1.8.1.1.2 DCLL R&D Task Area Reports

1. 1.8.1.1.2 DCLL R&D Task Area Reports Compiled by Neil Morley for the TBM Conference Call Oct 6, 2005

2. Purpose of R&D 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

3. Main DCLL R&D areas

4. 1.8.1.1.2.1 Tritium Permeation Brad Merrill – INL

5. 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

6. 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

7. 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)

8. 1.8.1.1.2.2 Thermofluid MHD Sergey Smolentsev - UCLA

9. Thermofluid MHD R&D • 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 R&D 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 R&D plans and develop diagnostics tools for TBM tests in ITER. • IMPORTANT COMMENTS ON R&D and COSTING • All major R&D 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 R&D, 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 R&D 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.

10. Thermofluid MHD R&D Schedule - R&D to support reference design - Development of modeling tools - Planning tests in ITER with supporting experiments and modeling; - Contribution to VTBM

11. Thermofluid MHD R&D Preliminary Cost Estimate TOTAL COST FOR 10 YEARS, M$: 15.3

12. 1.8.1.1.2.3 SiC/SiC FCI Fabrication and Properties Yutai Katoh - ONRL

13. 1.8.1.1.2.3 SiC/SiC FCI Fabrication and PropertiesTask List and Descriptions

14. 1.8.1.1.2.3 SiC/SiC FCI Fabrication and PropertiesTask Schedule

15. 1.8.1.1.2.3 SiC/SiC FCI Fabrication and PropertiesCosting Table

16. 1.8.1.1.2.4 SiC/PbLi/FS Compatibility Bruce Pint - ONRL

17. SiC/PbLi/FS Compatibility Task Descriptions(Bruce Pint)

18. 1.8.1.1.2.5 FS Box Fabrication & Material Issues Arthur Rowcliffe – Free agent Rick Kurtz – PNL

19. FS Box Fabrication Tasks, Schedule, Effort

20. 1.8.1.1.2.6 Helium Systems Subcomponent Tests Clement Wong - GA

22. Helium Systems Subcomponent TestsSchedule

23. Helium Systems Subcomponent R&D Preliminary Cost Estimate

24. 1.8.1.1.2.7 PbLi/Water Hydrogen Production Brad Merrill – INL

25. 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 performedthat 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 Pb–17Li 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

26. PbLi/H2O Hydrogen Production R&D 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)

27. PbLi/H2O Hydrogen Production R&D Task • Total estimated cost is 2.4 $M over 4 years (25% experiment design, 23% experiment fabrication, 32 % performing experiments, 0% data analysis)

28. Be to FS Joining R&D1.8.1.1.2.8 October 6, 2005 M. Ulrickson Presented on TBM R&D Call 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.

29. Be to FS Joining R&D R&D 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.

30. TBM PFC Development Schedule

31. Be to FS Joining R&D Cost Estimate

32. Virtual TBM Development1.8.1.1.2.9 Mohamed Abdou - UCLA

33. Virtual TBM Development Tasks

34. Virtual TBM Development Tasks 1.5 man-yr/yr 2.5 man-yr/yr 1 man-yr/yr

35. 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

36. Advanced Diagnostics1.8.1.1.2.10 Neil Morley - UCLA

37. Advanced Diagnostics Tasks

38. Advanced Diagnostics Schedule • Preparation/operation of mockups included under integrated testing • In-pile testing in fusion neutron source relying on International collaboration 0.25 man.year/yr 0.5 man.year/yr 0.25 man.year/yr 0.5 man.year/yr

39. 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)

40. TBM Integrated Testing DCLL and HCCB ½ scale tests Tina J. Tanaka Task list, schedule and rough costs October 6, 2005

41. 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.

42. Integrated Testing Task schedule

43. Integrated Testing Rough Cost Breakdown less $40K if DCLL is also done.

44. 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

45. Schedule Summary

46. How to proceed? • Detailed discussions are necessary. I want to schedule a weekly call to discuss details of groups of related R&D and get a better concensus and level of detail • People who didn’t 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