QUALIFICATION OF ULTRASONIC INSPECTIONS IN THE ITER VACUUM VESSEL

MANUFACTURING PROJECT

R. Martínez-Oña, A. García, M.C. Pérez, Tecnatom, Spain; G. Pirola, Ansaldo Nucleare, Italy

ABSTRACT
The vacuum vessel is one of the most important components of the ITER project in which the fusion
will take place. It is a double wall torus made of nine sectors of 40° each one. The weld joints that are
in the outer wall have one surface access only and their inspections have to be qualified. A consortium
led by Ansaldo Nucleare with Mangiarotti and Walter Tosto is in charge of manufacturing seven (out
of nine) sectors of the ITER vacuum vessel and Tecnatom is in charge of qualifying the inspection
system for the examination of the weldments mentioned before. The objective of this paper is to
describe the qualification methodology main features of the ultrasonic inspection system for the
examination of vacuum vessel weldments with one surface access. The qualification approach required
by the ITER European Domestic Agency, Fusion for Energy, in charge of the vacuum vessel
manufacturing is the one specified by the CEN/TR 14748 and the RCC-MR 2007 Code.

INTRODUCTION
ITER project has as objective the construction of a fusion facility to demonstrate the scientific and
technical viability of obtaining energy from fusion. It is a shared project between China, European
Union, India, Japan, Russia, South Korea, and the USA. ITER reactor is being erected at Cadarache, in
the South East of France. The fusion reactor is planned to start its operation at the end of this decade.
One of the main components of the facility is the vacuum vessel in which the fusion will take place.
The vacuum vessel (VV) is the first nuclear confinement barrier; therefore the integrity of the
VV is essential. Furthermore, it is the structure on which are mounted the measurement equipment and
other components within it, whereby it has to be manufactured with very high accuracy, overcoming
the welds deformation and to satisfy the high dimensional requirements. The VV is made of austenitic
stainless steel 316L (N) – IG ITER Grade. It has a toroidal shape with double wall and the section of
“D” shape. The torus dimensions are: Inner diameter: 6,456 mm; outer diameter: 19,400 mm; and
height: 11,337 mm (see Figure 1).

Figure 1. - General view and cut out of ITER Vacuum Vessel including ports and port
extensions (ITER Organization courtesy)

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 Due to the manufacturing process and limited access, the VV outer wall plates, that are the most
affected by the high pressure loads, are necessarily welded from one face only and this makes more
complex the required volumetric inspection. Therefore, for this and other reasons associated to its
constructive complexity, the European Domestic Agency named Fusion for Energy, responsible of
managing the VV fabrication, requires the qualification of the ultrasonic inspections of weldments
with only one surface access. Tecnatom is responsible of qualifying these inspections.
In the sections that follow, first, are described the VV main characteristics regarding geometry,
materials, and manufacturing process that could have an influence in the ultrasonic inspection
techniques. After that, it is presented the qualification methodology and other applicable requirements.
Finally, the inspection techniques initially devised and under development are described.

DESCRIPTION
The vacuum vessel is a torus of double wall with a section of “D” shape. Around the torus
circumference, different upper, middle and lower ports for access, instrumentation and maintenance
are distributed. The design includes, first, the fabrication of nine sectors of 40° each, then, the
weldments between sectors and, finally, the port extensions welds; Fusion for Energy is in charge of
manufacture 7 out of the 9 sectors.
Each sector is constructed from four segments, named PS1, PS2, PS3 and PS4, that once
manufactured are welded one to the other (see Figure 2). Each segment is made of pieces, flat and
forged plates of different sizes and shapes that after welded produced the desired segment. The weld
process, with pieces of 40 and 60 mm thickness in most of the cases, starts with the inner wall pieces
and progresses to end with the outer wall welds. In all cases, the plates are of austenitic stainless steel
316L (N) IG ITER Grade.

PS2

Port
extension

PS1
PS3

Port
extension
PS4

Figure 2. - ITER VV sector made of the assembly of four segments PS1, PS2, Ps3 and PS4

The VV design and manufacturing, and the associated inspections, are in accordance to the
requirement of the RCC-MR Code 2007 Edition. The welds categories 1 and 2 are required to
volumetric examination, either RT (Radiographic Testing) or UT (Ultrasound Testing). Inner wall
weldments and their reinforcements are classified as category 1, and outer wall weldments and their
reinforcements are classified as category 2.
For UT inspection of austenitic steel full penetration welds, the RCC-MR Code requires
examination from the two surfaces and two sides of the weld plus demonstration of the inspection

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procedure capability of detection. When the access is limited to only one surface weld, the ITER
project requires the inspection qualification in accordance to the CEN/TR 14748 Methodology and the
RCC-MR Code. Considering that the manufacturing of segments starts from the inner wall and
progresses to the outer wall, inspection qualification is required in all closure welds of the VV outer
wall; these welds have a “V” shape with a chamfer within a range of ±2° to ±6°. In addition to this,
due to the geometry complexity of the structure to fabricate and weld types (see Figure 3), it could also
occur access limitation to fulfill the inspection as required by the code.
Therefore, austenitic steel anisotropy, 60 mm thicknesses, difficult access to the examination
area, and limited scanning surface make a challenge the inspection and qualification of these welds.

(a)

(b)

Figure 3. –a) Different weld types considered in the ITER VV project and b) Suggested (left) and
required scanning according to RCC_MR Code (middle and right)

INSPECTION QUALIFICATION METHODOLOGY

The applicable Code for the inspection of ITER VV welds is the RCC-MR 2007 Edition and, for the
qualification activities, the CEN/TR 14748:2004. The inspection system to be qualified is the
prototype of the system to be used in the inspection of welds with one surface access during the
manufacturing phase.
In the qualification process, five phases can be distinguished (see Figure 4):
Phase I. Prior to qualification: In this phase is necessary to collect all required input information,
establish the qualification team and define the qualification objectives. Input information mainly refers
to the essential variables of component and postulated defectology. The Qualification Team is the
group of people that manage, plan, and carry out the qualification; it is made of representatives from
ITER Organization, Fusion for Energy, Agreed Notified Body and Manufacturers.
Phase II. Preparation for qualification: The main activities in this phase are the definition of the
qualification programme, the production of the experimental evidence and the draft of the inspection
procedure and the technical justification. The qualification programme explains the content, scope, the
evaluation criteria, the means and how the qualification is carried out.
Phase III. Executing the qualification: The main tasks are conduct the qualification programme,
record the results during the qualification process, evaluate the qualification results and compile the

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qualification dossier. The dossier includes the input information, the inspection procedure, its technical
justification, the qualification programme, the test results, and the conclusions reached.
Phase IV. Approval of qualification: Accredited documents are issued and explained their scope
and their applicable conditions.
Phase V. Application of qualification: The qualified inspection procedure is established and the
qualification dossier is maintained with the experiences derived of its application.

To prepare Input information.

Phase I. Prior
qualification To identify Qualification Team
To define Qualification Objectives

Phase II. Preparing To define Qualification Programme

for qualification To prepare UT Procedure
To prepare Technical Justification

Phase III. Executing To apply Qualification Programme

the qualification To evaluate Qualification Results
To Compile Qualification Dossier

Phase IV. Approving

the qualification

Phase V. Applying To establish Qualified Procedure

the qualification To maintain Qualification Dossier

Figure .- 4 Main phases of the qualification process (after CEN/TR 14748)

INPUT INFORMATION
Input information refers to the essential variables of the component weldments and postulated
defectology that are necessary to know and specify to start the definition of the inspection technique.
As mentioned above, there is a large number of weld types in the ITER VV design but we will
concentrate on those welds, to be qualified, with one surface access.
At present, these welds have “V” shape (see Figure 3a) but different chamfer parameters and
welding parameters. The following possibilities can be distinguished: a) Chamfer angle (±2°, ±5°,
±6°), b) Root preparation, and c) Weld procedure (First pass: GTAW manual, GTAW automatic;
Filling: SMAW manual, GTAW manual, GTAW automatic).
Currently the following component weldments essential variables are taken into account: a)
Geometry, b) Surface conditions, c) Weld configuration, d) Material specification, e) Repairs, f)
Access restrictions, and g) Environmental limitations.
Based on the experience of manufacturers and discussion within the Qualification Team, three
groups of defectology have been identified: a) Weld defects, b) Weld imperfections, and c) Perturbing
factors. In table 1 are listed the cases considered in the three groups of defects.
The essential variables of defects currently considered are: a) Size (length and through wall
extension), b) Position (base metal, weld metal or weld interface), c) Location along the thickness
(scanning surface breaking, embedded, or opposite to scanning surface breaking), d) Orientation
(perpendicular or parallel to the weld), e) Skew, and f) Nature (planar or volumetric).

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 Table 1.- Postulated defectology for qualification of “V” welds
Defect description Nature
Weld defects
Slag inclusion (for SMAW) Volumetric
Tungsten inclusion (for GTAW) Volumetric
Porosity and gas pore Volumetric
Crack Planar
Hot crack Planar
Lack of fusion Planar
Weld imperfections in the root area
Hollow bead Geometric
Excess penetration Geometric
Undercut Geometric
Shrinkage Geometric
Disturbing factors
Weld node --
Weld repair --
Misalignment --

WELDING MAP
The VV manufacturers are preparing the so called Welding Atlas that compiles the relevant weld
information. This includes, for each weld family, the weld geometry, the weld section, and the welding
parameters. The Welding Atlas is part of the input information.
Analyzing the Welding Atlas information, from the ultrasonic point of view, first the inspection
volume is calculated, second, the inspection volume is assessed and, third, the scan plan is defined.
These and other information related to the inspection technique form the named Welding Map that is
made of a set of cards, each one describing a weld type; see an example of this above in Figure 5.

Weld FORM D
- Manual TIG for the penetration passes
Section - SMAW for the filling passes
76.0 10.0
16.0°
ACCESIBLE SURFACE
23.8
Minimum scanning area

Inspection
60.0

volume
2.0

.0
R2 4.0

Figure 5.- Example of Welding Map card for “V” shape weld
SUGGESTED INSPECTION TECHNIQUES

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Inspection techniques are developed to satisfy the specified inspection requirements taking into
account the input information. Inspection requirements are to detect and characterize all defects above
the recording threshold; in addition to, any planar indication is unacceptable and any volumetric
indication whose length exceeds the maximum permitted length is also unacceptable. When designing
the inspection techniques is also worth to mention the reduced existing scanning space and the
importance of minimizing the scanning duration, therefore the scanning lines for detection purposes
are defined parallel to weld centre line (see Figure 6) and for characterization purposes perpendicular
to it.
At present, the following inspection techniques have been foreseen and are under development:
a) Pulse-Echo (P-E) with phased array (PA) probes: For detection of weld defects, weld imperfections,
and disturbing factors; an initial defect characterization assessment is also possible. b) P-E with creep
probes: For detection of weld defects breaking to scanning surface. c) P-E with low frequency probes:
For detection of weld defects perpendicular to the weld centre line breaking to opposite scanning
surface and weld node defects. d) P-E with straight beam probe: For detection and characterization of
weld imperfections. e) P-E with standard diffraction probes: For characterization of weld defects and
weld imperfections. f) Tandem with standard probes: For characterization of weld defects located in
the thickness middle part. g) Auto tandem with dual probes: For characterization of weld defects
located in the thickness lower part.
Y+

Salvo 0
Scan Y+
Salvo 1
Salvo 2

SCAN INDEX
X+
Trajectory of the probe. One UT
acquisition (three salvoes) is done
each red bullet.
RESOLUTION

Weld center line

Y- Y+
From the top of the Vacuum Vessel weld.

X-
Figure 6.- Scanning lines sketch for inspection detection phase

PRESENT STATUS
Different test blocks have been manufactured and others are under fabrication in order to have a set of
representative defects (see Table 1) on which develop, demonstrate and qualify the different proposed
inspection techniques. These test blocks reproduce the geometry and metallurgical configuration of the
weld and parent material. The intended defects in the test blocks are mechanized reflectors of planar
and volumetric shapes located in the areas of interest.
Test trials and simulations have been carried out to select the essential variables of the candidate
ultrasonic probes as well as to assess the capabilities of the inspection techniques. In that manner, the
inspection techniques for weld defects detection and characterization have been developed. When weld
imperfections and weld perturbing factors test blocks are ready the envisaged techniques will be
implemented and tested.
In order to perform the qualification, and taking into account the variety of weld configurations
and elements of inspection system, the qualification groups are defined. Within a qualification group
there is a set of welds with similar essential variables and an inspection system with similar essential
variables; then, the objective is to qualify this inspection system for inspecting this set of welds. To
define the qualification groups the criteria have been the following: 1st) select the weld “V” which has
the most adverse welding procedure from the ultrasonic point of view, 2 nd) consider the specificity of
the inspection technique, and 3rd) consider the weld trajectory (straight, circumferential or mixed: part

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curved / part straight) or the mechanical scanner necessary to carry out the ultrasonic inspection. For
straight welds the Galaxy scanner will be used, for circumferential welds the Flexible Housing scanner
will be applied, and for short length welds of either curve and/or straight trajectory the Wheel scanner
which allows ultrasonic probe position recording will be utilized. With the present VV design status
and these criteria nine qualification groups have been identified (see table 2 for details). However, it is
anticipated that additional qualification groups could appear associated to any complex geometry not
assessed yet.

Table 2.- Summary of Qualification Groups

Mechanical Scanner
Inspection technique
Galaxy Wheel Flexible Housing
P-E with PA probe G1 G2
P-E with Creeping probe G3
P-E with Low frequency probe G4 G5
P-E with Straight beam probe G6
P-E with Standard diffraction probe -- G7 --
Tandem with standard probes -- G8 --
Auto tandem with dual probes -- G9 --

Inspection procedures are not developed yet. To do so, it is necessary to have the set of
representative test blocks. Once the procedures are ready, the experimental evidence will be produced
and the technical justifications could be prepared.
The Qualification programme is being discussed and under preparation by the Qualification
Team. It mainly includes: a) the assessment of the technical justification and the inspection procedure;
b) conducting practical trials (type: open/blind, personnel requisites: EN 473 certification and specific
training, NDT tests: on test pieces containing representative defects, following the procedure “to the
letter”, scanner tests: acceptance tests on realistic mock-ups; c) evaluation of trials results: assessment
of documentation, fulfillment of qualification objectives, and explanation and justification of
inspection results using supporting information); d) details of qualification test pieces (purpose of
trials, number of test pieces, number of defects per test piece, and test piece quality checks).

CONCLUSIONS
The ITER VV is a double wall torus made of many welded thick pieces of austenitic stainless steel. In
order to perform a reliable inspection of those welds with one surface access the qualification of
inspection techniques, according to CEN/TR 14748 and RCC-MR Edition 2007 Code, is required.
The development of the inspection techniques covers a wide range to be able to detect and
characterize the postulated weldments defectology.
The qualification methodology managed by the Qualification Team, in which all the parts
involved in the project are present, is developing as expected and guaranteeing the performance of the
inspection qualification.

REFERENCES
1) RCC-MR, Design and Construction Rules for Mechanical Components of Nuclear
Installations, Section 3: Examination Methods and Section 4: Welding. Edition 2007.
2) CEN/TR 14748:2004, Non-destructive testing – Methodology for qualification of non-
destructive tests.

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