DEMO FUSION CORE ENGINEERING: Blanket Integration and Maintenance
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1 DEMO FUSION CORE ENGINEERING: Blanket Integration and Maintenance 1.) Overview on European Blanket Concepts and Integration principles 2.) Large Module Integration 3.) Multi Module Segment (MMS) Integration 4.) New MMS Blanket options presented by Thomas Ihli Contributions from: Christina Koehly, Joerg Rey, Daniel Nagy, Carolina Polixa, Zhanjie Xu et al. US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 1
2 DEMO in vessel components He cooled hot components Blanket Shield Manifolds DEMO = Fusion Reactor PLANT: Demonstration of all technologies (breeder blankets, He-cooled divertor..), High Availability! Divertor US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 2
3 HCPB Blanket Design for DEMO (FZK 2003) Strong against pressurization 2 m Orthogonal stiffening grid All manifolds behind the breeding zone Breeder Units 210 mm x 210 mm Li 4 SiO 4 2 m Helium 80 bars, ( C) Sructure: Eurofer Be US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 3
4 Design of the HCLL Blanket for DEMO Cap FW He inlet/oulet He inlet/oulet PbLi loop Back Plate - Manifolds Grid Cooling Plates PbLi manifold US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 4
5 FZK Dual Coolant He T PbLi US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 5
6 Blanket Integration Schemes 1.) Segmented Blanket Maintenance 2.) Vertical Segment ( banana ) Separate Modules connected to the vacuum vessel (VV) by flexible attachment The hot manifold needs flexibility Vertical segments have to be connected to the VV by flexible attachment 3.) Sector Maintenance Currently not considered in Europe 4.) MMS Maintenance (Op.2.2) ( Best from 1. and 2. ) Separate Modules connected to a manifold/back plate outside the VV Permanent self-supporting shield and manifold connected by bolts US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 6
7 Alternative maintenance scheme: Vertical Segments Open Issues: Open Issues: - Flexible attachment system - Remote handling of the flexible attachment system - Thermal stress during transient events - Fabrication (Eurofer/Austenite) Outboard blanket segment 15.8 m EU DEMO 95 US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 7
8 Alternative maintenance scheme: Large Sectors Currently not considered for DEMO in Europe Possible issues: - Building size, layout, logistics, costs - Disassembly of large parts of permanent 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 connection between sector elements etc.) US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 8
9 Integration of a modular He-cooled Blanket (FZK) He cooled pebble bed blanket (HCPB) C Low temperature shield Flexible He pipes MODULAR BLANKET Water cooled vacuum vessel DIVERTOR CASSETTES FZK FZK He cooled divertor: C US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 9
10 Transporter concept for a Fusion Power Plant Upper Port: 4 ports for RH of the 54 Blanket Cassettes Equatorial port: 4 ports for the RH of the equatorial IB and OB Blanket modules Lower port: 4 ports for the 54 Divertor Cassettes 20 Sector 8m plasma major radius, 1500 MW el US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 10
11 FUSION 500 C permanent components: shield + polodial pipes outlet Large Module Concept Cut-/ rewelding zone HCPB Shield key RH tool Shield Pipes 300 inlet ~350 modules ~700 pipes, Ø 200 mm In-bore cutting, welding, inspection C US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 11
12 3300 MW fusion power He production rates in steel (appm/fpy( appm/fpy) Reweldability limit: 1 appm He 20 fpy: 0.05 appm 40 fpy: appm Reweldability results: + sufficient for vacuum vessel + sufficient for LTS-MMS NEW effort for large module concept necessary turn US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 12
13 New effort to remove neutron streaming issue in large pipes A = m 2 FZK Hot Shield around bend Shield plate in bend inlet outlet D = mm US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 13
14 He production rates in steel (appm/fpy) 3300 MW fusion power Reweldability limit: 1 appm He 20 fpy: 0.05 appm 40 fpy: appm US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 14
15 3-D TIG in-bore welding tool TIG torch US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 15
16 What is the possible path bending radius for in-bore tools? 1.2 m r 1.5 x D internal D internal Further research for 3D welding torch necessary! US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 16
17 in-bore modules shield key bend blanket rotating in-bore welding head US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 17
18 Modular axial and lateral wave movements 1.5 mm lateral translation D internal =150 mm, P Op =8 MPa Telescope pipes 10 plies x 0.7mm 2 mm axial translation US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 18
19 Large modules: Remote handling US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 19
20 FUSION Remote Handling of Large Modules Precise operation in three axes required Æ Size of the RH machine strongly depends on the weight of the modules US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 20
21 FUSION System operation: element exchange Lower sections of the ports are used Step 1: Manipulator gives the blanket to the port transporter Port transporter with tilting plate Step 2: Port transporter takes the element out US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 21
22 FZK Integration concepts under investigation Large modules Multi Module Segments (MMS) HCPB blanket LTS He pipes VV Each MMS consists of an assembled array of blanket modules and the coolant manifolds FZK FZK US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 22
23 Multi-Module Module-Segment (MMS): new maintenance approach maintenance time Forces on flex. attachment due to electromagnetic loads Separate modules Vertical segments - + Multi Module Modules (MMS) Reasonable blanket module size for fabrication procedure Reduced thermal stresses by segmentation Quality Assurance US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 23
24 Option 1.1: Blanket Chain Option 1.2: LTS-Backplate + hot pipes MMS Options Option 2.1: Hot Backplate + LTS Option 2.2: Supporting Hot Ring Shield MMS cold cold hot US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 24
25 Fusion Core Concept MULTI MODULE SEGMENTS with flexible connection between blanket modules and manifold Rigid connection Self-supporting Hot Ring Shield with linear bearings at bottom side Remote handling with Vertical Insertion and rail-based transport machine US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 25
26 MMS concept (2.2) Selfsupporting hot ring structure detachable mechanical connection VV temperature: ~150 C Manifold temperature: ~330 C Shield temperature: ~330 C Concentric connection Ring Ring structure to to be be operated fairly fairly steady-state intermediate temperature near near the the helium helium inlet inlet temperature Linear bearing FZK Blanket temperature C US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 26
27 Hot ring system US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 27
28 IB element Segmentation: insertion constraint 11.25deg 18deg 11.25deg 20deg 22,5deg 18deg 20deg 22,5deg 18 degree IB MMS most reasonable US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 28
29 MMS / PORT configuration RH OB MMS 6 x 7.5 Vertical port OB MMS 28 x IB MMS 20 x 18 Helium Pipes Pipes can can be be routed routed through the the vertical ports ports He pipes (inner (inner pipe pipe diameter ~ mm) mm) Two Two four four remote handling ports ports RH US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 29
30 MMS SEGMENTATION OB MMS deg IB MMS 18 deg 16 coils: 22.5 deg segments In-Board MMS 18 deg (14x2) Out-Board MMS deg at RH port: 7.5 deg, 2X3 OB MMS 20 elements 34 elements 54 elements US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 30
31 M M r FUSION Torques from EM loads depend on module shape p f f ( s ) V w ( h ) V w 2 2 s w 2 s + w 2 2 h w 2 h + w Optimization for low poloidal torque. 2 2 V = volume of the module, f = shape factor M p small for elongated shape M p large for square shape Forces on flexible attachement are critical! w s h t p r CIEMAT 1.) Small size (w * h) 2.) Elongated shape and long lever against M p larger width than height is favorable US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 31
32 Forces (rel.) FUSION Forces at attachment due to Electromagnetic Forces A = 4 m 2 Vertical module > 1/4 1/2 1/1 2/1 Which module shape? 4/1 b a c t p TOROIDAL direction of modules for low forces on Flexibles! r 0.2 Force at shear keys (from rad. Torque) 0 Force at attachment (from pol. Torque) Ratio height/width US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 32
33 Forces MN FUSION Force flex A=4 m2 Force flex A=2 m2 Force flex A=3 m2 Force flex A=5 m2 Force flex A=8 m2 Forces at flexible attachment due to Electromagnetic Forces Assumption for module 1m high x 2 m wide: M rad = 2.5 MNm M pol = 1.5 MNm Smallest diameter of the attachment > 13 cm > 40 cm smaller Blanket sub- sub-modules to to be beconnected to to the the MMS MMS low lowforces forceson on flexibles b a c t p r Ratio height/width US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 33
34 MMS Blanket sub-modules IB OB Sub-module size: ~ 2 m wide, ~ 1 m high ~ 2 m 2 front surface US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 34
35 DEMO Reactor with MMS Blanket US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 35
36 Remote handling Concept MMS Crane-like MMS insertion machine Vertical insertion ports (2 4) Insertion by simple crane-like insertion machine Toroidal transport by divertor rail based transport machine Linear positioning system: MMS is moved towards the shield by use of slides on the transport machine MMS transport machine US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 36
37 Insertion & Transport position of IB MMS The 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 US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 37
38 IB Transport position Guidance (rolls on the wall) Gripping Weight support US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 38
39 IB MMS positioning US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 39
40 OB Transport position US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 40
41 OB MMS final positioning Path~1.7m US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 41
42 Below remote handling ports: last OB MMS element will be connected to the surrounding permanent shield structure from backside Segmentation at RH ports: Likely 3 OB MMS per 22.5 segment US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 42
43 Pipe compensation for upper port assembly version 2.2 1) Total elongation: 1) Vertical about 50mm 2) Radial about 30mm : 2) New strategy: 1.) Hydraulic connection in ports 2.) Compensation outside VV US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 43
44 MMS hydraulic connection pipes are routed through the vertical ports: US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 44
45 Possible approach for new MMS HCPB module shape: US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 45
46 NEW alternative breeder unit design Flexible for low stress during thermal expansion Strong for vibration during filling Uniform temperatures in cooling plate cross section low thermal stress reduced risk with plate bulging reduced risk with plate deflection One flow direction within and for all cooling plates reduced pressure drop reduced risk with leak between neighbouring cooling channels Optimization in terms of plate distance, enrichment etc. US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 46
47 FZK approach for new DCLL (MMS, hot backplate + LTS) US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 47
48 Approach for new MMS DCLL: Flow routing US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 48
49 Approach for new MMS DCLL: SiC/SiC Box US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 49
50 Approach for new MMS DCLL: FC Inserts US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 50
51 SUMMARY, Conclusions Integration schemes 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 Blanket concepts Remote handling with vertical insertion + transport machine involves 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. US/Japan Workshop on Power Plant Studies `06 Thomas Ihli slide # 51
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