Embed Size (px)
DESCRIPTION
US ITER TBM. US Test Blanket Module Partially Integrated Testing. 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) - PowerPoint PPT Presentation
Citation preview
US Test Blanket ModulePartially Integrated Testing
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.
Richard Nygren, Tina Tanaka, Dennis Youchison & Mike UlricksonFusion Technology (01658) Sandia National Laboratories
in collaboration with the US TBM Team, especiallyNeil Morley and Alice Ying (UCLA) and Clement Wong (GA)
US ITER TBM Meeting, 15-16 August 2006, ORNL
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
OutlineUS ITER TBM
R&D progresses in stages
Basic Properties
Single and Multiple Effects Testing
Partially-Integrated Mockup Testing
Final DesignFabricationQualification
FY2008 2009 2010 2011 2012 2013
DetDesFinalRevSeptember
PrototypeDoneApril
FinDesChngDecember
StartTBMfabJune
PrelDesRevJuly
BidPackAugust
FabRouteDec
US ITER TBM
R&D stages
Title3DesRevStartPrototype
June
FY2008 2009 2010 2011 2012 2013
DetDesFinalRevSeptember
PrototypeDoneApril
FinDesChngDecember
StartTBMfabJune
PrelDesRevJuly
BidPackAugust
FabRouteDec
US ITER TBM
Partially Integrated Mockup Tests
• HHF test – DCLL1, HCCB1• MHD test – DCLL2• Pressure test – DCLL-p,
HCCB-p Data
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
Final DesignFabricationQualification
R&D stages
Title3DesRevStartPrototype
June
FY2008 2009 2010 2011 2012 2013
DetDesFinalRevSeptember
PrototypeDoneApril
FinDesChngDecember
StartTBMfabJune
PrelDesRevJuly
BidPackAugust
FabRouteDec
US ITER TBM
Partially Integrated Mockup Tests
• HHF test – DCLL1, HCCB1• MHD test – DCLL2• Pressure test – DCLL-p,
HCCB-p Data
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
verify predictive capabilities,
complex geometry & conditions
Final DesignFabricationQualification
*Satisfy ITER qualification assure TBMs will not fail and jeopardize ITER
Partially Integrated TestData
Detailed DesignFab
Qual
Combined Schedule
Test Facility
DCLL PbLi loop
analysisDCLL mockup des/fab
MHD test
extended operation
Pressure Facility
HCCB mockup des/fab
ship He loop & PbLi
mockup
FW test
He Loop
HCCB P test
FW test
Title3DesRevStartPrototype
June
FY2008 2009 2010 2011 2012 2013
DetDesFinalRevSeptember
PrototypeDoneApril
FinDesChngDecember
startTBMfabJune
prototype
DCLL analysis
DCLL P test
HCCB analysis
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 TestsUS ITER TBM
1. FW Heat Flux Testing:
Three Partially-integrated Tests - #1US ITER TBM
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 (500C) He loop would have to be added to perform the TBM HHF tests.
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 - #2US ITER TBM
2. PbLi Flow and Heat Transfer Test (DCLL):
Three Partially-integrated Tests - #2US ITER TBM
BOB magnet
QTOR magnet and
LM Flow LoopFLIHY Electrolyte
loop
UCLA MTOR Lab UCLA has developed the MTOR lab for liquid metal MHD studies.
Use of the MTOR lab would require that the PbLi loop (DCLL test) fit an existing magnet. (also true elswehere)
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)
Three Partially-integrated Tests - #3US ITER TBM
Costing Process
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.
US ITER TBM
1.8 Test Blanket1.8.1 DCLL System and Testing Goals 8112105 Detailed Design Final Design Review 01SEP10 0
8112106 Title III Design Review - Initiate Prototype Fab 30JUN11 0
8112108 Complete Prototype Fabrication 30APR12 0 8112107 Final TBM Design Changes 31DEC12 0
8112109 Initiate TBM Fabrication 28JUN13 0
1.8.1.1 Test Module1.8.1.1.2 R&D
1.8.1.1.2.09 Partially Integrated Mockups Testing1.8.1.1.2.09.01 FW Heat Flux Tests 811210100 Helium loop specification & design 01OCT08 30DEC08 0
811210110 Helium loop procurement & fabrication 31DEC08 29SEP09 0
811210140 FW test mockup design 01JUL09 31DEC09 0
811210120 Helium loop installation 30SEP09 25FEB10 0
811210150 Mockup fabrication 02NOV09 29APR10 0
811210130 He Loop checkout 26FEB10 29JUN10 0
811210160 Mockup testing 30APR10 01NOV10 0
811210170 Mockup post-analysis 02NOV10 28FEB11 0
811210180 Mockup disposal & facility cleanup 01MAR11 28APR11 01.8.1.1.2.09.02 PbLi Flow & Heat Transfer Tests 811210300 PbLi Loop Specification & Design 01JUL09 28DEC09 0
811210340 LM test Mockup and FCI design/bid 29SEP09 30MAR10 0
811210320 PbLi loop procurement and fabrication 29DEC09 28SEP10 0
811210350 LM Mockup fabrication 31MAR10 28SEP10 0
811210330 Ship He loop to magnet facility 29JUL10 28SEP10 0
811210360 System (He, LM, Magnet) install. & checkout 29SEP10 26NOV10 0
811210370 Initial LM Mockup testing and post analysis 29NOV10 29APR11 0
811210375 Extended operation, post analysis, disposal 02MAY11 30OCT12 01.8.1.1.2.09.03 Pressurization & Internal LOCA Tests 811210200 Pressure test facility spec & design 01MAR11 30JUN11 0
811210210 Procurement for facility mods 01JUL11 31OCT11 0
811210220 Facility modification & checkout 01NOV11 30APR12 0
811210230 Package and ship prototype to test facility 01MAY12 29JUN12 0
811210240 Mockup installation & testing 29AUG12 27FEB13 0
811210260 Mockup post-analysis & design 28JAN13 25APR13 0
811210270 Disposal of mockup; facility decommisioning 26APR13 25JUL13 0
Title III Design Review - Initiate Prototype Fab
Initiate TBM Fabrication
Helium loop specification & design
Helium loop procurement & fabrication
FW test mockup design
Helium loop installation
Mockup fabrication
He Loop checkout
Mockup testing
Mockup post-analysis
Mockup disposal & facility cleanup
PbLi Loop Specification & Design
LM test Mockup and FCI design/bid
PbLi loop procurement and fabrication
LM Mockup fabrication
Ship He loop to magnet facility
System (He, LM, Magnet) install. & checkout
Initial LM Mockup testing and post analysis
Extended operation, post analysis, disposal
Pressure test facility spec & design
Procurement for facility mods
Facility modification & checkout
Package and ship prototype to test facility
Mockup installation & testing
Mockup post-analysis & design recommendations
Disposal of mockup; facility decommisioning
1.8 Test Blanket1.8.1 DCLL System and Testing Goals 8112105 Detailed Design Final Design Review 01SEP10 0
8112106 Title III Design Review - Initiate Prototype Fab 30JUN11 0
8112108 Complete Prototype Fabrication 30APR12 0
8112107 Final TBM Design Changes 31DEC12 0
8112109 Initiate TBM Fabrication 28JUN13 0
1.8.1.1 Test Module1.8.1.1.2 R&D
1.8.1.1.2.09 Partially Integrated Mockups Testing1.8.1.1.2.09.01 FW Heat Flux Tests 811210100 Helium loop specification & design 01OCT08 30DEC08 0
811210110 Helium loop procurement & fabrication 31DEC08 29SEP09 0
811210140 FW test mockup design 01JUL09 31DEC09 0
811210120 Helium loop installation 30SEP09 25FEB10 0
811210150 Mockup fabrication 02NOV09 29APR10 0
811210130 He Loop checkout 26FEB10 29JUN10 0
811210160 Mockup testing 30APR10 01NOV10 0
811210170 Mockup post-analysis 02NOV10 28FEB11 0
811210180 Mockup disposal & facility cleanup 01MAR11 28APR11 01.8.1.1.2.09.02 PbLi Flow & Heat Transfer Tests 811210300 PbLi Loop Specification & Design 01JUL09 28DEC09 0 811210340 LM test Mockup and FCI design/bid 29SEP09 30MAR10 0
811210320 PbLi loop procurement and fabrication 29DEC09 28SEP10 0
811210350 LM Mockup fabrication 31MAR10 28SEP10 0
811210330 Ship He loop to magnet facility 29JUL10 28SEP10 0 811210360 System (He, LM, Magnet) install. & checkout 29SEP10 26NOV10 0
811210370 Initial LM Mockup testing and post analysis 29NOV10 29APR11 0
811210375 Extended operation, post analysis, disposal 02MAY11 30OCT12 01.8.1.1.2.09.03 Pressurization & Internal LOCA Tests 811210200 Pressure test facility spec & design 01MAR11 30JUN11 0
811210210 Procurement for facility mods 01JUL11 31OCT11 0
811210220 Facility modification & checkout 01NOV11 30APR12 0
811210230 Package and ship prototype to test facility 01MAY12 29JUN12 0
811210240 Mockup installation & testing 29AUG12 27FEB13 0
811210260 Mockup post-analysis & design 28JAN13 25APR13 0
811210270 Disposal of mockup; facility decommisioning 26APR13 25JUL13 0
FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15
Title III Design Review - Initiate Prototype Fab
Initiate TBM Fabrication
FW test mockup design
He Loop checkout
Mockup disposal & facility cleanup
PbLi loop procurement and fabrication
System (He, LM, Magnet) install. & checkout
Pressure test facility spec & design
Package and ship prototype to test facility
Disposal of mockup; facility decommisioning
DCLL 1.8.1.1.2.0.9.01 FW HHF test
DCLL 1.8.1.1.2.0.9.02 PbLi flow & heat transfer test
DCLL 1.8.1.1.2.0.9.03 Pressurization & LOCA test
DCLL SchedulePart. Int. Mockup Test
WBS annual costs this level
Subtask costing at this level(examples later, purchases, labor, trav)
“Big Ticket Items”
1. He Loop (>$1M purchase)Dual use for FW HHF and PbLi MHD &
heat transfer tests; later comp. testingHigh P (8MPa), high T (500C) loop;
main elements are pump, heater, HX, piping; “system on sled” (portable)
Sandia estimate consistent (10%) with independent GA estimate.
2. PbLi Loop for DCLL mockup (>$1M mat/labor)PbLi loop (470C) 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.
He loop for ITER TBM
US ITER TBM
Concluding Statements
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
US ITER TBM
