FIRE Vacuum Vessel and Remote Handling Overview B. Nelson, T. Burgess, T. Brown, D. Driemeyer, H-M Fan, K. Freudenberg, G. Jones, C. Kessel, P. Ryan, M. Sawan, M. Ulrickson, D. Strickler, D. Williamson FIRE Physics Validation Review March 31, 2004 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling
Presentation Outline · Vacuum Vessel - Design requirements Design concept and features Analysis to date Status and summary · Remote Handling - Maintenance Approach & Component Classification In-Vessel Transporter Component Replacement Time Estimates Balance of RH Equipment · Design and analysis are consistent with pre-conceptual phase, but demonstrate basic feasibility of concepts 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 2
FIRE vacuum vessel 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 3
Vacuum vessel functions · Plasma vacuum environment · Primary tritium confinement boundary · Support for in-vessel components · Radiation shielding · Aid in plasma stabilization - conducting shell - internal control coils · Maximum access for heating/diagnostics 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 4
Vacuum vessel parameters · Configuration: - · Shielding Volume of torus interior Surface Area of torus interior Facesheet thickness Rib thickness Weight of structure, incl ports Weight of torus shielding Coolant - Normal Operation - Bake-out · Double wall torus water + steel with 60% packing factor 53 m^3 112 m^2 15 mm 15 - 30 mm 65 tonnes 100 tonnes Water, < 100 C, < 1 Mpa Water ~150 C, < 1 Mpa Materials - Torus, ports and structure - Shielding 31 March 2004 316 LN ss 304 L ss (tentative) FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 5
Vessel port configuration 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 6
Vessel ports and major components Cryopump Divertor 31 March 2004 Divertor piping Midplane port w/plug FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 7
Nuclear shielding concept · · Vessel shielding, port plugs and TF coils provide hands-on access to port flanges Port plugs weigh ~7 tonnes each as shown, assuming 60% steel out to TF boundary 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 8
Active and passive stabilizing sys. · passive plates ~25 mm thick copper with integral cooling Active control coils, segmented into octants 31 March 2004 IB and OB passive stabilizing conductor FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 9
Passive conductor is also heat sink VV splice plate · VV Passive plates are required in most locations anyway · Cu Passive stabilizer Copper layer required to prevent large temperature gradients in VV due to nuclear heating, PFCs · Cu filler (can be removed to allow space for mag. diag. ) PFCs are conduction cooled to copper layer PFC Tile Gasket 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling - Reduces gradient in stainless skin - Extends pulse length 10
FIRE and ITER first wall concepts similar • BE, Cu, SSt ITER • Detachable FW panel • Cooling integral with FW panel (requires coolant connections to FW) • BE, Cu, SSt FIRE • Detachable FW tiles • Cooling integral with Cu bonded to VV 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 11
VV octant subassy w/passive structure Outboard passive conductor Inboard passive cond. Vessel octant prior to welding outer skin between ribs 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 12
Vessel octant subassembly fab. (2) · · Octant-to-octant splice joint requires double wall weld All welding done from plasma side of vessel Splice plates used on plasma side only to take up tolerance and provide clearance Plasma side splice plate wide enough to accommodate welding the coil side joint 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 13
Vessel analysis · Vessel subjected to numerous loading conditions - Normal operation (gravity, coolant pressure, thermal loads, etc. ) - Disruption (including induced and conductive (halo) loads - Other loads (TF current ramp, seismic, etc. ) · Preliminary FEA analysis performed - Linear, static stress analysis - Linear, transient and static thermal analyses · Main issues are disruption loads, thermal stresses 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 14
Vacuum vessel mechanical loads 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 15
Disruption effects on VV · Disruptions will cause high loads on the VV due to induced currents and conducting (halo) currents flowing in structures - · Direct loads on vessel shell and ribs Direct loads on passive plates Reaction loads at supports for internal components Divertor assemblies and piping FW tiles Port plugs / in-port components (e. g. RF antennas) Dynamic effects should be considered, including: - Transient load application - Shock loads due to gaps in load paths (gaps must be avoided) · All loads should be considered in appropriate combinations e. g. Gravity + coolant pressure + VDE + nuclear / PFC heating + Seismic + … 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 16
TSC runs confirm induced currents will concentrate in passive structures · Several TSC disruption simulations prepared by C. Kessel · VDE simulation used as basis for further analysis 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 17
VDE analysis based on TSC runs · TSC output used to create drivers for Eddycuff model of VV · Peak loads applied to ANSYS model of VV · Halo loads from TSC mapped directly onto VV model Inner Face Sheet Outer Face Sheet Copper Plates EDDYCUFF EM Model 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling ANSYS Structural Model 18
Plasma Evolution (TSC), from earlier data I (A) 10 -ms 301 -ms TSC Filaments 301. 6 -ms 31 March 2004 302. 6 -ms FIRE Physics Validation Review: Vacuum Vessel and Remote Handling Reduced Filament Model (EDDYCUFF) 19
Typical Induced Eddy Currents Proportional Current Vectors 31 March 2004 Constant Current Vectors FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 20
Current vs Time, Slow VDE (1 MA/ms) 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 21
Typical EM loads due to Induced Current • Max force = -1 MN radial, +0. 7 MN vertical per 1/16 sector (~11 MN tot) 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 22
Total Force vs time, induced + halo currents • 1 MA/ms VDE FZ F(lbs) FR Case 2 Case 1 t(s) 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 23
Typ. EM Force distr. due to Halo Current • Mapped directly from TSC to ANSYS, Halo current = 12 -25% Ip • Max force = +0. 13 MN radial, +1. 2 MN vert. per 1/16 sector 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 24
Divertor loads from current loop · Loads based on PC-Opera analysis *ref Driemeyer, Ulrickson Lug 1 Reaction Fx=35121 Fy=40107 Fz=6987 Pin 1 Reaction Fx=12662 Fz=10708 Pin 2 Reaction Fx=-22147 Fz=6614 Y Z Lug 2 Reaction Fx=-32540 Fy=-36384 Fz=-6473 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling X Forces are in pounds 25
Combined stress, with VDE · · Stresses due to gravity, coolant pressure, vacuum, VDE load includes direct EM loads on vessel (induced current and halo) and non-halo divertor loads Stress is in psi 1. 5 Sm = 28 ksi (195 Mpa) Stress is in psi VV Torus Ports 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 26
Divertor attachment local stresses · · Global model not adequate for analysis Detailed model indicates adequate design Extended pins through the ribs and attached them to the outer shell Reinforced pins near connection points Increased hole Diameter to 0. 7” 31 March 2004 Modified rib thickness to correct values 1. 5 Sm = 28 ksi (195 Mpa) Stress is in psi FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 27
Nuclear heating and thermal effects · Vacuum vessel is subject to two basic heat loads: - Direct nuclear heating from neutrons and gammas - Heating by conduction from first wall tiles (which in turn are heated by direct nuclear heating and surface heat flux) · A range of operating scenarios is possible, but the baseline cases for analysis assume: - 150 MW fusion power - 100 W/cm^2 surface heat load assumed on first wall, · 45 W/cm^2 is current baseline (H-mode) · > 45 W/cm^2 for AT modes - pulse length of 20 seconds (H-mode - 10 T, 7. 7 MA) - Pulse length of 40 -ish seconds (AT mode - 6. 5 T, 5 MA) · Vessel is cooled by water - Flowing in copper first wall cladding - Flowing between walls of double wall structure 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 28
Heat loads on vessel and FEA model · · Fusion power of 150 MW Surface heat flux is variable, 0, 50, 100, and 150 W/cm 2 analyzed D C B A Double wall Vac Vessel 31 March 2004 Cu cladding Tile, (36 mm) FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 29
377 C 40 s pulse 383 C 20 s pulse 2 -D temp distr (100 W/cm 2 surface flux) Be limit ~ 600 C 619 C 622 C Inboard midplane 31 March 2004 Outboard midplane FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 30
Peak Be temp vs heat flux, pulse length Be limit 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 31
Nuclear heating distribution* Neutron wall loading Volumetric heating: plasma side, ss coil side, ss divertor * Ref 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling M. Sawan 32
Typical 3 -D temp distribution in VV 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 33
VV thermal deformation and stress Peak Typical Deformation 31 March 2004 Stress is in psi High stress region localized Stress < 3 x. Sm ( 56 ksi) FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 34
Combined stresses, 40 s pulse · Nuclear heating, gravity, coolant pressure, vacuum Stress is in psi Max Stress = 23 ksi, < 3 Sm (56 ksi) 31 March 2004 Max Deflection = 0. 041 in. FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 35
Combined stress, 10 T, 7. 7 MA, 20 s pulse, with VDE is worst loading condition · Nuclear heating, gravity, coolant pressure, vacuum, slow VDE Stress is in psi 3 x. Sm Max Stress = 58 ksi, > 3 Sm (56 ksi), but very localized 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 36
Combined stress, 6. 5 T, 5 MA, 40 s pulse, with VDE – not as severe as high field case · Nuclear heating, gravity, coolant pressure, vacuum, slow VDE Stress is in psi Max Stress = 46 ksi, < 3 Sm (56 ksi), also very localized 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 37
Preliminary VV stress summary (1) Normal, High field (10 T, 7. 7 MA), 20 s pulse operation – O. K. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 38
Preliminary VV stress summary (2) High field (10 T, 7. 7 MA), 20 s pulse with VDE – a little high 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 39
Preliminary VV stress summary (3) Normal, Low field (6. 5 T, 5 MA), 40 s pulse operation – O. K. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 40
Preliminary VV stress summary (4) Low field (6. 5 T, 5 MA), 40 s pulse with VDE – O. K. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 41
Conclusions of vessel analysis · Can vessel achieve normal operation? YES · Can vessel achieve pulse length? YES - 20 second pulse appears achievable - 40 second pulse should be achievable but depends on surface heat flux distribution and Be temperature · Can vessel take disruption loads? ITS CLOSE - Some local stresses over limit, but local reinforcement is possible - Additional load cases must be run 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 42
What analysis tasks are next? · · · Optimized geometry and refined FEA models Dynamic analysis with temporal distribution of VDE loads Fatigue analysis, including plastic effects Seismic analysis Plastic analysis Limit analysis 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 43
Longer term issues for FIRE · Refine design - Develop design of generic port plug Optimize divertor attachments for stress, remote handling Design internal plumbing and shielding Re-design / optimize gravity supports · Perform needed R&D - Select/verify method for bonding of copper cladding to vessel skin - Select/verify method for routing of cooling passages into and out of cladding - Develop fabrication technique for in-wall active control coils - Perform thermal and structural tests of prototype vessel wall, with cladding, tubes, tiles, etc. (need test facility) - Verify assembly welding of octants and tooling for remote disassembly/reassembly (need test facility) 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 44
Remote Handling Overview 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 45
Remote Handling* · Maintenance Approach & Component Classification · In-Vessel Transporter · Component Replacement Time Estimates · Balance of RH Equipment *ref T. Burgess 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 46
Remote Maintenance Approach · Hands-on maintenance employed to the fullest extent possible. Activation levels outside vacuum vessel are low enough to permit hands-on maintenance. · In-vessel components removed as integral assemblies and transferred to the hot cell for repair or processing as waste. · In-vessel contamination contained by sealed transfer casks that dock to the VV ports. · Midplane ports provide access to divertor, FW and limiter modules. Port mounted systems (heating and diagnostics) are housed in a shielded assembly that is removed at the port interface. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 47
Remote Maintenance Approach (2) · Upper and lower auxiliary ports house diagnostic and cryopump assemblies that are also removable at the port interface. · Remote operations begin with disassembly of port assembly closure plate. · During extended in-vessel operations (e. g. , divertor changeout), a shielded enclosure is installed at the open midplane port to allow human access to the ex-vessel region. · Remote maintenance drives in-vessel component design and interfaces. Components are given a classification and preliminary requirements are being accommodated in the layout of facilities and the site. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 48
Remote Handling, Classification of Components Class 1 Divertor Modules Limiter Modules Midplane Port Assemblies - RF heating - diagnostics Class 2 First Wall Modules Upper and Lower Horiz. Auxiliary Port Assemblies - cryopumps - diagnostics Class 3 Vacuum Vessel Sector with TF Coil Passive Plates In-Vessel Cooling Pipes - divertor pipes - limiter pipes Class 4* Toroidal Field Coil Poloidal Field Coil Central Solenoid Magnet Structure * Activation levels acceptable for hands-on maintenance 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 49
In-Vessel Remote Handling Transporter Cantilevered Articulated Boom (± 45° coverage) · Complete in-vessel coverage from 4 midplane ports. · Local repair from any midplane port. · Handles divertor, FW modules, limiter (with component specific endeffector). · Transfer cask docks and seals to VV port and hot cell interfaces to prevent spread of contamination. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 50
Port plug designed for RH · Plug uses ITER-style connection to vessel, accommodates transfer cask VV to Cryostat seal VV port flange Connecting plate Cryostat panel Midplane port plug 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 51
In-Vessel Remote Handling (2) Divertor and baffle handled as one unit 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 52
Divertor Handling End-Effector · · Six (6) positioning degrees of freedom provided by boom (2 DOF) and end-effector (4 DOF) Module weight = 800 kg Transport position 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling Installation position 53
Component Maintenance Frequency and Time Estimates Component or Operation RH Class Expected Frequency Divertor Modules One module: 3. 3 weeks Limiter Modules Midplane Port Assemblies 1 In-vessel Inspection TBD replacements >2 Frequent deployment Bank (5? ) modules: 3. 5 weeks One module: 3. 3 weeks** 2 TBD replacements ≤ 2 Auxiliary Port Assemblies † All (#TBD) modules: TBD 12 month time target Vacuum Vessel Sector with TF Coil Passive Plates All (32) modules: 5. 9 months One module: 3. 3 weeks FW Modules Combined FW and Divertor Modules Maintenance Time Estimate* 3 Replacement not expected In-Vessel Cooling Pipes TBD, replacement must be possible and would require extended shutdown * Includes active remote maintenance time only. Actual machine shutdown period will be longer by ~ > 1 month. ** Based on single divertor module replacement time estimate. † Based on midplane port replacement time estimate. 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 54
Remote Handling Equipment Summary · In-Vessel Component Handling System - In-vessel transporter (boom), viewing system and end-effectors (3) for: divertor module, first wall / limiter module and general purpose manipulator · In-Vessel Inspection System - Vacuum compatible metrology and viewing system probes for inspecting PFC alignment, and erosion or general viewing of condition - One of each probe type (metrology and viewing) initially procured · Port-Mounted Component Handling Systems - Port assembly transporters (2) with viewing system and dexterous manipulator for handling port attachment and vacuum lip-seal tools - Includes midplane and auxiliary port handling systems 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 55
Remote Handling Equipment Summary (2) · Component & Equipment Containment and Transfer Devices - Cask containment enclosures (3) for IVT, midplane and auxiliary port - Double seal doors in casks with docking interfaces at ports and hot cell interfaces - Cask transport (overhead crane or air cushion vehicles TBD) and support systems - Portable shielded enclosure (1) for midplane port extended opening · Remote Tooling - Laser based cutting, welding and inspection (leak detection) tools for: · vacuum lip-seal at vessel port assemblies (2 sets) · divertor and limiter coolant pipes (2 sets) - Fastener torquing and runner tools (2 sets) · Fire Site Mock-Up - Prototype remote handling systems used for developing designs are ultimately used at FIRE site to test equipment modifications, procedures and train operators - Consists of prototypes of all major remote handling systems and component mockups (provided by component design WBS) 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 56
Some generic issues for ITER/FIRE · Develop ASME code for Fusion (Section III, Division 4) to avoid force fitting designs to Section III · Develop remote, in-vessel inspection systems - leak detection - metrology - Detection of incipient failure modes, like cracks · Create a qualification / test facility for in-vessel and in-port components to quantify and improve RAM - Thermal environment Vacuum environment Mechanical loading, shock, fatigue Remote handling capability 31 March 2004 FIRE Physics Validation Review: Vacuum Vessel and Remote Handling 57
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