Abou-Sena, A.

Arbeiter, F.

Averhals, J.

Böttcher, T.

Chen, Y.

Dolensky, B.

Fischer, U.

Heinzel, V.

Heupel, T.

Klein, Ch.

Kondo, K.

Konrad, J.

Massaut, V.

Muche, A.

Möslang, A.

Pacquet, P.

Piecha, H.

Rolli, R.

Schlidwein, G.

Schwab, F.

KITopen

KIT – Universität des Landes Baden-Württemberg undnationales Forschungszentrum in der Helmholtz-GemeinschaftInstitut für Neutronenphysik und Reaktortechnik, Gruppe Messtechnik und Experimentelle Methodik (INR-MET)www.kit.eduDesign description and validation results for theIFMIF High Flux Test Module as outcome of theEVEDA phaseFrederik Arbeiter et al., ICFRM-17, 11.-16. October 2015, JülichInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik2ContentsHFTM Functions and RequirementsEngineering Design and AnalysesManufacturing of PrototypesValidation tests in helium loops and the BR2 reactorOutlook for further developmentConclusionsFrederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phase15.10.2015Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik3International Fusion Materials Irradiation Facility IFMIF – Mission and ConceptFrederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phase15.10.2015Mission: provide material data irradiated at fusion relevant neutron spectrumfor design, construction, licensing and safe operation of a fusion DEMO Reactor.IFMIF facility components:A suitable neutron source by the d,Li stripping reaction.A set of mission-relevant irradiation experiments.An efficient & safe environment for irradiated materials production and examination. 10-6 10-5 10-4 10-3 10-2 10-1 100 101 102109101010111012101310141015101610171018 IFMIF EVEDA refrence model (mdl69, Feb 2013)(no graphite moderator in LFTM)40 MeV 250 mANeutron flux (/cm2/MeV/s)Neutron energy (MeV) Back Plate HFTM CFTM TRTM LFTM Vessel Liner (front)14MeVNeutron energy [MeV]Neutron flux[/cm²/MeV/s][K. Kondo, KIT, 2013][IFMIF Team, 2013]Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik4Irradiation experiments in the IFMIF Test Cell15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phase(HFTM)(MFTM)(LFTM)The HFTMoccupies theirradiation spaceclosest to theneutron source~1015 #n/cm²/sat FW/blanketconditionsInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik5HFTM functions and requirements15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseTo irradiate qualified SSTT specimens of RAFMsteels in sufficient quantity/rate  for IFMIF missionIrradiation temperatures in the range 250°C ≤ Tirr≤ 550°C (for RAFM steels)Maintain low temperature spread (+/-3% of Tirr in 80% of specimen stack and temporal stability)Design for component lifetime of 1 year , 50dpa, meet RAMI requirementsIntegrate with IFMIF plant requirements (remote handling, (dis)assembly in hot cells, safety, wastedisposal80 SSTT specimensin specimen stack81 x 40 x 9.5 mm³of 1 irradiation capsuleHFTM disassembly81mmInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik6HFTM design constraints and paradigms15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe geometry of the IFMIF neutron source/radiation fieldsuggests a flat cuboid asirradiation spaceLimited building space : 56mm + 2x 2mm gap reserved for theHFTM in the „stack“ of irradiationexperiments a slenderstructure avoiding protrusions(flanges etc.) Low pressureminichannel He-cooling chosen.A radiation source with limited extension and possible temporal variations requires neutronreflectors to limit flux gradientsand active temperature control56mmHFTMHFTM installation spaceNuclear heating distribution~2500mmInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik7The HFTM assembly15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseSupport trussespositioning, fixpointHe feed pipesguide Helium tobottom of containerHFTM container(8 compartments)position rigs in beam footprintAttachment-AdapterHe return duct,attachment,cable channelIrradiation rigsContain specimensand temperaturecontrolElectricalfeedthroughsFor heaters andthermocouplesHelium flanges8 x DN32 feed2 x DN 100 returnInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik8HFTM container and irradiation rigs15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseFunctions & Requirements:• Position the rigs in the beam footprint• Guide the helium coolant• Widthstand the internal pressure• Act as saftey barrierFeatures:• Subdivision into 8 „compartments“• Wire-cut EDM from solid block• Built from AISI 316L steelRCC-MRx : 53dpa @ < 375°C• 2mm outer wall thickness• Spring loaded rig downholdersCut-open HFTM containerwith 8 compartments, each with 3 irradiation rigsInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik9Capsule temperature control15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThree (individually controlled) electrical heater circuits are used to(1) balance the axial profile of the nuclear heat release(2) balance temporal variations of the beam powerThey are guided by 3 thermocouple measurement positions.Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik10Rig packet in compartment15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phasePacket of 3 rigs(stripped layers) Cross section through 3 rigs inside compartmentInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik11Control system architecture15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik12Irradiation rig with capsule15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseFunctions & Requirements• Contain the capsule• Implement insulation gapsaround the capsule• Guide the helium coolant• Provide neutron reflectorsFeatures:• Contain the capsule in a thin rig hull• Insulation gap between capsule and rigis defined by knops on the capsule• Built from AISI 316L steel• Upper reflector is built from twohalf-shells to insert the capsule wiresCut-open irradiation rig with capsuleInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik13The irradiation capsule15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseFunctions & Requirements• Contain ~80 SSTT specimens• Allow irradiation between 250-550°C• Maintain „isothermal“ irradiationconditions• Hermetical confinement of contentsFeatures• Box-type design• Sample volume 81mm x 40mm x 9.3mm• Made of RAFM (Eurofer97/F82H)• Equipped with 3 THERMOCOAX heaters• Instrumented with 6 Type-K TCs• Specimens immersed in liquid NaK-78• Knops on the surface to define insulationgapLeft: outside skin with knops. Right: specimensInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik14Nuclear design analyses15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phase• Nuclear analyses performedwith McDeLicious-11 andFENDL-3 nucl. data library• Detailed geometry modelgenerated with McCADAfter 11 months:Decay heat per rig (t=0, 1.6kg) : 48WActivity per rig 3E+14Bq [K. Kondo, U. Fischer, P. Pereslavtsev, KIT]Global max. Rig „A“ Rig „B“ DEMO BZNeutron flux [/cm²/s] 2E15 9E14 4E14 6E14 ... 1E14Nuclear heating [W/cm³] 40 25 11 10 ... 0.5Struct. damage rate [dpa/fpy] 50 33 12 11 .. 0.6He production [ appm/dpa] 12.5 12.8 11 .. 2.3Rig „A“Rig „B“Map of neutron fluxInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik15Simulation features:½ HFTM container, approx. 10‘000‘000 cellsFor some simulations individual resolved specimens„EVEDA“ neutron beam profileCFX V 13.0, adapted turbulence models in each compartment, according to validation resultsRadiation and contact heat resistances are considered, natural convection on containerThermal design analyses15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phase[Y. Chen, KIT]Geometry model forcontainer with 12 rigsResult for helium gas flowInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik16Thermal design analyses15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseSummarized outcomes:Temperature spread in specimen stacks < 3% achieved in >97% of capsule volumeInfluence of NaK on temperature field: without NaK spread increases ~10KContainer temperature < 160°CGrace time for LOCA with decay heat: several hoursIntervention time scale for control with beam on : ~10s3D temperature mapwith resolved specimensTransient behaviourInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik17Irradiation campaign in the BR2 reactor15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseIrradiation rig for BR2[P. Jacquet, SCK-CEN]3 Irradiation capsulesObjectives:Build 3 fully functional irradiation capsules, complete with NaK filling and specimensIrradiate capsules and specimens at comparable nuclear heating (up to 3W/g)Heater controlHeater lifetimePractice specimen retrieval in hot cell conditionsSpecimen stack assamblyNaK filling in GloveboxInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik18Main outcomes:3 capsules were built, but some damages had occurred (heaters, one caps. without NaK) during manufacturingIrradiation was done for 3 BR2 irradiation-periods:Capsule #1 cycling 250-440°CCapsule #2 static 390°CCapsule #3 static 250°C (without NaK)Several heaters failed (mainly such with pre-damage)The cycling capsule weld seam ruptured after ~650 cyclesThe rise of the heater wire resistance saturated at about 10%The capsules were dismantled from the rig, NaK was purged and specimens retrieved. Manufacturing experience and irradiation results triggered a long list of necessary improvements for capsule design.Main points concern the heaters.Irradiation campaign in the BR2 reactor15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik19Manufacturing of the HFTM prototype15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe prismatic container with internal compartments was manufacturedby wire-cut EDMThe attachment adapter was machined from 2 large parts of 316L steelThe final assembly was TIG weldedMachining of HFTM attachment adapterHFTM assembly after final weldingContainer fabricated by wire-cut EDM[F. Schwab]Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik20Manufacturing of rig prototypes15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe key component is the rig-hull, a prismatic body with 0.5mm wall thicknessThe lower neutron reflector iswelded to the rig hullThe upper neutron reflectorencloses the capsule cabling andis inserted into the rig hull.Rig hull manufacturing Rig hull single part (ribs on surface) Rig assemblyUpperreflectorCapsuleRighullLowerreflectorInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik21The HELOKA-LP helium loop facility15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseMain features:Driven by 350kW screw type compressorSiemens Simatic S7 control systems~350 channels for data acquisition36 x 1.5kW DC sources for heatersTaken to service 12/2009Dedicated test facility for the HFTMOperation yields experiences for IFMIF He loopsGas-parameter HELOKA-LP HFTMMassflow 12 – 120g/s 96g/sPressure 0.3 – 0.6MPa 0.3MPaTemperature 20 – 250°C 50°CHELOKA-LP Test environmentHELOKA-LP 350kW compressor[G. Schlindwein]Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik22The HFTM double compartment experiments15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseInstallation of theHFTM-DC in HELOKA-LPObjectives:Demonstrate themal-hydraulic properties of the HFTM:temperature rangecontrol stabilitytemperature spreadInvestigate mechanical behaviour (strains, flow induced vibrations) 17 thermocouples per capsule measure the temperature distribution in the specimen stackThe HFTM body is instrumented with strain gages, displacement- and temperature sensorsNuclear heating (in the capsules) is substituted by a variable slope heater cartridgeInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik23Thermal performance in HELOKA-LP15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseSpecimentemperature[°C]Experiment runtime [s]Transient behaviour:The full required temperature range 250-550°C was demonstrated!The temperature control is swift and precise:heat-up with 1K/scool down 550-200°C in 109sSetpoint-jump overshoot < 4KBeam-on/off overshoot < 10KInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik24Thermal performance in HELOKA-LP15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseTemperature field in specimen stack:In the axial coordinate, the temperature spread is < 15KIn the transversal coordinate, the temperature spread is < 8KThe maximum observed deviation from the setpointtemperature is 1.5% (3% allowed) All thermal requirements of the HFTM are met[Ch. Klein, F. Schwab]Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik25Complementing studies : specimen handling15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe complete processes of specimen insertion & retrievalwere demonstratedIn case of re-irradiation, specimen insertion/retrieval must be performed in hot cellsSpecimen stack assembly was practiced with hot cellmanipulators and adapted gripper toolsTotal time for specimen stack assembly is about 2 hoursManupulator-based handling ofSSTT specimensGripper handling a 0.76mm thick flat tensile specimenExperience on requiredspecimen handling timesCutting of capsule for specimenretrievalInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik26Complementing studies : NaK corrosion & wetting15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseTwo capsules with Eurofer specimens immersed in NaK-78 were operated 3 / 6 months at 470-500°C cycl.After retrieval, specimens were investigated optically, mechanically, and by SEM/Energy Dispersive X-RayCleaning by Ethanol and ultrasound Influenced layer was limited to max. 5µm No effect in mechanical properties5µmONaKaCCr[A. Abou-Sena, A. Heinzel, KIT]NaK film after retrievalCleaned specimenComparison of base / NaK exposed materialsInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik27Conclusions15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe HFTM was developed according to the IFMIF EVEDA specifications and user requirementsAnalyses characterize all nuclear (material testing and operation relevant) properties and engineering propertiesPrototypes of all relevant components were fabricatedIntegrated function of all components was demonstrated by the tests of the HFTM prototype in the HELOKA-LP helium loop Complementing studies gave results on NaK handling, specimen handling/insertion/retrieval, NaK corrosion, thermal hydraulicsThe prototype fabrication and tests (especially irradiation in BR2) delivered many specific hints on improvements, such as capsule lifetimeInstitut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik28Outlook on further development15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseThe HFTM development continues in the frame of EUROFUSION WPENS (DONES):Improvements for capsule lifetime to be implemented and tested.The HFTM body will be adapted to the DONES environmentrelieved space requirements50% of nuclear heatingIntegrated channels HFTM body (fabrication test)Institut für Neutronenphysik und ReaktortechnikGruppe Messtechnik und Experimentelle Methodik29Acknowledgements15.10.2015 Frederik Arbeiter – Design & Validation of the IFMIF HFTM in the EVEDA phaseCore „HFTM“ Team at KIT:A. Abou-Sena, F. Arbeiter, T. Böttcher, Y. Chen, B. Dolensky, U. Fischer, V. Heinzel, T. Heupel, Ch. Klein, K. Kondo, J. Konrad, A. Möslang, A. Muche, H. Piecha, R. Rolli, G. Schlindwein, F. Schwab, FUSION Programme UnitResponsibles at SCK-CEN / BR2:J. Averhals, P. Jacquet, V. MassautThe IFMIF EVEDA Project Team, F4E, JAEA, European and Japanese Research Units involved in IFMIF EVEDA 

Design description and validation results for the IFMIF high flux test module as outcome of the EVEDA phase

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Design description and validation results for the IFMIF high flux test module as outcome of the EVEDA phase

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