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Overview of the Design and R&D of the ITER Blanket System

Overview of the Design and R&D of the ITER Blanket System. Presented by A. René Raffray Blanket Section Leader Blanket Integrated Product Team L eader ITER Organization, Cadarache , France with contributions from M. Merola and members of the ITER Blanket Integrated Product Team

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Overview of the Design and R&D of the ITER Blanket System

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  1. Overview of the Design and R&D of the ITER Blanket System • Presented by A. René Raffray • Blanket Section Leader • Blanket Integrated Product Team Leader • ITER Organization, Cadarache, France • with contributions from M. Merola and members of the ITER Blanket Integrated Product Team • 10th International Symposium on Fusion Nuclear Technology (ISFNT-10) • Portland, OR, September 12-16, 2011 • The views and opinions expressed herein do not necessarily reflect those of the ITER Organization ISFNT-10, Portland, OR, September 12-16, 2011

  2. Blanket Effort Conducted within BIPT Blanket Integrated Product Team DA’s - CN - EU - KO - RF - US ITER Organization • Include resources from Domestic Agencies to help in major design and analysis effort. • Direct involvement of procuring DA’s in design - Sense of design ownership - Would facilitate procurement ISFNT-10, Portland, OR, September 12-16, 2011

  3. Blanket System Functions • Main functions of ITER Blanket System: • Exhaust the majority of the plasma power. • Contribute in providing neutron shielding to superconducting coils. • Provide limiting surfaces that define the plasma boundary during startup and shutdown. ISFNT-10, Portland, OR, September 12-16, 2011

  4. Blanket System Modules 7-10 Modules 11-18 Modules 1-6 Shield Block (semi-permanent) FW Panel (separable) Blanket Module 50% 50% 50% 40% 10% ~850 – 1240 mm ~1240 – 2000 mm ISFNT-10, Portland, OR, September 12-16, 2011

  5. Blanket System Layout • The Blanket System consists of Blanket Modules (BM) comprising two major components: • a plasma facing First Wall (FW) panel and a Shield Block (SB). • It covers ~600 m2. • Cooling water (3 MPa and 70°C) is supplied to the BM by manifolds supported off the vacuum vessel behind or to the side of the SB. ISFNT-10, Portland, OR, September 12-16, 2011

  6. Blanket Design • Major evolution since the ITER design review of 2007 - Need to account for large plasma heat fluxes to the first wall - Replacement of port limiter by first wall poloidal limiters - Shaped first wall - Need for efficient maintenance of first wall components. - Full replacement of FW at least once over ITER lifetime - Remote Handling Class 1 • Design change presented at the Conceptual Design Review (CDR) in February 2010 and accepted in the ITER baseline in May 2010. • Post-CDR effort focused on resolving key issues from CDR, particularly on improving the design of the first wall and shield block attachments to better accommodate the anticipated electromagnetic (EM) loads. ISFNT-10, Portland, OR, September 12-16, 2011

  7. Blanket System in Numbers Number of Blanket Modules: 440 Max allowable mass per module: 4.5 tons Total Mass: 1530 tons First Wall Coverage: ~600 m2 Materials: - Armor: Beryllium - Heat Sink: CuCrZr - Steel Structure: 316L(N)-IG n-damage (Be / heat sink / steel): 1.6 / 5.3 / 3.4 (FW) 2.3 (SB) dpa Max total thermal load: 736 MW ISFNT-10, Portland, OR, September 12-16, 2011

  8. Design of First Wall Panel I-shaped beam to accommodate poloidal torque ISFNT-10, Portland, OR, September 12-16, 2011

  9. Why Shaping of First Wall is Needed? • The heat load associated with charged particles along the field lines is a major component of heat flux to first wall. Plasma Toroidal direction First wall Shield block Horizontal view Inboard wall Toroidal gap : 16 mm on the inboard ISFNT-10, Portland, OR, September 12-16, 2011

  10. Two Sides Need to be Considered Toroidal direction 5 mm 5 mm First wall First wall First wall First wall • The two situations are equally probable So chamfering on both sides is necessary Toroidal direction First wall ISFNT-10, Portland, OR, September 12-16, 2011

  11. Shaping the First Wall Toroidal direction 5 mm First wall First wall 16 mm q ISFNT-10, Portland, OR, September 12-16, 2011

  12. Final Shaping of First Wall Panel • Heat load associated with charged particles is a major component of heat flux to first wall. • The heat flux is oriented along the field lines. • Thus, the incident heat flux is strongly design-dependent (incidence angle of the field line on the component surface). • Shaping of FW to shadow leading edges and penetrations. Plasma - Allow good access for RH - Shadow leading edges Exaggerated shaping RH access ISFNT-10, Portland, OR, September 12-16, 2011

  13. First Wall Panels: Design Heat Flux ISFNT-10, Portland, OR, September 12-16, 2011

  14. First Wall Finger Design Normal Heat Flux Finger: • q’’ = ~ 1-2 MW/m2 • Steel Cooling Pipes • HIP’ing Enhanced Heat Flux Finger: • q’’ < ~ 5 MW/m2 • Hypervapotron • Explosion bonding (SS/CuCrZr) + brazing (Be/CuCrZr) SS Back Plate Be tiles Be tiles SS Pipes CuCrZr Alloy ISFNT-10, Portland, OR, September 12-16, 2011

  15. First Wall Analysis Schematic of EHF FW finger and Example Thermal Stress Results • Detailed blanket design activities on-going in parallel with supporting analyses in preparation for PDR. • They address EM, thermal, thermo-hydraulic and structural aspects based on ITER Load Specifications and requirements. • Design cases are categorized according to their probability of occurrence and allowable stress or temperature levels depend on the event category. • The capability of the design to withstand the design number of cycles for each of the events must be demonstrated. More details on thermo-mechanical analysis of EHF FW from M. Sviridenko’s poster presentation on Wednesday ISFNT-10, Portland, OR, September 12-16, 2011

  16. Shield Block Design • Slits to reduce EM loads and minimize thermal expansion and bowing • Poloidalcoolant arrangement. • Cooling holes are optimized for Water/SS ratio (Improving nuclear shielding performance). • Cut-outs at the back to accommodate many interfaces (Manifold, Attachment, In-Vessel Coils). • Basic fabrication method from either a single or multiple-forged steel blocks and includes drilling of holes, welding of cover plates of water headers, and final machining of the interfaces. More details on EM slit optimization study from J. Kotulski’s poster presentation on Wednesday ISFNT-10, Portland, OR, September 12-16, 2011

  17. Shield Block Analysis • Thermo-mechanical analysis indicates that the stress levels are acceptable and that the temperature level <~350°C , as illustrated by the example results for SB 1 shown here. More details on cooling optimization from Duck-Hoi Kim’s poster presentation on Tuesday ISFNT-10, Portland, OR, September 12-16, 2011

  18. Shield Block Attachment • 4 flexible axial supports • Keys to take moments and forces • Electrical straps to conduct current to vacuum vessel • Coolant connections ISFNT-10, Portland, OR, September 12-16, 2011

  19. Flexible Axial Support • 4 flexible axial supports located at the rear of SB, where nuclear irradiation is lower. • Compensate radial positioning of SB on VV wall by means of custom machining. • Adjustment of up to 10 mm in the axial direction and 5 mm transversely (on key pads) built into design of the supports for custom-machining process. • Cartridge and bolt made of high strength Inconel-718 • Designed for 800 kN preload to take up to 600 kN Category III load. ISFNT-10, Portland, OR, September 12-16, 2011

  20. Example Analysis of Flexible Cartridge: Fatigue Assessment of M66 Main Thread for BM 18 Elastic analysis – Design load for axial supports in Cat.II: 504 kNradial force, T = 1500C Max. Von Mises stress 952 MPa (Pa) (m) Linearization of equivalent stress - Elastic strain range (SDC-IC 3323.1.1) Equivalent stress, Pa - Total stress range - SDC-IC 3322: Fatigue usage fraction The number of Cat.II events will be limited to 400 (cf.VV load specification) 5111 cycles92.2%-margin ISFNT-10, Portland, OR, September 12-16, 2011

  21. Example Analysis of Flexible Cartridge: Collapse Load Assessment for BM 18 (immediate plastic collapse – SDC-IC 3211.2) Elastoplastic analysis Tension (Allowable (II) = 1.2 MN) Symmetric assembly Max. total strain 0.43% Total strain (tension force 600 kN) Reaction in pilot node from tensile force vs. displacement Collapse load: 1800 kN 1800 kN/600 kN LF,collapseIII = 3.00 > LF,criteriaIII = 1.2  Margin 150%LF,collapseII = 3.57 > LF, criteriaII = 1.5  Margin 138% Analysis model Friction coefficients: 0.4(metal - metal) 0.6 (metal – ceramic) 1800 kN/504 kN ISFNT-10, Portland, OR, September 12-16, 2011

  22. Shear Keys Used to Accommodate Moments from EM Loads Toroidal Forces Poloidal Forces ISFNT-10, Portland, OR, September 12-16, 2011

  23. Keys in Inboard and Outboard Modules • Each inboard SB has two inter-modular keys and a centering key to react the toroidal forces. • Each outboard SB has 4 stub keys concentric with the flexible supports. • Bronze pads are attached to the SB and allow sliding of the module interfaces during relative thermal expansion. • Key pads are custom-machined to recover manufacturing tolerances of the VV and SB. • Electrical isolation of the pads through insulating ceramic coating on their internal surfaces. ISFNT-10, Portland, OR, September 12-16, 2011

  24. Example Analysis of Inter-Modular Key • Analysis of the inter-modular keys indicate stresses above yield (~172 MPa at 100°C) in the case of Category III load. • Limit analysis then performed to check margin. ISFNT-10, Portland, OR, September 12-16, 2011

  25. Limit Analysis of Inter-Modular Key Eddy Forces Applied • Reasonable load factors of 1.5 for the pads and 1.9 for the neck of the key are obtained based on limit analysis under Category III load with 5% plastic strain. 1.725 MN 1.725 MN ISFNT-10, Portland, OR, September 12-16, 2011

  26. Analysis of Outboard Stub Key • Stub key for BM#11 • Worst-case EM loads (from PDR Protocol):- FMrII= 855 kN (cat. II)- FMrIII= 1014 kN(cat. III) Plus (mainly taken by axial supports):- FMpII= 300 kN- FMpIII= 360 kN Pad Stub key Reaction forces from forces due to radial moment, FMr Stub key Pad ISFNT-10, Portland, OR, September 12-16, 2011

  27. Limit Analysis of Stub Key of BM #11 1.27 (Pa) Stress redistribution at LFcollapseIII = 1.27 Plastic strain at LFcollapseIII = 1.27 • - LFcollapseIII= 1.27 > LFcriteriaIII= 1 (Margin 27%) • - LFcollapseII= 1.510 > LFcriteriaII= 1.171 (Margin 29%) Max. plastic strain: 5.01% ISFNT-10, Portland, OR, September 12-16, 2011

  28. Electrical Straps • Each SB is electrically joined to the VV by two electrical straps, formed and louvered from two sheets of CuCrZr alloy to achieve flexibility. • Each strap is bolted on to the rear of a SB using M8 bolts. The socket is welded to the VV. • An M20 bolt inserted through the front face of the SB connects the straps to the vessel socket via a compression block. • One electrical connection can handle up to 180 kA of electrical current. Socket now welded on VV M8 bolt VV side Blanket side M20 bolt Cu alloy strap ISFNT-10, Portland, OR, September 12-16, 2011

  29. Blanket Manifold • • A multi-pipe configuration has been chosen, with each pipe feeding one or two BM’s replacing the previous baseline with a large single pipe feeding several BM’s • Higher reliability due to drastic reduction of number of welds and utilization of seamless pipes. • Higher mechanical flexibility of pipes  reduction of space reservation at back of BM. • Superior leak localization capability due to larger segregation of cooling circuits. • Elimination of drain. • Reduction of cost: • Well established manifold technologies. • Simplification of Vacuum Vessel manufacturing due to elimination of heavy anchoring plates. • Must be balanced with cost associated with higher number of valves required for leak localization (2 valves per circuit). ISFNT-10, Portland, OR, September 12-16, 2011

  30. Blanket Remote Handling • Shield blocks designed for ITER lifetime (semi-permanent component) • First wall panels to be replaced at least once during ITER lifetime (designed for 15,000 cycles). • Both are designed for remote handling replacement (FW: RH Class 1). • Blanket RH system procured by JA DA. • RH R&D underway. More details from S. Mori’s oral presentation on Monday and S. Shigematsu’sposter presentation on Thursday. On-Rail Module Transporter ISFNT-10, Portland, OR, September 12-16, 2011

  31. Supporting R&D • A detailed R&D program has been planned in support of the design, covering a range of key topics, including: - Critical heat flux (CHF) tests on FW mock-ups. - Experimental determination of the behavior of the attachment and insulating layer under prototypical conditions. - Material testing under irradiation. - Demonstration of the different remote handling procedures. • A major goal of the R&D effort is to converge on a qualification program for the SB and FW panels. - Full-scale SB prototypes (KODA and CNDA). - FW semi-prototypes (EUDA for the NHF FW Panels, and RFDA and CNDA for the EHF First Wall Panels). - The primary objective of the qualification program is to demonstrate that: - Supplying DA can provide FW and SB components of acceptable quality. - Components are capable of successfully passing the formal test program including heat flux tests in the case of the FW panel. ISFNT-10, Portland, OR, September 12-16, 2011

  32. Example R&D for Hypervapotron CHF (RFDA) • The R&D program in support of the EHF hypervapotron CHF testing was conducted at the Efremov Institute, RF. • The results confirm the CHF margin of 1.4 for the EHF FW under an incident heat flux of 5 MW/m2. More details from I. Mazul’s oral presentation on Tuesday ISFNT-10, Portland, OR, September 12-16, 2011

  33. FW Pre-Qualification Requirements • Each DA must demonstrate technical capability prior to start procurement. • 2 phase approach: 2 slopes, 4 facets 6 Fingers in 1 to 1 scale I. Demonstration/validation joining of Be/CuCrZr and SS/CuCrZrjoint (done) II. Semi-prototype production/validation of large scale components (on-going)

  34. NHF FW Pre-Qualification Program (EUDA, on-going) • Engineering support activity • Manufacturing Development activity Standard NHF • 1 medium scale mock-up to study Be tile sizes + checking end-of-finger configuration • 1 semi-prototype for 1 MW/m2 heat flux (S-NHF) Upgraded NHF • 3 small-scale mock-ups for checking performance under Heat Flux • 1 semi-prototype for 2 MW/m2 heat flux (U-NHF) Be tiles CuCrZr heat sink SS beam

  35. Summary • The Blanket design is extremely challenging, having to accommodate high heat fluxes from the plasma, large EM loads during off-normal events and demanding interfaces with many key components (in particular the VV and IVC) and the plasma. • Substantial re-design following the ITER Design Review of 2007. The Blanket CDR in February 2009 has confirmed the correctness of this re-design. • Effort now focused on finalizing the design work . • Parallel R&D program and formal qualification process by the manufacturing and testing of full-scale or semi-prototypes. • Key milestones: • - Preliminary Design Review: Nov. 29 – Dec. 1, 2011 • - Final Design Review in late 2012. • - Procurement to start in early 2013 and should last till 2019. 35 ISFNT-10, Portland, OR, September 12-16, 2011

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