ITER-D-3G3SQN v1.1 1 THERMAL & MECHANICAL PRELIMINARY ANALYSIS ELM COIL ALTERNATE DESIGN Interim...

ITER-D-3G3SQN v1.1

1

THERMAL & MECHANICAL PRELIMINARY THERMAL & MECHANICAL PRELIMINARY ANALYSIS ANALYSIS

ELM COIL ALTERNATE DESIGNELM COIL ALTERNATE DESIGN Interim ReviewInterim Review

July 26-28, 2010July 26-28, 2010

In-Vessel Coil System Interim Review – July 26-28, 2010

ITER-D-3G3SQN v1.1 2

OutlineOutline

• BOUNDARY CONDITIONS

• NUCLEAR & RESTISTIVE HEAT GENERATION• LORENTZ & PRESSURE LOADS• RADIATION ; CONDUCTION ; COOLING WATER @ 6 m/sec• MAGNESIUM OXIDE to COIL & JACKETS

• STEADY STATE SANDWICH STRESS RESULTS :

– THERMAL + PRESSURE LOAD RESULTS– THERMAL + PRESSURE + LORENTZ LOAD RESULTS

• DESIGN IMPROVEMENT STRATEGIES

– THERMAL + PRESSURE LOAD RESULTS– THERMAL + PRESSURE + LORENTZ LOAD RESULTS– SUB MODELING ; CORRECTION STRATEGY

• CONCLUSIONS / PLAN:

In-Vessel Coil System Interim Review – July 26-28, 2010

ITER-D-3G3SQN v1.1

Nuclear Heat Operating Modes

ITER-D-3G3SQN v1.1

NUCLEAR HEAT GENERATIONNUCLEAR HEAT GENERATION(W/M^3)(W/M^3)

IVC Interim Design Review – 26-28 July 20104

0.264 m

The Toroidal Leg Nuclear Heat is Applied Based on a Curve fit of data fromUniversity of Wisconsin Team

The Poloidal Leg Applies a Similar Shaped Function

ITER-D-3G3SQN v1.1

IDEALIZED LOAD IDEALIZED LOAD DIAGRAMSDIAGRAMS

Thermal + Pressure Loading

Thermal + Pressure + Lorentz LoadingLo

ad

Time

Time

Load

5 hz

3,000 sec 9,000 sec

30,000 Pulses Unknown Spectrum

STEADY STATE TRANSIENT

ITER-D-3G3SQN v1.1

ELM LORENTZ LOAD VS POSITIONELM LORENTZ LOAD VS POSITION

SECTOR #5 UNIT LOADS ARE MORE CRITICAL IN THE LOWER LEFT QUADRANT

(LFT)

(BOT)(R

HT)

(TRC)

(BLC)

Critical Quadrant

SECTOR 5 FE MODEL LOADS in GLOBAL COORDINATES

Fx Fy Fz

ELM_MD_BOT 132,271 -31,397 -32,429

ELM_MD_BLC 130,406 -8,635 -41,265

ELM_MD_LFT 300,308 -10,272 7,491

ITER-D-3G3SQN v1.1

SANDWICH DESIGNSANDWICH DESIGNSection ViewSection View


Axial Translation Is Allowed

No Hard Mechanical Attachment for tension On the MGO

DESIGN CONCEPT ALLOWS THERMAL DISPLACEMENTWITH SUPPORTS TO REACT LORENTZ LOAD

ITER-D-3G3SQN v1.1

ELEMENT MESHELEMENT MESH

UNIFORM HEXAHEDRAL MESH

Rigid BoundaryRigid Boundary

Flexible Mounts To Facilitate Thermal Growth

Symmetric Boundary

Symmetric Boundary

STEADY STATE TEMPERATURE ANALYSIS

FULL OPERATING CONDITIONS

Resistive Heat Generation

Nuclear Heat Generation

Cooling Water Applied

ITER-D-3G3SQN v1.1

THERMAL BOUNDARY CONDITIONSTHERMAL BOUNDARY CONDITIONS

The Copper Coil Temperature Distribution is an Equilibrium of all Combined Effects

Conduction into Foundation at 100 Cat all foundation interfaces

Radiation Surfaces with View Factor =1 (dark blue surfaces)

Nuclear

HGEN

Temp in =105.7 CTemp out =131.5 C

Unspecified Surface Boundaries are conservatively assumed to be Adiabatic

ITER-D-3G3SQN v1.1

RADIATION ASSUMPTIONSRADIATION ASSUMPTIONS


All Form / View Factors equal to 1.0 Incident Radiation is very small from 100 C Far Field

Emissivity is a Hemispherical AverageAcross all wavelengths and directions

ITER-D-3G3SQN v1.1

Steady State TemperaturesSteady State Temperatures With Heat Generation ; 6 m/s Water Cooling With Heat Generation ; 6 m/s Water Cooling

RadiationRadiation

TEMPERATURES ARE REASONABLE and WITHIN OPERATING LIMITS OF MATERIALS

Max Temp = 476 C on Bracket

ITER-D-3G3SQN v1.1

Max Temperatures ( 472 C ) are within the limits of Stainless SteelWith Cooling Water


RadiationRadiation

Stainless Steel Jackets

ITER-D-3G3SQN v1.1

The Coil Temperatures are Consistent with Hand Calculations and the Net Energy Balance of all Applied Thermal Loads


RadiationRadiation

Applied Boundary is: Temp in =105.7 CTemp out = 127.2 C

ITER-D-3G3SQN v1.1

Steady State Steady State FaultFault Condition Conditionwith Radiation Coolingwith Radiation Cooling

Fault Condition (No Water Cool or Resistive Heating) with Far Field RadiationResults in Temperatures that are within Material Capacity (316 SS Melt at 1375 C)

Max Temperature Predicted on Surfaces that Exclude Radiation

ITER-D-3G3SQN v1.1

Steady State Steady State Fault Fault ConditionConditionwith Radiation Coolingwith Radiation Cooling

Fault Condition (No Water Cool or Resistive Heating) with Far Field RadiationResults in Temperatures that are within Material Capacity (CuCrZr Melt at 1,078 C)

Conservative Max Copper Temperature= 918 CMelting 1,078 C

ITER-D-3G3SQN v1.1

STEADY STATE STRESS ANALYSIS

THERMAL & DISRUPTION LOADS

ITER-D-3G3SQN v1.1 IVC Interim Design Review – 26-28 July 201019

Steady State Steady State Pressure + Thermal + Lorentz LoadPressure + Thermal + Lorentz Load

Support Reaction Loads Support Reaction Loads

RSYS 12 (Newtons) FX FY FZ14038. -0.16031E+06 -19,761.

.

RSYS 14 (Newtons) FX FY FZ-36461. -0.11263E+06 13456

+Z

+Y

+Z

+Y

Typical Bracket Reaction Loads: FY =36,036 lbs is away from the Reactor on the Toroidal Bracket

FY = 25,178 lbs is away from the Reactor on the Poloidal Bracket

Toroidal

Poloidal

ITER-D-3G3SQN v1.1

Steady State Steady State Pressure + Thermal + Lorentz LoadPressure + Thermal + Lorentz Load

Displacements Displacements

The Displacements are Reasonable for the Specified Boundary ConditionsLorentz Loads Acting Down Toward The Reactor

+Y

+Y0.0066 m = 0.259 in

Note: Local Y displacement is approximately a radial Global Load Coordinates

ITER-D-3G3SQN v1.1

Steady State Steady State Mechanical + Thermal Loads + LorentzMechanical + Thermal Loads + Lorentz

Max Principal StressMax Principal Stress

Stress shows:

1.) Bending across Restraints

2.) Exterior Jackets in Compression

3.) Interior Copper Coil in Tension

Restraint Location

Restraint Location

The Stresses are Excessive However they are ManageableWith the current Strategies in progress

0.19e8 = 2,755 psi

ITER-D-3G3SQN v1.1

Steady State Steady State Mechanical + Thermal LoadsMechanical + Thermal Loads

von Mises Stress von Mises Stress

The Max Copper Coil Stress of 6.5 ksi will be Reduced with Bridge Support The Max Copper Coil Stress of 6.5 ksi will be Reduced with Bridge Support

Copper Coil0.450 e8 Pa = 6,526 Psi


ITER-D-3G3SQN v1.1

Steady State Steady State Mechanical + Thermal Loads + LorentzMechanical + Thermal Loads + Lorentz

von Mises Stressvon Mises Stress

Copper Stresses Have Positive Limit Stress Margins and Low Fatigue MarginAdditional Section will be used to Redistribute These stresses

Copper Stresses Have Positive Limit Stress Margins and Low Fatigue MarginAdditional Section will be used to Redistribute These stresses

Max Copper Coil .184e9 Pa = 26,686 psi

20.11184

3.405

61.01184

297

FTU

FTY

M

M

ITER-D-3G3SQN v1.1

REVISED ANALYSISREVISED ANALYSISWith Bridge SupportWith Bridge Support



Updated - Steady State TemperaturesUpdated - Steady State Temperatures With Heat Generation ; 6 m/s Water Cooling With Heat Generation ; 6 m/s Water Cooling

RadiationRadiation

Revised Plan July 22, 2010 Inlet Temp 70 C Outlet Temp 120 C

Bridge Support to react outLorentz Loads

ITER-D-3G3SQN v1.1

Sub Modeling PlanSub Modeling Plan

Classical Cut Boundary Displacements applied from Global analysis

Stress to be evaluated forVariable Spring Stiffness and / or applied PreloadsSpringK

Sub Models will be used to test out various strategies in critical areas such as the corners or restraint locations to assure that the best design options are thoroughly investigated

Sub Models will be used to test out various strategies in critical areas such as the corners or restraint locations to assure that the best design options are thoroughly investigated

C0

eTemperatur

ITER-D-3G3SQN v1.1

Steady State Steady State Pressure + Thermal LoadsPressure + Thermal Loads

von Mises Stress von Mises Stress

Bridge Support can be used to Shape and Redistribute Stresses on the CoilAdditional Shaping and Stiffness Changes with Sections changes will be used to React out Stresses

Bridge Support can be used to Shape and Redistribute Stresses on the CoilAdditional Shaping and Stiffness Changes with Sections changes will be used to React out Stresses


ITER-D-3G3SQN v1.1

Steady State Steady State Pressure + Thermal + Lorentz Loads Pressure + Thermal + Lorentz Loads

Von Mises StressVon Mises Stress

50.01270

3.405

1.01270

297

FTU

FTY

M

M

Max Copper Coil= 0.18e8 Pa = 2,465 psi

Bridge Support can be used to Shape and Redistribute Stresses on the CoilAdditional Shaping, Stiffness Changes and Sections changes will be used to React out Stresses

Bridge Support can be used to Shape and Redistribute Stresses on the CoilAdditional Shaping, Stiffness Changes and Sections changes will be used to React out Stresses

ITER-D-3G3SQN v1.1

ConclusionsConclusions

• The Sandwich Design can be a viable option with the design changes and analysis options in progress.

• The MGO / Jacket Interface is critical to understand the load sharing between the components.

• This Design will survive Fault Operation without Water Cooling.

• An analysis methodology / plan is in place to resolve stress issues.



STRESS RESOLUTION TABLE

ITEM Reference Slides in Presentation Dated 7-26-10 STATUS

ISSUE RESOLUTION PRE or POST Column1

1.)Update on Thermal Boundary Conditions

M. Kalish / L. Bryant to Work this Issue PRE

IN PROGRESS

Using FCOOL Program

2.)Nuclear Heat Generation Functions are outdated

Update Curve Fits for Nuclear Heating from data PRE

IN PROGRESS

Provided last week

3.)Stress on Coil Corner too High Complete Sub-models to react load reduce stress PRE

IN PROGRESS

4.)Stress Adjacent to Brackets too high

Complete Sub-models to react load reduce stress PRE

5.) Design the Bolt & Clamp Interface Concept

Complte Hand Calculations & Recommend to Design POST

6.)Complete Transient Stress evaluation; PRE

IN PROGRESS

500 MW, 400 MW, 356 MW Power Levels

7.)Optimize Design Cooling Water Flow Rate

Run Multiple Temperature Data Sets POST

Evaluate Stresses and compare to erosion rates

ISSUE / RESOLUTIONISSUE / RESOLUTION

ITER-D-3G3SQN v1.1

ISSUE / RESOLUTIONISSUE / RESOLUTION


STRESS RESOLUTION TABLE

ITEM Reference Slides in Presentation Dated 7-26-10 STATUS

ISSUE RESOLUTION PRE or POST Column1

8.)Upade Mechanical Properties on MGO Completion of Mechanical Testing PRE

IN PROGRESS

9.)Determine Proper MGO Interface Boundary

Calibrate Parametric Model with Test data PRE

IN PROGRESS

Condition

10.)Complete Stress Pass on Fault Temperatures

Update Stress Model with Temperatures PRE

NO STARTED

With Radiation Cooling Run Fault Stress Pass on Restraints

ITER-D-3G3SQN v1.1 1 THERMAL & MECHANICAL PRELIMINARY ANALYSIS ELM COIL ALTERNATE DESIGN Interim...

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