1.8.1.1.2 DCLL R

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1.8.1.1.2 DCLL RD Task Area Reports

• Compiled by Neil Morley for the TBM Conference
  Call
• Oct 6, 2005

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Purpose of RD 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 RD areas
1.8.1.1.2 RD Morley
1.8.1.1.2.1 Tritium Permeation Merril
1.8.1.1.2.2 Thermofluid MHD Smolentsev
1.8.1.1.2.3 SiC/SiC Fab Process Properties Katoh
1.8.1.1.2.4 SiC/PbLi/FS Compatibility Pint
1.8.1.1.2.5 FS Box Fabrication Material Issues Rowcliffe,Kurtz
1.8.1.1.2.6 Helium Systems Subcomponent Tests Wong
1.8.1.1.2.7 PbLi Hydrogen Production Merril
1.8.1.1.2.8 Be Joining to FS Zinkle,Ulrickson
1.8.1.1.2.9 Virtual TBM Abdou
1.8.1.1.2.10 Advanced Diagnostics Morley
1.8.1.1.2.11 Integrated mockup tests Ulrickson,Tanaka
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1.8.1.1.2.1 Tritium Permeation

• Brad Merrill INL

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Potential Safety ExperimentsSupporting the US
ITBM Program, cont.
Thermal Cycle Performance of He Pipe Permeation
Barriers

• simulates thermal stress degradation of
  permeation barrier coatings for He pipes
• configuration matched to TBM design for coated
  components
• utilize tritium for barrier technology
  qualification
• external thermal cycles followed by testing in
  permeation rig for integrated effects
• thermal cycling in permeation rig for barrier
  dynamic response

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Tritium Permeation Schedule
associated design issues resolved
associated safety issues resolved

• Test schedule set to provide input into the
  initial licensing process but if the licensing
  procedure can be staged, then QA of barriers
  could be performed any time prior to DT operation
  

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Out-of-pile Qualification Tests for Permeation
Barriers

• Test cost estimated to be 2.8 M over 4 years

• Total estimated cost is 2.8 M over 4 years (15
  experiment design, 25 experiment fabrication, 60
  performing experiments and data analysis)

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1.8.1.1.2.2 Thermofluid MHD

• Sergey Smolentsev - UCLA

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Thermofluid MHD RD

• This WBS includes research and development tasks
  and their associated administration including
  experimental investigations, development of
  modeling tools, and performing numerical
  simulations to address the most critical aspects
  of Pb-17Li flows/heat transfer in the TBM under
  ITER DCLL conditions.
• The main purposes are
• to provide specific information on MHD flows and
  heat transfer needed for the completion of the
  reference TBM design and its safety operation in
  ITER
• to qualify and quantify the most critical
  MHD/heat transfer phenomena that can affect
  performance of the DCLL concept
• to develop and validate needed thermofluid MHD
  modeling tools
• to access main MHD/heat transfer issues related
  to the Flow Channel Insert (SiCf/SiC and sandwich
  FCIs) as a key element of the DCLL concept
• to provide other RD WBS with the information
  they need to accomplish their goals
• as a preparation to tests in ITER, simulate
  conditions when the reference design can be used
  for meaningful experiments, addressing the most
  important features of the higher performance
  regime
• in cooperation with other level 6 WBS, to
  establish RD plans and develop diagnostics tools
  for TBM tests in ITER.
• IMPORTANT COMMENTS ON RD and COSTING
• All major RD supporting the TBM design should be
  accomplished by the end of 2010.
• From 2011 to 2015 we will concentrate on planning
  ITER tests with supporting experiments and
  modeling, and will develop and integrate the
  Thermofluid MHD sub-module into the VTBM code.
• Almost all experiments will be supported with
  modeling.
• When doing the RD, we will specify special ITER
  tests to simulate basic features of the higher
  performance regime, while keeping the exit
  Pb-17Li temperature at 470?C.
• We will reduce our RD costs by using existing
  MHD facilities at UCLA and then projecting the
  moderate (1-2 T) magnetic field results to the
  higher field region (4 T) via engineering
  scaling and modeling.
• Some costs on modeling include SBIR.

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Thermofluid MHD RD Schedule
- RD to support reference design - Development
of modeling tools
- Planning tests in ITER with supporting
experiments and modeling - Contribution to VTBM
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Thermofluid MHD RD Preliminary Cost Estimate
TOTAL COST FOR 10 YEARS, M 15.3
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1.8.1.1.2.3 SiC/SiC FCI Fabrication and
Properties

• Yutai Katoh - ONRL

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1.8.1.1.2.3 SiC/SiC FCI Fabrication and
PropertiesTask List and Descriptions
1.8.1.1.2.3.1 1.8.1.1.2.3.1 Technical Planning Technical Planning  
  1.8.1.1.2.3.1.1   Recommendation on 0th-order SiC/SiC FCI fabrication Provide recommendation on materials for preliminary MHD experiment
  1.8.1.1.2.3.1.2   Initial analysis and reference strategy development Perform initial analysis of technical issues for SiC/SiC FCI
  1.8.1.1.2.3.1.3   Develop trans-electrical conduction measurement technique Establish electrical conductivity measurement in hot lab
  1.8.1.1.2.3.1.4   Develop test for stiffness matrix Establish test methods for mechanical properties including stiffness matrix
1.8.1.1.2.3.2 1.8.1.1.2.3.2 1st generation FCI SiC/SiC 1st generation FCI SiC/SiC
  1.8.1.1.2.3.2.1   Insulating composite development Design and fabricate 1st round SiC/SiC FCI 
  1.8.1.1.2.3.2.2   Failure mode analysis Identify potential failure modes of SiC/SiC FCI
  1.8.1.1.2.3.2.3   Non-irradiated characterization Perform electrical/thermal/mechanical tests on 1st generation samples
  1.8.1.1.2.3.2.4   Material/architectural design refinement Provide feedback for 2nd round FCI SiC/SiC fabrication
1.8.1.1.2.3.3 1.8.1.1.2.3.3 Alternative Concept Alternative Concept Plan, design, and perform small confirmative studies for alternative FCI concept.
  1.8.1.1.2.3.3.1   Reference strategy development Define initial strategy for alternative FCI  
1.8.1.1.2.3.4 1.8.1.1.2.3.4 2nd generation FCI SiC/SiC 2nd generation FCI SiC/SiC Production and testing of 2nd generation customized FCI SiC/SiC
  1.8.1.1.2.3.4.1   Material fabrication Fabricate material for FCI based on refined material / architectural design.
  1.8.1.1.2.3.4.2   Non-irradiated characterization Characterize non-irradiated physical and mechanical properties
  1.8.1.1.2.3.4.3   Model component fabrication Determine appropriate shaping technique and fabricate model components
  1.8.1.1.2.3.4.4   Analysis of FCI samples from flow channel experiment Perform analysis of samples taken from FCI in flow channel experiment.
1.8.1.1.2.3.5 1.8.1.1.2.3.5 Low Dose Irradiation Effects Low Dose Irradiation Effects Determine effects of low dose irradiation of FCI properties and performance
  1.8.1.1.2.3.5.1   Differential swelling and creep Determine differential swelling and irradiation creep compliance
  1.8.1.1.2.3.5.2   Irradiated conductivities and baseline properties Determine irradiation effect on transport properties of SiC/SiC FCI
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1.8.1.1.2.3 SiC/SiC FCI Fabrication and
PropertiesTask Schedule
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1.8.1.1.2.3 SiC/SiC FCI Fabrication and
PropertiesCosting Table
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1.8.1.1.2.4 SiC/PbLi/FS Compatibility

• Bruce Pint - ONRL

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SiC/PbLi/FS Compatibility Task Descriptions(Bruce
Pint)
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1.8.1.1.2.5 FS Box Fabrication Material
Issues

• Arthur Rowcliffe Free agent
• Rick Kurtz PNL

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FS Box Fabrication Tasks, Schedule, Effort
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1.8.1.1.2.6 Helium Systems Subcomponent Tests

• Clement Wong - GA

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1.8.1.1.2.6 Helium Systems Subcomponent Tests This WBS includes the administration, RD and subcomponents testing of helium systems in the TBM, specifically for the determination of FW heat transfer enhancement and module helium flow distributions.
1.8.1.1.2.6.1 Helium cooled first wall heat transfer enhancement This WBS includes the administration and RD to recommend the necessary first wall channel heat transfer enhancement design for the reference DCLL TBM design while satisfying all necessary design limits for all operation scenarios of the first test module, with consideration of efficient and cost effective design conversion to be applied to the integrated testing TBM. Both analytical and experimental work will be utilized. The experimental evaluation and demonstration of the heat transfer enhancement design will be performed with existing US facilities and/or with the DCLL mockup facility. If appropriate, international collaboration will be considered.
1.8.1.1.2.6.2 Helium cooled flow distribution This WBS includes the administration and RD to recommend the necessary helium flow channel design in order to satisfy the thermal-hydraulic performance of the DCLL TBM design with necessary uniform flow distribution and without the risk of flow instability for all operational phases of the first test module, and with consideration of efficient and cost effective design conversion to be applied to the integrated testing TBM. This WBS includes all components of the helium flow loops, including helium-cooled ferritic structure of the TBM, pipes and ancillary equipment. Design criteria will be established and both analytical and experimental work will be applied when appropriate. When analytical work cannot provide clear cut answers for the selected flow configuration, experimental investigation and demonstration will be applied to the problem area. Subsequent design recommendation will be made. The most likely areas that will need experimental demonstration are the flow plenum and distributions through all the coolant channels of the ferritic structure and first wall components. The experimental evaluation and demonstration of the flow distribution design will be performed with existing US helium flow loop facilities and/or with the DCLL mockup facility. If appropriate, international collaboration will be considered. The WBS will be closely coordinately with the engineering WBS 1.8.1.1.3
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Helium Systems Subcomponent TestsSchedule
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Helium Systems Subcomponent RD Preliminary Cost
Estimate
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1.8.1.1.2.7 PbLi/Water Hydrogen Production

• Brad Merrill INL

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Potential Safety ExperimentsSupporting the US
TBM Program

• The chemical reaction of primary concern for the
  DCLL TBM is the PbLi reaction with H2O
• ITER requires that the PbLi volume be limited to
  0.28 m3 to ensure that the in-vessel H2
  production is less than 2.5 kg
• Alternatively, a detailed analysis of PbLi/H2O
  reaction must be performed that considers a
  Pb-17Li spray into water (spray droplets that are
  2 mm in radius) this analysis is problematic
  because reaction rate data does not exist for
  such droplets
• Our DDD relied on data from a single test
  (pouring contact mode) that indicates that 50
  of the Li will react however only the amount of
  H2 generated and the time to achieve this
  quantity of H2 were reported and very little
  additional information was given regarding
  important modeling phenomena such as Pb17Li
  fragmentation, transient temperatures, and
  reaction rates at various conditions.

• simulates LOVA with pooling water and sprayed
  molten PbLi
• single and multiple droplet sizes or streamed
  injection
• variable surface area of exposed water
• gas analyzer measures moisture content and H2
  generation
• view ports allow imaging of reaction surfaces,
  temperature measurements, and droplet dynamics

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PbLi/H2O Hydrogen Production RD Task

• Test schedule set to provide input into the
  initial licensing process, since this issue must
  be resolved before the TBM can be installed in
  ITER
• Common problem for DCLL and HCLL TBMs
  (collaboration may be possible)

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PbLi/H2O Hydrogen Production RD Task

• Total estimated cost is 2.4 M over 4 years (25
  experiment design, 23 experiment fabrication, 32
  performing experiments, 0 data analysis)

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Be to FS Joining RD1.8.1.1.2.8

• October 6, 2005
• M. Ulrickson
• Presented on TBM RD Call

Sandia is a multiprogram laboratory operated by
Sandia Corporation, a Lockheed Martin
Company,for the United States Department of
Energys National Nuclear Security
Administration under contract DE-AC04-94AL85000.
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Be to FS Joining RD RD Tasks

• 1.8.1.1.2.8.1 Joining Research
• Study interlayers (diffusion barriers) and
  joining techniques such as HIP or brazing,
  mechanical tests (2 Phases)
• 1.8.1.1.2.8.3 TBM PFC Development
• Mockups of the TBM PFC will be fabricated for
  high heat flux testing. 20 by 100 mm (up to 1000
  cycles) at 0.3-1.0 MW/m2, NDE and post test. (2
  Phases)
• 1.8.1.1.2.8.5 Prototype PFC
• A prototype TBM PFC for HHF testing ( full width
  and thickness but shorter). At least 1000 (up to
  10000 cycles) at 0.3 to 1.0 MW/m2. Pre and Post
  test examination.
• 1.8.1.1.2.8.6 Irradiation of TBM PFC
• Measurement of the key properties of the Be to FS
  joints and joined (e.g., welded or HIPped) FS
  for irradiation to 2 dpa in HFIR. Testing of both
  irradiated and unirradiated samples will be done
  to compare the joints and measure reliability.

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TBM PFC Development Schedule
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Be to FS Joining RD Cost Estimate
Task Cost Estimate (FY06)
Joining Research 1220K
TBM PFC Development 2170K
Prototype TBM PFC Dev. 1000K
Irradiation Testing 314K
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Virtual TBM Development1.8.1.1.2.9

• Mohamed Abdou - UCLA

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Virtual TBM Development Tasks
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Virtual TBM Development Tasks
1.5 man-yr/yr
2.5 man-yr/yr
1 man-yr/yr
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Virtual TBM Development Preliminary Cost Estimate

• Total labor as identified on previous page is 19
  man.year, or roughly a burdened cost of 5.5M.
• Travel and computers, 0.3M
• Software costs, 0.3M
• Total cost over 10 years 6M

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Advanced Diagnostics1.8.1.1.2.10

• Neil Morley - UCLA

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Advanced Diagnostics Tasks
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Advanced Diagnostics Schedule
0.25 man.year/yr
0.5 man.year/yr
0.25 man.year/yr
0.5 man.year/yr

• Preparation/operation of mockups included under
  integrated testing
• In-pile testing in fusion neutron source relying
  on International collaboration

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Advanced Diagnostics Preliminary Cost Estimate

• Total labor as identified on previous page is
  6.75 man.year, or roughly a burdened cost of
  1.9M over 10 years
• Travel (largely international) 0.3M
• Mockups and mockup test facilities assumed to be
  provided under integrated testing task
• Neutron sources assumed to be provided
  internationally
• Cost of test diagnostics 0.5M
• Total cost over 10 years 2.7M (with some big
  assumptions)

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TBM Integrated Testing

• DCLL and HCCB ½ scale tests
• Tina J. Tanaka
• Task list, schedule and rough costs
• October 6, 2005

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Integrated Testing Task list

• He Loop
• Specify, purchase, install and test a Helium hoop
  that is adequate for testing both the DCLL and
  HCCB test blanket modules
• Integrated test of ½ scale DCLL
• Design and fabricate mockup, FW heating test with
  He cooling, Overpressure test
• Integrated test of ½ scale HCCB
• Design and fabricate mockup, Flow test,
  overpressure test.

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Integrated Testing Task schedule
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Integrated Testing Rough Cost Breakdown
Task Cost
He loop 2,660K
DCLL test 1,680K
HCCB test 200K
less 40K if DCLL is also done.
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Cost Summary and Observation

• Yearly average, 4M/yr
• Weighting is towards middle 5 years
• Still missing estimates for 2 subject areas
• 2nd TBM mockups not included

RD 41M
Tritium Permeation 2.8M
Thermofluid MHD 15.3M
SiC/SiC Fab Process Properties 1.89M
SiC/PbLi/FS Compatibility 0
FS Box Fabrication Material Issues 0
Helium Systems Subcomponent Tests .84M
PbLi Hydrogen Production 2.4M
Be Joining to FS (TBM PFC) 4.7M
Virtual TBM 6M
Advanced Diagnostics 2.7M
Integrated mockup tests 4.34M
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Schedule Summary
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How to proceed?

• Detailed discussions are necessary. I want to
  schedule a weekly call to discuss details of
  groups of related RD and get a better concensus
  and level of detail
• People who didnt get to comment on this call
  should send detailed chits with concerns,
  questions, comments to the task leader, with cc
  to neil, clement, abdou.
• I will continue to synthesize and talk to leaders
  individually to try to get a coherent plan and
  resource estimate by the end of October.
• I will keep the evolving dictionary, schedule and
  cost at www.fusion.ucla.edu/ITER-TBM