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ENGINEERING ANALYSIS AND CODES
Alfredo PortoneFusion for Energy
2 October 09 Engineering analysis and Codes 2
1. Mission of the F4E Engineering Analysis Group2. Core activities: Analysis, Codes & Standards3. Modus operandi, contracts and grants
OVERVIEW
2 October 09 Engineering analysis and Codes 3
F4E requires a whole range of engineering support activities in the field of general mechanics, remote handling, plant systems, nuclear and safety engineering:
• Conceptual and detailed designs• CAD support• FE analysis• Integration of systems• Safety and nuclear engineering• Cost assessment• Welding and fabrication • Standardization of components • Risk analysis• Quality assurance
ENGINEERING SUPPORT
2 October 09 Engineering analysis and Codes 4
Provide technical support in the area of Analysis, Codes &Standards to F4E Procurement Groups
WHY?
Support F4E Procurement Groups in handling of• Design/ Engineering Change Requests• Non-Conformities Reports approval• Backup Solutions investigations…Remark: Due to the large differences in procurement and
commissioning schedule, the design maturity of the ITER components varies from quite detailed (magnets) to rather conceptual (blanket) some areas need a lot of design/analysis work to be carried out provide support to ITER IO
GROUP MISSION
2 October 09 Engineering analysis and Codes 5
2 October 09 Engineering analysis and Codes 6
• Mechanical Analyses• Thermo-hydraulic Analyses• Electromagnetic Analyses
Toroidal Field CoilNb3Sn, 18 coils
Vacuum Vessel9 sectors
Central SolenoidNb3Sn, 6 modules
Additional HeatingIC, EC, NBI
Inner Divertor54 cassettes
Poloidal Field Coils6 coils
Blanket Module421 modules
+ DiagnosticsRemote Handling
Tritium PlantPumping/Fuelling Power Supplies…
• Civil Engineering Analyses• Neutronic Analyses• Material expertise, …
Analysis and Codes needs
GROUP MISSION
2 October 09 Engineering analysis and Codes 7
ANALYSISSeismicElectro-magnetic
Mechanical
Portion of VV
Blanket module #16
Blanket module #17
Flexible housings + stub keys and pads
Neutronic
2 October 09 Engineering analysis and Codes 8
ANALYSISElectro-mechanical analyses features• Coupled electromagnetic-mechanical analysis
through plasma (~mass-less) dynamics• Computation of eddy currents (linear) and
magnetization (nonlinear) to assess heating in cold structures, Lorentz forces, etc.
• Large & complex 3D models of vacuum vessel, blanket, FW, buildings (shell, solid,…)
• Wide range of mechanical analysis types (static, dynamic, linear, nonlinear, buckling, fatigue, cryogenics T, …)
Reference software• ANSYS (ITER IO) • Additional: ABAQUS, SAP 2000, Civil Fem
Choice impact on QA
2 October 09 Engineering analysis and Codes 9
Civil engineering analysis features• Definition of equivalent static forces• Floor response spectra computation• Soil-structure interaction modeling• Design of seismic isolators• Airplane crash• …
Reference softwareANSYS/CIVIL FEMSAP2000
ANALYSIS
2 October 09 Engineering analysis and Codes 10
Neutronic analysis features• Complex 3D geometries & neutron sources!• Transport calculations of neutron fluxes &
spectra for high energy neutrons in presence of thick shields (large flux gradients), penetrations (streaming), multiple materials, sky shine in the Tokamak complex and other controlled buildings;
• Computation of gamma spectra, nuclear heat & damage, material activation, T production (TBM), inventories, doses & occupational exposure…;
• Parallel processing acceleration, MC/FE acceleration algorithms, automated processing software;
• Benchmarking, development of tools and models, improvement of calculation techniques.
Reference software• MCNP5 v1.5, FISPACT 2007, FENDL 2.1 and
EAF 2007 nuclear data libraries, mesh tallies techniques, rigorous-two-step (R2S) when possible
ANALYSIS
1.E+10
1.E+11
1.E+12
1.E+13
1.E+14
1.E+15
1.E-10 1.E-08 1.E-06 1.E-04 1.E-02 1.E+00
ener
1
gy (MeV)
flux
per u
nit l
etha
rgy
(n/c
m2-
s
c9180 (fw)
c9218 (blanket)
1.E+10
1.E+11
1.E+12
1.E+13
1.E+14
1.E+15
1.E-10 1.E-08 1.E-06 1.E-04 1.E-02 1.E+00
energy (MeV)
flux
per u
nit l
etha
rgy
(n/c
m2-
1
s
c9180 (fw)
c9218 (blanket)
2 October 09 Engineering analysis and Codes 11
Nuclear database:• A fully qualified nuclear cross-section
database + validated computational tools are at the basis of any QA neutron & activation calculations as well as of their uncertainties assessment;
• F4E is driving a unique effort on the development of qualified nuclear data for fusion applications oriented to ITER, IFMIF and DEMO;
• This effort brings together recognized Experts and resources from EURATOM Associations and European industry
• This Nuclear Data R&D programme is part of the EU voluntary contribution (i.e. non credited) to ITER 0 2 4 6 8 10 12 14 16
0.0
0.5
1.0
1.5FZK'06
JENDL-3.3
C/E
Neutron Energy, MeV
ENDF-B6
10-4
10-3
10-2
10-1
FZK'06
JENDL-3.3
LLNL' Experiment
ENDF-B6
Ta shell: R = 3.4 cm (1mfp)
Leak
age
Spec
trum
, 1/s
r/MeV
NUCLEAR DATA R&D
Li2CO3pellets
2 October 09 Engineering analysis and Codes 12
Key features• To qualify the ITER components, it is necessary to verify the analysis results
according to different codes & standards Suppliers must have proven experience;
• ASME BPVC• RCC-MR• PED, ESPN• SDC-IC• SDC for Buildings• Eurocodes• EN…
CODES & STANDARDS
Multi-code approach for the ITER components• No single industrial code covers the variety of ITER components & loads;• Specific existing codes cover some particular operational requirements;• Some components (magnet, in-vessels) need special codes developments.
2 October 09 Engineering analysis and Codes 13
Component PED Categoryor ESPN category & level
Selected Codes Comments
Magnets Magnet structure no PEDManifolds and piping PED
Design – Structural Design Criteria - MagnetManufacturing – Technical specificationAcceptance criteria – SDC-MC, based on ASME XI
Notified Body is not involved.
Vacuum Vessel
ESPN:Category IV for pressure and Nuclear Level N2/N3
Metallic partsDesign and Manufacturing: RCC-MR 2007 Non-metallic windowsTechnical specifications
Agreed Notified Body shall check design, manufacturing and conformity.
Blanket
System
Blanket Modules – Cat. IVPiping and manifold – Cat. I, Level N3+ TBD
Design – Structural Design Criteria – In-Vessel Components
Manufacturing, inspection: ASME or EN standards (conventional parts) and TechSPecs
Agreed Notified Body shall check design, manufacturing and conformity. Divertor case to be considered
Tritium Plant and
Detritiation
Categories I-IV, Level N2, N3 or non-nuclear
Design and Manufacturing:- Vessels ASME Section VIII, Div. 2- Piping ASME B 31.3, Category M- Valves ASME B16.34-…And Technical Specifications
Conformity with PED/ESPN required, Agrreed notifyedBody required.Use of EN standards under consideration.
…
Complete table in “Codes and Standards for ITER Mechanical Components”
CODES & STANDARDS: Mechanical Engineering
2 October 09 Engineering analysis and Codes 14
RCC-MR 2002
Requirements of ESP and ESPN
Introduction of European (Harmonized) Standards
RCC-MR 2007
ITER needs - box type structure -
Generic - Integrated in the base Code - Rules for bolts (RB 3280 +A6) - Materials - Electron Beam and Laser
welding - Pressure test - Rules for box structures
(RC3800+RC4000)
Specific - Appendix A19 - Categorization of welded joints - Special rules for permanent
attachments sealing welds and Cu coating
- Use of alternative NDE methods (Ultrasonic Testing and Photo Thermal Camera)
- Low Co materials
EFDA - F4E Active involvement
CODES & STANDARDS: Mechanical Engineering
2 October 09 Engineering analysis and Codes 15
Use of international electrical standards (IEC) and adoption of French Standards + European Directives for (1) installation & operation rule, (2) design, manufacturing & testing of components affecting safety (nuclear and personnel) and fire protection
ITER Electrical Design Handbook, Part 3: Codes and Standards
CODES & STANDARDS: Electrical Engineering
SSEN EQUIPMENT Manufacturing Standard
Indoor / Outdoor Facilities
Site Installation Standard
Nuclear Safety Personal Safety
Tokamak Complex Test
MV / LV DISTRIBUTION TRANSFORMERS
IEC 60076-1 IEC 60076-2 IEC 60076-… IEC 60296 IEC 60664-1 IEC 61000-5 IEC 61000-6-2 IEC 61000-6-4 HD 538-2 S1 NF C 52-112 / NF EN 50464
IEC 60068-1 IEC 60364
IEC 60076-7 IEC 60364 IEC 60905 IEC 61000-5 IEC 61140 NF C15-100
IEC 60068-3-3 IEC 60780 (SR) IEC 60980 (SR)
IEC 60364-4 IEC 60479 IEC 61140 NF C15-100
IEC 60754 IEC 61249-2-21
IEC 60068-3-3 IEC 60076-1 IEC 60076-2 IEC 60076-… IEC 60076-11 IEC 60664-1 IEC 60754 IEC 61000-6-2 IEC 61000-6-4 IEC 61249-2-21
CIRCUIT BREAKER
IEC 60664-1 IEC 60947-1 IEC 60947-2 IEC 61000-5 IEC 61000-6-2 IEC 61000-6-4
IEC 60068-1 IEC 60364
IEC 60364 IEC 60947-1 IEC 60947-2 IEC 61000-5 IEC 61140 NF C15-100
IEC 60068-3-3
IEC 60364-4 IEC 60479 IEC 61140 NF C15-100
IEC 60754 IEC 61249-2-21
IEC 60068-3-3 IEC 60439-1 IEC 60664-1 IEC 60947-1 IEC 60947-2 IEC 61000-4-2 IEC 61000-4-4
SSEN EQUIPMENT Manufacturing Standard
Indoor / Outdoor Facilities
Site Installation Standard
Nuclear Safety Personal Safety
Tokamak Complex Test
MV / LV DISTRIBUTION TRANSFORMERS
IEC 60076-1 IEC 60076-2 IEC 60076-… IEC 60296 IEC 60664-1 IEC 61000-5 IEC 61000-6-2 IEC 61000-6-4 HD 538-2 S1 NF C 52-112 / NF EN 50464
IEC 60068-1 IEC 60364
IEC 60076-7 IEC 60364 IEC 60905 IEC 61000-5 IEC 61140 NF C15-100
IEC 60068-3-3 IEC 60780 (SR) IEC 60980 (SR)
IEC 60364-4 IEC 60479 IEC 61140 NF C15-100
IEC 60754 IEC 61249-2-21
IEC 60068-3-3 IEC 60076-1 IEC 60076-2 IEC 60076-… IEC 60076-11 IEC 60664-1 IEC 60754 IEC 61000-6-2 IEC 61000-6-4 IEC 61249-2-21
CIRCUIT BREAKER
IEC 60664-1 IEC 60947-1 IEC 60947-2 IEC 61000-5 IEC 61000-6-2 IEC 61000-6-4
IEC 60068-1 IEC 60364
IEC 60364 IEC 60947-1 IEC 60947-2 IEC 61000-5 IEC 61140 NF C15-100
IEC 60068-3-3
IEC 60364-4 IEC 60479 IEC 61140 NF C15-100
IEC 60754 IEC 61249-2-21
IEC 60068-3-3 IEC 60439-1 IEC 60664-1 IEC 60947-1 IEC 60947-2 IEC 61000-4-2 IEC 61000-4-4
2 October 09 Engineering analysis and Codes 16
Safety Related Buildings - ITER Structural Design Code for Buildings– Adaptation of state-of-the-art structural design criteria for civil works – Specificities of the configurations and loads of a fusion nuclear plant– Based on the concept of the limit state design used jointly with the method of
the partial factors, as stipulated in Eurocode EN 1990– First part devoted to the design specifications of the safety important
buildings of ITER – Construction rules defined in second part (topography, tolerances,
earthworks, concrete works, formwork, reinforcement, base isolation and elastomeric bearings, leak-tight metal parts on containment, etc.).
No safety related buildings - Application of Eurocode (mainly)
CODES & STANDARDS: Civil Engineering
2 October 09 Engineering analysis and Codes 17
Internal analyses activity• Analysis and Codes group (5 people) provides “in house”, light analysis
capabilities + general computational expertise (brain-storming phase with “clients” from other groups, problem formulation, check interfaces, …)
• Medium/large (>1 month) design work orders carried out – typically -through industrial contracts of different types;External contracts
• Large use of framework contracts, multiple lots, 3 cascade winners;• Specific contracts are also issued for well specified work packages via
single (<50 kEuro), restricted (<250 kEuro) or open tenders;• Grants (40% F4E contribution) rarely used, mostly for
University/Association R&D activities (e.g. nuclear data, code development, …)
• Yearly expenditure for analysis and codes activity ~ 1÷2 M€
MODUS OPERANDI
2 October 09 Engineering analysis and Codes 18
Contract deliverables and IPR• All MCNP/FE models, including input and result files, routines, and mesh
quality summaries are asked to be given to F4E as part of the ADP (Acceptance Data Package) to allow F4E to repeat all the calculations performed by the Supplier.
• The intellectual property of all routines, input files, databases and result files developed by the Supplier under the contract will belong to F4E.
• If the Supplier needs to use any database or routine developed in the past under any contract (excluding past F4E and EFDA), it shoulddeclare this beforehand in the Background Declaration Form.
CONTRACTS DELIVERABLES
2 October 09 Engineering analysis and Codes 19
REQUIREMENTS RECOMMENDED SOFTWARE
ALTERNATIVE
A unique CAD system (mechanical and networks)
CATIA v5 r19 SP 3IGEXAO
A unique analysis software ANSYS ( Civil FEM, LS-DYNA, FLUENT)
ABAQUS **
Enovia VPM (IO), EnoviaSmarteam (f4e,associations, suppliers)Primavera
Autocad (Buildings)
An efficient computer aided data management system
An efficient project management software
Microsoft Project **
* Suppliers may use any CAD SW but F4E must receive everything in CATIA v5 format
** Upon approval by F4E on special cases
CONTRACTSENGINEERING TOOLS
2 October 09 Engineering analysis and Codes 20
1. Nuclear Data Libraries• Improvement of European Fusion File (EFF) and European Activation
File (EAF) as part of the nuclear data source for ITER (by means of the FENDL activities), TBM and broader approach activities and safety studies (IO requirement from French Nuclear Authority).
• Benchmarking of updated and extended nuclear data evaluations2. Nuclear Data Experiments
• Development of measuring techniques for activation and T production• Integral benchmark experiments for data validation covering materials
relevant to ITER and fusion in general, including neutronic and nuclear data analysis of specific impurities for fusion relevant neutron spectra
• Design and implementation of experiments on fusion relevant mock-ups for evaluation and assessment of neutronic calculations
3. Nuclear Data Tools: • Development and validation of advanced numerical methods and
computational tools, in the field of nuclear models and covariances and uncertainties
NUCLEAR DATA R&D
2 October 09 Engineering analysis and Codes 21
ITER DB
ITER CATIA V5 data: Exported by ITER to DA (incl. trace-ability):studied component + context
Native CATIA V5 r19 sp3or:
Multi-CAD approach (Solidworks, Mechanical
Desktop…)
F4EDB
SUPPLIERS
INSTITUTES
ITER DMU review Saving into ENOVIA (Reconciliation)ITER DIDO MeetingsApproval process
Opportunity of CAD data exchanges (ITER + DA):
when required
CATIA V5 data only exported by F4E to ITER (incl. traceability, DET):studied component only
Process for Stable interfaces (frozen design)
FTP
FTP
FTP
ENGINEERING SUPPORTCAD scheme 1-Asynchronous
2 October 09 Engineering analysis and Codes 22
• Native CATIA V5 r19 sp3or:• Multi-CAD approach (Solidworks, Mechanical Desktop…)
F4ESMARTEAM DB
SUPPLIERS
INSTITUTES
ITER DMU review ITER DIDO MeetingsApproval process
Opportunity of CAD data exchanges (ITER + DA):
when required
Data Base sharing
F4E
ITER ENOVIA VPM DB
F4E WS Enovia VPM
F4EENOVIA VPMREMOTE DIRECT ACCESS
Process dedicated to collaborative design tasks
ENGINEERING SUPPORTCAD Scheme 2-Synchronous
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