Strawman R&D Tasks and R&D Costs

Neil Morley and Alice Ying

INL, August 10-12

US strategy for ITER testing of the DCLL Blanket and First Wall Concept

Develop and deploy a series (~4) of vertical half-port DCLL-TBMs during the period of the first 10 years of ITER operation with– Ferritic steel structure test articles from day one of ITER

operation with specific testing goals and diagnostic systems– Associated ancillary equipment systems of various materials

• in a transporter behind the bioshield and in space in the TCWS and tritium buildings

• using PbLi flow control (bypass/flowrates) to keep temperature of ancillary equipment below material limits (e.g. 475C for PbLi/FS)

Develop international collaboration on PbLi systems to the maximal extent

Electromagnetic/Structural (EM/S) TBM Testing Objectives

1. Explore/validate general TBM structure and design for later DT operation– Measure forces and the mechanical response of the TBM structure to transient EM loads– Determine ferromagnetic and MHD flow perturbation of ITER fields– Measure thermal and particle load effects on plasma facing surface (Be) and FW structure/heat

sink

2. Establish performance baseline and operational experience of the TBM and basic (He and PbLi flow) ancillary systems– Integration of control systems and diagnostics with ITER systems– Demonstration of required port integration and remote handling procedures– Measurement of thermal time constants and heat loss– Testing heating/filling/draining/remelting and accident response procedures

3. Perform initial studies of flow effects and Flow Channel Insert performance in steady and transient ITER magnetic field environment– MHD flow distribution and pressure drop in toroidal field and toroidal + poloidal field– FCI performance changes as a function LM exposure time and loading from EM events– Map ITER field in TBM area

Information in the early HH phase can be used: to modify designs of subsequent TBMs to be deployed in the later DT phase

for ITER DT Licensing.

Key areas and responsible persons for TBM R&D

1. SiC FCI Development [Katoh]2. SiC/PbLi/FS system compatibility [Pint]3. Thermofluid MHD [Smolentsev]4. Safety R&D [Merrill]5. Tritium removal/control systems R&D [Sze/Willms]6. TBM Plasma Interface [Ulrickson]7. Pebble bed thermomechanics [Ying/Calderoni ]8. Structural material and fabrication [Kurtz]9. Structural analysis and failure rates [Ghoniem/Sharafat]10. Mechanical design [???]11. Diagnostics/Instrumentation/Control [???]12. Thermofluid Helium systems [Wong ]13. Virtual TBM [???] 14. Mockup facilities [???]15. mockup tests [???]

R&D Definition and Costing Schedule

PhaseResponsible Persons

Duration(working days)

Draft R&D plan Morley/Ying 15 days

Iteration on R&D tasks and schedule R&D Area Leaders 20 days

Detailed estimate of resources R&D Area Leaders 15 days

Supporting quotes/expert estimates for required materials/fabs

R&D Area Leaders 20 days

R&D and Costs Draft ReportMorley/Ying

15 days

Iterate on Final Draft R&D costs reportR&D Area Leaders

15 days

Costing Report Due Abdou

The following information is requested from each responsible person:

Recommended list R&D tasks in your area needed to– Establish basic TBM feasibility– Understand/predict TBM performance– Design and fabricate first TBM – EM/S

Recommended scheduling of listed R&D tasks Description of each task including:

– Main purpose and method (numerical, experimental, …)– Identification of facility/code or description of new/upgraded

facility/code required– Description of test section and diagnostics to be fabricated– Anticipated duration and person-years of effort– Any perceived overlap with another US R&D area and similar

international R&D

Schedule cost profile costing methodologies Risks acquisition strategy Scaling of existing experience (this was what was done

for ITER Project Pre-CD0) Scaling international partner cost estimates on TBM

program Complete bottoms up based on WBS

SiC/PbLi/FS system compatibility [Pint]

– Need to establish reference design (materials, operating conditions) asap

– Near-term compatibility R&D activities would focus on analysis of existing compatibility for ferritic/martensitic steel with flowing Pb-Li and develop tool for blanket conditions.• Also continue limited number of static capsule tests on candidate

piping materials (possibility to avoid coatings or ceramic inserts)• SiC samples to EU for 500C flowing tests

– Medium-term activities would be centered on flowing loop experiments• Thermal convection loop• Other loops?

– Scoping experiments on stress-corrosion cracking should also be initiated in the near- to medium-term

SiC FCI Development [Katoh]

Initial analysis and strategy development– Confirm if expected cross-sectional distortion is within design allowance. – Develop material design strategy for low flexural modulus and compatibility with other

requirements (eg. porous mid-plane)– Develop FCI design strategy that allows longitudinal bending deformation of each face. – Develop method to determine stiffness matrix of relevant materials.– Develop research plan to be able to predict irradiation creep compliance of FCI material.

For electrical (and thermal) insulation:– Establish a reliable technique to measure trans-thickness electrical conductivity of SiC/SiC

plates at elevated temperatures.– Identify appropriate method(s) for engineering porous mid-plane components,

compensated high resistivity SiC matrix, and insulating SiC-based matrices. Trial-fabricate flat plates of these composites and evaluate baseline properties.

– Perform small scale irradiation experiment (rabbit type) on insulating SiC matrix composites.

For mechanical integrity:– Perform detailed evaluation of cross-sectional and longitudinal stress / strain due to

thermal gradient. Interact with design people– Design materials / components for low flexural / trans-thickness shear moduli and

compatibility with other requirements (eg. porous midplane)– Determine stiffness matrix and other design properties for FCI material. Develop

appropriate test methods. – Determine irradiation creep compliance of FCI material.– Perform mock-up (-like) testing to ensure mechanical integrity and sealing are maintained

up to design maximum thermal gradient.

Structural material and fabrication [Kurtz]

Structural analysis and failure rates [Ghoniem/Sharafat]

Themomechanical heat treatments after fab, hip, weldSpecial emphasis will be needed for specific manufacturing processes and joining techniques such as HIPped and difusion bonded materials (presently not nuclear qualified).

Pre-service Nondestructive inspection High temperature design rules Selection of an appropriate ferritic steel (F82H, Eurofer, other?). This is not trivial

since the U.S. will need to take advantage of databases developed in Japan and the EU.

Development of joining technology of Be to ferritic steel. (overlap) Effects of radiation to ~3 dpa at 100-550°C on the deformation and fracture

properties of structural materials. The planned U.S./Japan 15J/16J HFIR irradiation experiment provides a good

approximation of the TBM irradiation conditions (300/400°C, 2.5-5 dpa) Creep-fatigue interaction due to the high number of short operational pulses in ITER Iteration with Structural Analysis Tasks/Design/Materials and

Fabrication

Thermofluid MHD [Smolentsev]

Effectiveness of the FCI as electric/thermal insulator Flow effects on corrosion rate and thermal stresses in the FCI*(coupled) Pressure equalization on both sides of the FCI EM forces in and around the FCI during the disruptions* 3-D flow effects on the FCI and the whole TBM functions 3-D MHD pressure drop of flow elements an flow balancing – normal and

faulted conditions Multi-channel flow effect Design and optimization of the inlet Pb-17Li manifold Coaxial pipe vs. two separate pipes Thermal behavior of the TBM during the ITER cycle?* (coupled) Effect of natural convection, turbulence, etc. on the thermal behavior of

the TBM

Safety R&D [Merrill]

Tritium permeation through cooling system pipes Inventory analysis based on tritium extraction technique Hydrogen generation – PbLi spray experiment contact

mode characterization

Tritium removal/control systems R&D [Sze/Willms]

Fundamental R&D on Tritium extraction technologies for high temperature (coupled)– Permeators Nb, Ta, Pd– Direct contact

Tritium permeation ??? what to be done (coupled to saftey)

TBM Plasma Interface [Ulrickson]

Joining Be and FS (coupled)

Pebble bed thermomechanics [Ying/Calderoni ]

Diagnostics/Instrumentation/Control [???]

Thermofluid Helium systems [Wong ]

Headers and non-isothermal flow distribution Heat transfer coefficients

Virtual TBM [???]

Morley, Merrill, Sharafat, Smolentsev

Mockup facilities [???]

Mechanical Design [???]