JT-60 SA Toroidal Field coil structural analysis

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1 JT-60 SA Toroidal Field coil structural analysis Christophe Portafaix Introduction TF coil description TF coil design and electromagnetic loads Material and Criteria 2D structural analysis 3D structural analysis Conclusion 1

2 Nominal parameters Plasma major radius = 2.95 m Plasma minor radius = 1.18 m Aspect ratio = 2.5 Plasma current = 5.5 MA Introduction JT-60SA Toroïdal magnetic Field = 2.26 T Vacuum vessel Cryostat Equilibrium Field (EF) coils Central Solenoid (CS) Toroidal Field (TF) coils ~14m 2

3 TF coil description Association Inner leg section 18 TF coils case Gravity support Conductor NbTi 6 Double pancakes Temperature Current He flow rate Peak field Tmargin 4.4 K 25.7 ka 4 g/s 5.65 T > 1 K 3

4 Spherical Joints: Permit to reduce transmitted loads (no moment). Gravity support 1.5m Tube Inner ø 90mm Outer ø 140mm Tube section optimized to reduce heat leak. 1.4m 4

5 TF coil design and electromagnetic loads Wedged CS TF In plane load Fr and Fz : I ^ Bφ Forces caused by TF current and toroidal field Radial net force= 23MN Coil Contact Area on Sides z Hoop Compression Wedging of the TF Coils to withstand Centring Loads r 5

6 z r Toroids Forces Winding with constant tension Discussion on thin shell Segment of the winding with local curvature ρ In plane load Fr and Fz : I ^ Βφ T=(1/2) IBρ B m =µ 0 NI/(2πr 1 ) Bending free : D shape r 1 minimum distance from z axis T=I ρ B m r 1 /(2r) To maintain T constant and no bending moment: ρ=kr with k = 4 πt/(µ 0 NI 2 ) In plane (z,r), the curve must satisfy the following equation: d 2z r = dr ± k [ ] ( dz) 3/ 2 2 dr 6

7 In plane load Fr and Fz : I ^ Bφ Inner leg wedged Inner leg section z F r r Fz Fphi Fz =5 MN Fr= I* <Bphi> =5. MN/m (I=72*25.7kA <Bphi>=5.6/2T ) Fphi=Fr/(2 * sin 10 ) =14.4 MN/m The centring force is supported by a vault effect in the TF nose (Fphi) 7

8 Insulation : glass epoxy Jacket: Stainless steel Inner leg section cable Case cooling channel : stainless steel Stainless steel: 51% of the inner leg section N b T i : 4.5% of the inner leg section SS to withstand Lorentz forces Case: Stainless steel Eddy current insulation: glass epoxy 8

9 Forces caused by TF current and poloidal field Structural links have to include an eddy current insulation Out of plane loads Fφ : I ^ Br and Bz N 11 GR W 0.2 IM NUL XPF SOF SOB EOB Cyclic loads fatigue Connection of the TF Coils to withstand out of plane loads 9

10 OIS r z case Out of plane loads Fφ : I ^ Br and Bz OIS, bolts, keys withstand the Out of plane loads Friction between inner leg play an important role in supporting the out of plane loads bolts keys OIS is separated from the coil casing: Simplify the manufacturing Reduced welding in the coil casing Simplify cold testing Reduce hoop forces in the bolted connections, thus reducing number of bolt 10

11 Young s modulus E 1 (GPa) Young s modulus E 2 (GPa) Coulomb s Modulus G 12 (GPa) Coulomb s Modulus G 23 (GPa) Coulomb s Modulus G 13 (GPa) Thermal contraction dl 1 /l Thermal contraction dl 2 /l Thermal contraction dl 3 /l Material and Criteria Mechanical properties at 4K Stainless steel % 0.3% 0.3% Insulation Epoxy glass Young s modulus E 3 (GPa) Poisson s ratio nu Poisson s ratio nu Poisson s ratio nu % 0.25% 0.7% Resin % 0.5% 0.5% 1 and 2 along layer direction, 3 perpendicular to layer direction 7 7 cable % 0.3% 0.3% 11

12 Stainless steel criteria Limit stress value: Sm= 547MPa : 2/3 of the yield strength at 4K (820MPa) Membrane stress Pm < K*Sm Membrane + bending stress < 1.3*K*Sm Base metal : K=1 Welds : K=1 for plates under 20mm thick K=0.9 for plates from 20 to 150mm 12

13 Insulation criteria (σ n /σ 0 )+(τ n /τ 0 ) 2 < 1 (LHD criteria [1]) Association σ 0 : tensile strength at 77K= 38Mpa τ 0 : shear strength at 77K= 27Mpa σ n : stress perpendicular to the glass fiber τ n : shear stress Compressive strength: 600 MPa ITER criteria fatigue ITER criteria static [1] Cryogenic shear fracture tests of interlaminar organic insulation for a forced-flow superconducting coil, MT13, Victoria BC, Canada 1993, K. Kitamura et al., NIFS Tau NS (MPa) Sig NN (MPa) LHD criteria static 13

14 2D structural analysis Association The calculations are performed in 2D generalised plane strain hypothesis: constant vertical strain corresponding to a vertical force Fz Inner leg section Load steps: 1. Cool down from 293K to 4K 2. Cool down + In plane Lorentz forces 3. Cool down + In plane Lorentz forces + pressure (quench) 14

15 Bmax =5.6T Fr=5. MN/m Magnetic field map in the JT60-SA TF winding pack (T) 15

16 Radial displacement (m). Maximum contact gap distance = 1mm Von Mises Stress map in conductor jacket (MPa). Maximum von Mises stress = 494MPa Load: Cool down + In plane load 16

17 Normal stress along the wedge contact. In plane load σn max = 351MPa (compression stress) < 600 MPa Glass epoxy. (limit) 17

18 Von Mises Stress intensity map in casing. Maximum Von Mises stress = 447MPa. Cool down + In plane load 18

19 The LHD criterion for insulation. σ n σ 0 τ n + τ 0 2 = 1 σ 0 : tensile strength at 77K = 38MPa, τ 0 : shear strength at 77K = 27MPa. σ n : stress perpendicular to the glass fiber, τ n : shear stress Load: Cool down + In plane load LHD criteria max = < 1 19

20 OIS 3D structural analyses case CS1 CS2 EF3 TF3 FP3 TF2 EF2 TF1 FP2 FP1 EF1 CS3 FP4 FP6 TF coil CS4 FP5 EF6 EF4 EF5 TF, CS, EF coils and Plasma 20

21 Electro-magnetic analysis In plane forces calculated with TF current only (25.7kA per conductor) In Plane Forces (EOB) Magnetic force (MN/m) Upper Inner TF2 TF1 TF2 Lower Inner S = 0m S = S max /2 2.3 Leg TF3 TF3 Leg s (m) 21

22 Electro-magnetic analysis Out of plane forces determined S = 0m S = S max /2 22

23 Lateral SOF ~ 20mm Local peak shear panel connection 23

24 Max stress <130 MPa Bending stress < 20 MPa Load: Weight + VDE Gravity support Max stress < 140 MPa Bending stress < 10 MPa Load: Weight + Seism 24

25 Conclusions TFC structures design is well advanced. Design optimized in order to reduce mass and cost Actually detail design tasks are ongoing. Future activities (local models, half torus model) are planned. 25

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