Structural analysis of ITER TBM Frame and Dummy TBM

One of the main engineering performance goals of ITER is to test and validate design concepts of tritium breeding blankets. To accomplish these goals, three ITER equatorial ports are dedicated to the test of Test Blanket Modules (TBMs) that are mock-ups of tritium breeding blankets. These TBMs, associated with appropriate shield blocks, will also provide the same thermal and nuclear shielding as the main blanket. The main function of TBM Port Plug (PP) is to accommodate TBMs and provide a standardized interface with the vacuum vessel (VV)/port structure.The feasibility of the design concept of the Frame including two Dummy TBMs has been investigated by proposing design improvements of the reference design through an extensive set of thermal, electromagnetic (EM) and stress analyses. As well, the related static strength was evaluated in accordance with the structural design criteria for ITER in-vessel components (SDC-IC). This paper outlines the engineering aspects of the ITER TBM Frame and Dummy TBM and focuses on the feasibility of the present design by structural assessment.     

Progress in engineering design of Indian LLCB TBM set for testing in ITER

The Indian Lead–Lithium Ceramic Breeder (LLCB) Test Blanket Module (TBM) is the Indian DEMO relevant blanket module, as a part of the TBM program in ITER. The LLCB TBM will be tested from the first phase of ITER operation in one-half of an ITER port no. 2. LLCB TBM-set consists of LLCB TBM module and shield block, which are attached with the help of attachment systems. This LLCB TBM set is inserted in a water-cooled stainless steel frame called ‘TBM frame’, which also provides the separation between the neighboring TBM-sets (Chinese TBM set) in port no. 2. In LLCB TBM, high-pressure helium gas is used to cool the first wall (FW) structure and lead–lithium eutectic (Pb–Li) flowing separately around the ceramic breeder (CB) pebble bed to cool the TBM internals which are heated due to the volumetric neutron heating during plasma operation. Low-pressure helium is purged inside the CB zones to extract the bred tritium. Thermal-structural analyses have been performed independently on LLCB TBM and shield block for TBM set using ANSYS. This paper will also describe the performance analysis of individual components of LLCB TBM set and their different configurations to optimize their performances.     

Engineering studies for integration of the test blanket module (TBM) systems inside an ITER equatorial port plug

The European test blanket module (EU-TBM), first prototype of the breeding blanket concepts under development for the future DEMO power plant to produce the tritium, will be developed to be tested in three equatorial ports of ITER dedicated to this. The CEA Cadarache under the contract of Association EURATOM/CEA and in close relation with Association EURATOM/HAS works on the integration of the EU-TBM inside ITER tokamak.The installation of the TBM into the vacuum vessel is made with the help of a port plug, constituted with two components: the Shield module and the Port-Plug frame. The Shield module provides the neutron shielding inside the Port-Plug frame, which maintains in cantilever position the TBM and its shield module and closes the vacuum vessel port.This paper will describe the EU-TBM design and integration activities on the cooled shield module and on its interface with the TBM component. A particular attention, in term of thermal and mechanical studies, is dedicated to the design of the shield and test blanket module attachment, and also to the shield design and its internal cooling system.     

Preliminary Shielding Analysis for HCCB TBM Transport

A preliminary shielding analysis on the transport of the Chinese helium cooled ce?ramic breeder test blanket module (HCCB TBM) from France back to China after being irradiated in ITER is presented in this contribution. Emphasis was placed on irradiation safety during trans?port. The dose rate calculated by MCNP/4C for the conceptual package design satisfies the relevant dose limits from IAEA that the dose rate 3 m away from the surface of the package con?taining low specific activity III materials should be less than 10 mSv/h. The change with location and the time evolution of dose rates after shutdown have also been studied. This will be helpful for devising the detailed transport plan of HCCB TBM back to China in the near future.     

Detailed 3-D nuclear analysis of ITER blanket modules

In ITER, the blanket modules (BM) are arranged around the plasma to provide thermal and nuclear shielding for the vacuum vessel (VV), magnets, and other components. As a part of the BM design process, nuclear analysis is required to determine the level of nuclear heating, helium production, and radiation damage in the BM. Additionally, nuclear heating in the VV is also important for assessing the BM design. We used the CAD based DAG-MCNP5 transport code to analyze detailed models inserted into a 40-degree partially homogenized ITER global model. The regions analyzed include BM01, the neutral beam injection (NB) region, and the upper port region. For BM01, the results show that He production meets the limit necessary for re-welding, and the VV heating behind BM01 is acceptable. For the NBI region, the VV nuclear heating behind the NB region exceeds the design limit by a factor of two. For the upper port region, the nuclear heating of the VV exceeds the design limit by up to 20%. The results presented in this work are being used to modify the BM design in the cases where limits are exceeded.     

Design update,thermal and fluid dynamic analyses of the EU-HCPB TBM in vertical arrangement

In the frame of the activities of the EU Breeder Blanket Programme and of the Test Blanket Working Group of ITER, the Helium Cooled Pebble Bed Test Blanket Module (HCPB TBM) is developed in Forschungszentrum Karlsruhe (FZK) to investigate DEMO relevant concepts for blanket modules.The three main functions of a blanket module (removing heat, breeding tritium and shielding sensitive components from radiation) will be tested in ITER using a series of four TBMs, which are irradiated successively during different test campaigns. Each HCPB TBM will be installed, with a vertical orientation, into the vacuum vessel connected to one equatorial port. As the studies performed up to 2006 in FZK concerned a horizontal orientation of the HCPB TBM, a global review of the design is necessary to match with the new ITER specifications.A preliminary version of the new vertical design is proposed extrapolating the neutronic analysis performed for the horizontal HCPB TBM. An overview of the new HCPB TBM vertical designs, as well as the preliminary thermal and fluid dynamic analyses performed for the validation of the design, are presented in this paper. A critical review of the results obtained allows us, in the conclusion, to prepare a plan for the future detailed analyses of the vertical HCPB TBM.     

Status of Indian LLCB TBM program and R&D activities

The Indian LLCB TBM, currently under development, will be tested from the first phase of ITER operation (H–H phase) in one-half of the ITER port no-2. The present LLCB TBM design has been optimized based on the neutronic as well as thermal hydraulic analysis results. LLCB TBM R&D activities are primarily focused on (i) development of technologies related to various process systems such as Helium, Pb–Li liquid metal and tritium, (ii) development and qualification of blanket materials viz., structural material (IN-RAFMS), tritium breeding materials (Pb–Li, and Li₂TiO₃), (iii) development and qualification of fabrication technologies for TBM system. The present status of LLCB TBM design activities as well as the progress made in major R&D areas is presented in this paper.     

Design finalization and start of construction of ITER vacuum vessel

The vacuum vessel (VV) design is being finalized including interface components, such as the support rails and feedthroughs of coils for mitigation of edge localized modes (ELM) and vertical stabilization (VS) of the plasma (ELM/VS coils). It was necessary to make adjustments in the locations of the blanket supports and manifolds to accommodate the design modifications in the ELM/VS coils. The lower port gussets were reinforced to keep a sufficient margin under the increased VV load conditions. The VV support design is being finalized as well, with an emphasis on structure simplification. The design of the in-wall shielding (IWS) has progressed, considering assembly and required tolerances. The layout of ferritic steel plates and borated steel plates will be optimized based on on-going toroidal field ripple analysis. The VV instrumentation was defined in detail. Strain gauges, thermocouples, displacement meters and accelerometers shall be installed to monitor the status of the VV in normal and off-normal conditions to confirm all safety functions are performed correctly. The ITER VV design was preliminarily approved, and the VV materials including 316L(N) IG were already qualified by the Agreed Notified Body (ANB) according to the procedure of Nuclear Pressure Equipment Order.     

Development of TSACO and application to Chinese HCCB TBM cooling system

In this study, a thermal-hydraulic and safety analysis code (TSACO) for helium cooling system has been developed using Fortran 90 language, and the simulation has been performed for the cooling system of the Chinese helium cooled ceramic breeder test blanket module (CH HCCB TBM). The semi-implicit finite difference technique was adopted for the solution of the dynamic behavior of helium cooling system. Furthermore, a detailed illustration of the numerical solution for heat structures and critical model was presented. The code was verified by the comparison of RELAP5 code with the same initial condition, boundary condition, heat transfer and flow friction models. The TBM inlet/outlet temperatures and pressure drop were obtained and the results simulated by TSACO were shown in good agreement with those by RELAP5. Thereafter, the design basis accident in-vessel loss of coolant accident (LOCA), was investigated for the CH HCCB TBM cooling system. The critical flow model was also verified by comparing with RELAP5 code. The results indicated that the TBM can be cooled down effectively. The vacuum vessel (VV) pressure and the mass of helium spilled into the VV maintained below the design limits with a large margin.     

New progress on design and R&D for solid breeder test blanket module in China

ITER will be used to test tritium breeding module concepts, which will lead to the design of DEMO fusion reactor demonstrating tritium self-sufficiency and the extraction of high grade heat for electricity production. China plans to test the HCCB TBM modules during different operation phases. Related design and R&D activities for each TBM module with the auxiliary system are introduced.The helium-cooled ceramic breeder (HCCB) test blanket module (TBM) is the primary option of the Chinese TBM program. The preliminary conceptual design of CN HCCB TBM has been completed. A modified design to reduce the RAFM material mass to 1.3 ton has been carried out based on the ITER technical requirement. Basic characteristics and main design parameters of CN HCCB TBM are introduced briefly. The mock-up fabrication and component tests for Chinese test blanket module are being developed. Recent status of the components of CN HCCB TBM and fabrication technology development are also reported. The neutron multiplier Be pebbles, tritium breeder Li₄SiO₄ pebbles, and structure material CLF-1 of ton-class are being prepared in laboratory scale. The fabrication of pebble bed container and experiment of tritium breeder pebble bed will be started soon. The fabrication technology development is proceeding as the large-scale mock-up fabrication enters into the R&D stage and demonstration tests toward TBM testing on ITER test port are being done as scheduled.     

Nuclear Characteristics of D-D Fusion Reactor Blanket, (II)

The nuclear characteristics of the thermal blanket and blanket-shield designs are analyzed to provide a basis for optimizing the blanket design of D-D fusion reactors. The thermal blanket is devised to yield high energy deposition in a compact blanket through the use of neutron multiplier and energy converter with 1/v neutron absorption cross section. The blanket-shield design, on the other hand, aims at providing acceptably good shielding characteristics to protect the superconducting magnet by incorporating shielding substances within the blanket itself.

The results of calculation reveal that the thermal blanket design provides only modest energy deposition in the blanket despite its use of beryllium, which is limited in availability. In contrast, the blanket-shield concept is found to offer attractive possibilities in terms of nuclear characteristics, and the results of this analysis point toward the blanket-shield concept as the logical choice for D-D fusion reactor blankets.     

Preliminary design of a helium cooled molten lithium test blanket module for the ITER test in Korea

Through a consideration of the requirements for a DEMO-relevant blanket concept, Korea (KO) has proposed a He cooled molten lithium (HCML) blanket with ferritic steel (FS) as a structural material in the International Thermonuclear Experimental Reactor (ITER) program. The preliminary design and its performance of KO HCML test blanket module (TBM) are introduced in this paper. It uses He as a coolant at an inlet temperature of 300 °C and an outlet temperature up to 400 °C and Li is used as a tritium breeder by considering its potential advantages. Two layers of graphite are inserted as a reflector in the breeder zone to increase the tritium breeding ratio (TBR) and the shielding performances. A 3-D Monte Carlo analysis is performed with the MCCARD code for the neutronics and the total TBM power is designed to be 0.739 MW at a normal heat flux from the plasma side. From the analysis results with CFX-10 for the thermal-hydraulics, the He cooling path is determined and it shows that the maximum temperature of the first wall does not exceed 550 °C at the structural materials and the coolant velocities are 45 and 11.5 m/s in the first wall and breeding zone, respectively. The obtained temperature data is used in the thermal-mechanical analysis with ANSYS-10. The maximum von Mises equivalent stress of the first wall is 123 MPa and the maximum deformation of it is 3.73 mm, which is lower than the maximum allowable stress.     

ITER blanket manifold system: Integration,assembly and maintenance

The ITER Tokamak Cooling Water System (TCWS) provides coolant for blankets and divertor. The blanket system consists of 440 blanket modules (BMs). The blanket manifold consists of a system of seamless pipes arranged in bundles and routed in poloidal direction from the upper ports of the Vacuum Vessel (VV) to the bottom of the machine. In each of the 18 upper ports there are 20 inlet and 20 outlet pipes, which split at the port exit in two directions, supplying cooling water to either the inboard or the outboard blanket modules. The manifold is routed between the VV and BMs. Branch pipes provide the connection between the manifold and the blanket cooling circuits through a coaxial connector welded to the shield block. A complex, sequential installation sequence has been developed in order to enable the assembly. Once installed the manifold is considered a semi-permanent component, but since failure would prevent ITER operation a maintenance strategy has been planned.     

ITER Vacuum Vessel design and construction

After implementing a few design modifications (referred to as the “Modified Reference Design”) in 2009, the Vacuum Vessel (VV) design had been stabilized. The VV design is being finalized, including interface components such as support rails and feedthroughs for the in-vessel coils. It is necessary to make adjustments to the locations of the blanket supports and manifolds to accommodate design modifications to the in-vessel coils. The VV support design is also being finalized considering a structural simplification. Design of the in-wall shielding (IWS) has progressed, considering the assembly methods and the required tolerances. The detailed layout of ferritic steel plates and borated steel plates was optimized based on the toroidal field ripple analysis. A dynamic test on the inter-modular key to support the blanket modules was performed to measure the dynamic amplification factor (DAF). An R&D program has started to select and qualify the welding and cutting processes for the port flange lip seal. The ITER VV material 316 L(N) IG was already qualified and the Modified Reference Design was approved by the Agreed Notified Body (ANB) in accordance with the Nuclear Pressure Equipment Order procedure.     

Structural analysis and optimization for ITER upper ELM coil

ITER ELM coils are used to mitigate or suppress Edge Localized Modes (ELM), which are located between the vacuum vessel (VV) and shielding blanket modules and subject to high radiation levels, high temperature and high magnetic field. These coils shall have high heat transfer performance to avoid high thermal stress, sufficient strength and excellent fatigue to transport and bear the alternating electromagnetic force due to the combination of the high magnetic field and the AC current in the coil. Therefore these coils should be designed and analyzed to confirm the temperature distribution, strength and fatigue performance in the case of conservative assumption. To verify the design structural feasibility of the upper ELM coil under EM and thermal loads, thermal, static and fatigue structural analysis have been performed in detail using ANSYS. In addition, design optimization has been done to enhance the structural performance of the upper ELM coil.     

He冷却试验包层模块的热-力耦合分析

试验包层模块(TBM)是国际热核聚变实验堆(ITER)的关键核心组件,其设计涉及多学科综合优化分析.本文介绍了He冷却固态增殖试验包层的设计概念,并应用热功耦合模拟方法对所提出的包层概念模型的热力响应特性进行分析.结果表明,包层内部各区域的最大温度值和最大应力值均未超过材料容许的限值,所提出的包层设计概念在正常运行工况下是安全可靠的.     

基于RELAP5的双功能液态锂铅实验包层模块安全分析

利用嵌入了液态锂铅（LiPb）的热工水力子模块的系统程序RELAP5/MOD3,对双功能液态锂铅（DFLL）实验包层模块（TBM）的安全特性进行评价。对DFLL-TBM及其辅助冷却系统的稳态运行工况、预期运行事件和相关事故工况进行了建模、计算和分析。计算结果表明,稳态运行时第一壁（FW）结构材料表面最高温度低于允许值550 ℃。事故工况下氦气泄漏引起的ITER真空室（VV）、窗口设备室（port cell）以及托卡马克冷却水系统大厅拱顶（TCWS vault）的增压均低于ITER要求的限值0.2 MPa。实验包层钢结构不会熔化且可通过辐射换热有效地导出衰变余热。DFLL-TBM的设计可满足ITER对其热工水力安全方面的要求。     

The EU TBM systems: Design and development programme

This paper presents the status of the design and of the development programme of the two test blanket systems (TBSs) based on the blanket concepts supported by the EU, namely the helium cooled lithium lead (HCLL) and helium cooled pebble bed (HCPB) concepts.Both the test blanket modules (TBMs) box design and the associated systems (Helium Cooling Systems, PbLi loop for the HCLL system, helium processing systems for tritium extraction, etc.) have been revised and, where needed, modified according to the assumption that one ITER equatorial port could be available for testing the two European test blanket modules (TBMs).According to EU TBMs programme, two reliable test blanket systems shall be ready for installation on the first day of ITER operation. In order to comply with this ambitious objective, six EURATOM associates who have sustained the TBM program so far have joined themselves in a consortium aiming to ensure an efficient management of the project tasks and exploit specific competences enhancing potential synergies. The consortium objectives and development programme are summarised in the paper.     

The fundamental role of fluid dynamic analyses in the design of the solid EU Test Blanket Module

In the frame of the activities of the European Test Blanket Module Consortium of Associates, the Helium Cooled Pebble Bed Test Blanket Module (HCPB TBM), the so-called solid TBM, is developed in Karlsruhe Institute of Technology (KIT). In the EU experimental strategy, a series of 4 different HCPB TBMs will be connected to the dedicated equatorial port n.16 during the ITER lifetime. The ITER TBM program has to provide DEMO relevant experimental data for the main functions of the blanket modules of a future fusion reactor.The preliminary thermo-mechanical design assessment of the TBM box (based on transient, steady state and accidental analyses) has been presented. All along the design assessment phase the fluid dynamic analyses play a fundamental role for the TBM sub-components, the Breeder Units (BUs) and the manifolds (MF) stages. This paper highlights the methodology implemented for the Computational Fluid Dynamic (CFD) analyses in the TBM design life cycle, and presents the results and the impact on the overall performance evaluation of the HCPB TBM. The following models are presented in detail: the CFD model of the TBM First Wall and its application to a reduced scale First Wall, the 3D CFD model of the BUs, and the thermo fluid dynamic modelling of the manifold systems.     

Preliminary thermal-hydraulic and safety analysis of China DFLL-TBM system

China has proposed the dual-functional lithium-lead (DFLL) tritium breeding blanket concept for testing in ITER as a test blanket module (TBM), to demonstrate the technologies of tritium self-sufficiency, high-grade heat extraction and efficient electricity production which are needed for DEMO and fusion power plant. Safety assessment of the TBM and its auxiliary system should be conducted to deal with ITER safety issues directly caused by the TBM system failure during the design process. In this work, three potential initial events (PIEs) – in-vessel loss of helium (He) coolant and ex-vessel loss of He coolant and loss of flow without scram (LOFWS) – were analyzed for the TBM system with a modified version of the RELAP5/MOD3 code containing liquid lithium-lead eutectic (LiPb). The code also comprised an empirical expression for MHD pressure drop relevant to three-dimensional (3D) effect, the Lubarsky–Kaufman convective heat transfer correlation for LiPb flow and the Gnielinski convective heat transfer correlation for He flow. Since both LiPb and He serve as TBM coolants, the LiPb and He ancillary cooling systems were modeled to investigate the thermal-hydraulic characteristic of the TBM system and its influence on ITER safety under those accident conditions. The TBM components and the coolants flow within the TBM were simulated with one-dimensional heat structures and their associated hydrodynamic components. ITER enclosures including vacuum vessel (VV), port cell and TCWS vault were also covered in the model for accident analyses. Through this best estimate approach, the calculation indicated that the current design of DFLL-TBM and its auxiliary system meets the thermal-hydraulic and safety requirements from ITER.