U.S. Presentation in TBWG-16
Beijing, China
November 15 – 17, 2005
1.
2.
Overview of R&D, Time Schedule, and Cost
Estimation M. Abdou (25 min.)
Possible Practical Collaborations with Other Parties
D. K. Sze (10 min.)
3.
4.
Impact on TBM of Frame Design and Replacement
Procedure C. Wong (10 min.)
Comments on Quality Assurance R. Kurtz (10 min.)
1
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-TBM
Note this information is being continually updated and refined.
2
US ITER TBM Program: Selected Concepts
1. The Dual-Coolant Pb-17Li Liquid Breeder Blanket concept with selfcooled 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
-- Work closely with any Parties interested in this or similar concepts
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
3
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).
4
US Test Blanket “Project” Deliverables Based
on Reference Scenario Parameters
 US DCLL
–
–
–
–
–
Test Port
Primary He Coolant
Loop
TCWS
Secondary He
Coolant Loop
TCWS
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 Loop
Transporter, Port Cell Area
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.
5
US ITER TBM Costing Activity Milestones
 12-Aug-05
 31-Aug-05


7-Sep-05
9-Sep-05

6-Oct-05
 27-Oct-05
 7-Nov-05
 30-Nov-05
 12-14 Dec-05







16-Dec-05
13-Jan-06
15-Feb-06
22-23 Feb-06
1-Mar-06
15-Mar-06
28-Mar-06
Costing Activity Initiated
WBS established for Level 6 and lower
Responsible persons for Level 6 and lower assigned
WBS for Level 6 and lower revised
Conceptual design summaries for DCLL and HCCB
issued
Initial schedule and base cost estimate for
WBS level 6 of DCLL and HCCB
Initial schedule and base cost estimate for
engineering design, procurement/fabrication, and
ancillary equipment
R&D decision criteria established
Complete revised schedule and cost estimate for WBS level 6
and lower (include contingency factor)
“Physical” Meeting (all information about costing will be presented
and discussed)
R&D priorities finalized
Initial Draft Costing Activity Report Due
Complete Draft of Final Costing Activity Report
Physical meeting (internal review of draft report)
Complete incorporating comments into the Report
Send Final TBM Cost Estimate Report to DOE
“External” review
6
US DCLL TBM Reference Scenario Conditions
TBM Reference Scenario
FS Tmax
FS/PbLi
SiC/PbLi
SiC Tmax
He
PbLi
≤ 550° C
< 500° C
< 500° C
< 500° C
< 450° C
≤ 470° C
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)
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
7
US Test Blanket Project Organized
by Subsystem and Deliverables
US ITER
TBM Project
DCLL TBM
HCCB TBM
Project Support
Test Module
Test Submodule
Administration
He Loops
Ancillary Equipment
TBWG and
ITER/Parties Interface
PbLi Loop
Design Integration
Bi-laterals and
Multilaterals Projects
Tritium Processing
Qualification Report
Design Integration
Safety Report
8
US Test Blanket Work Breakdown Structure
1.8 Test Blanket
1.8.1 DCLL
1.8.2 HCCB
Helium flow loop (P+S)
1.8.3 Project Support
1.8.1.1
Test Module
1.8.1.2
1.8.2.1
Test Submodule
1.8.2.2
Ancillary equipment
1.8.3.1
Administration
1.8.1.1.1
Administration
1.8.1.2.1 Administration
1.8.2.1.1
Administration
1.8.2.2.1
Administration
1.8.3.2
TBWG, ITER/Parties Interface
1.8.1.1.2
R&D
1.8.1.2.2 R&D
1.8.2.1.2
R&D
1.8.2.2.2
R&D
1.8.3.3
Bilaterals/multilaterals Projects
1.8.1.1.2.1
Tritium permeation
1.8.1.2.3 Engineering
1.8.2.1.2.1
He flow & manifold tests
1.8.2.2.3
Engineering
1.8.3.4
Qualification Report
1.8.1.1.2.2
Thermofluid MHD
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
Safety Report
1.8.1.1.2.3
SiC/SiC FCI Fab and Properties
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
TBD
1.8.1.1.2.4
SiC/FS/PbLi Compatibility & Chem
1.8.1.2.4 Fabrication/procurement
1.8.2.1.2.4
T control and predictive capability
1.8.2.2.4
Fabrication/procurement
1.8.1.1.2.5
FS Box Fabrication & Material Issues
1.8.1.2.5 Assembly/Installation
1.8.2.1.2.5
Develop FS & SS transition joint
1.8.2.2.5
Assembly/Installation
1.8.1.1.2.6
He systems subcomponent tests
1.8.1.3
PbLi flow loop
1.8.2.1.2.6
Diagnostics and instrumentation
1.8.1.1.2.7
PbLi/H2O hydrogen production
1.8.1.3.1 Administration
1.8.2.1.2.7
Mockups and Qualification tests
1.8.2.3
HCCB/ITER Sysetm Integration
1.8.1.1.2.8
Be joining to FS
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
Virtual DCLL TBM
1.8.1.3.3 Engineering
1.8.2.1.3
Engineering
1.8.1.1.2.10 Advanced Diagnostics
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
1.8.2.1.3.2
Title III
1.8.1.1.3
Engineering
1.8.1.3.4 Fabrication/procurement
1.8.1.1.3.1
Preliminary Design
1.8.1.3.5 Assembly/Installation
1.8.2.1.4
Fabrication/procurement
1.8.1.1.3.2
Detailed Design
1.8.1.4
1.8.2.1.5
Assembly, testing, & installation
1.8.1.1.3.3
Title III
1.8.1.4.1 Administration
Tritium Processing
1.8.1.1.4
Fabrication/procurement
1.8.1.4.2 R&D
1.8.1.1.5
Assembly, testing, & installation
1.8.1.4.3 Engineering
1.8.1.4.3.1
Design
1.8.1.4.3.2
Title III
1.8.1.4.4 Fabrication/procurement
1.8.1.4.5 Assembly/Installation
1.8.1.5
DCLL/ITER System Integration
9
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
10
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
11
US DCLL TBM Testing Schedule
in the US DDD
ITER Year
ITER
Operation Phase
-1
1
2
3
4
5
6
7
8
9
10
Magnet
testing &
vacuum
HHFirst
Plasma
HH
HH
DD
Low
Duty
DT
Low
Duty
DT
Low
Duty
DT
High
Duty
DT
High
Duty
DT
High
Duty
DT
Heat flux
Progressive
ITER
Testing
Conditions
Electromagnetic/
Structural (EM/S)
TBM
Nuclear Field/
Tritium Prod.
(N/T) TBM
Thermofluid/
MHD (T/M) TBM
Integrated (I)
TBM
Toroidal
B field
Vacuum
• Install
• RH
• System
checkout
NWL
Small DD
neutron
flux
B Field
Disruptions
Fluence
Accumula
-tion
Full
disruption
energy
• Transient EM Loading on
structure and FCIs
• FW heat flux loading
• ITER field perturbation
• Hydrogen permeation
• LM-MHD tests
•
•
•
•
 Finalize
Design
Nuclear field
Tritium production
Nuclear heating
Structure and FW
heating
• FCI thermal and
electrical insulation
• Tritium permeation
• Velocity profiles
 Finalize
Design
 Finalize
Design
• High temperature effects in
TBM
• Tritium permeation/recovery
12
• Integrated function, reliability
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
–
–
–
–
–
–
3.
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
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
13
DCLL Test Module Fabrication Schedule Summary
(note: schedules are evolving)
Qualification Criteria
Safety Dossier
Permission to Install
First plasma
DCLL Test Module Schedule
2005
2006
2007
2008
Administration
R&D
Thermofluid & Performance R&D
Fabrication and Properties R&D
2009
2010
2011
2012
2013
2014
2015
TBM
Experiment
Execution
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
*Prototype may
or may not be full
scale
TBM
Experiment
14
Execution
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
15
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
16
DCLL Test Module R&D Schedule Summary
(note: schedules and R&D tasks are evolving)
Qualification Criteria
Safety Dossier
Permission to Install
First plasma
DCLL Test Module Schedule
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
Administration
R&D
Tritium Permeation/Control
Thermofluid MHD
SiC/SiC Fab Process & Properties
SiC/FS/PbLi Compatibility
FS Fabrication & Material Issues
Helium Systems Subcomponent Test
TBM
Experiment
Execution
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 Installation
Prototype Testing
TBM (QA Testing
 Installation)
TBM
Experiment
Execution
17
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
18
 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
Tritium pressure above PbLi (Pa)
Some R&D area highlights:
Tritium Inventory and
Permeation Modeling
2.0
1.5
1.0
0.5
0.0
0
TMAP model and resultant
tritium pressure for an
example DCLL case
10
20
30
40
Number of pulses
He/H2O HXs
Non-Hartmann Gaps
First wall
He
Pb-17Li core Permeator
PbLi/He HX
First
wall
Second
wall
Rib He
Rib walls
Concentric pipe
(FS walls)
Back plate
He pipes
(FS walls)
Hartmann Gaps
19
50
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
20
ORNL
21
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
22
Ceramic Breeder Test Submodule
Inserting “US” unit cells into the EU HCPB structural box
Electromagnetics/Neutronics
unit cell design
Unit (mm)
Neutonics Submodule Operating Conditions
Helium Coolant
Pressure
8 MPa
Temperature, In/Out
100/250 C
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
Helium Purge
23
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
24
HCCB Test Sub-Module Schedule Summary
(note: schedules and R&D tasks are evolving)
US ITER HCCB Test Submodule Schedule
ITER Director appointed
First plasma
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
1.8.3 Project Support
1.8.3.2 TBWG activities and ITER/parties interface
1.8.3.4 Qualification and Safety Report
1.8.2 HCCB
1.8.2.1 Test Submodule
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
25
Rough HCCB TBM Cost Estimate Summary
Covering the next 10 years
(Subject to revision in detailed evaluation of costs)
1.8.2 HCCB
1.8.2.1.2 R&D
1.8.2.1.2.1
1.8.2.1.2.2
1.8.2.1.2.3
1.8.2.1.2.4
1.8.2.1.2.5
1.8.2.1.2.6
1.8.2.1.2.7
1.8.2.1.2.8
Subtotal
He flow & manifold tests
SB PB thermomechanics & T recovery
RAFS Fabrication development
T control and predictive capability
Develop FS & SS transition joint
Diagnostics and instrumentation
1/2 Scale Mock-ups and Qualification tests
In-pile pebble bed assembly test
$XXX
$XXX
$XXX
$XXX
$XXX
$XXX
$XXX
$XXX
$XXX
 Engineering Design Activities: ~$XXX
 Fabrication of 1st series of unit cells ~$XXX
26
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
27
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.
28
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
29