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
PPE training session in Cadarache3 December 2009 Christian Zeile
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)
PPE training session in Cadarache4 December 2009 Christian Zeile
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
PPE training session in Cadarache5 December 2009 Christian Zeile
Introductory practical work
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
PPE training session in Cadarache6 December 2009 Christian Zeile
Introductory practical work
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
PPE training session in Cadarache7 December 2009 Christian Zeile
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
PPE training session in Cadarache8 December 2009 Christian Zeile
Design and Analysis of Structural Components
TBM Port Plug
First Wall
Backplate
ShieldInterface 1:
Location for Attachment-System
Location of the TBM inside a fusion reactor
PPE training session in Cadarache9 December 2009 Christian Zeile
Design and Analysis of Structural Components
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
PPE training session in Cadarache10 December 2009 Christian Zeile
Design and Analysis of Structural Components
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
PPE training session in Cadarache11 December 2009 Christian Zeile
Design and Analysis of Structural Components
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
PPE training session in Cadarache12 December 2009 Christian Zeile
Design and Analysis of Structural Components
Simplified model of the TBM-Box (2/2)
Comparison of simplified and complex model
Different load cases are considered
Maximum allowed deviation : 10%
PPE training session in Cadarache13 December 2009 Christian Zeile
Design and Analysis of Structural Components
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
PPE training session in Cadarache14 December 2009 Christian Zeile
Design and Analysis of Structural Components
Existing concepts of the Attachment-System (2/3):
Concept with keys and bolts
Concept with shear keys and flexible cartridges
PPE training session in Cadarache15 December 2009 Christian Zeile
Design and Analysis of Structural Components
Existing concepts of the Attachment-System (3/3):
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
PPE training session in Cadarache16 December 2009 Christian Zeile
Design and Analysis of Structural Components
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
PPE training session in Cadarache17 December 2009 Christian Zeile
Design and Analysis of Structural Components
Development of new concepts
+ high stiffness
+ no flexibility necessary
- Difficult manufacturing
- Difficult assembly
- space requirement
First analysis
Cage (translational motion)
Roll (rotatory motion)discarded
PPE training session in Cadarache18 December 2009 Christian Zeile
Design and Analysis of Structural Components
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)
PPE training session in Cadarache19 December 2009 Christian Zeile
Design and Analysis of Structural Components
Concept 1: Screw Coupling
+ lower tolerances required before assembly
+ easy assembly
- only friction contact
Name of Institute, Faculty, Department20 December 2009 Christian Zeile
Design and Analysis of Structural Components
Concept 2: Screw Coupling and Welding of identical materials
+ lower tolerances required before assembly
+ easy assembly
+ large area of contact
- high space requirements
- only friction contact
Contact loss
Name of Institute, Faculty, Department21 December 2009 Christian Zeile
Design and Analysis of Structural Components
Concept 3: Positive Locking
+ forces transferred by positive locking
+ easy assembly
- high precision of contact surfaces required
Name of Institute, Faculty, Department22 December 2009 Christian Zeile
Design and Analysis of Structural Components
Concept 4: Welding of different materials
+ lower tolerances required before assembly
- Accessibility for the welding tool
- Welding process has to be qualified according to codes and standards
- Heat:
- Effects of distortion
- Diagnostic
PPE training session in Cadarache23 December 2009 Christian Zeile
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…
PPE training session in Cadarache24 December 2009 Christian Zeile
Thank you for your attention