1.) overview on european blanket concepts and integration...
TRANSCRIPT
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 1
FUSION FZK - EURATOM ASSOCIATION
presented by Thomas IhliContributions from: Christina Koehly, Joerg Rey, Daniel Nagy, Carolina Polixa, Zhanjie Xu et al.
1.) Overview on European Blanket Concepts1.) Overview on European Blanket Conceptsand Integration principlesand Integration principles
2.) Large Module Integration2.) Large Module Integration3.) Multi Module Segment (MMS) Integration 3.) Multi Module Segment (MMS) Integration 4.) New MMS Blanket options4.) New MMS Blanket options
DEMO FUSION CORE ENGINEERING:DEMO FUSION CORE ENGINEERING:Blanket Integration and MaintenanceBlanket Integration and Maintenance
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 2
FUSION FZK - EURATOM ASSOCIATION
Blanket
Shield Manifolds
DEMO in vessel componentsDEMO in vessel components
DEMO = Fusion DEMO = Fusion ReactorReactor PLANT:PLANT:
Demonstration of all Demonstration of all technologiestechnologies ((breederbreeder blanketsblankets, , HeHe--cooledcooled divertor..), divertor..), High High AvailabilityAvailability !!
Divertor
He cooled hot components
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 3
FUSION FZK - EURATOM ASSOCIATION
HCPB Blanket Design for DEMO (FZK 2003)HCPB Blanket Design for DEMO (FZK 2003)
Orthogonal stiffening grid
Breeder Units210 mm x 210 mm
All manifolds behind the breeding zone2 m
2 m
Helium 80 bars, (300...500°C)Sructure: Eurofer
Li4SiO4
Be
Strong against pressurization
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 4
FUSION FZK - EURATOM ASSOCIATION
Design of the HCLL Blanket for DEMODesign of the HCLL Blanket for DEMO
Cap
PbLi loopBack Plate -Manifolds
He inlet/oulet
FW
PbLi manifold
Cooling Plates
Grid
He inlet/oulet
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 5
FUSION FZK - EURATOM ASSOCIATION
FZK Dual CoolantFZK Dual Coolant
T
PbLi
He
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 6
FUSION FZK - EURATOM ASSOCIATION
Blanket Integration SchemesBlanket Integration Schemes
• Separate Modules connected to thevacuum vessel (VV) by flexible attachment
• The hot manifold needs flexibility1.) Segmented Blanket
Maintenance
2.) Vertical Segment(“banana”)
3.) Sector Maintenance
4.) MMS Maintenance (Op.2.2)( “Best from 1. and 2.” )
• Vertical segments have to be connectedto the VV by flexible attachment
• Currently not considered in Europe
• Separate Modules connected to amanifold/back plate outside the VV
• Permanent self-supporting shield and manifold connected by bolts
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 7
FUSION FZK - EURATOM ASSOCIATION
Alternative maintenance scheme: Vertical SegmentsAlternative maintenance scheme: Vertical Segments
15.8
m
EU DEMO 95
Outboard blanket segment
Open Issues:Open Issues:- Flexible attachment
system- Remote handling of
the flexible attachment system
- Thermal stress during transient events
- Fabrication (Eurofer/Austenite)
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 8
FUSION FZK - EURATOM ASSOCIATION
Alternative maintenance scheme: Large SectorsAlternative maintenance scheme: Large Sectors
Currently not considered Currently not considered for DEMO in Europefor DEMO in Europe
Possible issues:Possible issues:
- Building size, layout, logistics, costs
- Disassembly of large parts ofpermanent reactor equipment(e.g. heating systems NBI, diagnostics)for regular blanket and divertor maintenance
- Divertor maintenance (Divertor lifetime likely only half of blanket lifetime)
- Assembly (mechanical connectionbetween sector elements etc.)
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 9
FUSION FZK - EURATOM ASSOCIATION
Integration of a modular HeIntegration of a modular He--cooled Blanket (FZK)cooled Blanket (FZK)
FZKFZK
He cooled pebble bed blanket (HCPB) 300 … 500°C
Water cooledvacuum vessel
Low temperature shield
Flexible He pipes
He cooled divertor: 540 … 700°C
MODULARBLANKET
DIVERTORCASSETTES
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 10
FUSION FZK - EURATOM ASSOCIATION
““TransporterTransporter”” concept for a Fusion Power Plantconcept for a Fusion Power Plant
Equatorial port: 4 ports for the RH of the equatorial IB and OB Blanket modules
Lower port: 4 ports for the 54 “Divertor Cassettes”
Upper Port: 4 ports for RH of the 54 “Blanket Cassettes”
8m plasma major radius, 1500 MWel20° Sector
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 11
FUSION FZK - EURATOM ASSOCIATION
inle
tou
tlet
RHtool
permanentcomponents:shield +polodialpipes
500°C
300°C
Large Module ConceptLarge Module Concept
Cut-/ rewelding zone
Shield key
Shield
Pipes
In-bore cutting,welding,
inspection
HCPB
~350 modules~700 pipes, Ø 200 mm
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 12
FUSION FZK - EURATOM ASSOCIATION
Reweldability limit: 1 appm He• 20 fpy: 0.05 appm• 40 fpy: 0.025 appm
Reweldability results:
+ sufficient for vacuumvessel
+ sufficient for LTS-MMS
NEW effort forlarge module conceptnecessary turn
3300 MW fusion power
He production rates He production rates in steel (in steel (appm/fpyappm/fpy))
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 13
FUSION FZK - EURATOM ASSOCIATION
New effort to remove neutron streaming issue in large pipes
inle
tou
tlet
D = 150 ... 200 mm
A = 2 ... 4 m2
FZK
Shieldplate in
bend
Hot Shieldaroundbend
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 14
FUSION FZK - EURATOM ASSOCIATION
He production He production rates rates
in steel in steel ((appm/fpyappm/fpy))
3300 MW fusion power
Reweldability limit: 1 appm He• 20 fpy: 0.05 appm• 40 fpy: 0.025 appm
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 15
FUSION FZK - EURATOM ASSOCIATION
3-D TIG in-bore welding tool
TIG torch
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 16
FUSION FZK - EURATOM ASSOCIATION
What is the possible path bending radius for in-bore tools?
r ≥ 1.5 x Dinternal Dinternal
Further researchfor 3D weldingtorch necessary!
≈ 1.2 m
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 17
FUSION FZK - EURATOM ASSOCIATION
blanket
shieldkey
rotatingin-borewelding head
in-boremodules
bend
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 18
FUSION FZK - EURATOM ASSOCIATION
Modular axial and lateral wave movements
1.5 mm lateraltranslation
2 mm axial translation
Telescope pipes
Dinternal=150 mm, POp= 8 MPa
10 plies x 0.7mm
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 19
FUSION FZK - EURATOM ASSOCIATIONLa
rge
mod
ules
:Rem
ote
hand
ling
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 20
FUSION FZK - EURATOM ASSOCIATION
Remote Handling of Large Modules Remote Handling of Large Modules
Precise operation in three axes required
Size of the RH machinestrongly depends on the
weight of the modules
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 21
FUSION FZK - EURATOM ASSOCIATION
System operation: element exchangeLower sections of the ports are used
Port transporter with tilting plate
Step 1: Manipulator gives the blanket to the port transporter
Step 2: Port transporter takes the element out
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 22
FUSION FZK - EURATOM ASSOCIATION
Large modules
FZKFZK
HCPB blanket
VV
LTS
He pipes
Multi ModuleSegments (MMS)
FZK Integration concepts under investigationFZK Integration concepts under investigation
Each MMS consists of an assembled array of blanket modules and the coolant manifolds
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 23
FUSION FZK - EURATOM ASSOCIATION
MultiMulti--ModuleModule--Segment (MMS): new maintenance approachSegment (MMS): new maintenance approach
maintenance time
Forces on flex. attachmentdue to electromagnetic loads
Reasonable blanket module size for fabrication procedure
Reduced thermal stresses by segmentation
Quality Assurance
Separate modules Vertical segmentsMulti ModuleModules (MMS)
+ +++++
+
+
++
---
-
-
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 24
FUSION FZK - EURATOM ASSOCIATION
MMS OptionsMMS OptionsOption 2.1: Hot Backplate + LTS
Option 2.2: Supporting Hot Ring Shield
Option 1.1: Blanket Chain
cold
cold ho
t
Option 1.2: LTS-Backplate
+ hot pipes
MMS
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 25
FUSION FZK - EURATOM ASSOCIATION
Fusion Core ConceptFusion Core Concept
MULTI MODULE SEGMENTS MULTI MODULE SEGMENTS with flexible connection between with flexible connection between blanket modules and manifoldblanket modules and manifold
SelfSelf--supporting Hot Ring Shieldsupporting Hot Ring Shieldwith linear bearings at bottom sidewith linear bearings at bottom side
Remote handling withRemote handling with Vertical Insertion Vertical Insertion and and railrail--based transport machine based transport machine
Rigid Rigid connectionconnection
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 26
FUSION FZK - EURATOM ASSOCIATION
MMS concept (2.2)MMS concept (2.2)
Self-supporting
hot ring structure
Linear bearing
Manifoldtemperature:
~330°C
Blanket temperature400...550°C
Shieldtemperature:
~330°C
FZK
VV temperature:
~150°C
detachablemechanicalconnection
Ring structure to be operatedfairly steady-state intermediate temperature near the helium inlet temperature
Ring structure to be operatedfairly steady-state intermediate temperature near the helium inlet temperature
Concentricconnection
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 27
FUSION FZK - EURATOM ASSOCIATION
Hot ring systemHot ring system
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 28
FUSION FZK - EURATOM ASSOCIATION
22,5deg
18deg
11.25deg
20deg
18deg
20deg
22,5deg
11.25deg
IB element Segmentation: insertion constraint
18 degree IB MMS18 degree IB MMSmost reasonablemost reasonable
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 29
FUSION FZK - EURATOM ASSOCIATION
⇒ Helium Pipes can be routedthrough the vertical ports (inner pipe diameter ~ 550 mm)
⇒ Two … four remote handling ports
⇒ Helium Pipes can be routedthrough the vertical ports (inner pipe diameter ~ 550 mm)
⇒ Two … four remote handling ports
MMS / PORT MMS / PORT configurationconfiguration
RH
Vertical port
IB MMS20 x 18°
OB MMS28 x 11.25°
He pipes
RH OB MMS6 x 7.5°
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 30
FUSION FZK - EURATOM ASSOCIATION
MMS SEGMENTATIONMMS SEGMENTATION
• 16 coils: 22.5 deg segments
• In-Board MMS 18 deg
• (14x2) Out-Board MMS 11.25 deg at RH port: 7.5 deg, 2X3 OB MMS
20 elements
34 elements
54 elements
OB MMS
11.25 degIB MMS
18 deg
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 31
FUSION FZK - EURATOM ASSOCIATION
Torques from EM loads depend on module shapeTorques from EM loads depend on module shape
22
22
22
22
)(
)(
whwhVw
hfM
wswsVw
sfM
p
r
+∝
+∝ V = volume of the module,
f = shape factor
Forces on flexible
attachementare critical !
Optimization for lowpoloidal torque.
CIEMAT
Mp small for elongated shapeMp large for square shape
p
rt
s
h
w
1.) Small size (w * h)2.) Elongated shape and long lever against Mp
larger width than height is favorable
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 32
FUSION FZK - EURATOM ASSOCIATION
Forces at attachment due to Electromagnetic ForcesForces at attachment due to Electromagnetic Forces
0
0.2
0.4
0.6
0.8
1
1.2
0.1 1 10Ratio height/width
Forc
es (r
el.)
Force at shear keys (from rad. Torque)
Force at attachment (from pol. Torque)
A = 4 m2
Vertical module ------>
p
rt
a
c
bWhich moduleshape?
4/1
TOROIDAL directionof modules for low
forces on Flexibles !
2/11/1
1/2
1/4
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 33
FUSION FZK - EURATOM ASSOCIATION
0
5
10
15
20
25
30
35
40
45
50
0.01 0.1 1 10 100
Ratio height/width
Forc
es M
N
Force flex A=4 m2Force flex A=2 m2Force flex A=3 m2Force flex A=5 m2Force flex A=8 m2
Forces at flexible attachment due to Electromagnetic ForcesForces at flexible attachment due to Electromagnetic Forcesp
rt
a
c
b
smaller Blanket sub- modulesto be connected to the MMS
low forces on flexibles
smaller Blanket sub- modulesto be connected to the MMS
low forces on flexibles
Smallest diameter of the attachment> 13 cm > 40 cm
Assumption for module1m high x 2 m wide:Mrad = 2.5 MNmMpol = 1.5 MNm
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 34
FUSION FZK - EURATOM ASSOCIATION
MMS BlanketMMS Blanketsubsub--modulesmodules
IBIB OBOB
SubSub--module size:module size:
~ 2 m wide,~ 1 m high
~ 2 m2 front surface
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 35
FUSION FZK - EURATOM ASSOCIATION
DEMO ReactorDEMO Reactorwith MMS Blanketwith MMS Blanket
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 36
FUSION FZK - EURATOM ASSOCIATION
Remote Remote handlinghandling ConceptConcept
•• VerticalVertical insertion insertion ports ports (2 (2 …… 4) 4)
•• Insertion by simple craneInsertion by simple crane--like like insertion machineinsertion machine
•• Toroidal transport by divertor rail Toroidal transport by divertor rail based based transport machinetransport machine
•• Linear positioning systemLinear positioning system::MMS is moved towards the shield MMS is moved towards the shield by use of slides on the transport by use of slides on the transport machinemachine
Crane-like MMSinsertion machine
MMS transportmachine
MMS
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 37
FUSION FZK - EURATOM ASSOCIATION
Insertion & Transport position of IB MMSInsertion & Transport position of IB MMSThe inboard MMS is inserted through the vertical port
The inboard MMS is placed on the support of the transport machine
The MMS is leant against the shield and carried in toroidal direction
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 38
FUSION FZK - EURATOM ASSOCIATION
IB Transport positionIB Transport position
Weight support
Guidance (rolls on the wall)
Gripping
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 39
FUSION FZK - EURATOM ASSOCIATION
IB MMS positioningIB MMS positioning
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 40
FUSION FZK - EURATOM ASSOCIATION
OB Transport positionOB Transport position
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 41
FUSION FZK - EURATOM ASSOCIATION
OB MMS final positioningOB MMS final positioning
Path~1.7m
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 42
FUSION FZK - EURATOM ASSOCIATION
Below remote handling ports: Below remote handling ports: last OB MMS element will be connected last OB MMS element will be connected to the surrounding permanent shield to the surrounding permanent shield
structure from backsidestructure from backside
Segmentation at RH ports:Likely 3 OB MMS per 22.5 segment
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 43
FUSION FZK - EURATOM ASSOCIATION
Pipe compensation for upper port assembly version 2.2Pipe compensation for upper port assembly version 2.2
:
Total elongation:1) Vertical about 50mm2) Radial about 30mm
New strategy:1.) Hydraulic connection
in ports2.) Compensation
outside VV
1)
2)
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 44
FUSION FZK - EURATOM ASSOCIATION
MMS MMS hydraulichydraulic connectionconnection pipespipes areare routedrouted throughthrough the the verticalvertical portsports::
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 45
FUSION FZK - EURATOM ASSOCIATION
Possible approach for new MMS HCPB module shape:Possible approach for new MMS HCPB module shape:
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 46
FUSION FZK - EURATOM ASSOCIATION
NEW alternative breeder unit designNEW alternative breeder unit design• Flexible for low stress duringthermal expansion
• Strong for vibration during filling
• Uniform temperatures in cooling plate cross section
low thermal stressreduced risk with plate bulgingreduced risk with plate deflection
• One flow direction within and forall cooling plates
reduced pressure dropreduced risk with leak betweenneighbouring cooling channels
• Optimization in terms ofplate distance, enrichment etc.
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 47
FUSION FZK - EURATOM ASSOCIATION
FZK approach for new DCLL FZK approach for new DCLL (MMS, hot (MMS, hot backplatebackplate + LTS)+ LTS)
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 48
FUSION FZK - EURATOM ASSOCIATION
Approach for new MMS DCLL: Flow routingApproach for new MMS DCLL: Flow routing
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 49
FUSION FZK - EURATOM ASSOCIATION
Approach for new MMS DCLL: Approach for new MMS DCLL: SiC/SiCSiC/SiC BoxBox
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 50
FUSION FZK - EURATOM ASSOCIATION
Approach for new MMS DCLL: FC InsertsApproach for new MMS DCLL: FC Inserts
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Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 51
FUSION FZK - EURATOM ASSOCIATION
SUMMARY, ConclusionsSUMMARY, Conclusions
Separate Module Handling seems feasible but maintenance time is likely longer than with MMS.
MMS maintenance very promising, combines advantages.
Self supporting hot ring shield removes the large flexible attachment issue.
Remote handling with vertical insertion + transport machineinvolves only relatively simple procedures and machines.
Small number of remote handling ports possible.
New version of HCPB blanket to be combined with the MMS.
Alternative DCLL for MMS being investigated.
Rem
ote
hand
ling
Inte
grat
ion
sche
mes
Bla
nket
conc
epts