1 THERMAL & MECHANICAL PRELIMINARY ANALYSIS ELM COIL ALTERNATE DESIGN Interim Review July 26-28, 2010 In-Vessel Coil System Interim Review – July 26-28, 2010

2 Outline BOUNDARY CONDITIONS NUCLEAR & RESTISTIVE HEAT GENERATION LORENTZ & PRESSURE LOADS RADIATION ; CONDUCTION ; COOLING 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 GENERATION (W/M^3) IVC Interim Design Review – July m The Toroidal Leg Nuclear Heat is Applied Based on a Curve fit of data from University of Wisconsin Team The Poloidal Leg Applies a Similar Shaped Function

IDEALIZED LOAD DIAGRAMS Thermal + Pressure Loading Thermal + Pressure + Lorentz Loading Load Time Load 5 hz 3,000 sec 9,000 sec 30,000 Pulses Unknown Spectrum STEADY STATE TRANSIENT

ELM LORENTZ LOAD VS POSITION SECTOR #5 UNIT LOADS ARE MORE CRITICAL IN THE LOWER LEFT QUADRANT (LFT) (BOT) (RHT)(TRC) (BLC) Critical Quadrant SECTOR 5 FE MODEL LOADS FxFyFz ELM_MD_BOT132,271-31,397-32,429 ELM_MD_BLC130,406-8,635-41,265 ELM_MD_LFT300,308-10,2727,491

SANDWICH DESIGN Section View IVC Interim Design Review – July Axial Translation Is Allowed No Hard Mechanical Attachment for tension DESIGN CONCEPT ALLOWS THERMAL DISPLACEMENT WITH SUPPORTS TO REACT LORENTZ LOAD

MAGNESIUM OXIDE BOUNDARY Shear Test / Analysis IVC Interim Design Review – July MGO Insulation Coil PARAMETRIC RESPONSE TO OFFSET BOUNDARY Contact offset may be required to enforce an interface load TEST DATA REQUIRED FOR CALIBRATION

ELEMENT MESH UNIFORM HEXAHEDRAL MESH Rigid Boundary Flexible Mounts To Facilitate Thermal Growth Symmetric Boundary

STEADY STATE TEMPERATURE ANALYSIS FULL OPERATING CONDITIONS Resistive Heat Generation Nuclear Heat Generation Cooling Water Applied

THERMAL BOUNDARY CONDITIONS The Copper Coil Temperature Distribution is an Equilibrium of all Combined Effects Conduction into Foundation at 100 C at all foundation interfaces Radiation Surfaces with View Factor =1 (dark blue surfaces) Nuclear HGEN Temp in =105.7 C Temp out =131.5 C Unspecified Surface Boundaries are conservatively assumed to be Adiabatic

RADIATION ASSUMPTIONS IVC Interim Design Review – July All Form / View Factors equal to 1.0 Incident Radiation is very small from 100 C Far Field Emissivity is a Hemispherical Average Across all wavelengths and directions

Steady State Temperatures With Heat Generation ; 6 m/s Water Cooling Radiation 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 Steel With Cooling Water Steady State Temperatures With Heat Generation ; 6 m/s Water Cooling Radiation Stainless Steel Jackets

The Coil Temperatures are Consistent with Hand Calculations and the Net Energy Balance of all Applied Thermal Loads Steady State Temperatures With Heat Generation ; 6 m/s Water Cooling Radiation Applied Boundary is: Temp in =105.7 C Temp out = C

Steady State Fault Condition with Radiation Cooling Fault Condition (No Water Cool or Resistive Heating) with Far Field Radiation Results in Temperatures that are within Material Capacity (316 SS Melt at 1375 C) Max Temperature Predicted on Surfaces that Exclude Radiation

Steady State Fault Condition with Radiation Cooling Fault Condition (No Water Cool or Resistive Heating) with Far Field Radiation Results in Temperatures that are within Material Capacity (CuCrZr Melt at 1,078 C) Conservative Max Copper Temperature= 918 C Melting 1,078 C

STEADY STATE STRESS ANALYSIS THERMAL & DISRUPTION LOADS

IVC Interim Design Review – July Steady State Pressure + Thermal + Lorentz Load Support Reaction Loads RSYS 12 (Newtons) FX FY FZ E ,761.. RSYS 14 (Newtons) FX FY FZ E 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 Pressure + Thermal + Lorentz Load Displacements The Displacements are Reasonable for the Specified Boundary Conditions Lorentz Loads Acting Down Toward The Reactor +Y m = in

Steady State Mechanical + Thermal Loads + Lorentz Max Principal Stress Stress shows: 1.) Bending across Restraints 2.) Exterior Jackets in Compression 3.) Interior Copper Coil in Tension Restraint Location The Stresses are Excessive However they are Manageable With the current strategies in progress

Steady State Mechanical + Thermal Loads 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 Coil e8 Pa = 6,526 Psi Copper Coil e8 Pa = 2,683 Psi

Steady State Mechanical + Thermal Loads + Lorentz von Mises Stress Copper Stresses Have Positive Limit Stress Margins and Negative Fatigue Margin Additional Section will be used to Redistribute These stresses Copper Stresses Have Positive Limit Stress Margins and Negative Fatigue Margin Additional Section will be used to Redistribute These stresses Max Copper Coil.184e9 Pa = 26,686 psi

REVISED ANALYSIS With Bridge Support IVC Interim Design Review – July

IVC Interim Design Review – July Updated - Steady State Temperatures With Heat Generation ; 6 m/s Water Cooling Radiation Revised Plan July 22, 2010 Inlet Temp 70 C Outlet Temp 120 C Bridge Support to react out Lorentz Loads

Sub Modeling Plan Classical Cut Boundary Displacements applied from Global analysis Stress to be evaluated for Variable Spring Stiffness and / or applied Preloads 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

Steady State Displacements The vertical displacements are reasonable for the specified boundary conditions +Y Pressure + Thermal Pressure + Thermal + Lorentz

Steady State Pressure + Thermal Loads von Mises Stress Bridge Support can be used to Shape and Redistribute Stresses on the Coil Additional 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 Coil Additional Shaping and Stiffness Changes with Sections changes will be used to React out Stresses Copper Coil 0.37 e8 Pa = 5,366 Psi

Steady State Pressure + Thermal + Lorentz Loads Von Mises Stress Max Copper Coil= 0.18e8 Pa = 2,465 psi Bridge Support can be used to Shape and Redistribute Stresses on the Coil Additional 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 Coil Additional Shaping and Stiffness Changes with Sections changes will be used to React out Stresses

CONCLUSIONS / 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) IVC Interim Design Review – July