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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

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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

Nuclear Heat Operating Modes

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

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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

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

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

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

SANDWICH DESIGNSANDWICH DESIGNSection ViewSection View

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Axial Translation Is Allowed

No Hard Mechanical Attachment for tension

DESIGN CONCEPT ALLOWS THERMAL DISPLACEMENTWITH SUPPORTS TO REACT LORENTZ LOAD

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

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

33Restistive m

kW

m

kW24.8

05.0

412Q

Temp in =105.7 CTemp out =131.5 C

Unspecified Surface Boundaries are conservatively assumed to be Adiabatic

RADIATION ASSUMPTIONSRADIATION ASSUMPTIONS

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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

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

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

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

RadiationRadiation

Stainless Steel Jackets

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

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

RadiationRadiation

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

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

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

STEADY STATE STRESS ANALYSIS

THERMAL & DISRUPTION LOADS

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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

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

+Y

0.0066 m = 0.259 in

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

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

Copper Coil0.185 e8 Pa = 2,683 Psi

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

von Mises Stressvon Mises Stress

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

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

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

33.01184

122

20.11184

3.405

61.01184

297

Fatigue

FTU

FTY

M

M

M

REVISED ANALYSISREVISED ANALYSISWith Bridge SupportWith Bridge Support

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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

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

Steady State Steady State Displacements Displacements

The vertical displacements are reasonable for the specified boundary conditions

+Y+Y

Pressure + ThermalPressure + Thermal + Lorentz

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

Copper Coil0.37 e8 Pa = 5,366 Psi

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

Von Mises StressVon Mises Stress

54.01270

122

50.01270

3.405

1.01270

297

Fatigue

FTU

FTY

M

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 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

CONCLUSIONS / PLANCONCLUSIONS / PLAN• The Sandwich Design will be a viable option. Current progress shows stress

levels can be shaped with design changes. Additional changes to meet fatigue requirements will be completed as required. (Post PDR)

• The Christmas Tree and Sandwich Design evaluated for merits in the coming weeks for a down select. (PRE PDR)

• Material property testing and MGO Interface boundary determined for accurate results. (PRE PDR)

• Revised Toroidal & Poloidal Nuclear Heat Functions Updated with revised coolant temperatures. (PRE PDR)

• All three load case scenarios including Transient and Steady State loadings will be completed. (Pre PDR)

• Steady State and Transient Load Cases to be completed with Sub-modeling to resolve stress issues. (Post PDR)

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