FIRE Engineering Summary

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FIRE Engineering Summary
Phil Heitzenroeder for the FIRE Engineering
Team Presented to the FIRE Physics Validation
Review Committee March 30, 2004
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Outline

• FIRE and its Status
• Engineering Evaluations of Coil Systems
• RD Plans for the Coil Systems
• Costs
• Summary

This talk concentrates on the coil systems
since the other key engineering systems are
covered in presentations by B. Nelson and M.
Ulrickson.
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Status

• The FIRE study began in late 1999.
• All major systems addressed.
• Preliminary cost estimates indicate a green
  field cost of 1.19B.
• Engineering Peer Reviews were held in June01.
  Included
• TF and PF coils
• Vacuum Vessel and PFCs
• Fueling and Pumping
• Nuclear effects and Activation
• Cryoplant
• Facilities and Siting
• Focused set of parameters were adopted RD plans
  have been outlined.
• Participated in and received good feedback from
  SNOWMASS.
• Many of these inputs are now reflected in the
  design and the FIRE 2003-4 Engineering Report
  Update
• Work so far indicates all major systems can be
  designed to meet or exceed requirements.

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FIRE Engineering Review Critical Issues (June
2001)
CRITICAL DESIGN ISSUES 1. FOCUS in an
expeditious manner on 2 Designs along the Q 10
zone, (not the Baseline design) that
indicate, at the Pre-Conceptual Design level, an
Engineering Margin value in the range of 1.2 to
1.3. (Done)This level of margin should also apply
to the insulation schemes. (Agreed) 2. Then
FOCUS, in an expeditious manner on one device,
either Wedged or Bucked/Wedged (to be selected by
the design team.) Done, Wedged 10T chosen 3.
Incorporated in the focusing effort should also
be the immediate design attention to the details
of leads, both TF and CS, associated cooling
fittings and design of all other critical systems
that are lacking detail at the Pre-Conceptual
level - (Not done, limited resources used to
address more global issues - I.e.,rep rate)- See
the material below and the associated attached
chits. (about 1/3 of the chits have been
addressed await resources for more detailed
items.) CRITICAL RD ISSUES 1. The qualification
of the properties, through RD of the TF coil
Materials (OFHC for the Bucked/Wedged and BeCu
for the Wedged device) in sizes and thickness
that are representative of those required for
fabrication. (Agreed, also Elbrudor for PF, will
pursue if CD-0) 2. For either device, the
qualification, through RD, of materials, that
are available today, for the insulation systems.
(Agreed, 4 Small Business Innovative Research
grants awarded by DOE for insulation development
in support of FIRE/fusion needs.)
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Key Components of FIRE
Modular Tungsten Brush Divertors
Double Walled VV with Integral Shielding.
LN2 Cooled Copper PF Coils
LN2 Cooled Segmented Central Solenoid
LN2 Cooled wedged Cu TF Coils
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Engineering Status of the TF Coil

• Stress and fatigue evaluations are performed in
  accordance with the FIRE Structural Design
  Criteria.
• Structural stress allowable exceeds requirements
• Calculated max. membrane bending stress 611
  MPa.
• MB allowable for C17510 BeCu 724 MPa.
• Shear allowable exceeds requirements
• Shear required 50 MPa.
• Shear Developed 60 MPa. (200 MPa compression
  m0.3)
• Fatigue life exceeds requirements
• requirement 3,000 full power shots (H-Mode)
  30,000 half power shots (L-Mode).
• Evaluation indicates 5,000 full power shots
  half power shots far exceed requirements.
• Pulse Duration meets requirements gt20s flat-top
  capability _at_10T

Structural model showing out of plane
displacements
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Engineering Status of the Central Solenoid and
PF Coils

• Structural stress allowable exceeds requirements
• 1.5 Sm Allowable for Elbrodur at that
  temperature 541
• Highest Max. VonMises stress is 414 MPa. at EOB
  for CS2 coils.
• Max. Temperature (at EOC) of 188 K. Is well
  within temp. limit of 373 K.
• Fatigue more work required.
• The FIRE design criteria requires a Factor of
  Safety (FS) of 20 on the number of cycles
• The CS-2 coil does not meet this requirement for
  H-mode operation its FS is 15.

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Meeting FIREs Operating Pulse Requirements

• As noted in the previous slide, the CS-2 coil
  falls short of the 20 X life ASME-Like fatigue,
  based on currently available fatigue information
  on Elbrodur .
• Possible remedies
• Work with the copper suppliers to develop
  Elbrodur with improved fatigue properties and
  more extensive testing of existing materials.
• Use a strip-wound copper design for all CS and PF
  coils.
• It is expected that metallurgical flaws will be
  smaller.
• inspection for flaws will be easier with strip
  compared to plate.
• Use a fracture based fatigue analysis rather than
  traditional fatigue analysis.
• This requires quantification of flaw size, but
  requirements for multiples of life are reduced to
  4.
• Requires investigation to see if, with expected
  flaw size, this is a net win.
• Other possibilities
• Carefully review the required operating pulse
  spectrum required for FIREs mission. We may find
  that the current fatigue life is acceptable.
• Another option might be to use the aircraft
  approach i.e., design the engine (central
  solenoid) to be readily replaced while still
  within its safe operating lifetime.

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Coil RD Highlights

• FIREs magnet systems have relatively modest RD
  needs
• Cryo cooled copper design.
• Much data to draw upon from CIT/BPX IGNITOR
  ALCATOR C-Mod.
• RD Focus
• Filling gaps in data bases of materials
  (Elbrodur insulators)
• RD which may permit higher performance (refined
  design criteria optimized materials improved
  inspection techniques)
• Cost reduction (manufacturing process
  development materials selection)
• Risk mitigation (component testing prototypes).

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TF Copper BeCu Plate Developed for BPX Should
Meet FIREs Needs.

• The C17510 BeCu plate shown was produced for BPX
  by Brush-Wellman.
• Properties and size are very similar to those
  required for FIRE.
• Brush-Wellman requires modest RD to establish
  production details.

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Copper Joining RD

• C17510 BeCu
• C10200 OFHC
• RD is planned to develop friction stir or e-beam
  welding for joining the TF copper segments.
• RD is also planned for electroform welding for
  possible use in the PF coils.

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PF Coil Conductor RD

• The CS and ring coils all use Elbrodur CuCrZr
  copper.
• RD will focus on
• Processing to optimize fatigue properties.
• Inspection techniques to reliably measure flaw
  sizes.
• Characterization of physical properties for the
  Elbrodur conductor in the sizes and forms FIRE
  plans to use.

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Radiation Resistant Insulating Materials RD

• Requirements
• FIRE plans 3,000 full power D-T shots producing
  5 TJ of neutrons 30,000 half power D-D shots
  producing 0.5 TJ of neutrons.
• End of life peak insulation dose 1.05 x 1010
  rads.
• BPX insulation would meet this requirement
• This is a high leverage area since it has the
  potential of permitting a greater number of D-T
  shots . It has a strong bearing on reliability
  and risk mitigation.
• Plans
• Collaborate with several existing SBIRs which
  are underway to develop high radiation resistant
  insulating materials with good processing
  characteristics.
• Characterize and life test the friction
  characteristics of insulating materials required
  between the CS coils and in the TF coils.

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Costs
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Summary

• The FIRE study has addressed all major systems.
  
• Results have been encouraging no show
  stoppers in technical or cost areas.
• An Engineering Peer Review was held in 2001.
• FIRE adopted a focused set of parameters in FY
  01, as recommended.
• The other detailed recommendations have been
  addressed.
• Favorable comments about depth of analysis,
  considering we are in Pre-Conceptual design
  phase.
• RD plans have been developed.
• FIREs Cryo cooled Cu design has modest RD
  requirements lots of data to draw upon.
• RD will focus on areas which will reduce
  uncertainties and costs and can improve
  performance.
• FIRE participated in and received much feedback
  from SNOWMASS in 02. Much of this has been
  factored into FIREs design and plans.
• Preliminary cost estimate is 1.19 B. If a site
  with modest credits is identified, the 1B cost
  goal can most likely be achieved.