Presentation on

C. K. PITHAWALA COLLEGE OF ENGINEERING

AND TECHNOLOGY, SURAT

Design and experimental validation of Internal Bore Welding Torch for

the INTF HVB Dish end to Pipe welding

PREPARED BY:
Name Enrollment No.
Mr. AVADHESH H. VYAS (150090709018)
Subject : Dissertation Mid Semester Review,
M.E., 4th Semester, Machine Design,
GTU, Gujarat.

GUIDED BY:
Industrial : Academic:
MR. JAYDEEP JOSHI & PROF. RITESH PATEL,
MR. ASHISH YADAV, Assistant professor,
ITER India, CKPCET,
Gandhinagar, Gujarat, Surat, Gujarat,
India- 382025 India 395007.
2
 OUTLINES

Introduction

Problem Identification

Objective of the work

Literature Review

Research gap

Methodology

Work plan

References

3
Introduction

Institute Of Plasma Research (IPR):

The Institute of Plasma Research (IPR) - large and leading plasma physics research centre

The institute owns two operational tokomaks (a machine for controlling thermonuclear

fusion) - ADITYA and Steady State Tokamak (SST) - 1.

IPR is playing major scientific and technical role in Indian partnership in the international

fusion energy initiative ITER(International Thermonuclear Experimental Reactor).

Through the participation of the country in ITER, the developed technologies are being

tested in the international arena.

4
Introduction
 Nuclear Fusion Reaction:
Hydrogen atoms are collide at very high speed and produces the heavier element, helium.

At higher temperature, electrons are separated from nuclei and gas becomes hot and

electrically charged which is called Plasma.

Plasma provides the environment in which light elements can fuse and produce large

amount of energy.
5
Introduction
 The temperatures inside the tokamak must reach ten times the temperature at the core of

the Sun in order to reach plasma state for fusion reaction to occur.

In ITER tokamak external heating is provided by neutral beam injectors to sustain

plasma at extreme high temperature in controlled manner.

Neutral Beam injection system:

Neutral Beam system installed inside tokamak is consist of:

- Two heating and current drive (H&CD) NB injectors: used for heating of plasma

- A diagnostic neutral beam (DNB) injector: used for diagnostic purpose

6
Introduction
 Diagnostic Neutral Beam (DNB) Injector :
The DNB system injects H0 beam at 100 keV radial to the ITER plasma as a beam for
active charge exchange recombination spectroscopy.

This technique is used mainly to measure the helium ash density in the core plasma region,
monitoring the light emitted from the helium atom in an excited state following charge
exchange with the beam.

As neutral beam in this system is used for diagnosis purpose so it is called DNB
(Diagnostic Neutral Beam).

DNB Beam source (Beam source used in DNB injector) which produces neutral beam is
developed and it will be tested by ITER India.

7
Introduction
 Indian Test Facility (INTF):
The Indian Test Facility (INTF) is a serious effort from INDIA to test DNB and to explore
in the R&D, one of the most important challenges in ITER.

INTF is a facility being constructed at IPR, with following objectives

1. To test the performance of beam source

2. To characterize the transmission of the Neutral Beam to a length of 20.665 m

3. To measure content of Helium ash in the fusion plasma.

Configuration of facility will be identical to the DNB facility for ITER, only some
simplification in design of vessel and other components is adopted.

8
Introduction
 INTF injector facility is a vacuum vessel having internal components and duct for
providing 20.665 m transmission length.

INTF has negative Hydrogen Ion source of dimensions ~ 1.6m*0.6m, beam energy of
100kev & 60A of extracted & accelerated current. Beam has to travel 20.665 m with
compatible beamline components.
9
Introduction
 INTF Vacuum vessel is designed in cylindrical shape having length of 9 m with diameter
of 4.5 m and has a detachable top-lid for mounting as well as removal of internal
components.

INTF vacuum vessel is of 180 m3 volume and capable of providing Ultra High Vacuum
Environment for the beam operation. As negative ions are easy to accelerate , negative ions
are firstly produce later it will be neutralized to get high energy neutral beam in vessel.

10
Introduction
 High Voltage Bushing (HVB):

The high-voltage Bushing (HVB) is an important component of the beam injector (BI).
The 100 kV High voltage Bushing is one of the most important and technologically
challenging component of the INTF vessel.
Vacuum
Vessel

High voltage Bushing

11
Introduction
 The High Voltage Bushing (HVB) or HV Feedthrough has undergone considerable
simplification, taking into account the fact that the ITER design had to address this
component as a part of the primary vacuum boundary and radiative environment.

Interface between the transmission line and Beam Source, which constitutes all HV
electric and cooling water line connection for Beam Source (except grounded grid)
between them.

The vacuum interface is through a dish head provided in the HV bushing where all the
feedthrough lines are mounted.

Dish head would provide the structural support to the feedthrough lines as well as it works
as a vacuum isolation between vacuum vessel and the HV bushing.

12
Introduction
 The main purpose of HVB is therefore (i) to carry the requirements of source and
accelerator like high current busbars, RF transmission lines, water cooling services, gas
feed and diagnostic lines and (ii) to form a part of primary safety barrier and vacuum
confinement in ITER

13
Introduction
Problem Identification

There is a need of joining process of all the incoming and outgoing feedlines with the

plate of HV bushing. These feedlines are very close to each other.

There are constraints as far as space and operation ability is concern.

Space around the pipes are so less that it is almost impossible to make it weld from out

side by any of the welding process.

Weld penetration is another issue if able to do welding operation from outside.

The criticality of the pipe alignment is too high so it is not possible to weld it with HV

bushing Dished head top cover plate at remote location and then to move to desired

place.

14
 Design Parameters
considered:
Pipe ID:
For FS cooling, EG cooling &
Chamber cooling : 47.55 mm
For PG cooling and RF cooling
: 22.15 mm
Movement Mechanism (Kinematic
design) :
360 Degree
Pipe considered for present development Current and Gas flow controller

15
Problem Identify
Objectives of the work

Understanding the criticality of connection of pipes with plate

Figured out the space and operational constraints

Design of IBW torch

Selection of driving mechanism for torch

Flow analysis of shielding gas inside the torch

Fixture design and setup Installation

16
Literature Review
Review on INTF vessel and DNB
Sr. Journal/
Author Topic Comment
no. Thesis
An Indian test
Fusion facility to This paper presents introduction about INTF as a facility to
M.J.
Engineering characterize test DNB beam source. It describes BS,BLC, high voltage
1 Singh
and Design, diagnostic bushing, diagnostic system, magnetic shielding, pumping
et al
86. 2011. neutral beam system, power supply etc used in the facility.
for ITER

This paper presents the design and analysis of vacuum

vessel, with respect to its functional and operational
Design of requirements as per ASME-BPVC SectionVIII-Div.1. Finite
vacuum Element Analysis (FEM) method has been adopted to verify
Fusion vessel for the design.
J. Joshi Engineering Indian Test
2 In results the maximum deflection is coming around the
et al. and Design, Facility
vessel flange, which is the most critical portion in the INTF
2015. (INTF) for
vessel design.
100 keV
neutral beams Deflections have been controlled at the design stage by
making effective use of stiffeners and stability has been
assessed for operational, seismic and handling requirements.
17
 Sr. Journal/
Authors Topic Comment
no. Thesis
This report registers considerable progress in the
A. Indian Test
development of INTF. Some design changes have been
Chakrab Facility
3 IEEE, 2015. made in INTF comparing to DNB for simplification such
orty and (INTF) a
as cylindrical vessel in place of rectangular, beam source
et al Status Update
integration.

Review on High Voltage Bushing (HVB)

Sr. Journal/
Author Topic Comment
no. Thesis
Design and
analysis of This paper presents explanation about HV feedthrough
Korean
Sejal 100-kV designed to connect all the feedlines from HV desk to beam
Physical
1 Shah et feedthrough source along with other brittle component mount on it.
Society,
al for the Indian Design requirement according to Electrical, Structural and
2014.
test Facility vacuum point of view is explained.
(INTF)
18
Literature
Sr. Journal/
Author Topic Comment
no. Thesis

Design This literature gives the information about 100kV High

Fusion
optimization voltage Bushing of Diagnostic Neutral Beam (DNB)
Sejal Engineering
of the 100kV injector. It is a cylindrical feedthrough which acts as a
2 Shah et and Design,
HV bushing interface between gas insulated transmission line and the
al 2011.
for ITER torus primary vacuum and provides all necessary service to
DNB the beam source.

Review on GTAW parameters

Sr. Journal/
Author Topic Comment
no. Thesis
Process parameter
Journal of selection for This paper enlist the selection of process parameter for
S.C. Materials optimizing the weld GTAW welding for SS. It was concentrated for optimal
1 Juanget Processing pool geometry in weld pool geometry. Modified Taguchi method was
al Technology, the tungsten inert adopted . Front height, front width, back height and
2002. gas welding of back width of weld pool are greatly improved.
stainless steel
19
Literature
Sr. Journal/
Author Topic Comment
no. Thesis

Optimization of
International They Investigate the effect of TIG welding
Process Parameters for
Raghuv Journal of parameter such as welding speed, current,
TIG welding of 304L
2 ir singh Mechanical current and flux for the depth of penetration
Stainless Steel using
et al Science and Civil for 304l SS. Result speaks that Flux has the
Response Surface
Engineering, 2013. most significant effect on weld penetration.
Methodology.

International
A Review on This paper highlight the parametric
Naitik Journal of
Parametric optimization of GTAW. It is proved that
3 S. patel Computational
Optimization of TIG GTAW is better then other welding in most
et al Engineering
Welding. critical welding requirement.
Research, 2014.
The influence of
technological This paper elaborate the Arc welding
Matusi
conditions on the parameters and emission of welding fume for
4 ak J et Metalurgija, 2010.
emission of welding SS. They conclude that fume emission is quite
al
fume due to welding higher and mainly depends on current.
of stainless steels
20
Literature
Sr. Journal/
Author Topic Comment
no. Thesis

Evaluation of
This paper informs the Analysis of GTAW for
Mechanical Properties
Arunku pipe welding. The effect of shielding gas flow
of Dissimilar Metal
5 mar et ITERA, 2012. over the weld pool and weld geometry is
Tube Welded Joints
al explains. Contribution of Tungsten electrode
Using Inert Gas
is highlighted.
Welding. Evaluation.

International This study on welding parameter of GTAW

Gejend Study of welding
Journal of Recent concentrate the selection of best optimal
6 hiran et parameters on MIG
Scientific method to weld. Effect of process parameters
al and TIG welding.
Research, 2016. on selected process is enlisted.

International
Bharga This paper emphasis the study of effect
Journal of Optimizing and
v C. different input parameter for GTAW process
7 Engineering analysis of parameter
patel et on weld quality. This was carried out by
Research & for pipe welding.
al experimental method.
Technology, 2013.

21
Literature
 Review on Comparison of GTAW over other
welding process
Sr. Journal/
Author Topic Comment
no. Thesis
In this paper Comparison of Ti-5Al-5V-5Mo-
Comparison of Ti- 3Cr Welds Performed by Laser Beam,
5Al-5V-5Mo-3Cr Electron Beam and Gas Tungsten Arc
T.
Procedia Welds Performed by Welding. The weld joints were performed by
1 Prasang
Engineering, 2013. Laser Beam, Electron LBW, EBW and GTAW. The weld profiles
a et al
Beam and Gas due to LBW and EBW showed an hour glass-
Tungsten Arc Welding like appearance, while those from GTAW had
a common V-liked shape.
Comparative study on
In this paper Comparative study on transverse
transverse shrinkage,
shrinkage, mechanical and metallurgical
mechanical and
properties of aluminum weld joints prepared
metallurgical
A. Arun by gas tungsten arc and gas metal arc welding
Defense properties of AA2219
2 kumar processes. Based on the mechanical and
Technology aluminum weld joints
et al metallurgical properties it is inferred that
prepared by gas
GTAW process is used to improve the
tungsten arc and gas
aforementioned characteristics of weld joints
metal arc welding
in comparison to GMAW process.
processes.
22
Literature
Research Gap

Key Issue:
The High Voltage Bushing Dished end top plate is
considered under the PIC ( Protection Important
class) component and also forms the first
confinement Vacuum Boundary. Therefore
followings are the basic points to be taken care,
(1) There must be full weld penetration
(2) It must fulfill 100% volumetric Inspection

Reliable welding configuration/solution to fulfill the above requirement is yet not identified

The presentation shows some efforts in developing the configuration and corresponding
welding technique along with hardware development to realize the required welding
characteristics
23
Motivation
 Possible methods to fulfill the requirements:

There are following options of welding available to fulfill the requirement.

Option 1 :

Fillet welding :

Limitations: (1) This is not a full penetration weld

(2) It is not possible to have 100% volumetric inspection

24
Motivation
 Option 2 :
Orbital TIG welding :
In orbital TIG welding method, the welding head rotates around a fixed vertical or
horizontal pipe. Available
Min. Max. size
head available
size of between
Orbit pipes
welding
200 +mm 66.9 mm

Limitations: (1) There is a space availability issue as far as setup is concern.

25
Motivation
 Because of the design constraints and other related interfaces, it is assessed that space is

limited around the pipes and therefore it is not feasible to weld in the required

configuration by Orbital TIG welding and also not feasible by manual TIG welding

A No Orbital or manual welding is possible at given place of

welding due to design constraints and space constraint

26
Motivation
 Option 3 :
Manual welding :

Limitations:
(1) This could be a full penetration fillet weld No butt weld

(2) It is not possible to have 100% volumetric inspection

Not possible due to space restriction and reliability issue

27
Motivation
 Option 4 :
HV bushing
Welding from Inside : Dish end top
plate

Pipe
(1) Full penetration butt weld

(2) 100% volumetric Inspection

28
Motivation
 Concept of IBW : The welding torch will
move inside the pipe by means of
specialized torch and welding will be carried
out such that weld bead forms from inside
and root can be seen outside.

Some of the examples available in literature

is shown here

Internal bore
welding

29
 Summary of prior work done in this area:

There is a need of customized torch development.

In market very less availability of torch for this specified work, especially in Indian
market this product is not available at all.
Very less literature available for the IBW torch.
The only known application for such torch is at SGA PFER ( Steam Generator Assembly
for Prototype Fast Breeder Reactor) for tubesheet to pipe welding. Even for that
application, Indigenous torch was developed. Details are not accessible..!!

Therefore, a fully customized torch is configured and being presented here

to suit our application.

30
IBW concept
Methodology

Understand the connections between pipes and plate

The 100 kV High voltage Bushing is one of the most important and technologically
challenging of the beam injector (BI). It mainly forms a vacuum interface while
connecting all the feedlines to the BS. It also provides the isolation to the 100-kV high
voltage.

Considering the plate size of HVB, the space was one of the major constraints during
welding of HVB plate to feedlines. Due to its alignment and space requirement, it was
difficult to make it weld from outside at remote location.
Full penetration and space availability around the pipes are two major constraints
approach to the core of the problem. Following is the side view of the arrangement of
pipes on to the Plate.

31
 Approach for development of torch :

To configure IBW torch for pipe to pipe welding

Check for functionality, Operation ability & Reliability

Carry out the dry run

Check for welding parameters

Check for welding quality

Recommendation for HVB configuration

32
 Selection of welding process:
Many different energy sources can be used for welding,
including a gas flame, an electric arc, a laser, an electron
beam, friction, and ultrasound.
It can be done in many different environments, including
open air, underwater and in space.

Welding Processes:

Gas welding : Oxyacetylene Gas welding

Arc Welding : SMAW, GMAW, GTAW, SAW.
Energy beam welding : Laser Beam Welding, Electron Beam Welding

33
Methodology
 Automatic welding :

Automatic welding is the use of mechanized programmable tools, which completely

automate a welding process by both performing the weld and handling the part. Robot
welding is commonly used for arc welding in high production applications, such as the
automotive industry.

The major components are the manipulator or the mechanical unit and the controller,
which acts as the robot's "brain.
34
Methodology
 Justification for selection of GTAW :

Following are the enlisted advantages of Gas Tungsten Arc Welding (GTAW) over other
process of welding, which leads to concentrate the GTAW towards the center of attention
for the present welding work.

It works on almost all types of metals with higher melting points. The process provides
more precise control of the weld than any other arc welding process.
For metals of varying thickness including very thin metals.
It creates strong joints and produces top quality welds in almost all metals and alloys used
by industry. It gives high level of visibility when working due to low levels of smoke.
TIG welding also has reduced distortion in the weld joint because of the concentrated heat
source. It ensures Minimal finishing required after welding.
The heat source and the addition of filler metal can be separately controlled and because
the electrode is non-consumable, it can be used without the addition of filler metal.
35
Methodology
 GTAW Welding:

Hardware component of GTAW equipment:

Mechanized TIG equipment may

include devices for checking and
adjusting the welding torch level,
equipment for work handling,
provisions for initiating the arc and
controlling gas and water flow, and
filler metal feed mechanisms.
36
Methodology
 In DCEP Welding Direct current flowing from the electrode () to the work piece (+) is
direct current straight polarity, or DCEP. Most TIG welding is done with AC or DCSP
current. In DCRP welding Current which flows from the work piece () to the electrode
(+) is direct current reverse polarity, or DCRP.

37
Methodology
 GTAW Torch:

It holds the non-consumable electrode, assures the transfer of current to the electrode and
the flow of shielding gas to the weld pool.
Torches up to 200 A - gas-cooled
200 A to 500 A - water-cooled

38
Methodology
 GTAW Shielding gases:

This Gas Tungsten Arc Welding process uses following two kind of gases as a Shielding
gas around weld to separate from surrounding air and atmosphere.
Argon (Ar)
Helium (He)
This gases can be used in Pure form or mixture of it depends on the working condition
and requirement. Separate cylinder is used along with regulator indicator on it for flow
and pressure regulation.

39
Methodology
 Detail Study of GTAW torch:

It come in different sizes, shapes, amperage and capacities.

It provide a means for holding and changing the tungsten electrode that conducts the
current to the arc and carry shielding gas, electricity and cooling water.

40
Methodology
 Nozzles :

It directs the flow of shielding gas around the electrode, the arc and the molten weld pool.
Standard nozzles are 6.5 mm diameter for aircooled torches and 10.0 mm diameter for
watercooled torches.

41
Methodology
 Collet and Collet Body:
The collet body screws into the torch body. It is replaceable and is changed to
accommodate various size tungsten and their respective collets.
The welding electrode is held in the torch by the collet. The collet is usually made of
copper or a copper alloy.
Handle
It is used for primarily
passing the electrical
supply to the collet body
as well as to pass the
shielding gas from pipe
end to front of the
nozzle.
42
Approach
 The selection of the correct type and diameter of tungsten electrode is extremely
important to performing a successful gas tungsten arc weld.

43
Approach
 Other points taken under consideration :

Check for space availability

Checked for welding current flow

Selection of Proper insulating material

Material selection for the torch body component

Calculate dielectric strength for insulating materials to finalize thickness

Selection of driving mechanism

44
Approach
 IBW torch First conceptual design :

Improvements envisaged:
(1) No water supply required as welding current is less then 200 amp hence gas
cooled required.
(2) To separate the current to flow from collet tip to motor body there is a need of
insulating separator.
45
Approach
 IBW torch second conceptual design :

Improvements envisaged :
(1) Pressurized shielding gas flow is required in closed medium having only one exit.
(2) Welding current is striking at the shortest contact point so fixing tungsten
electrode with two bolt from top is not appropriate.
(3) Gas flow through previous pipe entering shielding chamber is not finalized yet so
size of holes are not defined.

46
Appraoch
 Model of IBW torch test setup with nozzle:

47
Approach
 7 8 15
1
9
12

16

3
13

14

4 5 6 10
17 11

48
Approach
 Flange
support Flange
insulator
Insulator

Stepper motor

Job

End cap

Collet body Flange

Purging Extension Rotating pipe
chamber pipe

49
Approach
50
Approach
 Front Middle Back
section section section

51
Approach
 Front section:

52
Approach
 Collet body with Nozzle

53
Approach
 Shielding chamber

54
Approach
 Extension pipe

C/S

55
Approach
 Middle section:

56
Approach
 Flange
Support Flange support
Insulator

Flange
face

Job Rotating
pipe

Job End disc Stepper motor

side side

Roller
bearing

Flange
Flange cap
base

57
Approach
 Flange support

58
Approach
 Flange (With bearing)

59
Approach
 Rotating pipe

C/S

60
Approach
 Back section:

Motor
support disc Motor Support
Insulator

Shaft of motor connected

with back cap

Rotating
pipe

Stepper
Back cap motor
insulator

Back cap

61
Approach
 Bottom cap and insulator

Main
Assy.

62
Approach
 1 3

68
Approach
 Motors for motion transfer:

Specification considered here are:

Bipolar motor
Full step
4 pole
2.5 kgcm Torque

70
Approach
 For the specification listed above there are options of selecting the driver such that it can

ensure best output for long run even with modification in future.

PLC based stepper motor driver

Microprocessor based stepper motor driver

For the better modification, update and connection with computer for automatic control,

Microprocessor based stepper motor driver is the best option need to be select for the

selected motor to fulfill rotation of welding torch in present work of welding.

Back
71
Approach
 Carry out the dry run:

Check circularity of each critical part with dial gauge

Measurement of welding speed

Gap between Tungsten electrode and workpiece

Study of different weld edge preparation

Position of tungsten electrode with respect to weld edge preparation

Portability of the components

Back
72
Approach
 Calculation of welding speed:
For the present work there is a need of the motion which provides rotation to the whole
assembly of torch. As per the Welding machine manufacturing company Miller, there is a
chart as well as online speed calculator to figured out the desired welding speed for the
present work.

73
Appraoch
74
Appraoch
 Check for welding parameters:

Welding current and polarity

Welding voltage

Welding speed

Arc Length

Type of Shielding gas

Flow rate of Shielding gas

Joint preparation

Power source Back

75
Approach
 Check points :

Pre welding :
Fit up and fixture
Tungsten positioning
Gap between tungsten and pipe (arcing distance)
Gas flow rate (preflow- shielding- purging-post flow)
During welding :
Weld pool characteristics
Speed, welding current, voltage

Post welding :

Profiling

Weld pool shape

76
Approach
 Check points (Continue):

Destructive testing :

Mechanical testing

Tensile testing

Bend test

Hardness testing

Non destructive testing :

RT

Power source arcing:

Back
77
Approach
 Recommendation for HVB pipe welding:

Spacer rods

HV bushing
Dish end top
plate

Pipe

78
Approach
Summary

Over view of work till date

Figure out the constraints present against fulfillment of the work.
Select the best process for joining the pipe.
Justify the selection of Internal Bore Welding technique for welding.
Enlist the scope of success for IBW method.
Select GTAW process to join the pipe by IBW technique.
Defines and arrange the parameters works behind the best GTAW.
Examine the conventional torch and its component.
Define the sequence of development for IBW torch.
Finalize the design of torch with Nozzle and without nozzle for CFD purpose.
Specified the welding speed and selection of motor.

79
Summary
 Model of IBW torch test setup without nozzle:

80
Appraoch
81
Appraoch
82
Approach
83
Approach
 Future work plan

86
Work plan
Reference

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