1 U.S. Presentation in TBWG-16 Beijing, China November 15 – 17, 2005 1.Overview of R&D, Time Schedule, and Cost Estimation M. Abdou (25 min.) 2.Possible.

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U.S. Presentation in TBWG-16Beijing, China

November 15 – 17, 2005

1. Overview of R&D, Time Schedule, and Cost Estimation M. Abdou (25 min.)

2. Possible Practical Collaborations with Other Parties D. K. Sze (10 min.)

3. Impact on TBM of Frame Design and Replacement Procedure C. Wong (10 min.)

4. Comments on Quality Assurance R. Kurtz (10 min.)

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Overview of US ITER TBM R&D, Time Schedule, and Cost Estimation

Mohamed Abdou, Alice Ying, Neil Morley, Clement Wong, Tom Mann, Dai-Kai Sze, Mike Ulrickson, and the US ITER TBM Team

TBWG-16

Detailed information is available at http://www.fusion.ucla.edu/ITER-TBMNote this information is being continually updated and refined.

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US ITER TBM Program: Selected Concepts

1. The Dual-Coolant Pb-17Li Liquid Breeder Blanket concept with self-cooled Pb-Li breeding zone and flow channel inserts (FCIs) as MHD and thermal insulator-- Innovative concept that provides “pathway” to higher outlet

temperature/higher thermal efficiency while using ferritic steel.

-- Plan an independent DCLL TBM that will occupy half an ITER test port with corresponding ancillary equipment

2. The Helium-Cooled Solid Breeder Blanket concept with ferritic steel structure and beryllium neutron multiplier, but without an independent TBM-- Support EU and Japan efforts using their TBM structure & ancillary

equipment

-- Contribute unit cell /submodule test articles that focus on particular technical issues

-- Work closely with any Parties interested in this or similar concepts

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A Detailed TBM Planning and Costing Activity for the US TBM Program has been requested by the DOE

Planning will be for the US Reference Scenarios: – DCLL TBM with PbLi exit temperature of 470ºC and a series of TBM

that occupy half a port.– HCCB submodule that has a size of 1/3 of one-half port in cooperation

with the EU or Japan Detailed planning and cost is for a 10 year period between now and

the shipment of the TBM deliverables in 2015 for DAY ONE ITER operation.

The cost is the total cost for the TBM project including R&D, design, engineering, fabrication, qualification, etc., as well as the cost of interface with ITER and other parties.

The R&D Cost includes all costs related to the Reference Scenarios that occur within the next 10 year period whether they are related to the first (Day ONE) Test Articles or subsequent test articles.

Cost of the deliverables includes only the cost of the First Test Article and associated equipment (See Project Deliverables slide).

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US Test Blanket “Project” Deliverables Based on Reference Scenario Parameters

US DCLL– Test Module

– Helium Flow Loop (primary)

– PbLi Flow Loop

– Tritium Processing Systems

– Secondary Helium Flow Loop (and Heat Exchanger for PbLi Flow Loop)

US HCCB– Test Submodule

– Ancillary Equipments (primary helium flow conditioners, measuring systems for helium, tritium, and test submodule)

Pb-Li Primary Coolant LoopTransporter, Port Cell Area

Secondary He Coolant Loop

TCWS

Test PortPrimary He Coolant

LoopTCWS

DCLL TBM coolant circuits, Red-doted circuit shows the primary He loop cooling the first wall and all FS structures, Blue-dash circuit shows the Pb-Li loop and the Green-dash circuit shows the secondary helium loop.

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US ITER TBM Costing Activity Milestones

12-Aug-05 Costing Activity Initiated 31-Aug-05 WBS established for Level 6 and lower Responsible persons for Level 6 and lower assigned 7-Sep-05 WBS for Level 6 and lower revised 9-Sep-05 Conceptual design summaries for DCLL and HCCB

issued 6-Oct-05 Initial schedule and base cost estimate for

WBS level 6 of DCLL and HCCB 27-Oct-05 Initial schedule and base cost estimate for

engineering design, procurement/fabrication, and ancillary equipment

7-Nov-05 R&D decision criteria established 30-Nov-05 Complete revised schedule and cost estimate for WBS level 6

and lower (include contingency factor) 12-14 Dec-05 “Physical” Meeting (all information about costing will be presented

and discussed) 16-Dec-05 R&D priorities finalized 13-Jan-06 Initial Draft Costing Activity Report Due 15-Feb-06 Complete Draft of Final Costing Activity Report 22-23 Feb-06 Physical meeting (internal review of draft report) 1-Mar-06 Complete incorporating comments into the Report 15-Mar-06 Send Final TBM Cost Estimate Report to DOE 28-Mar-06 “External” review

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US DCLL TBM Reference Scenario Conditions

TBM Reference ScenarioFS Tmax ≤ 550° C

FS/PbLi < 500° C SiC/PbLi < 500° C SiC Tmax < 500° C

He < 450° C PbLi ≤ 470° C

Module Geometry:

Port frame thickness, mm 200

“Dog leg” width, mm 30

Frame and TBM gap width, mm 20

TBM height, m 1.66

TBM width, m 0.484

Radial depth, m 0.413

Frontal area, m2 0.803

First wall shape flat

Module Materials:

Structural material Ferritic Steel (FS), e.g. F82H or EUROFER

Breeding material Pb-17Li

FW/structural coolant 8 MPa helium

Intermediate loop coolant 8 MPa helium

Flow channel insert SiCf /SiC or metallic

sandwich e.g. FS/Al2O3

FW coating 2 mm Be

Notes: DCLL features will be tested at PbLi

temperatures compatible with ferritic steel (500C). He and PbLi flowrate, and inlet and outlet temperature, will be varied depending on experiment underway, but these limits will not be exceeded

External piping material for Helium system will be austenitic steel (transition element required)

External piping material for the PbLi has not yet been decided, but likely to be a commercial ferritic/martensitic steel up to the HX (Cutting/rewelding technique required)

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US ITER TBM Project

DCLL TBM HCCB TBM Project Support

Test Module

He Loops

PbLi Loop

Tritium Processing

Design Integration

Test Submodule

Ancillary Equipment

Design Integration

Administration

TBWG and ITER/Parties Interface

Bi-laterals andMultilaterals Projects

Qualification Report

Safety Report

US Test Blanket Project Organized by Subsystem and Deliverables

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US Test Blanket Work Breakdown Structure

1.8.1.1 Test Module 1.8.1.2 1.8.2.1 1.8.2.2 1.8.3.1

1.8.1.1.1 1.8.1.2.1 Administration 1.8.2.1.1 Administration 1.8.2.2.1 1.8.3.2

1.8.1.1.2 1.8.1.2.2 R&D 1.8.2.1.2 R&D 1.8.2.2.2 1.8.3.3

1.8.1.1.2.1 1.8.1.2.3 1.8.2.1.2.1 1.8.2.2.3 1.8.3.4 Qualification Report

1.8.1.1.2.2 1.8.1.2.3.1 Design 1.8.2.1.2.2 SB thermomechanics & T recovery 1.8.2.2.3.1 Design 1.8.3.5

1.8.1.1.2.3 1.8.1.2.3.2 Title III 1.8.2.1.2.3 RAFS Fabrication development 1.8.2.2.3.2 Title III 1.8.3.6

1.8.1.1.2.4 1.8.1.2.4 1.8.2.1.2.4 T control and predictive capability 1.8.2.2.4

1.8.1.1.2.5 1.8.1.2.5 1.8.2.1.2.5 Develop FS & SS transition joint 1.8.2.2.5

1.8.1.1.2.6 1.8.1.3 1.8.2.1.2.6 Diagnostics and instrumentation

1.8.1.1.2.7 1.8.1.3.1 1.8.2.1.2.7 Mockups and Qualification tests 1.8.2.3 HCCB/ITER Sysetm Integration

1.8.1.1.2.8 1.8.1.3.2 R&D 1.8.2.1.2.8 In-pile pebble bed assembly test

1.8.1.1.2.9 1.8.1.3.3 1.8.2.1.3

1.8.1.1.2.10 1.8.1.2.3.1 Design 1.8.2.1.3.1 Preliminary Design

1.8.1.1.2.11 Integrated mockups, 1/4 to 1/2 scale 1.8.1.2.3.2 Title III 1.8.2.1.3.2 Detailed Design

1.8.1.1.3 1.8.1.3.4 1.8.2.1.3.2 Title III

1.8.1.1.3.1 Preliminary Design 1.8.1.3.5 1.8.2.1.4

1.8.1.1.3.2 Detailed Design 1.8.1.4 1.8.2.1.5

1.8.1.1.3.3 Title III 1.8.1.4.1

1.8.1.1.4 1.8.1.4.2 R&D

1.8.1.1.5 1.8.1.4.3

1.8.1.4.3.1 Design

1.8.1.4.3.2 Title III

1.8.1.4.4

1.8.1.4.5

1.8.1.5 DCLL/ITER System Integration

Engineering

Fabrication/procurement

Assembly/Installation

Fabrication/procurement

PbLi flow loop

Administration

Assembly/Installation

Tritium Processing

Safety Report

TBD

Helium flow loop (P+S)

Engineering

Bilaterals/multilaterals Projects

He flow & manifold tests

Advanced Diagnostics

Engineering

Fabrication/procurement

Assembly, testing, & installation

He systems subcomponent tests

PbLi/H2O hydrogen production

Be joining to FS

Virtual DCLL TBM

Administration

R&D

Tritium permeation

FS Box Fabrication & Material Issues

1.8 Test Blanket 1.8.1 DCLL 1.8.2 HCCB

Administration

Assembly/Installation

Ancillary equipment

Administration

R&D

Engineering

Test Submodule

Fabrication/procurement

Assembly, testing, & installation

Engineering

Fabrication/procurement

Engineering

Assembly/Installation

Fabrication/procurement

Thermofluid MHD

SiC/SiC FCI Fab and Properties

SiC/FS/PbLi Compatibility & Chem

1.8.3 Project Support

Administration

TBWG, ITER/Parties Interface

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Most Work Breakdown Structure Elements are further broken down into the following subcategories:

Administration R&D Engineering

Preliminary Design Detailed Design Fabrication Support

Fabrication/procurement

Assembly, testing, & installation

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US strategy for ITER testing of the DCLL Blanket and First Wall Concept

Develop and deploy a series (~4) of vertical half-port DCLL-TBMs during the period of the first 10 years of ITER operation with– Test articles from day one of ITER operation with specific testing

goals and diagnostic systems– Associated ancillary equipment systems

• in a transporter behind the bioshield and in space in the TCWS and tritium buildings

• using bypass PbLi flow to keep temperature of ancillary equipment below material limits

Develop international collaboration on PbLi systems to the maximal extent

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US DCLL TBM Testing Schedule in the US DDD

ITER Year -1 1 2 3 4 5 6 7 8 9 10

ITEROperation Phase

Magnet testing & vacuum

HH-First

PlasmaHH HH DD

LowDutyDT

LowDutyDT

LowDutyDT

High DutyDT

High DutyDT

HighDutyDT

ProgressiveITERTesting Conditions

Toroidal B field

Vacuum

Heat flux

B Field

Disrup-tions

Small DD neutron

flux

NWL

Full disruption

energy

FluenceAccumula

-tion

Electromagnetic/Structural (EM/S) TBM

• Install• RH• System check-out

• Transient EM Loading on structure and FCIs

• FW heat flux loading• ITER field perturbation• Hydrogen permeation• LM-MHD tests

Nuclear Field/ Tritium Prod.(N/T) TBM

FinalizeDesign

• Nuclear field • Tritium production• Nuclear heating• Structure and FW

heating

Thermofluid/ MHD (T/M) TBM

FinalizeDesign

• FCI thermal and electrical insulation

• Tritium permeation• Velocity profiles

Integrated (I)TBM

FinalizeDesign

• High temperature effects in TBM

• Tritium permeation/recovery• Integrated function, reliability

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Electromagnetic/Structural (EM/S) TBM (for Hydrogen Phase) Testing Goals

1. Validate general TBM structure and design – Measure forces and the mechanical response of the TBM structure to transient EM loads– Determine ferromagnetic and MHD flow perturbation of ITER fields– Measure thermal and particle load effects on plasma facing surface (Be) and FW structure/heat

sink

Information in the early HH phase can be used: • to modify designs of subsequent TBMs to be deployed in the later DT phase • for ITER DT Licensing.

2. Establish performance baseline and operational experience of the TBM and ancillary systems– Integration of control systems and diagnostics with ITER systems– Demonstration of required subsystems and port integration– Demonstration of remote handling procedures– Measurement of thermal time constants and heat loss– Measurement of tritium (hydrogen) permeation characteristics– Testing heating/filling/draining/remelting and accident response procedures

3. Perform initial studies of MHD effects and Flow Channel Insert performance– MHD flow distribution (manifold design, multichannel effects) – 3D pressure drop (toroidal field and toroidal + true poloidal field)– FCI performance changes as a function LM exposure time – FCI response to loading from EM events (water hammer, transient eddy current forces)– Map ITER field in TBM area

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DCLL Test Module Fabrication Schedule Summary(note: schedules are evolving)

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Administration

R&D

Thermofluid & Performance R&D

Fabrication and Properties R&D

Partially Integrated Tests

Engineering

Preliminary Design

Detailed Design

Title III Activities (Fab Support)

TBM Fabrication

Bid Package Contract Award

Material Procurement

Tooling & Processing

Prototype Fabrication

TBM Fabrication

Assembly, Testing, and Installation

Prototype Packaging & Shipping

Prototype Testing

TBM QA Tests

TBM Packing and Shipping

TBM Assembly & Port Integration

DCLL Test Module Schedule

First plasmaQualification Criteria Safety Dossier

TBMExperiment Execution

Permission to Install

TBMExperiment Execution

*Prototype may or may not be full scale

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Purposes of R&D activities in a “project” are to reduce risk

Risk that the experimental device will negatively impact ITER – plant safety, licensing– operation schedule

Risk that TBM experiments will not achieve experimental mission– Understanding of phenomena and modeling capability is

insufficient to interpret or utilize data– Failures in diagnostics or large inaccuracies in measurements

give incomplete or poor data– Unanticipated system performance leads to irrelevant or

unquantifiable operating conditions

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Main DCLL TBM R&D Areas Identified in the US Activity. Several are common issues of interest to all Parties

Test Module R&D Tasks Areas(some have several subtasks)

US Person – Morley

Tritium Permeation Merrill

Tritium Extraction (PbLi & He) Willms

Thermofluid MHD Smolentsev

SiC/SiC Fab Process & Properties Katoh

SiC/PbLi/FS Compatibility Pint

FS Box Fabrication & Material Issues Rowcliffe/Kurtz

Helium Flow Distribution and HX Wong

PbLi/H20 Hydrogen Production Merrill

Be Joining to FS Zinkle/Ulrickson

Virtual TBM Simulation Suite Abdou

Advanced Diagnostics Morley

Integrated mockup tests Ulrickson/Tanaka

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DCLL Test Module R&D Schedule Summary(note: schedules and R&D tasks are evolving)

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Administration

R&DTritium Permeation/Control

Thermofluid MHD

SiC/SiC Fab Process & Properties

SiC/FS/PbLi Compatibility

FS Fabrication & Material Issues

Helium Systems Subcomponent Test

PbLi/H2O Hydrogen Production

Be joining to FS and TBM PFC

Virtual DCLL TBM

Advanced Diagnostics

Integrated mockups, 1/4 to 1/2 scale

Engineering Preliminary Design

Detailed Design

TBM Fabrication (Bid Completion)Prototype

1st TBM

Assembly, Testing, and InstallationPrototype Testing

TBM (QA Testing Installation)

DCLL Test Module Schedule

First plasmaQualification Criteria Safety Dossier

TBMExperiment Execution

Permission to Install

TBMExperiment Execution

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Some R&D area highlights: Thermofluid – MHD

Thermofluid – MHD is an important class of issues for the DCLL design, operation and safety

Several R&D subtasks are being planned– Continued model development: 3D-HIMAG

and other research codes needed to predict basic performance of DCLL and to utilize/interpret TBM experimental data

– Experiments on basic FCI performance: 3D pressure drop, flow development, effect of / need for pressure equalization holes, overlap regions, etc.

– Experiments on manifolds design: needed to explore range of achievable flow uniformity under various operating conditions

– Partially integrated MHD flow tests on flow mockups

Example: Effect of FCI pressure equalization gap on Hartmann wall side, SiC=20

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Some R&D area highlights: Tritium Inventory and Permeation Modeling

Simulations have lead to a new strategy for tritium control

1. Swept secondary containment around transporter cask and TCWS skid for controlling leaked or permeated tritium

2. More aggressive permeator development to reduce tritium partial pressure in PbLi

3. Swept secondary containment around all PbLi (and He) piping

4. Operation at lower He/PbLi temperatures if ITER limit is approached

Concentric pipe(FS walls)

PermeatorPb-17Li core

PbLi/He HX

Non-Hartmann Gaps

Hartmann Gaps

First wall

Second wall

Rib wallsBack plate

First wall He

Rib HeHe pipes(FS walls)

He/H2O HXs

0 10 20 30 40 500.0

0.5

1.0

1.5

2.0

Trit

ium

pre

ssu

re a

bo

ve P

bL

i (P

a)

Number of pulsesTMAP model and resultant

tritium pressure for an example DCLL case

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An Idea: Virtual TBM

Better integration and management of codes used for predicting TBM conditions and interpreting TBM experiments– CAD– MCNP– HIMAG– TMAP– ANSYS– RELAP– …

Experience with CAD/MCNP should just be the start

21

ORNL

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Rough DCLL TBM Cost Estimate Summary Covering the next 10 years

(Subject to revision in detailed evaluation of costs)

Preliminary DCLL R&D Cost Summary

Tritium Permeation XXX

Thermofluid MHD XXX

SiC/SiC Fab Process & Properties XXX

SiC/PbLi/FS Compatibility XXX

FS Box Fabrication & Material Issues XXX

Helium Systems Subcomponent Tests XXX

PbLi Hydrogen Production XXX

Be Joining to FS (TBM PFC) XXX

Virtual TBM XXX

Advanced Diagnostics XXX

Integrated mockup tests XXX

Design, analysis and DCLL TBM and systems fabrication

• rough cost estimate is XXX

• some key costs still not included

Prioritizing and trade-off assessment activity underway

Risk assessment activity underway

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Ceramic Breeder Test SubmoduleInserting “US” unit cells into the EU HCPB structural box

Unit (mm)

Electromagnetics/Neutronics unit cell design

Helium Coolant

Pressure 8 MPa

Temperature, In/Out 100/250 C

Helium Purge

Pressure 0.1 MPa

Temperature, average 225 C

Breeder Min/Max 100/350 C

Beryllium Min/Max 100/350 C

FS Min/Max 100/300 C

Neutonics Submodule Operating Conditions

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Main HCCB Test Sub-Module R&D Areas Identified in the Activity

Test Module R&D Ying

Helium flow distribution and manifold testing Calderoni

Pebble bed thermomechanics and T recovery Calderoni/Katoh

RAFS fabrication development (overlap with US DCLL) Rowcliffe/Kurtz

T-control and predictive capability Ying/Merrill

Development of FS & SS transition element Zinkle/Kurtz

Diagnostics and instrumentation (some overlap with US DCLL) Calderoni

½ scale mockup and qualification tests (some overlap with US DCLL) Tanaka

In-pile pebble bed assembly test Katoh/Calderoni

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HCCB Test Sub-Module Schedule Summary(note: schedules and R&D tasks are evolving)

US ITER HCCB Test Submodule Schedule

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

1.8.3 Project Support

1.8.2.1.1 Administraion

1.8.2.1.2 R&D

Helium flow distribution and manifold testing

Pebble bed thermomechanics and T recovery

RAFS fabrication development

T-control and predictive capability

Development of FS & SS transition element

Diagnostics and instrumentation

1/2 scale mockup and qualification tests

In-pile pebble bed assembly test

1.8.2.1.3 Engineering

Design with Party

Preliminary Design

Detailed Design

1.8.2.1.4 Fabrication/procurement

Call for Tender

Manufacturing Design

Material procurement

Fabrication

1.8.2.1.5 Assembly, testing and Installation

Integration and QA testing at Host Party's site

Delivery to ITER site installation

1.8.2.1 Test Submodule

1.8.3.2 TBWG activities and ITER/parties interface

1.8.3.4 Qualification and Safety Report

1.8.2 HCCB

First plasmaITER Director appointed

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Rough HCCB TBM Cost Estimate Summary Covering the next 10 years

(Subject to revision in detailed evaluation of costs)

Engineering Design Activities: ~$XXX

Fabrication of 1st series of unit cells ~$XXX

1.8.2.1.2 R&D1.8.2.1.2.1 He flow & manifold tests $XXX1.8.2.1.2.2 SB PB thermomechanics & T recovery $XXX1.8.2.1.2.3 RAFS Fabrication development $XXX1.8.2.1.2.4 T control and predictive capability $XXX1.8.2.1.2.5 Develop FS & SS transition joint $XXX1.8.2.1.2.6 Diagnostics and instrumentation $XXX1.8.2.1.2.7 1/2 Scale Mock-ups and Qualification tests $XXX1.8.2.1.2.8 In-pile pebble bed assembly test $XXX

$XXX

1.8.2 HCCB

Subtotal

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Categorizing R&D Tasks

A system needs to be established to categorize R&D tasks to give a cost range

Simple rating system being tried in the US: E = Essential for the qualification and successful execution of

the TBM experiment, and no other party is doing it I = Important for the qualification and successful execution of

the TBM experiment, or Essential but is definitely being done by another party

D = Desirable but the risk is acceptable if not performed

According to this system: International effort affects US prioritization

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Some initial conclusions(that some have already realized, but all need to face)

TBMs are generally much more expensive than initial estimates might show– Many hidden expenses will continue to be discovered

– Undefined elements of ITER QA/licensing requirements can impact cost significantly (~>10%)

R&D efforts are a large portion of costs– They must be scrutinized and prioritized

– R&D activities mostly address areas of interest to other Parties

Tested full scale prototypes are likely necessary to avoid failures in first years of operation that jeopardize mission of validating DT phase TBM

There is very little time left if subscale mockups and prototypes are to be attempted.

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TBWG should identify and coordinate effort on key, common, R&D areas

Suggestion, For each common R&D area, one or two parties (depending on issue difficulty and criticality) should “volunteer” to do the research, and share the results

– Be layer joining to FS – Tritium extraction and cleanup in He purge and coolants– Common diagnostic sensors and controllers– Common test and qualification tests and test facilities– Virtual TBM simulation capabilities– FS technology (joining, shaping, in-situ rewelding, irradiation database)– FS to Austenitic Steel Transition Sections– PbLi/Water hydrogen generation (all PbLi systems with volume > 280 liters)

(Another US Presentation will elaborate on practical possibilities…)

Cooperation on R&D issues is the first step to cooperative test programs – once common needs and purposes are clearly evident to the parties