Recent Progress in HCCB Design Analysis

1. Recent Progress in HCCB Design Analysis Ying, Alice With contributions from M. Narula, R. Hunt, S. Park, M. Youssef, W. Zhang TBM Meeting February 14-15, 2007 UCLA

2. Summary • Efforts were carried out in the following areas: • Continued thermo-fluid design analysis for Helium coolant manifold designs (Narula) • Progress in the integrated design analysis approach • Input to FMEA • Nuclear optimization of the HCBB TBM with varying Li-6 enrichment and plan for 3-D analysis (Youssef- 10 minutes)

3. He purge gas pipe Be pebbles Ceramic breeder pebbles RAFS FWwith He coolant channels Cooling plate Basic Configuration and Partnership Scheme for HCCB remain the same as Aug. 2006 US HCCB TBM sub-module (710  389  510 mm) HCCB Joint Partnership The proposed US HCCB sub-module will occupy 1/3 of an ITER horizontal half-port

4. Fix CAD model .MDL model CAD model CADthru Engineering Design Analysis Emphasizes Integrated Computer Aided Engineering (CAE) Approach • Preliminary effort focuses on Thermo-fluid and Structural Thermo-mechanical coupling • EM and pebble bed thermomechanics integration as the next step .MDL file format input to SC/Tetra preprocessor Example Thermo-fluid Analysis Velocity, Temperature, and Pressure in fluid domain Temperature in solid domain SCTPre SCTsolver SCTpost FLDUTIL SC/Tetra Primary and Thermal Stress Analysis Stress and Strain in the solid domain .cdb file format to input geometry and temperature load for ANSYS ANSYS Transient and steady state thermal stress Analysis Code choices for EM: ANSYS/OPERA Code choices for pebble bed thermomechanics: ANSYS/MARC

5. Data Transfer Between Various Physics Simulation Codes Nodal/Element Based Data Interpolation Elements in SC/T mesh : 3 million (first order tetrahederons and prisms) Elements in ANSYS mesh: 0.25 million (second order tetrahederons, etc.) In ANSYS only the solid domain is meshed with second order elements (SOLID 186). The mid-node temperature loads are interpolated during data transfer SOLID186 - 3-D 20-Node Structural Solid first order tetrahederons

6. 3-channels model CFD SC/Tetra mesh 16-channels model ANSYS Structural mesh Higher order elements used with mid-node temperature interpreted first order tetrahederons remain with reduced number of elements High order element (accuracy) can not be applied in a full simulation model

7. Temperature (Body force load) and pressure surface loads as well as nodal information imported from SC/Tetra CFD code to ANSYS structural code BC: Two edges at the back clamped first order tetrahedral elements used in the structure to restrict the number of computational nodes below 0.5 million Stress and deformation calculations were performed to guide manifold design Deformation + un-deformed edges and temperature distribution

8. Von Mises stress and displacement • Outlet coolant duct deformed significantly • shape and wall thickness need to be redesigned He Pressure applied to the coolant channels

9. Plots of Von Mises stress & displacement FW helium distributor 1/4 Plot of stress & displacement at mid-plane of side wall coolant channels FW Outlet 1/2

10. Side Wall FW Plots of Von Mises Stress and Displacement on First and Side Walls

11. 0.55 Zorigin 0.51 0.49 0.44 0.29 0.01 0.04 0.14 0.03 0.498

12. Slice show of Von Mises Stress distribution at different Z cutting planes (High stress magnitudes located at manifold plane) Maximum stress at FW Ferritic steel structural surface: 230 MPa Yield strength (sY)at 550oC ~ 340 MPa sp < 1.5 Sm and sp + st < 3 Sm (Sm = 1/3 sY)

13. Exploded view of the HCCB sub-module Breeding zone cooling plate manifold assembly Cap (2) FW structural panel Breeding units (4) FW cooling manifold assembly The HCCB is based on Edge-on configuration Be pebbles filled into places through Upper Cap A completely assembled breeding unit to be inserted into the structural box • Hot isostatic pressing (HIP) technology to join square tubes to form the FW structural panel, and fabrication of other elements such as internal cooling plates. • Electron-beam, laser welding, and possibly other techniques to join manifolds to the first-wall structural panel and internal cooling plates.

14. Weld caps length= 4 x(11+18+362x2) = 3012 mm Side weld length = 2x 2x(18+ 590)=2432 mm Poloidal height = 590 mm Radial depth= 362 mm Plate thickness = 6mm Breeding zone width = 11 to 18 mm Weld length per BU= 5444mm Hip length per BU= 185256 mm 2 Mirrored Sections made through investment casting Breeder cover plates welded onto coolant channel parts 64 channels Hip length= 64 x2 x (362+362+23)= 92628 mm SC2-U Holes in top cover used for filling with breeder pebbles SC2-C Casted Channel section HIPed to bent plates SC2-S Manufacturing Process for breeder unit cooling plate is under evaluation (similar cooling plate being used in HCPB, HCLL, etc. concepts)

15. Section A cover weld to front of Section A distributor plates Input to FMEA: Example Breeding zone manifold formed by 4 radially dividing “plates” and 2 ducts with grooves

16. Example List of Failure Modes with Components

17. Figure 15 View of majority of manifold systems upon assembly Total weld length = 90641.5 mm Total hip length = 1011552 mm FW manifold total weld length (Figs: 11-14)= 14177.2 mm Breeding unit manifold total weld Length (Figs: 5-10)= 44108.3 mm BU caps + side walls (Fig. 4) = 4 x5444= 21776mm BU/FSW (Fig. 3) = 3980 mm Cap/FSW (Fig. 2) = 6600 mm Hip length FW (Fig. 1) = 270528 mm BU (Fig. 4) = 4 x 185256 mm = 741024 mm Longitudinal failure rate = 5 x10-8 /h.m (high end) Failure rate for welds = 4.5 x10-6/h Hipping failure rate use failure rate for straight pipe= 1 x10-9 /h.m Failure rate from hipping =1x10-6/h

18. Draft Qualification program for HCCB

19. Common Back Wall Manifold Assembly US sub-module Breeding zone manifold FW manifold Key-way (3) He coolant pipes (3): Inlet, outlet, by-pass Flexible support (4) Near-term tasks1. Perform structural analysis (primary + thermal stress) to validate breeding zone manifold design2. Develop flow distribution schemes for three sub-modules