1. 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,

2. 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

3. 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.

4. 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.

5. 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㎡

6. 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

7. 3D Coordinate Measure Machine
Cold Helium Leak Test Facility
Ultrasonic Phased Array NDT System
10MPa Hydraulic Pressure Test Equipment

8. 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

9. 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

10. 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

11. 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

12. Personal Air Sampling PAS Occupational Exposure Limits(OELs)
GBZ_ : 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 : 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

13. PAS: same brand and same type as IO recommend

14. Area sampling(Sampler Flow:1.0~10L/min )
2. Airborne contamination measurement
Occupational Exposure Limits(OELs)
GBZ_ : 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

15. 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

16. Plan of the typical site sampling in the FW manufacturing workshop6 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.

17. 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

18. 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 , 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: µg/m2
Sampled on , 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

19. 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.

20. 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

21. 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

22. 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；

23. 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;

24. 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)

25. 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

26. 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.

27. 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

28. 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.

29. Thank you!