US Test Blanket Module
Partially Integrated Testing
US ITER TBM
Richard Nygren, Tina Tanaka, Dennis Youchison & Mike Ulrickson
Fusion Technology (01658) Sandia National Laboratories
in collaboration with the US TBM Team, especially
Neil Morley and Alice Ying (UCLA) and Clement Wong (GA)
US ITER TBM Meeting, 15-16 August 2006, ORNL
Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,
for the United States Department of Energy’s National Nuclear Security Administration
under contract DE-AC04-94AL85000.
Outline
US ITER TBM
• Basic schedule – rationale for costing
facilities  mockups  testing  ITER qualification
• Three “partially integrated” test
(fully integrated tests require volumetric heating, neutron damage)
• Cross reference
detailed WBS schedules, milestones
R&D progresses in stages
US ITER TBM
Basic
Properties
Single and Multiple
Effects Testing
Partially-Integrated
Mockup Testing
Final Design
Fabrication
Qualification
PrelDesRev FabRoute
July
Dec
FY2008
2009
BidPack
August
2010
DetDesFinalRev
September
2011
PrototypeDone FinDesChng StartTBMfab
April
December
June
2012
2013
R&D stages
US ITER TBM
Fabricate Mockups
• FW HHF He-cooled mockups
• PbLi flow mockups, PbLi loop
• Pressurization mockup
Partially Integrated
Mockup Tests
• HHF test – DCLL1, HCCB1
• MHD test – DCLL2
• Pressure test – DCLL-p,
HCCB-p
Data
Test Facilities
• FW HHF facility – heat + He loop
• MHD facility – magnet + LM loop
P facility - + burst enclosure
PrelDesRev FabRoute
July
Dec
FY2008
2009
BidPack
August
2010
Final Design
Fabrication
Qualification
DetDesFinalRev
September
2011
Title3DesRev
StartPrototype PrototypeDone FinDesChng StartTBMfab
April
December
June
June
2012
2013
R&D stages
US ITER TBM
Fabricate Mockups
• FW HHF He-cooled mockups
• PbLi flow mockups, PbLi loop
• Pressurization mockup
Test Facilities
• FW HHF facility – heat + He loop
• MHD facility – magnet + LM loop
P facility - + burst enclosure
PrelDesRev FabRoute
July
Dec
FY2008
2009
BidPack
August
2010
Partially Integrated
Mockup Tests
• HHF test – DCLL1, HCCB1
• MHD test – DCLL2
• Pressure test – DCLL-p,
HCCB-p
Data
verify
predictive capabilities,
complex geometry
& conditions
Final Design
*Satisfy ITER qualification
Fabrication
assure TBMs will not fail
Qualification
and jeopardize ITER
DetDesFinalRev
September
2011
Title3DesRev
StartPrototype PrototypeDone FinDesChng StartTBMfab
April
December
June
June
2012
2013
Combined Schedule
US ITER TBM
Partially Integrated Test
Data
Detailed Design
Test Facility
He Loop
DCLL mockup des/fab
HCCB
P test
FW
test
FW
test
DCLL PbLi loop
2009
2010
MHD
ship test
He loop
& PbLi
mockup
2011
DCLL DCLL
P test analysis
analysis
DetDesFinalRev
September
FY2008
Qual
HCCB
analysis
Pressure Facility
HCCB mockup des/fab
Fab
extended operation
prototype
Title3DesRev
StartPrototype PrototypeDone FinDesChng startTBMfab
April
December
June
June
2012
2013
Three Partially-integrated Tests
US ITER TBM
1. FW Heat Flux Testing:
 Goals:
1) Verify acceptable He flow characteristics, structural
temperatures and deformation, and (perhaps) failure modes;
2) Further experience with high temperature He coolant loops
and testing of any non-standard He flow loop components.

He-cooled mockup 1/3-1/2 size; materials & fab based on current
state of the detailed design; FW heat load characteristic of ITER;
portable He loop also used for MHD mockup; Be armor TBD.
Three Partially-integrated Tests - #1
US ITER TBM
1. FW Heat Flux Testing:
Sandia’s Plasma Materials Test Facility is
a world class high heat flux test facility
with two e-beam systems. EB1200 (right),
has a large D-shaped vacuum chamber
that could accommodate a TBM test.
A high pressure (8MPa),
high temperature (500C)
He loop would have to be
added to perform the
TBM HHF tests.
Three Partially-integrated Tests - #2
US ITER TBM
2. PbLi Flow and Heat Transfer Test (DCLL only):
 Goals:
1) Verify MHD PbLi pressure drop, flow distribution, heat transfer,
and initial chemical compatibility; scale to match MHD parameters
rather than TBM dimensions; fit into existing magnet facilities.
2) Practice safe handling, preheating and uniform filling of the TBM
with PbLi, and testing of non-standard flow loop components.

Inlet/outlet manifolds, parallel poloidal channels, He cooled flow
divider plates and walls, coaxial PbLi inlet/outlet pipes, all FCIs;
“dual use” of He loop requires shipment to MHD test site.
Three Partially-integrated Tests - #2
US ITER TBM
2. PbLi Flow and Heat Transfer Test (DCLL):
UCLA has developed
the MTOR lab for liquid
metal MHD studies.
UCLA MTOR Lab
FLIHY Electrolyte
loop
BOB
magnet
QTOR
magnet and
LM Flow
Loop
Use of the MTOR lab
would require that the
PbLi loop (DCLL test)
fit an existing magnet.
(also true elswehere)
Three Partially-integrated Tests - #3
US ITER TBM
3. Pressurization tests:
 Goal:
Qualify system against overpressure.*
He breach into PbLi (DCLL) or He breach into breeder (HCCB)
 Prototype TBM mockups prepared exactly as the first test article in
order to test all procedures and steps, except perhaps Be armor
*over-pressure per final ITER acceptance test requirements (1.25, TBWG ITA Report)
Costing Process
US ITER TBM
Initial Cost Estimates:

US TBM Team discussed mockups, characterizations needed,
potential failure mechanisms, and identified tests and test facilities.

Sandia evaluated facility features for FW HHF and pressurization
tests, plus costs for purchases, manpower and travel (collaborators).
 UCLA performed similar type of evaluation for MHD flow test, but
with the constraint that an existing facility (magnet) be used.
 Initial cost estimates were entered into TBM WBS data base, then
cost elements moved as needed to integrate overall schedule.
n
b
n
ckout
31 D E C 12
0
28 JU N 13
0
RO em
%
r ig
E ar ly
D ur
S tar t
Fi na l TB M D e s i gn C ha n ge s
I n i ti a te T B M F a b ri c a ti o n
E ar ly
Finish
FY 0 6
FY 0 7
01 S E P 10
31 D E C 09
L0 9 Mockup
Part.01 JUInt.
Test
30 JU N 11
25 FE B 10
30 S E P 09
A P R 10
2912
02 N O V 09 30 A P R
31 D E C2912
JU N 10
26 FE B 10
13N O V 10
30 A P R 10 28 JU N01
0
0
0
Co m pl e te Prototy pe F a bri c a ti on
M o c k u p fa b ri c a ti o n
0
DCLL 1.8.1.1.2.0.9.01
0
Fi na l TB M D e s i gn C ha n ge s
He L o o p c h e c k o u t
0
FW HHF
0 test
0
I ni ti a te TB M F a bri c a ti on
M o c k u p te s ti n g
M o c k u p p o s t-a n a ly s i s
0
01 M A R 11
28 A P R 11
0
01 JU L0 9
28 D E C 09
01 O C T08
30 D E C 08
31 D E C 08
29 S E P 09
0
He li um l oop p ro c ure m e nt & fa b ri c a ti on
01
R 910
M AL0
31 JU
31
10
P 09
EC
SE
28 D
00
FW te s t m ocLkMupM de
s i gn
o c k u p fa b ri c a ti o n
29 D E C 09
28 S E P 10
M o c k u p d is p o s a l & fa c il i ty c le a n u p
0
DCLL 1.8.1.1.2.0.9.02
0
PbLi flow0& heat transfer test
Pb L i L o o p S p e c ifi c a ti o n & De s i g n
He li um l oop s pe c ifi c a ti on & de s i gn
L M te s t M o c k u p a n d F CI d e s ig n / b i d
Pb L i l o o p p ro c u re m e n t a n d fa b ri c a ti o n
0
Subtask
costing
at this level
30
P 009
25
00
10
S EBP10
28 FE
JUEL1
29 S
He li um l oop
ll aotipon
to m a g n e t fa c il i ty
H eta lo
Sh ipi ns
(examples
purchases,
labor, trav)
02
09
29
0
V 10
OR
NP
26 A
10
Plater,
EV
SO
29 N
osal
11
Y 10
AR
MP
02 A
30
T12
CV
OO
30 N
01
10
0
WBS annual
costs
02 N O V 10
28 FE B 11
30 JU N 11
01 M A R 11
01 M A R 11
28 A P R 11
this level
31 O C T11
01 JU L1 1
0
01 M A Y 12
29 JU N 12
0
29 A U G 12
27 FE B 13
0
28 JA N 13
25 A P R 13
0
26 A P R 13
25 JU L1 3
0
29 JU L1 0
28 S E P 10
0
26 N O V 10
0
29 S E P 09
29 D E C 09
31 M A R 10
29 S E P 10
Ear ly Bar
Crit ical Act ivit y
28 S E P 10
28 S E P 10
l oc k up te s ti ng
Ex te n d e d o p e ra ti o n , p o s t a n a l y s is , d i s p o s a M
M oc k up p os t-a na ly s i s
Pre s s u re te s t fa c i li ty s p e c & d e s ig n
M oc k up d is pos a l & fa c il i ty c le a nu p
Pro c u re m e n t fo r fa c il i ty m o d s
Pb Li L oop S pe c ifi c a ti on & De s i gn
0
F a c i li ty m o d i fic a tio n & c h e c k o u t
Pa c k a g e a n d s h i p p ro to ty p e to te s t fa c i l ity
LM te s t M oc k up a n d FCI de s ig n/ bi d
0
M o c k u p i n s ta ll a ti o n & te s ti n g
Pb Li l oo p proc u re m e nt a nd fa b ri c a ti on
0
M o c k u p p o s t-a n a ly s i s & d e s ig n re c o m m e n d a ti o n s
LM M oc k up fa b ri c a ti on
0
Di s p o s a l o f m o c k u p ; fa c i li ty d e c o m m i s i o n i n g
Sh ip H e lo op to m a gn e t fa c il i ty
Sy s te m (H e , L M , M a g ne t) i ns ta ll . & c he c k ou t
Sheet 1 of 1
TBM 9
29 N O V 10
Progress Bar
30 M A R 10
He L oop c he cI nkiou
ti a tl L M M o c k u p te s ti n g a n d p o s t a n a l y s i s
0
30 A P R 12
28 D E C 09
M oc k up fa
c amti on
(H e , L M , M a g n e t) i n s ta ll . & c h e c k o u t
Sybsrite
DCLL 1.8.1.1.2.0.9.03
0
0
0
Pressurization
& LOCA test
01 N O V 11
01 JU L0 9
FY 1 5
Ti tle I I I De s i gn Re v i e w - I ni tia te P ro to ty pe Fa b
28 FE B 11
30 M A R 10
FY 1 4
He li u m l o o p i n s ta ll a ti o n
0
02 N O V 10
29 S E P 09
FY 1 3
De ta il e d D e s i gn F in a l D e s i gn R e v i e w
0
sis
FY 1 2
F W te s t m o c k u p d e s i g n
0
29 JU
11
A PNR10
ckout
FY 1 1
He li u m l o o p p ro c u re m e n t & fa b ri c a ti o n
0
29 S E P 09
31 D E C 08
FY 1 0
He li u m l o o p s p e c ifi c a ti o n & d e s i g n
0
30 D E C 08
01 O C T08
26
10
N OBV10
29 FE
sioning
FY 0 9
DCLL Schedule
sis
ity
FY 0 8
29 A P R 11
0
WBS 1 .8 .1 .1 .2 .9
Dat e
Ex te nde d ope ra ti on , po s t a na l y s is , di s p os a l
IRevi
nistiiona l LM M oc k up te s ti ng a n d posChecked
t an alysis
Appr oved
“Big Ticket Items”
US ITER TBM
1. He Loop (>$1M purchase)
 Dual use for FW HHF and PbLi MHD &
heat transfer tests; later comp. testing
 High P (8MPa), high T (500C) loop;
main elements are pump, heater, HX,
piping; “system on sled” (portable)
 Sandia estimate consistent (10%) with
independent GA estimate.
He loop for ITER TBM
2. PbLi Loop for DCLL mockup (>$1M mat/labor)
 PbLi loop (470C) is auxiliary for PbLi mockup and prototype.
3. Facility mods for Pressurization (>$1M mat/labor)
 Qualification test at operating temperature and overpressure requires
chamber around mockup for controlled atmosphere and containment.
Concluding Statements
US ITER TBM
TBM effort on integrated testing included:
• Development of an integrated schedule
(facilities, mockups, testing, ITER overpressure qualification)
• Initial specifications of three tests - 1) FW HHF tests,
2) DCLL MHD & heat transfer test and 3) pressure test
(qualify prototypes)
• Identified WBS schedules, milestones, detailed costs