Plan on how to work safely with Beryllium

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Presentation transcript:

Plan on how to work safely with Beryllium Pinghuai Wang1, Jiming Chen1, Kun Wang2 1 Southwestern institute of Physics (SWIP) 2 Chinese Domestic Agency (CNDA) Workshop on Beryllium Applications and Health & Safety, 2017.6.28-30

Contents Current status of CN ITER FW FW progress: Preparation for series production in SWIP Be involving activities in SWIP How to work safely with Beryllium Personnel Protection Airborne contamination measurement Surface contamination measurement Waste water and exhaust gas treatment R&D on the cleaning and smearing of the CN EHF FW components

Current status of CN ITER FW FW SP passed qualification, which is the necessary final step before PA sign 1st FW semi-prototype: Three finger pairs were successfully passed the high heat flux test (HHFT) HHFT: 4.7MW/㎡,7500 cycles + 4.7MW/㎡,1500 cycles 2nd FW semi-prototype Have been successfully manufactured. Three finger pairs were laser welded to the central beam.

CN EHF FW PA signature between CNDA and IO on Nov.16 2016 This is the final PA for CNDA, after the signature, CNDA has entered into a new stage of fully implementing PAs. Phase I: call for tender (on- going) SWIP is one of the potential suppliers.

FW progress: Preparation for series production in SWIP Two workshop were constructed for the manufacturing and inspection of the FW in SWIP. ITER FW manufacturing center: ~ 1000㎡ ITER FW Inspection center: ~ 500㎡

Hot Isostatic Pressing Machine (200MPa, 1400℃) 400kW High heat flux test EB facility Automatic Ultrasonic Beryllium Cleaning Line 16kW Laser Welding Machine PVD Coating Facility

3D Coordinate Measure Machine Cold Helium Leak Test Facility Ultrasonic Phased Array NDT System 10MPa Hydraulic Pressure Test Equipment

Be involving activities in SWIP Manufacturing and inspection of EHF FW fingers Befor HIPing: Be tiles selection --DT & VT Be tiles cleaning Be tiles assembly for coating Be tiles baking and coating in vacuum chamber Welding the HIPing canister After HIPing Non-Destructive Examination, --DT & VT & PT & HLT & UT Hydraulic test Cleaning Beryllium contamination test Assembly Be tiles for coating Assembly Beryllium tiles into HIP canister Removal of graphite Visual Inspection Dimensional Inspection

Manufacturing and inspection of EHF FW panels Finger pairs Assembly and welding Cleaning and smearing NDT High heat flux test Storaging FW panels Final machining Hot helium leak test Packaging

Contents Current status of CN ITER FW FW progress: Preparation for series production in SWIP Be involving activities in SWIP How to work safely with Beryllium Personnel Protection Airborne contamination measurement Surface contamination measurement Waste water and exhaust gas treatment R&D on the cleaning and smearing of the CN EHF FW components

1. Personnel Protection Mandatory required during manufacturing: Disposable masks (3M 95 series) for normal condition or special for pickling and welding Disposable hair hats Gloves, over-sleeves Shoe covers Work clothes And the wastes will be collected and treated by qualified companies. Medical examination: twice a year Training: for the new employees; for all the employees, twice a year. No access without permission

Personal Air Sampling PAS Occupational Exposure Limits(OELs) GBZ_2.1-2007: Occupational exposure limits for hazardous agents in the workplace Chemical hazardous agents OELs(μg/m3) PC-TWA 0.5 PC-STEL 1 PC-TWA: permissible concentration-time weighted average PC-STEL: permissible concentration-short term exposure limit PAS Flow:0.1~3L/min Long time sampling :2~8h, 1L/min Number of workers Number of sampling object 6 5 7~9 10~14 7 15~26 8 27~50 9 50~ 11 GBZ 159-2004: Specifications of air sampling for hazardous substances monitoring in the workplace Within the sampling object, if the workers who are exposed to the hazardous agent in the highest concentration and longest time can not be confirmed, each type of operation determine the number of sampling object in accordance with the table below. If the number of workers in each type of operation less than 6, all of them should be chosen as sampling object.(suitable for FSP production stage) Within the sampling object, if the workers who are exposed to the hazardous agent in the highest concentration and longest time can be confirmed, each type of operation determine the number of sampling object in accordance with the table below. And the sampling object should contain the ones who are exposed to the hazardous agent in the highest concentration and longest time. If the number of workers in each type of operation less than 3, all of them should be chosen as sampling object.(suitable for series production stage) Number of workers Number of sampling object 3~5 2 6~10 3 >10 4

PAS: same brand and same type as IO recommend

Area sampling(Sampler Flow:1.0~10L/min ) 2. Airborne contamination measurement Occupational Exposure Limits(OELs) GBZ_2.1-2007: Occupational exposure limits for hazardous agents in the workplace Chemical hazardous agents OELs(μg/m3) PC-TWA 0.5 PC-STEL 1 sampler Area sampling(Sampler Flow:1.0~10L/min ) Long time sampling : 2~8h, 1L/min Short time sampling:15min, 5L/min PC-TWA: permissible concentration-time weighted average PC-STEL: permissible concentration-short term exposure limit Sampling equipment: Air collector Sampling requirement for the permissible concentration - time weighted average At the time of the peak airborne contamination every Be-involving activities Typical site

Airborne contamination measurement results During the SP manufacturing stage, all of the test results meet the requirement (Below Detectable Limit 0.06μg/m3). Coating Baking Dimensional Inspection Cleaning Helium leak test at RT Laser welding

Plan of the typical site sampling in the FW manufacturing workshop 6 4 1 5 2 3 7 1) Ultrasonic cleaning of Be tiles; 2) Control room of HHFT facility; 3) Laser welding; 4) Coating facility; 5) TIG welding and assembly; 6) HIP equipment; 7) Control room of HIP equipment.

UT Plan of the typical site sampling in the FW inspection workshop 1 Storage room UT 3 2 Cold He leak test 4 3D Coordinate Measure Machine 1) Storage room; 2) Cold helium leak test facility; 3) UT and assembly desk; 4) 3D coordinate measure machine

3. Surface contamination measurement surface contamination measurement results Sample 1 (assembly desk) Smear area: 0.09 m2 Result: 6.9 µg/m2 Sample 2 (measuring desk) Smear area: 0.09 m2 Result: 1.7 µg/m2 Sample 3 (CMM load plate) Smear area: 0.09 m2 Result: <LOD Sample 4 (exhibition cover) Smear area: 0.09 m2 Result: <LOD Sampled on 2016.6.23, Analyzed by CCFE Sample 1 (assembly desk) Smear area: 0.09 m2 Result: 13.8 µg/m2 Sample 2 (measuring desk) Smear area: 0.09 m2 Result: 1.33 µg/m2 Sample 3 (CMM load plate) Smear area: 0.09 m2 Result: 0.2 µg/m2 Sample 4 (exhibition cover) Smear area: 0.09 m2 Result: 0.098 µg/m2 Sampled on 2016.7.25, Analyzed by NIMTT More attention shall be paid on the surface contamination Before Be activities, the surface of desks/testing plates shall be carefully cleaned. The surface contamination smearing procedure shall be established

4. Waste water and exhaust gas treatment Waste water and exhaust gas treatment system According to the requirement of China domestic environmental regulations: waste water will be treated and not discharge waste gas will be treated by ventilation system in the whole workshop.

Contents Current status of CN ITER FW FW progress: Preparation for series production in SWIP Be involving activities in SWIP How to work safely with Beryllium Personnel Protection Airborne contamination measurement Surface contamination measurement Waste water and exhaust gas treatment R&D on the cleaning and smearing of the CN EHF FW components

Be contamination requirement With the support from IO and CCFE, several round R&D works on the cleaning and smearing of EHF FW components have been carried out since 2015. Be contamination requirement For SP: ≤100μg/m2 .For PA: ≤10μg/m2 EHF FW fingers EHF FW finger pairs Finger pairs after HHFT

Equipment for cleaning 1) Ultrasonic Cleaner -- Traditional cleaning Ultrasonic cleaning in bath for 15 minutes Sprayed for 10 minutes with deionised water at room temperature Rinsed by ethyl alcohol and blow-dried by Argon to remove the water Ultrasonic cleaning tank: 91×80×92cm3; Power:28KHZ Spraying tank: 91×80×84 cm3;

2) Auto Ultrasonic cleaning line There are 13 ultrasonic cleaning bath and the function of each bath are shown in the table In this R&D work, bath 01, bath02, bath03, bath04, bath05, bath07 and bath13 were used. IN bath-01# bath-02# bath-03# bath-04# bath-05# bath-06# bath-07# bath-08# bath-09# bath-10# bath-11# bath-12# bath-13# OUT Liquid Level × Heating Ultrasonic Bubbling Spraying Nitrogen Flowing Note: × means the function is available; Bubbling and spraying are two kinds of rinsing process;

Be surface (Dry Method) Smearing Process According to the Guidance note smearing for beryllium ITER_D_RGF26W v1.0 Smear papers Be surface (Dry Method) Be slots (Dry Method)

Test results for the finger and finger pairs Be surface Single finger Finger pairs Single finger Finger pairs Be slots Multiple cleaning sequences can achieve 10 μg/m2 for surface but not slots Cleaning cycle is much helpful for the single finger than finger pairs Compared with single finger, the Be contamination of finger pair is much lower. Because the fingers has been traditional cleaned before welding of finger pairs Traditional cleaning is effective both for the single finger and finger pairs

Test results for the HHFTed finger pairs (PFG01-1) Area Location Pre-cleaning After 1st traditional cleaning at RT After 2nd traditional cleaning at RT After 1st cleaning line cycle After 2nd cleaning line cycle Non-HHFTed Surface 248 21 22.5 7.78 5 Slots 149 93 57.3 55.9 48 4.7MW/m2 7500cycles 260 25 12.7 9.58 9 102 79 60.5 28.0 39 5.9MW/m2 1500cycles 421 165 130 78.4 73 190 97 51.8 42.8 122 Tested by CCFE PFG01-1, Surface PFG01-1, Slots CCFE CCFE CCFE CCFE On surfaces tested up to 4.7MW/m2 , < 10 µg/m2 is feasible for achievable surface contamination level following 1st auto line cleaning cycle. ·Slots remain to be more difficult to clean, results similar to previous results for other CN mock ups ·Testing at 5.9 MW/m2 brings a more significant change to the slot and surface contamination level The 2nd cleaning line cycle seems can be cancelled.

Test results for the HHFTed finger pairs (PFG01-2) Area Location Pre-cleaning After 1st traditional cleaning at 60℃ After 2nd traditional cleaning at RT After 1st cleaning line cycle After 2nd cleaning line cycle Non-HHFTed Surface 94.5 10 4.93 3.32 4 Slots 127 51 21.5 13.8 19 Initial thermal screening 356 25 8.01 8.48 5 230 92 53.8 42.1 18 Tested by CCFE PFG01-2, Slots PFG01-2, Surface CCFE CCFE CCFE CCFE Compared with PFG01-1, which suffered the full HHFT procedure, Be contamination of PFG01-2 is much smaller. Ultrasonic cleaning at 60℃ seems better than that at room temperature It seems that < 10 µg/m2 is achievable on surface contamination level, even after one or two cycle traditional cleaning at 60℃。 However, < 10 µg/m2 is still very difficult to achieve on slots contamination

HHFT brings a more significant change to the slot and surface contamination,especially after testing at 5.9 MW/m2 Surfaces contamination of < 10 µg/m2 is achievable, even after HHF testing up to 4.7MW/m2. However, it is hard to achieve the goal after HHF testing up to 5.9MW/m2. Slots remain to be more difficult to clean, < 10 µg/m2 is not achievable based on the current cleaning process. Ultrasonic cleaning at 60℃ seems more effective, but a higher Be contamination in cleaning water will be produced and waster water treatment needed. A further R&D work for smearing and cleaning on the HHFTed FW fingers will be carried out.

Thank you!