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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

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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

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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

Questions or comments

Questions or Comments?

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