 08-Mar-2012:approved IO/DG/DIPDocument Security: level 1 (IO unclassified)RO: Wilson DavidRead Access LG: M&I ext, AD: Only-staff, AD: Division - Diagnostics - EXT, AD: Directorate - Central Integration andEngineering - EXT, AD: Division - Magnet - EXT, AD: DA-US, AD: DA-RF, AD: DA-KO, AD: DA-JA, AD:DA-IN, AD: DA-EU, AD: DA-CN, project administrator, ROIDM UID46FN9BVERSION CREATED ON / VERSION / STATUS08 Mar 2012 / 2.1/ ApprovedEXTERNAL REFERENCEPDF generated on 27-Jun-2012DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDMChange LogTitle (Uid) Version Latest Status Issue Date Description of ChangeITER DimensionalMetrology Handbook(46FN9B_v2_1)v2.1 Approved 08 Mar2012Reference to Design Authority Policy removedHyperlink to SRD 62-13 correctedITER DimensionalMetrology Handbook(46FN9B_v2_0)v2.0 Signed 25 Jan 2012 Version for senior management approval afterinternal reviewITER DimensionalMetrology Handbook(46FN9B_v1_4)v1.4 Signed 20 Jun 2011 M Kondoh and D Sands added as reviewers at therequest of K BlacklerITER DimensionalMetrology Handbook(46FN9B_v1_3)v1.3 Signed 15 Jun 2011 Following technical review, document issue raisedto add reviewers/approver for sign off AuthorityITER DimensionalMetrology Handbook(46FN9B_v1_2)v1.2 Signed 16 May2011references to Manual replaced with Handbook+/- 1mm value removedReference to temperature control requirementsaddednote on MQP requirements addedITER DimensionalMetrology Handbook(46FN9B_v1_1)v1.1 Signed 03 May2011Comments included following reviewITER DimensionalMetrology Handbook(46FN9B_v1_0)v1.0 Signed 04 Mar2011Page 1 of 23Table of Contents1 PURPOSE.22 SCOPE.23 DEFINITIONS.24 COMMUNICATIONS AND ACCEPTANCE.35 ALIGNMENT AND METROLOGY (A&M) CLASSIFICATIONS.36 MANDATORY REQUIREMENTS FOR A&M TASKS.46.1 MANDATORY REQUIREMENTS FOR SITE (MRS) BASED A&M CLASS 1 ACTIVITIES.56.2 MANDATORY REQUIREMENTS FOR SITE (MRS) BASED A&M CLASS 2 ACTIVITIES.76.3 MANDATORY REQUIREMENTS FOR SITE (MRS) BASED A&M CLASS 3 ACTIVITIES.76.4 MANDATORY REQUIREMENTS PROCUREMENT (MRP) FOR A&M CLASS 1 ACTIVITIES.76.5 MANDATORY REQUIREMENTS PROCUREMENT (MRP) FOR A&M CLASS 2 ACTIVITIES.107 STANDARDS.118 INFRASTRUCTURE - SURVEY NETWORKS AND DATUMS.118.1 PRIMARY SURVEY NETWORK.128.2 TOKAMAK PIT NETWORK.138.3 TOKAMAK GALLERIES NETWORKS.138.4 GENERIC BUILDINGS NETWORKS.148.5 ASSEMBLY DATUMS.149 SURVEY AND ALIGNMENT DURING BUILDINGS CONSTRUCTION.1410 DESIGN FOR ALIGNMENT AND METROLOGY.1511 PROCESS CONTROL AND BEST PRACTISE.1611.1 LARGE VOLUME PORTABLE MEASUREMENT SYSTEMS.1711.2 BEST-FIT ANALYSIS AND ALIGNMENT TRANSFORMATIONS.1711.3 CONTROL OF INSPECTION MEASUREMENT AND TEST EQUIPMENT.1811.4 COORDINATE SYSTEMS AND MEASUREMENT UNITS.1811.5METROLOGY SOFTWARE AND DATA FORMATS.1811.6MEASUREMENT UNCERTAINTY.1911.7MEASUREMENT SCALE.1911.8 COMPONENT ORIENTATION AND FIXTURING FOR MEASUREMENT.2011.9 FIDUCIALISATION.2011.10 TARGETS AND TOOLING.2112 COORDINATION FOR METROLOGY ACTIVITIES.2112.1 INTERFACE CONTROL.2212.2 DESIGN REVIEWS.2313 QA AND DOCUMENTATION.23Page 2 of 231 PurposeThe purpose of this document is to supply information relating to dimensional metrology to allDepartments of the ITER Organisation and Domestic Agencies. To define strategies andinfrastructure provision, identify requirements and best practises and provide a standardisedapproach to dimensional control and alignment processes2 ScopeThe Dimensional Metrology Handbook (DMH) outlines the mandatory requirements fordimensional control of the components, assemblies and systems for the ITER machine. Inaddition the handbook provides significant guidance and helpful information on best practisefor large volume metrology applications. The handbook also provides information on the ITERmetrology infrastructure and the provision of alignment and metrology services duringassembly of the machine and its ancillary components and systemsThe DMH is issued as a supplement to project requirements documents, since it is necessarythat the requirements contained in this handbook are followed by the ITER Organisation, theDomestic Agencies and industry to ensure the successful construction and operation of ITER3 DefinitionsAbbreviations and Acronyms3D Three DimensionalA&M Alignment and MetrologyAIMS Advanced Integrated Mathematical SystemASCII American Standard Code for Information ExchangeCAD Computer Aided DesignCBD Cryostat Base DatumCCL Current CentrelineCCR Corner Cube ReflectorDA Domestic AgencyDCM Design Compliance MatrixDMH Dimensional Metrology HandbookDMIS Dimensional Measurement Interface StandardGD&T Geometric Dimensioning and TolerancingGPS Geometrical Product SpecificationsICD Interface Control DocumentIDM ITER Document Management SystemIGES Initial Graphics Exchange SpecificationIO ITER OrganisationIS Interface SheetLVM Large Volume MetrologyMIP Manufacturing Inspection PlanPage 3 of 23MQP Management and Quality ProgramMRP Mandatory Requirements for ProcurementNRK New River KinematicsPA Procurement ArrangementPF Raw 3D Scan data FormatPIF Parametric Image FormatPIT Pit DatumPOL InnovMetric’s Binary FormatRO Responsible OfficerSA Spatial AnalyzerSAT Standard ACIS TextSMR Spherically Mounted ReflectorSRD System Requirements DocumentSTEP Standardised Exchange of ProductTAD Tokamak Assembly DatumTRO Technical Responsible OfficerTF Toroidal FieldTFGS Toroidal Field coil Gravity SupportTGCS Tokamak Global Coordinate SystemVVGS Vacuum Vessel Gravity Support4 Communications and acceptanceTo satisfy the requirements of this handbook, processes and procedures relating to alignmentand dimensional control must be clearly documented and where stated: approved or acceptedby the Metrology RO or nominated representative. Section 11 and its sub-sections “Process control and best practise” identify areas that will bereviewed prior, during and on completion of the activity and will require IO acceptance atpredefined stages. Acceptance/Approval is to be a positive and recorded action, either bysignature or by electronic means. A possible route of communication and acceptance could be:-Supplier (Contractor) ↔ Domestic Agency Contract Responsible Officer ↔ ITER TechnicalResponsible Officer ↔ ITER Metrology Responsible Officer5 Alignment and Metrology (A&M) ClassificationsMachine components and plant systems requiring alignment and/or dimensional control shallbe given an A&M classification by the applicable TRO. The classification shall reflect theimportance placed on A&M for the system to function and the consequence of failure on theproject. This classification shall be reviewed with the Metrology RO and acceptedPage 4 of 23Alignment & Metrology (A&M) Class 1Components or assemblies requiring alignment and/or dimensional control, where failure tocomply in these areas will significantly impair or prevent machine assembly and/or operationand could potentially cause schedule delay in excess of one month or cost risk in excess of1M€. A&M Class 2Components or assemblies requiring alignment and/or dimensional control, where failure tocomply in these areas will significantly impair or prevent machine assembly and/or operationand could potentially cause schedule delay in excess of one week or cost risk in excess of0.1M€. A&M Class 3No dimensional control oversight by IO is required through the supply chain or on receipt atthe ITER site. No component alignment requirements however; setting out points/lines will berequired from the IO metrology team to facilitate the installation. UnclassifiedNo IO infrastructure required or support from the ITER metrology teamNote: It is the responsibility of the Technical RO to make an assessment of the A&Mrequirements for his system following the processes in this document in order to determine theA&M class, which is be reviewed by the metrology RO. 6 Mandatory requirements for A&M TasksFor the ITER machine to operate to specification it is essential that the supply of its constituentparts is controlled throughout their life cycle from raw material through manufacture, assemblycommissioning and operation. From a metrology perspective this means that dimensionalcontrol processes must be qualified and traceableThe Metrology RO shall be available to provide technical advice to system ROs duringpreparation of PAs and Technical Specifications, reviewing metrology related documentationand providing support where necessary during manufacture, assembly/installation andacceptance. In the following sections, information is provided on best practise guidance for metrologyrelated processes and will be used as the basis for reviewing process documentation relating todimensional control activities. Within this section are the mandatory requirements relating to A&M for the supply andassembly/installation of the systems for ITER. If an exceptions to a mandatory requirement isrequested it must be agreed by the IO MAI section through a deviation requestPage 5 of 23Mandatory requirements relating to A&M are dependent on the A&M classification applicable(section 5) to the component or assembly concerned. These requirements are detailed in thefollowing sub-sections:6.1 Mandatory Requirements for Site (MRS) based A&M Class 1activitiesA&M Class 1 activities are critical to the successful assembly/installation andoperation of the ITER machine and as such require the highest level ofqualification and control. Listed below are the mandatory requirements, asapplicable for the system concerned, identifying responsibilities for their deliveryand acceptance. The Metrology RO or his delegate shall review all key documentspertaining to A&M tasks within this classification[MRS1] The System Requirements Document (SRD), Interface ControlDocument (ICD) or other document, shall define the alignment and/ordimensional control requirements. These shall be included in the DCMand the methods to achieve them shall be reviewed and approved aspart of the ITER Design Review Procedure with the Metrology ROaccepting the process for the A&M tasks. [MRS2] The ITER RO shall identify all A&M quality documentation that willform part of the supply for the applicable system. The dossier ofdocuments shall be certified compliant with the requirements of thetechnical specification or shall be supported by a non-conformancereport. This shall be in place prior to any A&M work commencing at theITER site[MRS3] For items requiring goods inwards, in-process or final inspection, a listof key characteristics shall be compiled by the RO to identify the scopeof the inspection. Datums and tolerances shall be identified in a drawingor other medium acceptable to the inspection team carrying out the task. A method statement or procedure shall be prepared by the partyresponsible for the inspection which shall be accepted by the MetrologyRO or his delegate[MRS4] For items requiring setting out, pre-alignment and/or final alignment atthe ITER site, a procedure shall be prepared detailing the requirements,process description, reference data, output data together with reportingand acceptance criteria. This procedure shall be accepted by theMetrology RO or his delegate prior to task commencement[MRS5] The coordinate/datum systems used during inspection and alignmenttasks on the ITER site shall be clearly defined in the A&M procedure forthe task and applicable drawings. Where datums evolve to reflect as-built variation in the assembly/installation process the logic shall betraceable back to the nominal requirement[MRS6] Inspection reports shall identify the nominal dimensions, applicabletolerances and the dimension achieved for the feature, with non-Page 6 of 23complying values flagged in red on the report. These features shall bethe subject of rework or a non-conformance report[MRS7] All metrology equipment used for A&M tasks shall hold a currentcalibration certificate issued by an accredited laboratory (Referencestandard BS EN ISO/IEC: 2005). The equipment selected by the suppliershall be fit for the requirements of the measurement process consideringareas such as: measurement uncertainty, speed of data acquisition,measurement geometry, local environmental conditions etc. [MRS8] Measurement uncertainty shall be calculated for all reportedmeasurements at a confidence level of 2σ. As a general rule, theuncertainty value shall not exceed 20% of the tolerance applicable to thefeature measured. Maintaining an uncertainty of 10% or less isrecommended to optimise the available tolerance applicable to thefeature concerned. [MRS9] The IO drawings specify dimensions at the reference temperature of20˚C. The environmental conditions for A&M will depend very much onthe location in which the activity is to be carried out. The RO shall makean assessment of the impact of thermal expansion/contraction on theA&M task and specify controls to be put in place as necessary tocompensate. Consideration shall be given to the thermal inertia of thecomponents being measured, where necessary allowing sufficient soaktime in the measurement environment to ensure thermal stabilisation. For critical items Temperature measurements (better than ± 1°C) shall berecorded throughout the measurement task of both the component andthe environment, logged against time and saved with the measurementfile. For large components, multiple measurements shall be required toenable the detection of thermal gradients. [MRS10] For measurement surveys utilising multiple instrument stations, bundleadjustment algorithms shall be utilised to ensure error propagation, viamultiple best-fit alignments, does not occur[MRS11] All “as-built” drawings/3D models/electronic data shall be supplied in aformat agreed with the IO to demonstrate compliance with the design. The IO does not prescribe which software should be used however; it iscritical that measurement data can be easily transferred been all partiesrequiring access to it. [MRS12] All inspection/dimensional control and alignment reports shall include,as a minimum, the following information:Identification of measuring instruments used including calibrationcertificate numberIdentification of ancillary equipment, as applicable, used including type,make unique identifier and calibration certificate number i.eo Test unito Probes (dimensions, frequencies)o Targets and toolingPage 7 of 23o Scale barsIdentification of the part examinedReference drawing or CAD model identification defining the tolerances,datum etc. which the part has been inspected to, including issue statusTime and place of the inspection plus signature of the operatorName and qualification of the operator and his employerProcedure followed and issue statusMeteorological data (temperature, humidity, pressure)Identification of all computer files generated during the inspection, allraw and processed data must be in a format acceptable to the IOWritten values tabulated to provide: nominal dimensions, applicabletolerances and the dimension achieved for the feature, with non-complying values flagged in red on the report. Graphical data may beused if agreed by IOInterpretation of results, including an explanation for any readingsconsidered invalidIdentification of any non-conformity reports raised[MRS13] All drawings and/or electronic data used for A&M activities shall beissued through the ITER document control process and certified at thestatus to which they shall be used. 6.2 Mandatory Requirements for Site (MRS) based A&M Class 2activitiesComponents or assemblies with an A&M class 2 will require a significant amountof dimensional control on the IO site. They may need to go through a pre-alignment process to provide references (fiducials) for assembly/installation andmay also need inspections during and on completion of assembly/installationA&M class 2 tasks however have a reduced impact on cost and schedule in theevent of failure therefore requiring a reduced level of input by the Metrology ROThe A&M class 1 mandatory requirements [MRS1] through to [MRS13] shall bemaintained for this classification, as applicable to the task, but the requirement forreview/approval by the Metrology RO is removed. 6.3 Mandatory Requirements for Site (MRS) based A&M Class 3activitiesA&M class 3 activities only require setting out points/lines to facilitate theirinstallation therefore the mandatory requirements for these activities are [MRS4],[MRS7] and [MRS13]6.4 Mandatory Requirements Procurement (MRP) for A&M Class 1activitiesA&M Class 1 activities are critical to the successful assembly/installation andoperation of the ITER machine and as such require the highest level ofqualification and control. Listed below are the mandatory requirements, asapplicable for the system concerned, identifying responsibilities for their deliveryPage 8 of 23and approval. The Metrology RO or his delegate shall be given the opportunity toreview all key documents pertaining to A&M tasks within this classification[MRP1] The System Requirements Document (SRD), Interface ControlDocument (ICD) or other document, shall define the alignment and/ordimensional control requirements relating to the subject of theprocurement. These shall be included in the DCM and shall be reviewedas part of the ITER Design Review Procedure[MRP2] The A&M requirements for the procurement shall be included within theTechnical Specification (Annex B for PA’s) with design drawings andassociated design documents defining the fundamental designdimensions and tolerances. The supplier shall produce shop floordocumentation that demonstrates how the manufacturing and/orassembly process shall be controlled throughout the production cycle. This shall include tolerance requirements for relevant stages of themanufacturing process that shall be agreed with the IO prior tocommencement of manufacture[MRP3] Prior to contract commencement the supplier shall produce animplementation plan defining all quality related activities to be carriedout during the contract. Elements relating to A&M shall include: Reference standards Design change control procedures – Drawings and CAD models Document control Instrument calibrations and test procedures Control of non-conformities Data management procedures Measurement procedures- data acquisition, post processing andvalidation Reporting proceduresThe Metrology RO shall be given the opportunity to review theimplementation plan and any documents referenced within it, prior tocontract commencement[MRP4] Inspections shall be carried out at all crucial stages of the manufacturingprocess to guarantee adherence to final tolerances and set as early aspossible corrective measures where necessary. The frequency anddetails of these inspections shall be defined by the supplier in the MIPfor the procurement which the IO will be given the opportunity towitness at their discretion[MRP5] The coordinate/datum system used during inspection and dimensionalcontrol processes shall be as defined in the design drawings. Inspectionreports shall identify the nominal dimensions, applicable tolerances andthe dimension achieved for the feature with non-complying valuesflagged in red on the reportPage 9 of 23[MRP6] All metrology equipment used for A&M tasks shall hold a currentcalibration certificate issued by an accredited laboratory (Referencestandard BS EN ISO/IEC: 2005). The equipment selected by the suppliershall be fit for the requirements of the measurement process consideringareas such as: measurement uncertainty, speed of data acquisition,measurement geometry, local environmental conditions etc. [MRP7] The supplier shall draft a dimensional control plan (DCP) that shallinclude all inputs and outputs relating to the measurement process, seesection 9. The DCP shall be supplied to the IO for acceptance, prior tocommencement of manufacture[MRP8] Measurement uncertainty shall be calculated for all reportedmeasurements at a confidence level of 2σ. As a general rule, theuncertainty value shall not exceed 20% of the tolerance applicable to thefeature measured. Maintaining an uncertainty of 10% or less isrecommended to optimise the available tolerance applicable to thefeature concerned. [MRP9] The IO drawings specify dimensions at the reference temperature of20˚C. Dimensional control for factory acceptance shall be carried out ina controlled environment with a maximum temperature variation of ±2˚C. Key dimensions shall be measured at the reference temperature orcorrected to this temperature therefore temperature stability during themeasurement process is critical. Raw measurement data and correctedvalues shall be made available to the IO. Consideration shall be given tothe thermal inertia of the components being measured allowing sufficientsoak time in the measurement environment to ensure thermalstabilisation. Temperature measurements (better than ± 1°C) shall berecorded throughout the measurement task of both the component andthe environment, logged against time and saved with the measurementfile. For large components, multiple measurements shall be required toenable the detection of thermal gradients. [MRP10] For measurement surveys utilising multiple instrument stations, bundleadjustment algorithms shall be utilised to ensure error propagation, viamultiple best-fit alignments, does not occur[MRP11] The supplier shall produce “as-built” drawings/3D models/electronicdata, in a format agreed with the IO demonstrating compliance with thedesign. The IO does not prescribe which software should be usedhowever; it is critical that measurement data can be easily transferredbetween the parties to the ITER agreement. During manufacture this datamay be required to qualify measurement processes, address non-conformance issues, and consider concession requests. In addition, thedata may be used to construct a configuration model representing thetrue geometry of the item concerned. [MRP12] Deviations from the design requirements shall be the subject of a non-conformance (NCR) report with corrective measures involvinggeometric or material property changes requiring the prior approval ofPage 10 of 23the IO. To enable a decision to be made the supplier shall furnish the IOwith documents justifying their proposal delivered within the NCRsystem[MRP13] All inspection/dimensional control reports shall include, as a minimum,the following information: Identification of measuring instruments used includingcalibration certificate number Identification of ancillary equipment, as applicable, usedincluding type, make unique identifier and calibrationcertificate number i.eoTest unitoProbes (dimensions, frequencies)oTargets and toolingoScale bars Identification of the part examinedReference drawing or CAD model identification defining thetolerances, datum etc. which the part has been inspected to,including issue status Time and place of the inspection plus signature of the operator Name and qualification of the operator and his employerProcedure followed and issue status Meteorological data (temperature, humidity, pressure) Identification of all computer files generated during theinspection, all raw and processed data must be in a formatacceptable to the IO Written values tabulated to provide: nominal dimensions,applicable tolerances and the dimension achieved for thefeature, with non-complying values flagged in red on thereport. Graphical data may be used if agreed by IO Interpretation of results, including an explanation for anyreadings considered invalid Identification of any non-conformity reports raisedIn order to avoid unnecessary duplication, some of the information listedabove can be provided in documents identified by the supplier andattached to the report6.5 Mandatory Requirements Procurement (MRP) for A&M Class 2activitiesComponents or assemblies with an A&M class 2 for procurement will require asignificant amount of dimensional control during manufacture, overseen by the IO. They may need to go through a pre-alignment process to provide references(fiducials) for assembly/installation at the ITER site and may also need some formof inspection during factory acceptance or on receipt by the ROPage 11 of 23The TRO for the system involved shall need to consider the level of control to beapplied during the procurement process and identify the mandatory requirements inthe technical specification applicable to the procurement. As a minimum the following mandatory requirements from A&M class 1 shall beapplied: [MRP1], [MRP2], [MRP3], [MRP4], [MRP5], [MRP6], [MRP7] and[MRP12]. Other requirements may be added at the discretion of the RONote: Components of A&M Class 3 or below require no specific dimensionalcontrols of alignment activities during the procurement process. 7 StandardsThere are a large number of standards relating to dimensional metrology which can broadly begrouped under the scope of two Technical Committees within the International StandardsOrganisation (ISO) namely:TC 213 - Dimensional and geometrical product specifications and verificationStandardisation in the field of geometrical product specifications (GPS), i.e. macro- andmicrogeometry specifications covering dimensional and geometrical tolerancing,surface properties and the related verification principles, measuring equipment andcalibration requirements including the uncertainty of dimensional and geometricalmeasurement. The standardisation includes the basic layout and explanation of drawingindications (symbols)TC 176 - Quality management and quality assuranceStandardization in the field of quality management (generic quality managementsystems and supporting technologies), as well as quality management standardization inspecific sectors at the request of the affected sector and the ISO Technical ManagementBoard. Note:ISO/TC 176 is also entrusted with an advisory function to all ISO and IEC technicalcommittees to ensure the integrity of the generic quality system standards and theeffective implementation of the ISO/IEC sector policy on quality management systemsdeliverables. Non ISO standards useful for reference:Guidelines for the Evaluation of Dimensional Measurement Uncertainty (Technical Report)(B89.7.3.2 - 2007)Performance Evaluation of Laser-Based Spherical Coordinate Measurement Systems (B89.4.19- 2006)8 Infrastructure - Survey Networks and datumsAll measurement tasks need a fixed reference base (the datum) from which measurements canbe made and calculated. For large volume metrology (LVM) applications this referencePage 12 of 23typically takes the form of a survey network consisting of a collection of target nests and/orinstrument stations of known geometry and computed uncertaintyThe accuracy and precision of the survey network(s) directly affects the measurement accuracythat can be achieved for subsequent alignment tasks. Accuracy and precision are terms thatoften get confused therefore for the purposes of this document their definitions are as follows:Accuracy: The degree of conformity of a measured or calculatedquantity to its actual (true) valuePrecision: The degree of repeatability achieved when the same quantityis measured a number of timesThe survey network design process starts with a specification detailing how the network will beutilised and defining the ultimate measurement tolerances to be achieved. A perfectmeasurement does not exist therefore it is important to be able to determine the measurementuncertainty for each stage of the measurement process and thus create a tolerance budgetMeasurement uncertainty: The parameter, associated with the result of a measurement(e.g. a calibration or test) that defines the range of values thatcould reasonably be attributed to the measured quantity. When uncertainty is evaluated and reported in a specifiedway it indicates the level of confidence that the value actuallylies within the range defined by the uncertainty intervalThe survey networks for ITER will cover the whole of the site, providing a global coordinatematrix for survey instruments to reference against. The accuracy requirements for each networkwill vary, dependent on the alignment tasks for which they are being supplied. As such,interface control documents need to clearly define the alignment requirements of ITERcomponents, assemblies and systems8.1 Primary Survey NetworkThe first survey network installed was the Primary Survey network which defines the sitereference system for buildings construction, provides the datum for monitoring stability andis the global datum for dedicated secondary networks installed throughout the siteThe network consists of a collection of geodetic pillars, spread around the site and tied intofoundations designed to optimise stability. A common interface for force-centring surveyinstruments and survey targets is embedded in the top of each pillarThe network was installed and measured in the summer of 2010. A least squares adjustmentwas made to optimise the network and determine the co-ordinate and uncertainty values foreach survey monument. The measurement uncertainty for the network was calculated to be~1mm when initially measured. The network will be periodically monitored for stabilityThe coordinates of the primary survey network are reported within the Lambert III mappingprojection with elevations relative to sea level. The Tokamak Global Coordinate System(TGCS) is an orthogonal system with the gravity vector defining the Z-axis at machinecentre, the Y-axis points towards site north (37˚ counter-clockwise from geographic north)with the X-axis mutually perpendicular to Z & Y in an easterly direction. The origin of thePage 13 of 23coordinate system is at the nominal tokamak centre. For more information on ITER co-ordinate systems refer to document ITER_D_2A9PXZ8.2 Tokamak Pit NetworkMachine assembly activities within the tokamak pit shall require accurate and precisealignment of components. The design specification for the network is to achieve anuncertainty no greater than ± 0.2 mm within a temperature controlled environment of ± 2˚C(ref. SRD 62-13), this requirement is achievable if the environment remains stable. However, it is clear that with the immense transfer of loads occurring during constructionthat the network will move and distort to a certain extent. This distortion will need to bemonitored and modelled during machine assembly to ensure that the final machine isaligned to specification. Both dynamic and passive measurement systems are beingconsidered to provide an efficient system for monitoring the network movement and thusenable adjustments to be calculated and employedThe initial network shall consist of many targets, or target nests, distributed around the pitwall covering the full height of the pit and extending into the adjacent port cells. The bestfit centre of the pit shall be derived from the pit wall targets defining the vertical datum axisfor machine assembly. The datum for toroidal position and elevation will be derived fromthe best fit position of the port cells. Once the lower cryostat cylinder is installed, lines of sight to the lower pit wall targets willbe blocked however, lines of sight from the pit into the port cells and vice versa shall bemaintained. The pit wall targets above the cryostat lower cylinder shall remain visiblethroughout the vacuum vessel construction, only becoming obscured when the cryostatupper cylinder is installed. The port cell targets are very important to the pit network asthey provide the link to systems external to the pit within the adjacent galleries. It is likely that a number of different instrument types will be used during the tokamakbuild process such as photogrammetry cameras, laser trackers and total stations. Lasertrackers and total stations measure to similar spherically mounted reflectors called SMRs orcorner cube reflectors CCRs, different names for the same item. Photogrammetry usesretroreflective however, common targeting mounts are readily available from supplierssuch as Hubbs and Brunson enabling interchangeability of instruments utilising thenetwork8.3 Tokamak Galleries NetworksSurvey networks shall be installed external to the bio shield wall within the port cells andgalleries. These multi-level networks shall provide the dimensional control for all systemsexternal to the tokamak pit within the tokamak building and will be linked to the TokamakPit Network via the port cells. The network shall consist of a collection of wall and floormounted target nests distributed throughout the galleries. These will be a standardiseddesign as used for the pit network thus allowing flexibility of instrument selection formeasurement tasksProvision shall be made to link the tokamak hall network to the primary network. This willbe carried out with a total station and level and will be periodically checked for stabilitywhist lines of sight remain available. Page 14 of 238.4 Generic Buildings NetworksThere are various buildings around the site having different requirements for dimensionalcontrol. Users of these buildings need to consider their requirements at an early stage sothat fit for purpose networks can be installed and measured in a timely mannerWhere required, building networks shall be linked to the primary survey network thusproviding a global position for all setting out, alignment and measurement tasks. Where alocal reference is required co-ordinate transformations into the building co-ordinate systemcan be made (ref. ITER_D_2A9PXZ). 8.5 Assembly DatumsDuring assembly of the ITER machine it will be necessary to adjust the build datum tooptimise the assembly process with respect to the as-built geometry of key machinecomponents. Each build datum shall define the position and orientation of a coordinateframe within which the coordinates of the targets/target nests of the Tokamak Pit Networkshall be valuedThe pit datum (PIT) as described in section 8.2 will be the initial datum used to align thefollowing components: Cryostat Column Baseplates Cryostat Columns Cryostat Base Section assemblyThe as-built position of the cryostat base shall be used to define the cryostat base datum(CBD) this shall be used to align: Cryostat lower Cylinder TF CoilsThe key characteristics on the cryostat base that are used to establish the CBD are thegravity support interfaces for both the TF coils (TFGS) and the vacuum vessel (VVGS)The key characteristic of the coils to be aligned is the current centre line (CCL) of thewinding back, its position defined with respect to fiducials on the coil case. When the 18 TF Coils are in place, the Tokamak Assembly Datum (TAD) shall beestablished representing the Least Square best Fit of the 18 TF Coils. This datum shall beused for final alignment of the vacuum vessel, remaining magnet systems and the internalvacuum vessel components9 Survey and Alignment during buildings constructionDuring the construction phase of the ITER buildings there will be many requirements foraccurate alignment. ROs need to carefully consider the alignment requirements of their systemsespecially in areas of restricted access where opportunities to define reference points may belimitedPage 15 of 23The alignment path of systems that will ultimately be separated by physical barriers, such asconcrete walls, may not be restricted at an early stage of the project. Providing the alignmentreferences at this early stage may be the only opportunity to carry out the task and thereforeguarantee the success of the installationSome large or heavy pieces of plant and equipment may have to be installed during theconstruction process if access to deliver such component will not be possible once constructionis complete. In these instances, alignment references will need to be established in advance tofacilitate the setting out and alignment as requiredGenerally speaking; if a piece of equipment needs to be installed accurately to a global co-ordinate i.e. not positioned to local features like adjacent walls, building columns etc., thenaccess to a survey network or pre-defined and established reference points will be required. Local alignment tasks need clear lines of sight or a network or dedicated reference points tofacilitate the taskThe installation of the primary survey network is complete however the addition, pace andsequence of secondary networks will be driven by the requirements defined by the varioussystem ROs on the project and should be clearly defined in the project schedule10 Design for Alignment and MetrologyThe ITER machine is made up of many complex components and assemblies which need tointeract in specific ways for the experiment to be successful. The design process will identifythe optimum configuration for these systems identifying key characteristics to be focussed onwith realistic parameters for manufacture and assembly, achieving a fit for purpose design. From a metrology perspective, measurement uncertainty is a key contributor to the overalltolerance budget and as such needs to be carefully considered. For example; if a componentcan be manufactured to a perceived tolerance of +/- 1 mm but the measurement process canonly deliver to +/- 2 mm then the overall process is clearly out of controlIt has already been identified that survey networks can be designed and installed to provide thedatum for alignment activities. This however is only part of the requirement; the componentsthemselves also need to be equipped with alignment features, designed to interface with themost appropriate measurement instruments and positioned to deliver the required alignmentaccuracy. In addition, the survey features need to be positioned with due consideration to thekinematics of the alignment system. There is no point in having an accurate and precisemeasurement system if the alignment mechanism cannot respond efficiently to the dataprovided by the measurement surveyThe list below identifies areas for consideration when designing components for alignment:Alignment tolerances Position Elevation Angle: Roll, Pitch, YawDatum references PIT CBD TAD Local to componentAlignment features Target nests Tooling Ball Retroreflective targets Scribed reference linesPage 16 of 23Adjustment Mechanisms Screw threads Jacks CamsAlignment Geometry Plane Line Centre of rotation Coupled or decoupledMetrology Instruments Laser Trackers Total Stations Theodolites Articulatedmeasurement arms Photogrammetry Laser Scanners LevelsDuring the design and planning stages for ITER and in support of the procurementarrangements (PAs), the Metrology RO is available to give advice on aspects relating togeometrical and dimensional control for the project. Inspection and alignment surveys can besimulated at the design stage enabling qualification of measurement processes and thedetermination of uncertainty values for measured points and features within the survey. 11 Process control and best practiseThe control of dimensional measurement is an essential part of the supply chain for the ITERcomponents and the subsequent assembly activities to be carried out at the ITER site. For allcritical inspections/surveys the measurement process needs to be clearly defined, controlledand accepted by the IOInputs to the process may include: design specifications, drawings, CAD models quality plans, procedures, method statements measuring instruments, calibrations, reference artefacts components and assemblies plant and equipment personnel, skills, training computer software, simulations, uncertainty analysisWith outputs such as: raw measurement data Meteorological corrections Scale adjustments co-ordinate frame transforms quality control inspection reports best-fit analyses and transformation matrices aligned component / assemblies fiducially referenced components / assemblies survey uncertainty analyses signed off method statements, procedures, quality plans Survey ReportPage 17 of 23The measurement process needs to be fit for purpose; delivering the required outputs in anefficient manner and providing assurances that the process is under control. The IO shall begiven the opportunity to review the process documentation prior to commencement and towitness inspections/surveys during manufacture, hold points shall be specified in theManufacturing and inspection Plan (MIP) as required. In exceptional circumstances the IOreserves the right to carry out its own dimensional control measurements utilising its ownpersonnel or a third party supplierThe IO shall identify key interfaces which must be inspected during manufacture andmonitored during assembly operations, such as welding, which may affect the fit, form orfunction of the assembly. The control of such operations shall be clearly defined in the processdocumentation with measurement data recorded in an appropriate format11.1 Large volume portable measurement systemsFor large volume metrology it is often necessary to bring the measuring instrument to thejob. Portable co-ordinate measurement systems such as Laser trackers, total stations,theodolites and photogrammetry, enable the surveyor/inspector to carry out themeasurement task in the workplace however, with this flexibility comes added variablesthat must to be controlledThe workshop environment is unlikely to be as rigorously controlled as a dedicatedmetrology lab. Changes in temperature, humidity and pressure all contribute tomeasurement variance and therefore need to be recorded and compensated for. Measuring a large component or assembly will often require the use of multiple instrumentstations. This may be due to line of sight constraints or as a means of reducing observationlengths within the survey to minimise measurement uncertainty. Whatever the reason, if theresults are to be considered within a single coordinate system then a network solution to thefit will be required. Best practice is to carry out a bundle adjustment of the network; thisiterative process will optimise the network by minimising the combined pointing errors ofthe measurements. With the instrument stations optimised the uncertainty of the measuredpoints within the network can be calculated through a variance algorithmMinimising the potential for error will come from a good understanding of the technicalspecification, consideration and compensation for the working environment and byapplying best practice processes. 11.2 Best-fit analysis and alignment transformationsInitial measurements taken during a survey will be valued within the measuringinstrument’s local co-ordinate system. Their relationship to each other will be clearlydefined but they will require aligning to the part or assembly to which they relateThe alignment can be defined by geometry measured within the measurement session i.e. points, lines and planes or by referencing measured points to features within the CADmodel such as faces, surfaces etcUnlike the CAD model, the measured points will not fit perfectly to the design nominaltherefore a series of weighted best-fits will need to be applied to optimise the alignment. The IO shall identify the key characteristics to be used for the alignment and prioritise theirimportance. This information shall either be provided within engineering drawings,annotated to the CAD model or as written instructionsPage 18 of 23The supplier’s measurement procedure shall identify best fit processes to be carried outincluding any data filtering that will be applied. In general, all raw data shall be maintainedand stored for ease of recall and review by the IO. 11.3 Control of inspection measurement and test equipmentAll measuring equipment must be fit for purpose to deliver to the tolerances specified. Adocumented calibration system must be in operation traceable to national standards andcertificated through an accredited body. A calibration schedule must be in place with allcalibrations logged within a register and all calibration certificates filed for ease of recall. A Quality document shall clearly identify where and when measurement equipment hasbeen used. Each piece of equipment shall be uniquely identified and must only be usedwhen its calibration status is within dateFor critical measurements it may be necessary to calibrate a measuring instrument morefrequently than the suppliers recommended interval. Where the IO deems this necessary itshall mark up the quality plan accordingly11.4 Coordinate systems and measurement unitsIn general, when conveying results of a survey/inspection the co-ordinate system used shallbe coincident and of the same type as that used to specify the design. The measurementunits shall be as defined in the drawing or model and the deviation from nominal of the as-built dimensions shall be reported in the same manner as they are tolerancedResults from an inspection shall be expressed in quantative terms when a designcharacteristic is expressed in numerical units. Attribute data may be used (e.g. go/no-go) ifno inspection technique resulting in a quantative measurement is feasible. Where this is thecase the gauge used for the process shall be traceable to an appropriate national standard11.5 Metrology software and data formatsThe ITER organisation has adopted Spatial Analyzer (SA), supplied by New RiverKinematics (NRK), as its preferred metrology software. The software interfaces with thevast majority of measurement instruments; its architecture maintains full traceability of themeasurement process storing all raw measurement data and environmental monitoringcorrections. The software has been specifically designed for large volume metrology applications; itsoptimisation algorithms for network configurations, computes measurement uncertainty bydefault and analyses instrument performance in the process. The system can be used offlinefor measurement simulations by utilising constructed geometry within the application or bydirectly importing Catia V5 models, complete with embedded GD&T if requiredThe IO does not prescribe which software should be used however; it is critical thatmeasurement data can be easily transferred between the parties to the ITER agreement. During manufacture this data may be required to qualify measurement processes, addressnon-conformance issues, consider concession requests and certainly to build up as-builtmodels of the supplyPage 19 of 23The following data formats can be read into SA:ASCII, STEP, IGES,VDA, SAT, DMIS, AIMS-TDF, Polyworks (POL, PIF, PF, DPI),Direct Catia V4 V5 *.CGR process, Direct UG process, Direct ProE process, VSTARS.xyzfile, VSTARS Cameras (outstar.txt), xyz ijk File (IJK), Digital network levels, IMETRIC,1-D data (Datamyte). In all cases measurement data must include uncertainty values, see following section11.6 Measurement uncertaintyMeasurement uncertainty is the parameter, associated with the result of a measurement (e.g. a calibration or test) that defines the range of values that could reasonably be attributed tothe measured quantity. When uncertainty is evaluated and reported in a specified way itindicates the level of confidence that the value actually lies within the range defined by theuncertainty intervalNo measurement is complete unless its uncertainty can be quantified. In a similar way thata tolerance relays the acceptance specification for a given dimension, the measurementuncertainty must be considered when determining whether a measured characteristic meetsthe design criteria. For example: if the distance between 2 points is required to be10m +/- 0.003m then a measurement returning avalue of 10.0025m appears to be acceptablehowever; if the measurement uncertainty for eachpoint is +/- 0.001m then the reality is that themeasured dimension could be out of spec by up to0.0015m.. Figure 1 demonstrates this pictoriallyFigure 1: example of an uncertainty analysis for a linear dimension11.7 Measurement scaleComponents for the ITER machine are dimensioned nominally at 20˚C. For large objectsthe effects of temperature change on the physical size of the object can be considerable andas such must be taken into account during the measurement processMeasurements, especially those carried out over a prolonged period, must be carried out inthermally stable conditions. The measuring instrument and component must be given timeto acclimatise to the environment and the temperature must be monitored throughout themeasurement task10.002510.00450.001 0.001Measured Point Uncertainty EllipsePage 20 of 23Where the measurements cannot be taken at 20˚C a scale factor will need to be applied tothe measurement job. In consideration of the components orientation and fixturing, thescaling vector(s) shall be identified in the measurement plan for acceptance by the IOWhen using optical measuring systems such as laser trackers or total stations considerationneeds to be given to distance measurements from these instrument’s interferometers orabsolute distance meters. Environmental factors such as changes in atmospheric pressure,temperature and humidity will affect the wavelength and as such need to be corrected. Allenvironmental monitors used for this process must be calibrated in line with themanufactures recommendations and traceable to national standardsIntersecting theodolite systems and photogrammetry rely on defined calibrated lengthmeasurements to scale the measurement job. Scale bars, interferometer measured distancesor a controlled and traceable network of stable points can all be used to introduce scale. Theimportant factor is that the scale system is controlled, fit for purpose and traceable11.8 Component orientation and fixturing for measurementThere are many large and heavy components which are assembled together to make theITER machine. These components will distort to varying degrees depending on how theyare supported during manufacture and assembly therefore it is essential that theseparameters are considered and clearly defined within the measurement procedureWhere a component is to be supported, machined and inspected in one orientation but putinto service in another, the effects of the transformation need to be established. By default, CAD models describe a components shape and size in a state of equilibrium,unaffected by external influences such as gravity. Computer added manufacturing andinspection systems often use the CAD model to drive the manufacturing and inspectionprocesses therefore the CAD model either needs be morphed to reflect the geometriccondition for inspection or offset values need to be supplied for the specific areas ofinterest11.9 FiducialisationFiducialisation is the process used to define reference points (fiducials) on a component orassembly with respect to a reference coordinate frame. The position and orientation of theframe is constructed from as-built measurement data and reflects the optimum alignmentachievable from the data set measuredTo define an object’s 3D position and orientation, a minimum of 3 fiducials are requiredhowever, utilising more fiducials will add redundancy to the survey and provide a betterrepresentation of the measurement volume. The quantity and position of the fiducials willbe driven by the design specification and qualified through tolerance assessment anduncertainty analysisWhere fiducials are required to facilitate an alignment at the ITER site, their design,position and orientation will be defined by the IO. Fiducials used by the supplier shalleither be permanently attached to the object or fitted temporarily during the measurementvia a standard interface as descried in section 11.10Page 21 of 2311.10 Targets and toolingLaser trackers and total stations measure to similar spherical targets called SMRretroreflectors or corner cubes. Photogrammetry also uses retroreflective targets but of adifferent type however, interchangeable targeting mounts are readily availableA typical interface for these mounts could be an H7 hole of diameter 6, 8, or 10 mm reamedperpendicular into a reference face. The important thing to note is that whilst the mount willposition the target coincident with the axis of the hole, the target will be offset from thereference face by a defined amountFig. 1 Example of an SMR mounted in a pin nestThe example above shows a laser tracker SMR retroreflector mounted within a targetmount. Dimension “H” identifies the offset applied and the manufacturing toleranceAll targeting mounts or generically speaking tooling, that contributes to the measurementprocess shall be controlled within the supplier’s calibration system and shall be uniquelyidentified. The measurement process shall specifically record when such tooling has beenused defining the offset applied and its direction12 Coordination for metrology activitiesMany of the components for the ITER machine have extremely demanding tolerances withrespect to alignment and dimensional control. Their installation locations are often veryconstrained and their large size makes adjustment all the more difficult. These componentsmay be standalone items or an embodiment of constituent parts combined to deliver a specificfunction. Whatever the requirement, if metrology is a contributor then it is an interface thatneeds to be resourced and managed. The Metrology RO is available to give technical advice during the design phase of the projectand is tasked to put in place and manage the requisite infrastructure to support the machinebuild and its associated systems. This will include the design and realisation of surveyPage 22 of 23networks (section 8) development of alignment strategies, procurement of equipment and theday to day management of the metrology teamThe ITER metrology team shall be assembled to support the programmed metrologyrequirements of the ITER project therefore it is important that these needs are identified asearly as possible to optimise the resourcing with respect to equipment and personnel. 12.1 Interface controlROs for components, assemblies and systems requiring support from the ITER metrologyteam shall specify their requirements in an appropriate technical document i.e. SRD, ICD,dedicated IS. Typical details required shall include: General description of the measurement task detailing processes and required outputs Reference datum systems to be used i.e. site primary datum system, pit datum system,locally defined system etc Tolerance requirements for dimensional control and or alignment i.e. positionangularity, elevation, level etc Fiducialisation requirements (section 11.9) Location where the survey / inspection is to be carried out Scheduled date for the task andsub-tasks State of plant during the task(s); component orientation, supporting structures,scaffolding, adjacent work activities etc Environmental controls envisaged during the surveyFrom the above information the Metrology RO will elaborate a measurement plan,detailing the work scope, equipment and tooling requirements, estimated task duration andmanpower allocation. Any inputs required from the customer such as drawings, CADmodels etc. will be identified and their required delivery dates included in the metrologyscheduleThe ITER ‘Assembly and Installation Management Manual’ details the processes andprocedures to be followed in preparation for and during implementation of assembly andinstallation activities. Reference 3 of the document details the ‘System AssemblyCompatibility Assessment Procedure’ this procedure will be used by the MachineAssembly and Installation Section to assess compliance with assembly methodologies andstandards and to determine readiness for development of assembly operating procedures. Appendix 1 to the document ‘ITER System Assembly Compatibility Assessment Form’includes an input table specific to metrology activities; ‘Table 6: Dimensional control andAlignment’. This table shall be completed by the Metrology RO in conjunction with theRO for the system applicable providing information, as applicable, relating to the followingrequirements: First article inspection Goods inwards inspection Datum references and setting out Pre-alignment (fiducial measurement) Final alignmentPage 23 of 23 Data processing As-built measurements Measurement simulation12.2 Design reviewsAlignment and metrology requirements and processes will typically be reviewed at thedesign reviews for the system to which they apply. Design reviews will be carried out inaccordance with ITER Design Review Procedure (2832CF) current at the timeThe conceptual design review shall demonstrate that the alignment requirements andtolerances for the system under review have been identified and included in the DesignCompliance Matrix (DCM). Specific details shall be included in the interface sheet of theappropriate interface control document as they are developed and must be in place beforethe final design review. At the preliminary design review the outline processes for alignment should be presented toprovide an overview of the scope of the task including an indicative schedule. At this timeit should be clear where responsibilities lie for the various stages of the installation be itwith the IO the DA(s) or as a combined effortAlignment and Metrology activities could include: Goods inwards dimensional inspection of system components Fiducialisation of components for assembly (section 11.9) Provision of reference datums, network points, elevation lines (section 8.0) Setting out for enabling activities: marking out for location systems, stillages etc As-built reconstruction for customisation of interfaces Alignment of components: position, orientation, elevation…Following the preliminary design review the alignment and metrology processes will beelaborated by the responsible officer(s) concerned. The level of elaboration will bedependent on a number of contributors such as the uniqueness of the task, the complexity ofthe process, access restrictions, required accuracy etc. The preliminary design review willdefine the scope of this elaboration which will subsequently identify the metrology inputfor the final design reviewThe final design review shall demonstrate that dimensional control and alignment processeshave been sufficiently addressed to ensure that the system under review can be successfullymanufactured and subsequently installed at the ITER site. The Metrology RO will use themetrology handbook as reference for the review process and the DCM to assess compliancewith the design requirements, contributing to the overall acceptance process13 QA and documentationAll components, processes, documents and data within the scope of this handbook shall besubject to the ITER Quality Assurance Program (IDM Ref; ITER_D_22K4QX) and its relatedManagement and Quality Programme (MQP) (IDM Ref; ITER_D_2NS3UH)