US ITER TBM

DCLL ITER-TBM Plan and Cost Summary

PbLi Flow Channels

He-cooledFirst Wall

PbLi

He

He

SiC FCI

2 mm gapUS DCLL TBM – Cutaway Views

484 mm

US DCLL TBM and PbLi Loop – Port Cell View

2

A US TBM Technical Plan and Cost Estimate has been developed and reviewed

A technical plan for US ITER TBM has already been developed.

– A good cost estimate was generated through the combined efforts of the technical experts from:

• Plasma Chamber• Materials, • PFC, and • Safety Programs• Plus ORNL costing &

management professionals– An external review by US DOE

technical and project experts found the cost and plan “complete and credible”

The costs depend strongly on the level of international collaboration and timing– IF US is “going it alone”, R&D costs

are likely to be larger than that given in this estimate.

– Some tritium extraction R&D and fabrication delayed till 2nd module

DCLL TBM Deliverables: Hardware for 1st TBM experiments during H-H

A full size, vertical half-port, DCLL test blanket module

1.6 m

Primary and secondary DCLL helium coolant flow loops

A DCLL PbLi coolant flow loop and HXs

3 m

2 m

TBM Deliverables: Software and Specifications needed for 2nd

TBM and TBM experiment operations

.

Component specifications sufficient to fabricate the tritium processing systems

A verified predictive capability sufficient to design, qualify, operate, and interpret data for the H-H phase TBMs, and to design later D-D and D-T phase TBMs and ancillary systems and diagnostic systems;

Preliminary T Processing Systems Flow Chart

HCCB thermofluid and DCLL MHD flowsimulations

T2/BreederSeparator

HeatExchanger

Breeder, T2, He

Breeder

T2

Breeding

He, T2

Breeder, T2

T2, He

He

Permeator

T2

He, T2

He

Permeator

To Tritium Plant

T2

To Tritium Plant

Dual CoolantBlanket

HeatExchanger

He

He

US ITER TBM

5

Breakdown of DCLL TBM Program Cost Estimate by Major Categories

Category Examples of Activities Reference Comment

Basic R&D

• Joining technologies for RAFS• SiC FCI development • LM MHD flow behavior experiments• Tritium control and extraction• Advanced predictive capabilities

$37MNeeded

before either TBM or CTF

testing

2007-2016timeframe

Design and Development Activities

• TBM design and analysis• Safety analysis and support• Testing of scaled mockups in non-fusion

facilities

$32M

TBM & Ancillary Equipment Fabrication

• TBM fabrication & acceptance tests• Ancillary coolant loops and support systems

fabrication and acceptance tests$7M 2012-2015

timeframe

“Project” Costs• Administration and management for US share• Integration with ITER and Partner systems• Contingency

$17M 2007-2016

Total US Costs (over the next 10 years) $93MIncluding

escalation and contingency

US ITER TBM

R&D tasks must directly contribute to satisfying design, qualification, safety, and operation requirements

TBM R&D tasks have been reviewed based on the minimum necessary to:

– Form the basis for important design, material, and fabrication decisions

– address safety issues and reliability risks that must be resolved for qualification of the first TBMs

– plann operate and analyze US TBM experiments in ITER

At a minimum, this same R&D will be needed before testing the DCLL in any US FNS device

ITER TBMAcceptance Requirements

(still being quantitatively defined)

Ancillary systems must be licensed as safety grade

TBMs must be DEMORelevant

TBMs must not interfere withITER operation or safety

US ITER TBM

1. US ITER Proj.

DCLL R&D Tasks affect a variety of systems

1.8 US ITER TBM

1.8.1 DCLL

1.8.1.1 Test Module

1.8.1.5 Design Integration

1.8.1.4 Tritium Systems

1. Thermofluid MHD 2. SiC FCI Fabrication and Properties 3. SiC/FS/PbLi Compatibility & Chemistry 4. FM Steel Fabrication & Materials Prop.5. Helium System Subcomponents Tests 6. PbLi/H2O Hydrogen Production 7. Be Joining to FS 8. TBM Diagnostics 9. Partially Integrated Mockups Testing

1. Model Development and Testing2. Fate of Tritium in PbLi3. Tritium Extraction from PbLi4. Tritium Extraction from He

1. He and PbLi Pipe Joints2. VV Plug Bellows Design3. Chemistry control

DCLL R&D tasks vary considerably in cost and scope

US ITER TBM

RAFS Fab. Devel, $12,243, 30%

Partially-Integrated Mockup Testing,

$8,297, 21%

Thermofluid MHD, $7,040, 18%

FCI Fabrication, $3,060, 8%

Main contributors to DCLL R&D Costs

Total $39,964 k

• RAFS fabrication and Partially-integrated Mockup Testing make up >50% of projected costs

• FCI development and MHD databaseare also an appreciableportion of total R&D

• Other smaller activities:diagnostics, helium thermofluid,PbLi compatibility,tritium, etc.

Escalated cost over Period: FY06-FY15Percentages refer to fraction of total DCLL R&D

US ITER TBM

DCLL TBM Development MilestonesDCLL TBM Development Milestones

Significant up-front R&D on ferritic steel fabrication technologies and simulation code QA

Progressive mockups and testing required for qualification

Key early design decisions

Approve Prototype Fabrication

Approve 1st TBMfabrication

US ITER TBM

International R&D efforts can save the US significant time and money

RAFS Fabrication, Properties, Irradiation database– All parties interested in HIP and welding techniques, but some

proprietary issues– EU and JA programs have considerable investment

NDE of RAFS components– All parties interested, fewer proprietary issues

Be joining to RAFS– All parties interested, no research underway

PbLi MHD and Heat transfer– 3 or 4 Parties interested, Common operational and safety database

PbLi/H20 reaction– 3 or 4 Parties interested, Common safety database

~ $10M savings assumed in current cost estimate

Extrapolation of DCLL TBM costs to FNF Testing

DCLL TBM Program costs are to deliver the first DCLL module and support systems, So for several modules:– the TBM & ancillary equipment cost needs to be multiplied by number of

modules (~6-12 modules PER ONE Concept)– R&D and Design and Development  costs will increase (but perhaps

modestly ) to account for number of modules for the same DCLL to consider variations in: conditions, design, materials, fabrications, etc.

– Project Cost will increase with number of modules , but < linear– Accounting for installation, operation, decommissioning, PIE must be included

Each other concept to be tested will have its own R&D, fabrication and project costs, although some synergy is expected in:– Test facilities– RAFS fabrication technology– Diagnostics/PIE facilities

Backup slides

US ITER TBM

13

TBM Testing in ITER (Phase I), combined with FNF, is the most effective development path for FNT

FNT/Blanket development is critical to fusion A strong base FNT R&D program, together with fusion environment testing is

essential ITER is a unique, unparalleled and “real” opportunity to begin stage I fusion

break-in and scientific exploration ITER will provide the first, and likely the only, opportunity to explore the fusion

environment for many years Low fusion power CTF is required for stage II engineering feasibility, and stage

III reliability growth phases of FNT development Even if CTF exists parallel to ITER, you still do TBM in addition to CTF

– If we do CTF and invest billions to test and develop FNT, this means we are serious. The cost of experiments in ITER is very small and cuts years and huge costs from the required CTF operation

– TBM tests in ITER will have prototypical Interactions between the FW/Blanket and Plasma, thus complementing tests in CTF (if CTF plasma and environment are not exactly prototypical, e.g. highly driven with different sensitivity to field ripple, low outboard field with different gradients)

– Testing in any fusion environment will require same R&D, qualification, mockup testing, testing systems, licensing as for ITER TBM, none of this effort for ITER TBM is wasted

US ITER TBM

14

The Safety and Licensing benefits to US Fusion program are:– A licensed-prototypical breeding blanket module that has demonstrated safe and

reliable operation in a D-T fusion reactor environment, which would be very valuable in licensing of FNF or DEMO

– Developed and demonstrated maintenance techniques plus approaches for reducing worker exposure for DEMO relevant blankets

– R&D on tritium safety and accountancy for future fusion reactors that produce tritium

The Safety and Licensing requirements from ITER on TBMs require that– TBM Equipment be on site prior to first plasma in ITER for acceptance testing– The TBMs and AEUs will be built to the highest standards for any ITER system and

should therefore be just as reliable; the best time to demonstrate and improve the TBM reliability is during the non-nuclear phase of ITER operation

– Concepts that are not covered by ITER’s RPrS will not be licensed with ITER and the PT proposing these concepts will have to deal directly with the French Authorities to license their TBM

– TBMs will be required to present a minimal risk to ITER safety and operation, or they will not be accepted

Summary of TBM Safety & Licensing

US ITER TBM

Evaluating R&D Tasks

A system has been established to evaluated R&D tasks

E = Essential for the qualification of TBM deliverable and successful execution of the TBM experiments, and no other party is doing it

I = Important for the qualification of TBM deliverables and successful execution of the TBM experiment, or Essential but is definitely being done by another party

D = Desirable but the risk may be acceptable if not performed

R&D subtasks are evaluated separately, if a task includes many subtasks.

R&D lower than desirable has already been eliminated

US ITER TBM

DCLL R&D Breakdown and Evaluation

WBS# WBS DescriptionBaseline Cost

(esc. K$)Evaluation

Rating

1.8.1.1.2 TBM Research and Development $37,968

1.8.1.1.2.01 Thermofluid MHD $7,040

1.8.1.1.2.01.01 Modeling Tool Development $2,668 Essential

1.8.1.1.2.01.02 Flow Channel Inserts Experiments & Modeling $1,873 Essential

1.8.1.1.2.01.03 TBM Manifold Experiments & Modeling $958 Essential

1.8.1.1.2.01.04 Thermofluid MHD Integrated Code Improvement $1,542 Important

1.8.1.1.2.02 SiC/SiC FCI Fabrication and Properties $3,060

1.8.1.1.2.02.00 SiC/SiC FCI Fabrication and Properties - Admin $391 -

1.8.1.1.2.02.01 Technical Planning $381 Essential

1.8.1.1.2.02.02 1st Generation FCI SiC/SiC $363 Essential

1.8.1.1.2.02.03 2nd Generation FCI SiC/SiC $589 Important

1.8.1.1.2.02.04 Low Dose Irradiation Effects $1,335 Essential

1.8.1.1.2.03 SiC/FS/PbLi Compatibility & Chemistry $942

1.8.1.1.2.03.01 Technical Planning and Detailed Data Analysis $35 Essential

1.8.1.1.2.03.02 Capsule Tests for Dissimilar Material Effects $88 Important

1.8.1.1.2.03.03 Testing/Analysis of 1st-Gen Reference SiC Samples $370 Important

1.8.1.1.2.03.04 Testing/Analysis of 2nd-Gen & MHD Exp. SiC Samples $449 Important

US ITER TBM

DCLL R&D Breakdown and Evaluation (Cont.)

WBS# WBS DescriptionBaseline Cost

(esc. K$)Evaluation

Rating

1.8.1.1.2 TBM Research and Development (cont.) $37,968

1.8.1.1.2.04 FM Steel Fabrication Development and Mat Properties $12,243

1.8.1.1.2.04.01 Fabrication Technology for Mock-ups $862 Essential

1.8.1.1.2.04.02 Investment Casting Feasibility Assessment $564 Important

1.8.1.1.2.04.03 FW Investment Casting Development $2,715 Important

1.8.1.1.2.04.04 Grid Plate/Manifold Investment Casting Tech Devel $1,227 Important

1.8.1.1.2.04.05 First-Wall HIP Technology Development $2,206 Important

1.8.1.1.2.04.06 Grid Plate/Manifold HIP Technology Development $991 Important

1.8.1.1.2.04.07 Weld Procedure Development $850 Important

1.8.1.1.2.04.08 Test Methods Development and ITER SDC & DB $820 Important

1.8.1.1.2.04.09 Irradiated Properties Database $973 Important

1.8.1.1.2.04.10 Non-Destructive Examination Methods $1,034 Important

1.8.1.1.2.05 Helium System Subcomponents Analyses and Tests $923

1.8.1.1.2.05.01 Helium Cooled First Wall Heat Transfer Enhancement $483 Important

1.8.1.1.2.05.02 Helium Coolant Flow Distribution $439 Important

US ITER TBM

DCLL R&D Breakdown and Evaluation (Cont.)

WBS# WBS DescriptionBaseline Cost

(esc. K$)Evaluation

Rating

1.8.1.1.2 TBM Research and Development (cont.) $37,968

1.8.1.1.2.06 PbLi/H2O Hydrogen Production $880 Important

1.8.1.1.2.07 Be Joining to FS $1,478

1.8.1.1.2.07.01 Joining Research, Small Mock Fab, Strength Testing $211 Important

1.8.1.1.2.07.02 Small HHF Test Mockups and NDE $548 Important

1.8.1.1.2.07.03 Prototype PFC mockup $429 Important

1.8.1.1.2.07.04 Irradiation of TBM PFC joints $290 Important

1.8.1.1.2.08 Advanced Diagnostics $3,106

1.8.1.1.2.08.01 Participation in International Diagnostics $721 Important

1.8.1.1.2.08.02 Testing H-H TBM Diagnostics on Mockups $619 Important

1.8.1.1.2.08.03 Diagnostics Development for Nuclear Parameters $1,766 Important

1.8.1.1.2.09 Partially Integrated Mockups Testing $8,297

1.8.1.1.2.09.01 FW Heat Flux tests $3,938 Essential

1.8.1.1.2.09.02 PbLi Flow and Heat Transfer Tests $3,342 Essential

1.8.1.1.2.09.03 Pressurization and Internal LOCA Tests $1,017 Essential

US ITER TBM

DCLL R&D Breakdown and Evaluation (Cont.)

WBS# WBS DescriptionBaseline Cost

(esc. K$)Evaluation

Rating

1.8.1.4.2 Tritium Processing Systems R&D $1,649

1.8.1.4.2.01 Model Development and Testing $213 Essential

1.8.1.4.2.02 Fate of Tritium in PbLi $577 Important

1.8.1.4.2.03 Tritium Extraction from PbLi $621 Essential

1.8.1.4.2.04 Tritium Extraction from He $238 Important

1.8.1.5.2 DCLL/ITER System Integration R&D $347

1.8.1.5.2.01 He and PbLi Concentric Pipe Joints - Essential

1.8.1.5.2.02 VV Plug Bellows Design - Essential

1.8.3.3 Data / Codes Integration $3,268

1.8.3.3.1 Integrated Strategy Development $256 Important

1.8.3.3.2 Executive Routines & Data Structure $938 Important

1.8.3.3.3 Integration of Simulation Capabilities & Data $1,237 Important

1.8.3.3.4 Integrated Code Benchmarking & Application $837 Important