Design Optimization of ITER Auxiliary Systems Water-Cooled Lithium-Lead Test Deck Modules (WCLL-TBM)

In recent years, global energy demand has increased significantly, both due to a significant increase in the world population and to an increased use of new technologies in everyday life. In this context, energy produced by nuclear fusion provides a promising answer to this problem; it represents not only a solution to the energy crisis but also an alternative, sustainable and environmentally friendly energy source, which does not produce greenhouse gases or highly radioactive waste. This thesis is part of the ITER (International Thermonuclear Experimental Reactor) project, that is one of the most important realities in fusion research, with the main objective of demonstrating the safety and large-scale feasibility of fusion, paving the way for the realization of the future nuclear fusion power plants. However, its success depends on overcoming significant technological challenges, including those related to system maintenance in radiation-exposed environments. This research focuses on the Water-Cooled Lithium-Lead (WCLL) Test Blanket Module (TBM), which plays a critical role in tritium breeding and heat capture within ITER’s complex system. Maintenance operations, especially for complex systems in the nuclear field, are one of the key elements of any industrial system; as it is necessary to ensure the continuous flow of operations, working at the same time in safe conditions. The starting point, from which to build a maintenance research project, are the indications and guidelines defined by ITER in terms of ergonomics and safety, in order to reduce and where possible eliminate all the risks to which workers are exposed during maintenance operations. The auxiliary systems of this module (WCLL-TBM) will be installed inside a glove box that has the purpose of confining the tritium produced which, being radioactive, represents a risk for human health. These systems, among the various requirements of ITER, must respect precise safety and maintainability criteria. The aim of this thesis is to simultaneously utilize the advantages of: - System Engineering to design a handling system for the extraction of components inside the glove box, such as the valves placed in a pipe forest, in order to be able to maintain them. - Industry 4.0 to enhance the efficiency and safety of maintenance tasks for WCLL-TBM components through the development of a Virtual Reality (VR) simulation platform. Using HTC Vive Pro hardware and the Unity 3D game engine, this VR platform replicates key maintenance procedures for the TBM’s diagnostic and structural elements. The simulation allows operators to carry out training tasks that involve replacing critical components in high-radiation areas. Two key parameters are evaluated: (1) Time of each single operation, which is crucial for minimizing radiation exposure, and (2) Ergonomic compliance to reduce the risk of musculoskeletal strain. Results demonstrate VR’s effectiveness in creating a realistic environment where both task timing and ergonomics can be accurately analysed and optimized, offering valuable insights for ITER’s maintenance protocols and helping reduce risks to personnel. Furthermore, the adaptable nature of this VR system provides a versatile tool for training, simulation, and safety assessment, with potential applications extending beyond the nuclear sector.