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HCCB TBM Mechanical Design. Presented by Ryan Hunt. R. Hunt, A. Ying, M. Abdou Fusion Science & Technology Center University of California Los Angeles May 11, 2006. Overview. Allocated ½ Port Design Requirements Description of HCCB Subcomponents Overall He Flow Routing Scheme

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hccb tbm mechanical design

HCCB TBM Mechanical Design

Presented by Ryan Hunt

R. Hunt, A. Ying, M. Abdou

Fusion Science & Technology Center

University of California Los Angeles

May 11, 2006

  • Allocated ½ Port
  • Design Requirements
  • Description of HCCB Subcomponents
  • Overall He Flow Routing Scheme
  • Assembly Process
  • Manufacturing Requirements

Figure 1

UCLA Fusion Science & Technology Center

u s submodule within port
U.S. Submodule within ½ Port

Figure 2

UCLA Fusion Science & Technology Center

tbm design requirements
TBM Design Requirements
  • Overall size must fit within available space (51cm x 38.9cm x 71cm)
  • He must cool first wall to acceptable temperatures
  • He must cool breeding zones
  • All cooling plates & manifolds must satisfy stress criteria
  • Helium channels (for both FW and cooling channels) must be economically fabricable
  • Must house appropriate amounts of breeder and beryllium multiplier
  • Back wall must align with JA Submodules into common ½ port back wall manifold
  • Must ensure survival of structural box under accidental conditions (TBD)

UCLA Fusion Science & Technology Center

connection to port frame back shield



Connection to Port Frame Back Shield
  • Opening Space of 1248 x 750mm is available (minus 20mm between TBM and frame on each side for TBM grasping)
  • 3 Large Pipe Openings, 1 medium (instrumentation), 7 small openings
  • Piping must also avoid allotted space for structural attachment keys
  • Optimization of pipe connections and communication with IT and JA

Figure 3: Front view of port frame back shield

Figure 4: Back view of half-port TBM

UCLA Fusion Science & Technology Center

common back wall manifold assembly
Serves to collect and combine pipes from each Submodule

Collaboration with JA for acceptable design/solution

System of internal manifolds

Keys will be too long if pipes are combined behind manifold (problems with torque)

Accepts from each Submodule:

3 He coolant lines (inlet, outlet, & bypass)

2 Gas Purge Lines

1 to 2 instrumentation conduits

( = 6 to 7 lines total from each Submodule)


3 Large Penetrations allocated to 3 main helium coolant lines

7 small penetrations

3 of 7 for purge gas outlet lines (one for each Submodule) for tritium concentration measurement

3 of 7 for purge gas inlet lines to accommodate different gas compositions for tritium

(1 small penetration and 1 medium remaining for instrumentation)

Common Back Wall Manifold Assembly

Figure 5

UCLA Fusion Science & Technology Center

overview of hccb sub components
Overview of HCCB Sub-components
  • First Wall Panel
  • Breeder & He Channels
  • Internal Cooling Manifolds
  • Beryllium Zones
  • Top & Bottom Walls
  • Back Plates and FW He manifolds for inlet & outlet

Figure 6

UCLA Fusion Science & Technology Center

flow diagram summary
Flow DiagramSummary

UCLA Fusion Science & Technology Center

u s planning for rafm steel fabrication technology development for iter tbm
U.S. Planning for RAFM Steel Fabrication Technology Development for ITER TBM
  • Four Parallel lines of technological development planned:
    • Square tube manufacturing and bending to produce first-wall.
    • Hot Isostatic Pressing (HIP) technology to join square tubes to form the first wall, and the fabrication of other elements such as internal cooling plates and manifolds.
    • Investment casting as an alternative to HIP.
      • Reduces the need for extensive joining operations.
      • Reduces the amount of NDE needed (fewer joints).
      • Potentially less expensive than other fabrication methods.
      • Complex castings of 9-10 Cr steels have been produced with mechanical properties similar to those of wrought products.
    • Electron-beam, laser welding, and possibly other techniques to join internal cooling plates and manifolds to the first-wall structure.

UCLA Fusion Science & Technology Center

first wall panel
First Wall Panel
  • Utilize 3 pass snaking system to distribute He
    • Turns in the snake achieved in back plates
  • Stack 16 Paths (as below) to constitute first wall

Figure 7

Figure 8

UCLA Fusion Science & Technology Center

first wall fabrication
First Wall Fabrication
  • Two Methods
    • Components of first wall are bent into U-shape before assembly, and are then pressed between two metal plates and joined with HIPPING process
      • Sealing welds must be made at ends and along pipe path (likely must be done prior to giving to a manufacturing co.)
    • Two thicker plates each with desired half-channels milled out. Pressed and joined with HIPPING process, and finally bent into U-shape of first wall
      • Much more machining
      • Have had inaccurate channel dimensions (at corners) when bending occurs after welding

UCLA Fusion Science & Technology Center

back plates
Back Plates
  • System of three metal Plates:
    • 5mm plate to direct inlet flow to first wall and outlet flow to outlet.
    • 20mm plate attached via HIP weld (alternatively have both as one thick plate ~25mm)
      • Once attached, sections are milled to create flow conduits
      • Alternatively could use investment casting to form flow conduits
      • Creates inlets/U-turns/outlets for the FW 3 pass snake concept
        • necessitates accurate welding to match back plate with each first wall path
    • 5mm cover with holes for inlet/outlet

Figure 9

UCLA Fusion Science & Technology Center

internal view of a fw segment
Internal View of a FW Segment

1 of 16 Paths of First Wall (3 passes)

He Inlet


Back Plates (Milled section)

Welding Plane

Figure 10: (6mm Shaved off side of Submodule to achieve the above cut view)

UCLA Fusion Science & Technology Center

breeder zone cooling plates
Breeder Zone Cooling Plates
  • Necessary Dimensions dictate geometry
    • (top/bottom of multiplier, breeder)
  • Designed as two snakes starting from sides and interweaving
  • Alternate Method contains 1 pass for simpler manifolds
    • Much cooler on one side than the other
      • Uneven breeder cooling
      • Thermal expansion problems

Figure 11

UCLA Fusion Science & Technology Center

breeder coolant channel fabrication
Breeder Coolant Channel Fabrication
  • Difficult as geometry is much more complex.
  • Options available:
    • Half Plates joined by Hipping. Manufactured either through:
      • milling and bending, or
      • Investment casting
    • 1mm square tubes stacked and HIPPED between 0.5mm plates
    • Entire model is cast, no HIPPING is involved.

Figure 12: Example of Outer Half of Coolant Channels

UCLA Fusion Science & Technology Center

internal manifolds
Internal Manifolds
  • Allows double snake design to occur
    • Green diverts flow from top & bottom walls
    • Orange transfers flow from one pass to the next
      • 4 vertically & horizontally compartmented sections (TBD)
    • Blue is outlet collector
    • Tan tubes distribute flow poloidally to all parallel channels
  • Uneven coolant flow will make manifold design challenging

Figure 13

UCLA Fusion Science & Technology Center

top wall
Top Wall
  • Accepts flow from first wall at center via back plates
  • Outlets to breeder zone
  • Number of passes and channel size
    • TBD as it is highly dependent on mass flow rate vs. amount of necessary cooling of wall
  • Thickness of wall
    • TBD based on stress analysis and deformation of wall
  • Manufactured in similar fashion as back plates

Figure 14

UCLA Fusion Science & Technology Center

assembly process
Assembly Process
  • Problems with welding accessibility?

Figure 15

UCLA Fusion Science & Technology Center

obstacles to overcome
Obstacles to Overcome
  • Thin walled members could have high deformation under thermal expansion (tolerance)
    • Future stress analyses will tell what thicknesses and supports will be necessary.
  • Very small He channels (with thin walls) are hard to manufacture
    • Need to decide manufacturing strategy of coolant channels and first wall channels so more detailed design can begin.
  • Parallel flow
    • Need system of baffles, buffers, and diverters to assure equal flow to all channels in Poloidal direction.
  • Attachments to Port Frame Back Shield
    • Limitation on number of pipes from Submodule means coordinated effort with JA to combine each pipe system from 3 in to 1
      • i.e. each Submodule has 1 He outlet pipe = 3 total for ½ Port. Needs to be combined into a single common pipe.

UCLA Fusion Science & Technology Center