1. Mitglied der Helmholtz-Gemeinschaft ESS cold and thermal Moderators Moderator & Reflector System Project Introduction Meeting 2015-08-19 | Yannick Beßler, Johannes Wolf, Petra Schumacher, Marc Hofmann, Jörg Wolters, Michael Butzek

2. Mitglied der Helmholtz-Gemeinschaft Updates current work Top cold Moderator from neutronic to real Modell Running weld tests (through welding) Weld test for Invar pipework Lower cold Moderator Manufacturing tests (th. Moderator disc Al6061-T6) Parameter study eBeam welding FEM simulation top cold Moderator Twister design optimization General questions (requirement ESS-0034225) RCC-MRx??? Contents 29. Januar 2016 2

3. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 3 BF2.1 PDR ModelBF2.2 + holding structureBF2.3 + cover Full contact with FG and outer surface Necessary because Stress locally>84 MPa Including fluid guide structure (FG) From neutronic Modell to real Modell

4. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 4 BF2.4 with real contact surface FG contact with cover (1,5 mm) shown in red are the real contact surfaces thickness FG 2mm / real contact 1.5...1.8 mm thickness cover (weld area) 1.5 mm for eBeam power reduction in order to keep as much as possible T6 conditions run-in and out length (<10 mm) is necessary for the eBeam in order to reduce burn out risk From neutronic Modell to real Modell Reducing thickness of the cover Real contact

5. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 5 Grooves for filler BF2.5 with filler (AlSi12) Because heat crack risk! Increasing of Si content is necessary (see weld report DUP) Welding from the inside with beam deflection (mirror system) From neutronic Modell to real Modell

6. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 6 upper moderator pipework space for welding 40 mm space necessary for connecting the pipework

7. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 7 Running weld tests (through welding)

8. Mitglied der Helmholtz-Gemeinschaft Through welding test 29. Januar 2016 8 Groove for filler (AlSi12) Beam power reduction

9. Mitglied der Helmholtz-Gemeinschaft Weld test for Invar pipework 29. Januar 2016 9  Filler = base material! for low temperature applications

10. Mitglied der Helmholtz-Gemeinschaft Lower cold Moderator 29. Januar 2016 10 First simulation model ready!

11. Mitglied der Helmholtz-Gemeinschaft Manufacturing tests (th. Moderator disc Al6061-T6) 29. Januar 2016 11 There are no significant deformation during machining! at the used time-consuming and expensive machining type Background: the tempering process create additional inner stress. This stress could deform the structure during machining….

12. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 12

13. Mitglied der Helmholtz-Gemeinschaft Parameter study eBeam welding 29. Januar 2016 13 1,6 1,5 4 “Top plate” “Vessel”

14. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 14 BF2.1 PDR Model BF2.2 + holding structureBF2.3 + cover FEM simulation top cold Moderator

15. Mitglied der Helmholtz-Gemeinschaft FEM simulation top cold Moderator 29. Januar 2016 15 BF2.4 with real contact surface

16. Mitglied der Helmholtz-Gemeinschaft  Twister handling and bearing  Twister shielding  LH2 pipework 29. Januar 2016 16 Potential for optimization

17. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 17 Twister handlding and bearing additional sliding and handling device is required empty pit with radial bearing flange final alignment, shielding completely mounted

18. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 18 Twister handling and bearing contact / spring insert axial bearing

19. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 19 Twister handlding and bearing 6 radial bolts lifting device bayonet, gearing bubble level 4 lifting shafts

20. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 20 Twister shielding 2,5 internal gap 30 internal step 30 external step 5 external gap milled shaft welded tubes shielding stone milled groove

21. Mitglied der Helmholtz-Gemeinschaft 29. Januar 2016 21 LH2 pipework interface plate, H 2 O, vacuum

22. Mitglied der Helmholtz-Gemeinschaft 2.3.2 The MR Plugs are cooled by water and liquid hydrogen. Water and hydrogen will get activated when passing through. The MR Plugs shall be tight and confine the radioactive water and hydrogen inventory. 2.3.3 The MR Plugs will be leak controlled and monitored. 3.3.6 The total weight of the MR Plugs and MR Plugs Structure shall be 5,5 t or less 3.4.1 p.H2O=4 bar / p.H2O.Design=5 bar SS 1.4306 / 304L (X2CrNi19-11) or better (<10dpa) Materials Handbook 316LN or 316L (<7,5dpa) 4.4.1 MR Plug reliability 0,9997 and availability 0,99???  361 d/y??? 4.4.5.2 A new set of top and bottom MR Plugs and MR Plugs Structure shall be available. General questions (requirement ESS-0034225) 29. Januar 2016 22

23. Mitglied der Helmholtz-Gemeinschaft basic material still 3.2 3.2 is equivalent to 3.1 The main difference during manufacture stamped by extern (3.2) during manufacture stamped by internal authorized (3.1)  With 3.2 we lose a lot of important time! 3.2 certificate versus 3.1 certificate 29. Januar 2016 23

24. Mitglied der Helmholtz-Gemeinschaft Heat Deposition File (top plug only) 29. Januar 2016 24 Top Plug RCC Modell real Modell comment Cell IDMaterialDensityVolumeErrorHeatingErrorHeat densityVolumeHeatingdeltaQ [-] [g/cm3][cm3] [W] [W/cm³][cm3][W] 80001Hydrogen0,07530,178,141519,350,302,87494,471417,03-102,31without pipes! 80002Cryo-Al2,73163,572,401655,310,6610,12193,301956,16300,86without pipes! 80003Void0,00323,194,190,00 80004Al2,70225,552,862120,670,859,40 80005Hydrogen0,07530,178,141499,370,302,83494,471398,40-100,97without pipes! 80006Cryo-Al2,73163,572,401148,750,467,02193,301357,54208,79without pipes! 80007Void0,00323,194,190,00 80008Al2,70225,552,861479,940,446,56 80009Water1,00565,737,924761,580,958,42 Plus Heat Vakuummantel (Teil) 80010Al2,7066,611,31490,400,347,36 80011Water1,00716,9910,573745,651,505,22 80012Al2,7093,501,71563,800,456,03 80013Water1,00716,9910,572216,290,663,09 real LH2/Valuum/Al/H2O 80014Al2,7093,501,71254,670,152,72 80015Water1,008362,0441,8154807,255,486,55 80016Al2,701589,628,277885,081,584,96 80017Water1,001168,8910,055842,580,585,00 80018Al2,70549,184,672727,400,554,97 80019Void0,0099,521,630,00 wo zu???? 80020Al2,70449,653,822096,470,634,66 80021Be+Water1,7879793,63239,38108124,7510,811,36 80022Al2,703343,7512,374747,700,951,42 realTop cold Moderators 6,13[kW]without pipes! RCC Mo. Top th, Modertor 86,90[kW] Vorsicht Reflektor/th Modertor gleiche Wand oben RCC Mo. Top Be Reflector 114,97[kW]

25. Mitglied der Helmholtz-Gemeinschaft Backup Design / operating Pressure…… 29. Januar 2016 25

26. Mitglied der Helmholtz-Gemeinschaft RCC-MRx 29. Januar 2016 26 ??????????????????? 20-23.10.15 RCC-MRx training in Jülich!