isfnt-11, barcelona, spain, september 16-20, 2013 © 2013, iter organization slide 1 de sign,...
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ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 1
Design, Fabrication and Testing of the ITER First Wall and Shielding Blanket
Presented by A. René RaffrayBlanket Section Leader; Blanket Integrated Product Team Leader
ITER Organization, Cadarache, France
With contributions from B. Calcagno1, P. Chappuis1, G. Dellopoulos2, R. Eaton1, Zhang Fu1, A. Gervash6, Chen Jiming3, D-H. Kim1, S-W.Kim4, S. Khomiakov5, A. Labusov6, A. Martin1, M. Merola1, R. Mitteau1, M. Ulrickson7, F. Zacchia2
and all BIPT contributors
1ITER Organization; 2F4E, EU ITER Domestic Agency; 3SWIP, China ITER Domestic Agency; 4NFRI, ITER Korea; 5NIKIET, RF ITER Domestic Agency; 6Efremov, RF ITER Domestic Agency; 7SNL , US ITER
Domestic Agency;
11th International Symposium on Fusion Nuclear Technology, Barcelona, Spain, Sept. 16-20, 2013The views and opinions expressed herein do not necessarily reflect those of the ITER Organization
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 2
Blanket Effort Conducted within BIPT
Blanket Integrated Product Team
ITER Organization
DA’s-
CN-
EU-
KO-
RF-
US
• 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-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 3
Blanket System FunctionsMain functions of ITER Blanket System:
• Contribute in absorbing radiation and particle heat fluxes from the plasma
• Contribute in providing shielding to reduce heat and neutron loads in the vacuum vessel and ex-vessel components
• Provide a plasma-facing surface which is designed for a low influx of impurities to the plasma
• Provide limiting surfaces that define the plasma boundary during startup and shutdown
• Provide passage for the plasma diagnostics
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 4
Mod
ules
1-6
Modules 7-10
Mod
ules
11-
18
~850
– 1
240
mm
SB (semi-permanent) FW Panel (separable)
Blanket Module
Blanket System
• The Blanket System consists of Blanket Modules (BM) comprising two major components: a plasma facing First Wall (FW) panel and a Shield Block (SB).
50% 50%50% 40%10%
SB Attachment to VV
100%
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 5
Blanket System in NumbersNumber of Blanket Modules: 440Max allowable mass per module: 4.5 tonsTotal Mass: 1530 tons
First Wall Coverage: ~600 m2
Materials:- Armor:Beryllium- Heat Sink:CuCrZr- Steel Structure:
316L(N)-IG- Axial attachment (bolt/cartridge) Alloy 718- Pad
Al Bronze- Insulating layer
Alumina
Max total thermal load: 736 MW
Cooling water conditions: 4 MPa and 70°C
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 6
Impact of Interface Requirements on Blanket Design
• Interface requirements impose challenging demands on the blanket in particular since the blanket is in its pre-PA phase whereas several major interfacing components are already in procurement.
• Such demands include:- Accommodating plasma heat loads on FW- Maintaining acceptable load transfer to the vacuum vessel- Providing sufficient shielding to the vacuum vessel and TF coils- Accommodating the space allocations for in-vessel coils,
manifolds and plasma heating systems.
• These are highlighted in subsequent slides as part of the blanket design description.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 7
• The blanket is a major contributor to neutron shielding of the coils and vacuum vessel.
• e.g. to enhance shielding, blanket-related modifications were introduced following PDR: - a flat inboard profile - an addition of 4 cm to mid-plane radial thickness - a reduction of the vertical gaps between inboard SB’s from 14 to
10 mm. • This has resulted in lowering the integrated heating in the
coil to from 17 to 15.7 kW (as compared to a target of 14 kW)
Inboard Module Shape and Size Optimized for Neutron Shielding of VV and TF Coil
• An assessment indicates that this could still allow fusion power close to the design value of 500MW for a 1800s rep period without any adjustment of the cryo-plant operating conditions.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 8
I-shaped beam to accommodate poloidal torque
Design of First Wall Panel Impacted by Accommodation of Plasma Interface Requirements
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 9
Plasma
RH accessExaggerated shaping
- Allow good access for RH
- Shadow leading edges
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.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 10
Plasma Loads to the First wall- Combination of steady-state and off-normal loads- Design based on steady-state loads and maximum armor thickness- Beryllium surface damage accepted during off-normal events- Learn from early operation before moving to higher power scenarios to minimize off-
normal events with major impact on FW armor lifetime
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 11
First Wall Panels: Design Heat Flux
• 218 Normal heat flux panels EU
• 222 Enhanced heat flux panels RF, CN
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 12
Normal Heat Flux (NHF) First Wall
CuCrZr AlloySS PipesBe tiles
SS Back Plate
Normal Heat Flux Semi-PrototypeNormal Heat Flux Finger:• q’’ = 2 MW/m2 • Steel Cooling Pipes• HIP’ing
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 13
Enhanced Heat Flux (EHF) First WallEnhanced Heat Flux Finger:• q’’ = 4.7 MW/m2 • Hypervapotron• Explosion bonding (SS/CuCrZr) + brazing (Be/CuCrZr)
Be tilesBimetallic structure
CuCrZr/SS 316L(N)-IG
Finger body (Steel 316L(N)-
IG)
Coolant channel lid (Steel 316L(N)-IG)
Hypervapotron (HVT)
Central weldingExternal welding
Brazing
Laser welding
Laser welding
EHF FW Semi-Prototype
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 14
Shield Block Design
260
280
300
320
340
360
380
0.7 0.75 0.8 0.85 0.9 0.95 1
Volume fraction of SS in blanket shield block
Inbo
ard
TF
coil
nucl
ear
heat
(#1
-#14
)W
/leg
New Mix, Water30%- 0.95g/ cc (fendl2.1)
NAR,Water16%- 0.9g/ cc(fen1)Water16%- 0.9g/ cc(fen2)
Water16%- 0.9g/ cc(fen2.1)
• Slits to reduce EM loads and minimize thermal expansion and bowing
• 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).
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 15
Shield Block Full-Scale Prototypes
KODA: SB08
CNDA: SB14 (example of some processes)
• Basic fabrication method from a single high-quality forged steel block and includes drilling of holes, welding of cover plates for water headers, and final machining of the interfaces.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 16
Shield Block Attachment• 4 flexible axial supports• Keys to take moments and forces• Electrical straps to conduct current to vacuum vessel
e.g. BM 4 Interfaces
MANIFOLD
FLEXIBLE CARTRIDGE
INTERMODULAR PADS
SHIELD BLOCK
FIRST WALL
ELECTRICAL STRAPS (SB & FW)
CENTERING PADS
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 17
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.
• Cartridge and bolt made of high strength Alloy-718• Designed for 800 kN preload to take up to 600 kN Category III load.
FSP for testing (NIKIET, RF)
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 18
Keys in Inboard and Outboard Modules to Accommodate Moments and Forces from EM Loads
• 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.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 19
Pads and Insulating Layer
• Pads moved to Shield Block to minimize impact on VV interfaces
• Electrical insulation of the pads through ceramic coating on their internal surfaces.
• Cylindrical pads for IMK; rectangular pads for stub keys• Insulating layer performance determined by R&D (8000 cycles at 1.5 MN and 1 run at 2
MN))
Scheme of Testing
Test Samples: Al-bronze, plasma sprayed Al2O3
Inter-Modular Key pads on Inboard
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 20
Shield Block and Attachment Designed to Respect Pre-Defined Load from Vacuum Vessel Load Specifications
• Optimizing blanket design (radial thickness and slitting) to reduce EM loads based on the following analysis:- DINA analysis of disruptions and VDEs- Eddy and halo analysis to obtain superposition of wave forms- Dynamic analysis of BM structural response using ANSYS (NIKIET)
• For example, results for BM 1 (one of the most loaded modules) show that the loads on the keys are within the VV LS for Cat. II and Cat. III cases
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 21
Interface with Blanket Manifold and In-Vessel Coils• A multi-pipe manifold configuration has been chosen, with
each pipe feeding one or two BM’s - Higher reliability due to minimization of welds and utilization of seamless pipes.
- Superior leak localization capability due to larger segregation of cooling circuits.
- Elimination of drain lines.
• In-Vessel coils: three sets of ELM control coils per outboard sector to control ELMs by applying an asymmetric resonant magnetic perturbation to the plasma surface and 2 sets of vertical stability (VS) coils for plasma stabilization.
• BMs to be designed with cut-outs to accommodate these space reservations.
Multi-pipe Manifold Configuration
Example outboard SB 12 with manifold and ELM coil
cut-outs
ELM coils
VS coils
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 22
Interface with Neutral Beam System
• The NB region with the neutron bean injection ports create a particular geometry challenge for the blanket design
• Special modules have been developed to accommodate this as well as the other design constraints
• The NB shine-through also needs to be accommodated by the impacted Blanket Modules
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 23
FW 16 to Accommodate Neutral Beam Shine-Through
• Detailed Model done following EHF FW guidelines (central-slot insert not shown here for simplicity).
• Special shaping to accommodate shine-though beam and protect slot.
• Analysis assessment performed to verify stress compliance with SDC-IC (ITER structural design criteria) for both M-type (monotonic) and C-type (cyclic) damage.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 24
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 part of the R&D effort is the 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).- Qualification tests include: He leak test, pressure test, FW heat flux test
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 25
Procurement Schedule
Component SMP PA Start/End Date*
Blanket First WallRFDACNDAEUDA
Nov-2013 / Dec-2020Sept-2014 / July-2020Dec-2014 / Feb-2021
Blanket Shield BlockCNDAKODA
Nov-2013 / Feb-2021Nov-2013 / Oct-2020
Blanket Module ConnectorsRFDA July-2014 / Jan-2020
- FDR: April 2013 (successfully held)- FDR Approval: July 2013 (ahead of schedule)
*End date = delivery of last component to ITER site
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 26
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, PDR and FDR have confirmed the correctness of this re-design.
• Effort now focused on finalizing the design work based on input received at the FDR and to prepare for procurement starting at the end of 2013.
• Parallel R&D program and DA pre-qualification process by the manufacturing and testing of full-scale or semi-prototypes.
ISFNT-11, Barcelona, Spain, September 16-20, 2013 © 2013, ITER Organization
Slide 27
Latest Blanket Major Milestone
Blanket FDR successfully held in April 2013