christian zeile supervisor: heiko neuberger contributors: hcpb tbm-team, bernhard dolensky

KIT – University of the State of Baden-Wuerttemberg and National Laboratory of the Helmholtz Association www.kit.edu

Christian Zeile

Supervisor: Heiko Neuberger

Contributors: HCPB TBM-Team, Bernhard Dolensky

Institute for Neutron Physics and Reactor Technology (INR)

ITER GOT PPE Training Session / Cadarache

WP4 – Design, manufacturing and integration of ITER relevant structural components

PPE training session in Cadarache2 December 2009 Christian Zeile

Outline

Introductory and Training CoursesIntroductory practical workDesign and Analysis of Structural Components

Studied component: Attachment-SystemLocation of Attachment-SystemBoundary conditionsExisting conceptsCarried-out analysisNew conceptsConnection between Attachment-System and Shield

Outlook / Future Work


Introductory and Training Courses

Engineering Tools:CATIA V5 Training: Basic and advanced (2 weeks)Ansys Workbench and ClassicPDM System: Smarteam

Project relevant introduction:Training session at JET (June 09)Summer School on Fusion Technology in Karlsruhe (September 09)

Project relevant meetings:Design Coordination Meeting (July 09)Monitoring Meeting CoA and F4E (October 09)


Introductory practical work

Involvement in the layout of a heater integration in a structural component:

Goal: Simulation of volumetric heating (neutron radiation)

Boundary conditions:Neutronic heat generation analysis and resulting temperature distribution



Approach:Development of different conceptsPreliminary calculation of required heat generation rates and appropriate locations for the heaters

Realistic temperature distribution inside the breeder unit

No realistic temperature distribution inside the breeder unit

Relevant thermal expansion of box structure

Fewer heaters required

Staged power level

Heaters attached to box structure surfaces

Constant power level

Heaters inside pebble beds



Approach:Development of different conceptsPreliminary calculation of required heat generation rates and appropriate locations for the heatersStudy of different electrical heater conceptsContact with electrical heater manufacturers in order

to check the feasibility

WatlowBach RC

Plate heaters Cartridge heaters


Design and Analysis of Structural Components

Studied component: Attachment-System of plasma facing structural components

Using the example of the HCPB Test Blanket Module (TBM):

4 main tasks:

- Shield sensitive components of radiation

- Breed tritium (inside Breeding Units)

- Transform kinetic energy of neutrons into thermal energy

- Transmit thermal energy to cooling circuit



TBM Port Plug

First Wall

Backplate

ShieldInterface 1:

Location for Attachment-System

Location of the TBM inside a fusion reactor



Boundary conditions (1/2):

EM loads

370 kN

27 kN

50 kN

360 kNm

42 kNm142 kNm

Normal operation:

Maxwell forces

Plasma disruption:

Maxwell forces

+ Lorentz forces

toroidal

poloidal

radial



Boundary conditions (2/2):

Thermal loadsThe temperature gradient between First Wall and Backplate leads to a deformation

of the Backplate

Temperature distribution dependent on design



Simplified model of the TBM-Box (1/2)

Required for fast preliminary analysisSimilar stiffness behaviour as complex model

Simplification of the geometry:Deletion of edge filletsMerging of cooling channelsSimplification of pockets



Simplified model of the TBM-Box (2/2)

Comparison of simplified and complex model

Different load cases are considered

Maximum allowed deviation : 10%



Existing concepts of the Attachment-System (1/3):

CEA-Concept

Upper and lower key provide rigid contact to withstand the high radial torque

Central flexible element resists the thermal expansion and the structural loads except radial torque




Concept with keys and bolts

Concept with shear keys and flexible cartridges




KIT-Concept

All structural loads distributed on the four Attachment blocks

High stiffness in the direction of the high torque

Low stiffness in the direction of the thermal expansion

Lamellas



Analysis of KIT Attachment-System considering thermal expansion and additional stiffness due to the TBM-Box

Former analysis without considering thermal expansion and preliminary simplified box model

Maximum equivalent stress under radial force

52 MPa

Analysis including thermal expansion and new simplified box model

97 MPa

Maximum equivalent stress under radial force

268 MPa(rough estimation of temperature distribution in TBM-Box)

Maximum equivalent stress with additional thermal expansion

Strong effect of thermal expansion on total stresses

Radial force

+ thermal expansion

Radial force



Development of new concepts

+ high stiffness

+ no flexibility necessary

- Difficult manufacturing

- Difficult assembly

- space requirement

First analysis

Cage (translational motion)

Roll (rotatory motion)discarded



HCPB-TBM Design Proposal:Different connection concepts between Attachment-System and Shield

Requirements:Feasible connection of two different materials (Eurofer-Stainless Steel)Feasible assembly in limited spaceTransfer of high dynamic forces

Possible approaches:Screw couplingPositive lockingWelding of different materialsCombination of these connection types

Shield

TBM(Attachment-System attached by welding)



Concept 1: Screw Coupling

+ lower tolerances required before assembly

+ easy assembly

- only friction contact

Name of Institute, Faculty, Department20 December 2009 Christian Zeile


Concept 2: Screw Coupling and Welding of identical materials


+ easy assembly

+ large area of contact

- high space requirements

- only friction contact

Contact loss



Concept 3: Positive Locking

+ forces transferred by positive locking

+ easy assembly

- high precision of contact surfaces required



Concept 4: Welding of different materials


- Accessibility for the welding tool

- Welding process has to be qualified according to codes and standards

- Heat:

- Effects of distortion

- Diagnostic


Outlook / Future Work

Check of feasibility with manufacturing team 2010Consolidated design and analysisDesign of relevant mock-upEvaluation of Process Parameters 2011Organisation of mock-up fabricationDestructive testing

Training courses:Project relevant design codes (ASME, RCC) 2010Project ManagementQuality Assurance…


Thank you for your attention

christian zeile supervisor: heiko neuberger contributors: hcpb tbm-team, bernhard dolensky

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