Modeling the blanket module: Multiphysical computations and rapid turnaround capabilities Ramakanth Munipalli, C.M.Rowell, K.-Y. Szema, P.-Y.Huang HyPerComp.

Modeling the blanket module: Multiphysical computations and rapid turnaround capabilities

Ramakanth Munipalli, C.M.Rowell, K.-Y. Szema, P.-Y.HuangHyPerComp Inc., 2629 Townsgate Rd., #105, Westlake Village, CA 91361

Alice Ying, Neil Morley, Mohamed Abdou, Sergey Smolentsev, Manmeet NarulaUCLA

FNST Meeting, UCLA, August 14, 2008

CADMultiphysicsSimulation Management

VirTual Blanket Module



Objective:

To create a simulation management software with integrated prediction capability for blanket modules (extendable to the divertor and other PFCs) operating in a fusion environment

Phase-I SBIR: CAD-Centric Management System for a virtual blanket module

Period of performance: July 2008 – March 2009

• Conventional modeling involves using various codes to individually model physics

• This is a CAD-centric multiphysical software integration project – no new physical modeling ability is sought in individual disciplines

Outline

Scope of the VTBM project

A description of the functionality and uniqueness of the VTBM environment

Some details on implementation

Phase-I tasks

TBM Assembly

Solid breeder (HCCB) TBM

Liquid breeder (DCLL) TBM

First Wall, Side Wall Assembly

Top Plate

Bottom PlatePbLi Inlet/Outlet Pipe

He Inlet/Outlet Pipe

Back Plate

PbLi Inlet Manifold

PbLi Outlet Manifold

Grid Plate x 9

Grid Plate He Manifold

Vertical He I/O Manifold

He Inlet Manifold

He Outlet Manifold

First Wall

PbLi Inlet/Outlet Pipe

PbLi Flow Channels

Back Plate

He Inlet/Outlet Pipe

Blanket Module: Location and attributes

FW

Top Plate

SiC

Grid Plate Assy

Bottom Plate

Back Plate Assy

Blanket Module: Details and flow features

Key Physical Phenomena:

Fluid flow, MHD

(we will focus on liquid breeder)

Heat transfer

Structural mechanics

Neutronics

Tritium transport

Inputs:Blanket geometry including front and return ducts:

Toroidal width, radial depth, poloidal height,FCI dimensions, gap thicknessHelium duct dimensionsInlet manifold geometry

Surface Heating (function of poloidal coordinate)

Volumetric heating as a function of (r,p) coordinates

Temperature distribution in cooling He channels

Heat transfer coefficient in He flows

Thermophysical properties of PbLi, He, Fe, SiC

Inlet/Outflow Delta T in PbLi and in He

Inlet PbLi velocity for each duct

Magnetic field distribution Outputs:

Velocity field in the bulk flow and in all sections of the gap

MHD pressure drop

Temperature distribution in PbLi, ferritic structure and FCI

Temperature drop across the FCI

Interface temperature between FCI and PbLi

Calculated inlet/outflow temperature in PbLi for each duct

Heat losses from PbLi into He flows

Structural deformation

Tritium concentration

Typical Input and Output data

File Management<Project title>

CAD Interface

Grid generation

Communications

Resource Management

Multiphysical solver

Preprocessing

Process control andPost-processing

Performance Estimates

TBM Geometry, Test ConditionsUser Interface Network Interface

VTBM: A description based on functionality

Major VTBM attributes: Project management – manage the entire simulation process from one convenient interface Assistance in problem setup across multiple software platforms Time and Space coupling – “loosely” or “tightly” coupled simulation process Intelligent problem setup, maintain I/O schedules for each solver Conservative and accurate interpolation techniques – Fast octree approaches CAD-based data transfer: Redo CAD when geometry deforms Visualization of results

AML (Technosoft Inc.): Adaptive Modeling Language. Product, process development cycle integration, multidisciplinary modeling. Knowledge based engineering (KBE) framework that captures knowledge from the modeled domain and creates parametric models.

ISIGHT (Engineous Software): Rapid integration of commercial and in-house simulation programs. Automates code executions. Optimization, design of experiments, quality engineering, visualization.

ModelCenter (Phoenix Integration): Visual environment for process integration. “Adaptable”. Design, archive, update the design process all in a visual environment. Process Data Management (PDM) tools help store information about process and design data.

ANSYS Multiphysics: The capability is available. However, the basic survey shows that the usage in industry is virtually non-existant.

MDOPT (Boeing): CORBA based interdomain communication facility creates workflow criteria for multiphysical coupling and optimization.

Some commercial MDA implementations

http://www.phoenix-int.com/index.html

http://www.technosoft.com/

http://www.ansys.com/default.asp

User concerns

“Every business needs a great deal of customization”

“How does one troubleshoot a multiphysical solution: Who is the culprit?”

“I would like to be able to go under the hood and perform diagnostics. The dash-board type control is insufficient”

“Existing commercial Multi Disciplinary Analysis (MDA) environments require a lot of customization before they can be integrated into a development cycle”

“A truly adaptable MDA environment does not currently exist”

Physical phenomena encountered are extreme:Strong sensitivity to geometry changes, high EM interaction, large gradients in material properties, intense material interface effects in heat, current and mass transfer, multiscale coupling across physics

Our emphasis will be on the accurate and robust coupling of physics relevant to the fusion environment.

The graphical interfaces, as well as geometry generation and post-processing utilities will be customized to modeling blanket/heat-shield physics

Problem setup, and troubleshooting using an “intelligent” front-end

Change in cross sectional velocity profile due to change in SiC conductivity (left – 5 /ohm/m , right – 500 /ohm/m

Uniqueness of the VTBM approach

Unstructured second order Hex/Tet (node based)

Finite Element

ABAQUS

Requires second order elements for accuracy. The elastic stress and strain analysis is followed by a plastic analysis where needed. Fusion relevant material properties and constitutive equations have to be incorporated into the analysis

Unstructured second order Hex/Tet(node based)

Finite Element

ANSYSStructural Analysis

Requires external meshing tools. Special mesh requirement to capture fine MHD boundary/shear layers

Unstructured hybrid mesh(cell based)

Finite Volume

HIMAGMHD


Finite Volume

FLUENT

Unstructured hybrid mesh (node based)

Finite Element

CFdesign

CAD model to mesh requires intermediate translators. The translators modify, clean and convert the geometry into the required input format for the specific analysis code. Special mesh considerations needed to capture boundary layers (correct application of turbulence models)


Finite Volume

SC/TetraThermo-Fluids

Need to incorporate large scale 3D fusion device models (e.g. 20 degree toroidal sector)

Unstructured Hex/Tet mesh(node based and edge based formulations)

Finite Element

ANSYS

Requires external meshing tool (CUBIT). Need to incorporate large scale 3D fusion device model (e.g. 20 degree toroidalsector)

Unstructured Hex/Tet mesh(node based)

Finite Element

OPERAElectro-magnetics

Standard CAD data import. Need to incorporate large scale 3D fusion device model (e.g. 40 degree toroidal sector)

Unstructured tetrahedral mesh (node based)

Finite Element

Attilla

CAD models have to be imprinted and merged before import into MCNP. Need to incorporate large scale 3D fusion device model (e.g. 40 degree toroidal sector). Direct geometry method does not require CAD translators for MCNP but requires modification of MCNP code

Particle in Cell (PIC)Monte Carlo Simulation

MCNPNeutronics

Geometry to Analysis preparationMesh specificationComputational Scheme

Analysis codePhysics

Unstructured second order Hex/Tet (node based)

Finite Element

ABAQUS

Requires second order elements for accuracy. The elastic stress and strain analysis is followed by a plastic analysis where needed. Fusion relevant material properties and constitutive equations have to be incorporated into the analysis

Unstructured second order Hex/Tet(node based)

Finite Element

ANSYSStructural Analysis

Requires external meshing tools. Special mesh requirement to capture fine MHD boundary/shear layers


Finite Volume

HIMAGMHD


Finite Volume

FLUENT


Finite Element

CFdesign

CAD model to mesh requires intermediate translators. The translators modify, clean and convert the geometry into the required input format for the specific analysis code. Special mesh considerations needed to capture boundary layers (correct application of turbulence models)


Finite Volume

SC/TetraThermo-Fluids

Need to incorporate large scale 3D fusion device models (e.g. 20 degree toroidal sector)

Unstructured Hex/Tet mesh(node based and edge based formulations)

Finite Element

ANSYS

Requires external meshing tool (CUBIT). Need to incorporate large scale 3D fusion device model (e.g. 20 degree toroidalsector)

Unstructured Hex/Tet mesh(node based)

Finite Element

OPERAElectro-magnetics

Standard CAD data import. Need to incorporate large scale 3D fusion device model (e.g. 40 degree toroidal sector)

Unstructured tetrahedral mesh (node based)

Finite Element

Attilla

CAD models have to be imprinted and merged before import into MCNP. Need to incorporate large scale 3D fusion device model (e.g. 40 degree toroidal sector). Direct geometry method does not require CAD translators for MCNP but requires modification of MCNP code

Particle in Cell (PIC)Monte Carlo Simulation

MCNPNeutronics

Geometry to Analysis preparationMesh specificationComputational Scheme

Analysis codePhysics

Computational analysis tools of interest to VTBM

Check availability of resources ( licenses, codes, disk-space, etc.)

Initialize projectSelection of physics

Update GUI to reflect problem statement

Check availability of resources ( licenses, codes, disk-space, etc.)

Initialize projectSelection of physics

Update GUI to reflect problem statement

MaterialsLoading conditionsConstraints / BCsInitial conditions

Global InputsMaterials

Loading conditionsConstraints / BCsInitial conditions

Global Inputs

Parametrized geometry specification (B-rep)

Conversion to CAD model (IGES/STEP) and grid template

CAD representationTBM specific development

Specific inputs for numerics

Automated Grid generationAll selected physics

Numerical model

initialization

Solve for / Import Neutronics data

Interpolate to appropriate solvers

Source definition

Setup (CDB, PRE, etc.) filesPatch definition and boundary mappings

Parallelization Preprocessing

TBM specific development




Numerical model

initialization



Source definition





Numerical model

initialization




Numerical model

initialization



Source definition



Source definition







VTBM Work-flow diagram: problem setup

Dynamics data visualization(adapted tecplot, etc.)

Coupling mechanisms

Post processing



Coupling mechanisms

Post processing


Coupling mechanisms

Post processing


CAD Data

Mesh data

CAD Data

Mesh dataSolver-1

mesh_datasolution_data

Solver-2mesh_data

solution_data

TemplateTemplateCAD SystemCAD System TemplateTemplateCAD SystemCAD System

Solver-3mesh_data

solution_data

Solver-1Solver-3

Solver-2

IN

OUT

VTBM Work-flow diagram: Field solution and postprocessing

Pressure loadHeat loadEM load

Radiation load

StressesStructural deformation

Structural Mechanics

Grid, BCsMaterial properties

Grid, non-thermal BCsRadiation loadThermal BCs

Temperature distributionHeat transfer rate

Fluid pressureFluid velocity

Thermal/hydraulics


Temperature distributionFluid Pressure

Heat transfer rate Fluid velocity

Magnetohydrodynamics

Initial CAD (native, generic)Field properties


Physics specific grid/geometry info,grid-to-grid data transfer

Interpolation of fields ( + )

CAD - Grid Engine

(R)(R)

(R)(R) (R)(R)

(G)

(G)(G)

(G)(G)

(G)(G)

+

+

+

+


Radiation load





Radiation load







Thermal/hydraulics




Thermal/hydraulics













CAD - Grid Engine





CAD - Grid Engine

(R)(R)

(R)(R) (R)(R)

(G)(G)

(G)(G)

(G)(G)

(G)(G)

+

+

+

+

Geometry, BCsPlasma parameters

Radiation loading(R)

Neutronics

Geometry, BCsPlasma parameters

Radiation loading(R)

Neutronics

VTBM: Integrated physics modeling schematic

(G)

Neutronics Treatment

In the phase-I project neutronics data will be assumed to be given, computed from prior studies. We will use one-dimensional distributions of power density as a source term in thermal and flow modeling.

Thermal analysis

Traditional thermal analysis for non-conducting flows such as Helium and water will be performed using off-the-shelf third part software – motivated by their speed

MHD flows with heat transfer and natural convection, including heat transfer in conducting solid walls will be computed using HIMAG.

While numerous commercial codes are able to compute flow and heat transfer in complex structures, we will focus on the use of SC/Tetra in Phase-I.

Future extensions will include FLUENT and CFdesign.

MHD(PbLi)

Helium

Thermal and electrically conducting wall

Radiative heat input

1 / Ha

1 / sqrt(Ha)

U(z)

j(y,z)

Ha≈Ha-1

B

//≈Ha-1/2

2h

Hartmann layerSide layer

B

Side layersHa

1~

Hartmann layersHa

1~

BBB

Side layersHa

1~Side layers

Ha

1~

Hartmann layersHa

1~Hartmann layersHa

1~

FLOW

The exacting needs of numerical MHD

Second order convergencefor high Hartmann no. flowsBenchmarked against expt. data

at fusion relevant conditions

Complex geometries, non-orthogonal,hybrid meshes, parallel computing

HyPerComp Incompressible MHD solver for Arbitrary Geometry

Task-PaneChangesOn Demand

Task-PaneChangesOn Demand

Development of an effective user interface - 1

Physics model editor (left),

Graphical BC selection (below)

Development of an effective user interface - 2

Customization of the view pane based onsimulation stage

CGNSLibraryVersion_t(CGNS version number)

Axisymmetry_t BaseIterativeData_t(number o f steps)

Da taClass_t(data class)

Descriptor_t(text)

DimensionalUnit_t(base units)

Fam ily_t(fam ily nam e)

FlowEquationSet_t ConvergenceHistory_t(number o f ite rations)

Grav ity_t In tegralData_t ReferenceState_t Ro tatingCoord inates_t

Simu lationType_t(simula tion type)

UserDefinedData_t Zone_t(ve rtex and cell sizes)

CGNSB ase_t(physical and cell dim s)

root node

VTBM : Use of CGNS as a common data file format

We seek to provide a common base-formatto maintain simulation data throughout.

CGNS (CFD General Notation System) is a likely candidate. It is open-source, welldocumented and used by various commercial software already

In general, simulation codes use native grid/data formats. e.g.:

TEMPUS-GIGES, STEP CAD files, and native TGP formatHIMAGUX Unstructured GridUGM Boundary patches and BC info

SC/TetraPRE Computational Mesh including material regionsFLD Field data, including computational mesh and other physical informationANSYSCDB Common database format including mesh and field solution

nofelmts : Number of FCI channelsnoftube_l: Number of He channels along width

s_length

d1

d2

d3

d4

s_width

s_length

d1

d2

d3

d4

s_width

RAFS wall 4 mm thick

SiC wall 5 mm thick

20 mm

z

y

2 mm

gap 5 mm

120 mm

SiC wall 5 mm thick

z

y

2 mm

gap 66 mm

120 mm

436 mmRAFS wall 4 mm thick

SiC wall 5 mm thick

142 mm

z

y

2 mm

gap 66 mm

484 mm


50 mm13 x 5 mm

12.5 mm wide (for the 2 side channels)

160 mm

35 mm

121 mm


SiC wall 5 mm thickSiC wall 5 mm thick

20 mm

z

y

2 mm

gap 5 mm 5 mm

120 mm


z

y

2 mm

gap2 m

m gap 66 mm66 mm

120 mm

436 mmRAFS wall 4 mm thick

436 mmRAFS wall 4 mm thickRAFS wall 4 mm thick


142 mm142 mm

z

y

2 mm

gap2 m

m gap 66 mm66 mm

484 mm


50 mm13 x 5 mm

12.5 mm wide (for the 2 side channels)

160 mm

35 mm

121 mm

5

3

1

7121 mm

35 mm

5

3

1

7121 mm

35 mm

Template-based approach: Geometry parameterization

Template-based approach: Geometry creation

Template-based approach: Grid generation

HeliumFerritic Steel

SiC PbLi

Pb17Li

Helium

Pb17LiPb17Li

HeliumHelium

Mesh generation by segregation of geometrical features

Interpolation techniques:Point-element relations for standard interpolationElement-element relations based on intersectionPoint-point relations for matching grids/nearest neighbor

E

P

E1

E2

P

Interpolation techniques

Octree search procedures

CAD based surface data interpolationis being developed

P1 P2

P3

P4

P5P6

P7

P8

P1 P2

P3

P4

P5P6

P7

P8Unified

CAD-Based Coupling

P1 P2

P3

P4

P5P6

P7

P8

P1 P2

P3

P4

P5P6

P7

P8

P1 P2

P3

P4

P5P6

P7

P8Unified

CAD-Based Coupling

P1 P2

P3

P4

P5P6

P7

P8Unified

CAD-Based Coupling

MHD mesh Stress analysis mesh

CAD Model

Two types of data communication:All-to-all: n2-n interactionsCAD Based: 2n interactions

Technical challenge:Conservation of forces, moments, etc.

nodes Solidfaces Fluid

nodes Solidfaces Fluid

,

solidfluid

solidfluid

MM

FF

Coupling across physical disciplines

VTBM : Data interpolation

(a) (b)

(c) (d)

VTBM : Data interpolation – contd.

I

i

J

jjqipij

I

i

J

jijjqipij

vBuBW

PvBuBW

vuR)()(

)()(

),(

PCvuR ),(

1

1FCCCF TT

C

NURBS (NonUniform Rational B-Spline) procedure for structural deformation

CAD Surfaces are represented parametrically with NURBS as:u,v are parameters, Wij are weights, Bip is a B-spline of degree p at control point iPij are locations of NURBS control points

The field solver computes loads, deflections, etc. at discrete points rm

These are projected onto the NURBS surfaces and corresponding um, vm are found(This is done at the grid generation stage itself)

If the NURBS expression above is rewritten as:

A new NURBS surface is fitted using least squares after deformation, using:

VTBM : “Appropriate” visualization of physics

2-D dominant

3-D dominant

Customized post-processing: TECPLOT EDGE®

Traditional TECPLOTlayout

TECPLOT layout can be customized to suit the application

Integrated TECPLOT for complex visualizations

Dealing with third party software and APIs

Communication issues, resource management

Compliance with industry standards for I/O data

Interaction with the TBM community and timeline for development

Licensing, Documentation and Software dissemination

Using open source modules: CGM (Sandia, Argonne), CGNS (NASA)

VTBM – Software Development Issues

Preprocessing

B/C specification

Input file generation

Parallel partitioning

Control surface definition

Preprocessing

B/C specification

Input file generation

Parallel partitioning

Control surface definition


Neutronics

Thermal analysis

CFD / MHD

Structural analysis


Neutronics

Thermal analysis

CFD / MHD

Structural analysis


DiagnosticsConvergence, debug info

Visualization(static/dynamic) Solution restart

Code coupling mechanisms



DiagnosticsConvergence, debug info

Visualization(static/dynamic) Solution restart

Code coupling mechanisms



Design parametersPhysical conditions

Input/Output files

Grids, BCs,Solutions

Restart files

VTBMnative

file formatAPI


Design parametersPhysical conditions

Input/Output files

Grids, BCs,Solutions

Restart files

VTBMnative

file formatAPI

User Interface

Network Interface

User Interface

Network Interface

Grid generation

Template based,or full featured

Meshing / remeshing

Higher order elements,curvature

Clustering requirements

Grid import,boundary matching

Grid smoothness,orthogonality

Grid generation

Template based,or full featured

Meshing / remeshing

Higher order elements,curvature

Clustering requirements

Grid import,boundary matching

Grid smoothness,orthogonality

Communications

Volume to VolumeInterpolation

Volume to surfaceextraction

Daemon based data access

Translation and formatconversion

Application Programming

Interface(API)

Communications

Volume to VolumeInterpolation

Volume to surfaceextraction

Daemon based data access

Translation and formatconversion

Application Programming

Interface(API)

CAD Interface

Raw CAD inputBREP, STEP, IGES

Geometry cleanup

Template / detailedsurface model,

grouping

Unified data exchangevia IGES

NURBS Parametrization, surface update

CAD Interface

Raw CAD inputBREP, STEP, IGES

Geometry cleanup

Template / detailedsurface model,

grouping

Unified data exchangevia IGES

NURBS Parametrization, surface update

Resource Management

O/S issues andcompatibility

CPUs available, andcorresponding executables

Network based control,Queuing system

Software licensing,Third part software version

control

Resource Management

O/S issues andcompatibility

CPUs available, andcorresponding executables

Network based control,Queuing system

Software licensing,Third part software version

control

VTBM – Object Oriented Software Development

Phase-I Project Objectives

Task-1: TBM model assessment, redefinition of the VTBM concept in light of current developments in neutronics, existing template-based tools and advancements in CAD-coupling.

Task-2: Development of a unified data flow system which will enable storage and transfer of simulation data across heterogeneous software relevant to TBM using CGNS and native data.

Task-3: Physics-dependent accurate interpolation technique across computational meshes

Task-4: Perform essential visualization procedures and plan automation

Task-5: Development of a preliminary geometry deformation scheme for CAD/parametric model.

Task-6: Verification and validation of the managed simulation technique on test problems.

Task-7: Assessment of project needs and scope of a full scale implementation of the VTBM





P1 Q1 P1 Q2 P1 Q3 Y2Q4Y2Q3Y2Q2Y2Q1Y1Q4Y1Q3Y1Q2Y1Q1P1 Q1 P1 Q2 P1 Q3 Y2Q4Y2Q3Y2Q2Y2Q1Y1Q4Y1Q3Y1Q2Y1Q1Task

T1: Model assessmentVTBM concept formulation

T2: Unified data flow system

T3:Accurate interpolation across meshes

T4: Visualization procedures

T5: Geometry deformation via CAD

T-6: Verification

T-7: Assessment, phase-II planning, documentation

Phase-I Phase-II

Phase-I Timeline

Modeling the blanket module: Multiphysical computations and rapid turnaround capabilities Ramakanth Munipalli, C.M.Rowell, K.-Y. Szema, P.-Y.Huang HyPerComp.

Documents

process integration

design process

simulation management

entire simulation process

project management

heinlet pbli velocity

vtbm project

blanket geometry