US Test Blanket Module Partially Integrated Testing

1. 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) 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.

2. 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

3. US ITER TBM PrelDesRev July FabRoute Dec BidPack August DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June FY2008 2009 2010 2011 2012 2013 R&D progresses in stages Basic Properties Single and Multiple Effects Testing Partially-Integrated Mockup Testing Final Design Fabrication Qualification

4. US ITER TBM PrelDesRev July FabRoute Dec BidPack August DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June FY2008 2009 2010 2011 2012 2013 R&D stages • 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 Final Design Fabrication Qualification Title3DesRev StartPrototype June

5. US ITER TBM verify predictive capabilities, complex geometry & conditions R&D stages • 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 Final Design *Satisfy ITER qualification assure TBMs will not fail and jeopardize ITER Fabrication Qualification Title3DesRev StartPrototype June PrelDesRev July FabRoute Dec BidPack August DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June FY2008 2009 2010 2011 2012 2013

6. He Loop Title3DesRev StartPrototype June DetDesFinalRev September PrototypeDone April FinDesChng December startTBMfab June FY2008 2009 2010 2011 2012 2013 Combined Schedule US ITER TBM Partially Integrated Test Test Facility Data Detailed Design Fab Qual HCCB analysis Pressure Facility HCCB P test HCCB mockup des/fab FW test DCLL P test DCLL analysis DCLL mockup des/fab FW test analysis DCLL PbLi loop MHD test extended operation ship He loop & PbLi mockup prototype

7. US ITER TBM Three Partially-integrated Tests 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.

8. US ITER TBM Three Partially-integrated Tests - #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.

9. 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.

10. 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 Use of the MTOR lab would require that the PbLi loop (DCLL test) fit an existing magnet. (also true elswehere) QTOR magnet and LM Flow Loop BOB magnet FLIHY Electrolyte loop

11. 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)

12. 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.

13. DCLL Schedule Part. Int. Mockup Test 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 Subtask costing at this level (examples later, purchases, labor, trav) WBS annual costs this level DCLL 1.8.1.1.2.0.9.03 Pressurization & LOCA test

14. “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.

15. 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