Since 2009 Founded 2000 Founded 1993 Today First

Since 2009 Founded 2000 Founded 1993 Today First Plasma 2025 D-T Plasma > 2035 ITER-Workshop on Beryllium Applications and Health & Safety 2017

Working with Beryllium since 1991 Pebbles, Powder Beryllium, Titanium Tablet pressing cold, hot, vacuum Arc melting Wet-Ball-Milling HIP and / or hot extrusion in closed capsules Tempering in vacuum oven Form giving Processes Sintering with oven induction, microwave, normal Pebbles (Potatoes), Electrodes for REM, Ingots Be / Be-Ti Material Testing on Beryllium Pebble Beds, Material Design (Beryllides), Production Research & Safety

es and Alloys e-W ), mixing and canning the powders followed by Hot Extrusion t and dismanteled (Elektrodes for REM) or capsuled again tron Beam (EB) welded and Hot Isostatic Pressed (HIP)

Workers’ Health Care and Safety • Medical examination for workers once a year, including the capability to wear respirator masks • In addition, regular instruction on all aspects of hazard identification and safety regulation • A safety representative from KIT and I are working out details for the briefing • In case of new or never done before activities, a risk assessment is foreseen • Full size respirator masks with P 3 Filters are located at every entrance to the safety areas

Introductory Beryllium (Be) Safety Topics covered 1. Physical Properties 7. Engineering Controls 2. Uses 8. Personal Protective Equipment 3. Hazards 9. Monitoring 4. Medical Treatment 10. Medical Surveillance 5. Legal Aspects 11. Movement of items 6. Working Standards 12. Waste … based on lessons given at JET, modified for our purpose

Usual and … • Building with ventilation, airflow about 10 times an hour • Lower pressure (- 5 Pa) in the building to save the environment • Emergency generator • Particle filtering units • Inventory that can easily be decontaminated KIT Campus North High Safety Laboratory for the Handling of Beryllium on the KIT Campus

… unusual solutions • Modular glove boxes for all activities connected to Beryllium • Controlled lower pressure (- 5 mbar) in the glove boxes • Inert gas atmosphere to protect materials and allows a leak detection • Airlock with control panel for all systems • All systems are connected with the “Central intelligence” of the building

Hazard and risk assessment for developed system Results for the individual hazards Hazardous event Building / System Result SIL Defect in the gas line Building 453, Glove box system S 2, A 2, G 2, W 1 SIL 2 Flammable solids, liquids and Gases can ignite Building 453, Building 454 S 1, A 2, G 1, W 1 No SIL Undue high-pressure (1) in the glove box (15 mbar > Prel> 0 mbar) Glove box system S 2, A 2, G 2, W 1 SIL 2 Undue high-pressure (2) in the glove box (Prel > 15 mbar) Glove box system S 2, A 2, G 2, W 1 SIL 2 Undue low-pressure in the glove box ( Prel < -15 mbar) Glove box system S 2, A 2, G 2, W 1 SIL 2

Building – Safety Instrumented System (B-SIS) Sicherheit safety Gebäude 454 building 454 (B-SIS_454) - (B-SIS_454) Engine Room ensure properation minimize energy consumption Lüftungssystem L Ventilation system A Fire dept. alert Alarmierung Feuerwehr R inert gas distribution rack Oven cooling In case of fire: flood with argon O O F R oven-sensor: temperature observation G oxygen-sensor: detect gas leaks Gallery / Control. Room V emergency exit Hot Zone people- airlock D WC TD Foyer material lock D Storage D

Safety Requirements Ø Central monitoring, fault detection, logging and reporting with top priority across all modules Ø Redundancy of the individual sub-systems to bypass in case of failure Ø Recording of environmental conditions (e. g. detection of persons, gas warning, temperature, pressure, . . ) Ø Minimizing the energy consumption (e. g. situation depends on the ventilation of the high safety laboratory) Ø Possibility to use Remote Control for the overall system and individual sub-systems Gloveboxes safety-related control Gas cleaning unit Airlock control unit

Support from KIT Institutes 14 Bachelor- and Master theses were necessary to build up this model facility for the Handling of Beryllium on the KIT Campus

Alternative Health Care and Safety solutions • The safest solution is not to produce dusts or fumes during the processing of Beryllium • This can be done by choosing electrical wire- or water-jet cutting as manufacturing method • The second best solution concerning safety is to encapsulate the process • Alternatively, a remote control or full automatic manufacturing process (rapid prototyping) • If all this is not possible a “Frogman-Unit” connected to a Walk-In-Glovebox could be useful • “Frogman-Units” allow the same safety as Gloveboxes and can contain inert gas atmosphere • In this case the movement of the flexible connection has to be compensated for or disconnected

Based on experience gained thus far with the Be. YOND industrial forum, organizers plan to expand the scope of their communications for the period 2018 -2025 (First Plasma) Be. YOND will continue to act as a fusion “think tank”, gathering and presenting information on research trends, political developments, business models and transfer ideas on a regular basis (see also article: “From Lab to Practice”, http: //www. atlantic-innovation. org/cases/lab-practice) The plan is to expand the scope of the forum to include continuing professional training/development and competency development catering to a diverse range of scientific, economic, national and international interests The expanded format will take effect with the Be. YOND VIII (fall 2018) forum, which will include various industry workshops on theme of “Handling Extreme Materials, Fusion and Sustainable Business Models” Partners from business, research, and the public sector will be invited to attend You are invited to join us next time, as well!

THANK YOU FOR YOUR ATTENTION ! Hot extrusion of “Electrodes” for the REM Process at the TU Berlin during the Be. YOND Workshop 2016

Next Be. YOND, September 2018 at ITER?