1. U.S. Presentation in TBWG-16 Beijing, China November 15 – 17, 2005
Overview of R&D, Time Schedule, and Cost Estimation M. Abdou (25 min.)
Possible Practical Collaborations with Other Parties D. K. Sze (10 min.)
Impact on TBM of Frame Design and Replacement Procedure C. Wong (10 min.)
Comments on Quality Assurance R. Kurtz (10 min.)

2. Overview of US ITER TBM R&D, Time Schedule, and Cost Estimation
Mohamed Abdou, Alice Ying, Neil Morley, Clement Wong, Tom Mann, Dai-Kai Sze, Mike Ulrickson, and the US ITER TBM Team
TBWG-16
Detailed information is available at
Note this information is being continually updated and refined.

3. US ITER TBM Program: Selected Concepts
1. The Dual-Coolant Pb-17Li Liquid Breeder Blanket concept with self-cooled Pb-Li breeding zone and flow channel inserts (FCIs) as MHD and thermal insulator
-- Innovative concept that provides “pathway” to higher outlet temperature/higher thermal efficiency while using ferritic steel.
-- Plan an independent DCLL TBM that will occupy half an ITER test port with corresponding ancillary equipment
-- Work closely with any Parties interested in this or similar concepts
2. The Helium-Cooled Solid Breeder Blanket concept with ferritic steel structure and beryllium neutron multiplier, but without an independent TBM
-- Support EU and Japan efforts using their TBM structure & ancillary equipment
-- Contribute unit cell /submodule test articles that focus on particular technical issues

4. A Detailed TBM Planning and Costing Activity for the US TBM Program has been requested by the DOE
Planning will be for the US Reference Scenarios:
DCLL TBM with PbLi exit temperature of 470ºC and a series of TBM that occupy half a port.
HCCB submodule that has a size of 1/3 of one-half port in cooperation with the EU or Japan
Detailed planning and cost is for a 10 year period between now and the shipment of the TBM deliverables in 2015 for DAY ONE ITER operation.
The cost is the total cost for the TBM project including R&D, design, engineering, fabrication, qualification, etc., as well as the cost of interface with ITER and other parties.
The R&D Cost includes all costs related to the Reference Scenarios that occur within the next 10 year period whether they are related to the first (Day ONE) Test Articles or subsequent test articles.
Cost of the deliverables includes only the cost of the First Test Article and associated equipment (See Project Deliverables slide).

5. US Test Blanket “Project” Deliverables Based on Reference Scenario Parameters
Pb-Li Primary Coolant Loop
Transporter, Port Cell Area
Secondary He Coolant Loop
TCWS
Test Port
Primary He Coolant Loop
US DCLL
Test Module
Helium Flow Loop (primary)
PbLi Flow Loop
Tritium Processing Systems
Secondary Helium Flow Loop (and Heat Exchanger for PbLi Flow Loop)
US HCCB
Test Submodule
Ancillary Equipments (primary helium flow conditioners, measuring systems for helium, tritium, and test submodule)
DCLL TBM coolant circuits, Red-doted circuit shows the primary He loop cooling the first wall and all FS structures, Blue-dash circuit shows the Pb-Li loop and the Green-dash circuit shows the secondary helium loop.

6. US ITER TBM Costing Activity Milestones
12-Aug-05 Costing Activity Initiated
31-Aug-05 WBS established for Level 6 and lower
Responsible persons for Level 6 and lower assigned
7-Sep-05 WBS for Level 6 and lower revised
9-Sep-05 Conceptual design summaries for DCLL and HCCB issued
6-Oct-05 Initial schedule and base cost estimate for WBS level 6 of DCLL and HCCB
27-Oct-05 Initial schedule and base cost estimate for engineering design, procurement/fabrication, and ancillary equipment
7-Nov-05 R&D decision criteria established
30-Nov-05 Complete revised schedule and cost estimate for WBS level 6 and lower (include contingency factor)
12-14 Dec-05 “Physical” Meeting (all information about costing will be presented and discussed)
16-Dec-05 R&D priorities finalized
13-Jan-06 Initial Draft Costing Activity Report Due
15-Feb-06 Complete Draft of Final Costing Activity Report
22-23 Feb-06 Physical meeting (internal review of draft report)
1-Mar-06 Complete incorporating comments into the Report
15-Mar-06 Send Final TBM Cost Estimate Report to DOE
28-Mar-06 “External” review

7. US DCLL TBM Reference Scenario Conditions
FS Tmax ≤ 550° C
FS/PbLi < 500° C
SiC/PbLi < 500° C
SiC Tmax < 500° C
He < 450° C
PbLi ≤ 470° C
Module Geometry:
Port frame thickness, mm
200
“Dog leg” width, mm 30
Frame and TBM gap width, mm 20
TBM height, m
1.66
TBM width, m
0.484
Radial depth, m
0.413
Frontal area, m2
0.803
First wall shape
flat
Module Materials:
Structural material
Ferritic Steel (FS), e.g. F82H or EUROFER
Breeding material
Pb-17Li
FW/structural coolant
8 MPa helium
Intermediate loop coolant
Flow channel insert
SiCf /SiC or metallic sandwich e.g. FS/Al2O3
FW coating
2 mm Be
Notes:
DCLL features will be tested at PbLi temperatures compatible with ferritic steel (500C). He and PbLi flowrate, and inlet and outlet temperature, will be varied depending on experiment underway, but these limits will not be exceeded
External piping material for Helium system will be austenitic steel (transition element required)
External piping material for the PbLi has not yet been decided, but likely to be a commercial ferritic/martensitic steel up to the HX (Cutting/rewelding technique required)

8. US Test Blanket Project Organized by Subsystem and Deliverables

9. US Test Blanket Work Breakdown Structure

10. Most Work Breakdown Structure Elements are further broken down into the following subcategories:
Administration
R&D
Engineering
Preliminary Design
Detailed Design
Fabrication Support
Fabrication/procurement
Assembly, testing, & installation

11. 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
Test articles from day one of ITER operation with specific testing goals and diagnostic systems
Associated ancillary equipment systems
in a transporter behind the bioshield and in space in the TCWS and tritium buildings
using bypass PbLi flow to keep temperature of ancillary equipment below material limits
Develop international collaboration on PbLi systems to the maximal extent

12. US DCLL TBM Testing Schedule in the US DDD
ITER Year -1 1 2 3 4 5 6 7 8 9 10
ITER
Operation Phase
Magnet testing & vacuum
HH-
First Plasma HH DD
Low
Duty DT
High Duty
High
Progressive
Testing Conditions
Toroidal B field
Vacuum
Heat flux
B Field
Disrup-tions
Small DD neutron flux
NWL
Full disruption energy
Fluence
Accumula-tion
Electromagnetic/Structural (EM/S) TBM
Install RH
System check-out
Transient EM Loading on structure and FCIs
FW heat flux loading
ITER field perturbation
Hydrogen permeation
LM-MHD tests
Nuclear Field/ Tritium Prod.
(N/T) TBM
 Finalize
Design
Nuclear field
Tritium production
Nuclear heating
Structure and FW heating
Thermofluid/ MHD (T/M) TBM
FCI thermal and electrical insulation
Tritium permeation
Velocity profiles
Integrated (I)
TBM
High temperature effects in TBM
Tritium permeation/recovery
Integrated function, reliability

13. Electromagnetic/Structural (EM/S) TBM (for Hydrogen Phase) Testing Goals
Validate general TBM structure and design
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
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.
Establish performance baseline and operational experience of the TBM and ancillary systems
Integration of control systems and diagnostics with ITER systems
Demonstration of required subsystems and port integration
Demonstration of remote handling procedures
Measurement of thermal time constants and heat loss
Measurement of tritium (hydrogen) permeation characteristics
Testing heating/filling/draining/remelting and accident response procedures
Perform initial studies of MHD effects and Flow Channel Insert performance
MHD flow distribution (manifold design, multichannel effects)
3D pressure drop (toroidal field and toroidal + true poloidal field)
FCI performance changes as a function LM exposure time
FCI response to loading from EM events (water hammer, transient eddy current forces)
Map ITER field in TBM area

14. DCLL Test Module Fabrication Schedule Summary
(note: schedules are evolving)
*Prototype may or may not be full scale

15. Purposes of R&D activities 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

16. Main DCLL TBM R&D Areas Identified in the US Activity
Main DCLL TBM R&D Areas Identified in the US Activity. Several are common issues of interest to all Parties
Test Module R&D Tasks Areas
(some have several subtasks)
US Person –
Morley
Tritium Permeation
Merrill
Tritium Extraction (PbLi & He)
Willms
Thermofluid MHD
Smolentsev
SiC/SiC Fab Process & Properties
Katoh
SiC/PbLi/FS Compatibility
Pint
FS Box Fabrication & Material Issues
Rowcliffe/Kurtz
Helium Flow Distribution and HX
Wong
PbLi/H20 Hydrogen Production
Be Joining to FS
Zinkle/Ulrickson
Virtual TBM Simulation Suite
Abdou
Advanced Diagnostics
Integrated mockup tests
Ulrickson/Tanaka

17. DCLL Test Module R&D Schedule Summary
(note: schedules and R&D tasks are evolving)

18. Some R&D area highlights: Thermofluid – MHD
Thermofluid – MHD is an important class of issues for the DCLL design, operation and safety
Several R&D subtasks are being planned
Continued model development: 3D-HIMAG and other research codes needed to predict basic performance of DCLL and to utilize/interpret TBM experimental data
Experiments on basic FCI performance: 3D pressure drop, flow development, effect of / need for pressure equalization holes, overlap regions, etc.
Experiments on manifolds design: needed to explore range of achievable flow uniformity under various operating conditions
Partially integrated MHD flow tests on flow mockups
Example: Effect of FCI pressure equalization gap on Hartmann wall side, SiC=20

19. Some R&D area highlights: Tritium Inventory and Permeation Modeling10 20 30 40 50
0.0
0.5
1.0
1.5
2.0
Tritium pressure above PbLi (Pa)
Number of pulses
Simulations have lead to a new strategy for tritium control
Swept secondary containment around transporter cask and TCWS skid for controlling leaked or permeated tritium
More aggressive permeator development to reduce tritium partial pressure in PbLi
Swept secondary containment around all PbLi (and He) piping
Operation at lower He/PbLi temperatures if ITER limit is approached
TMAP model and resultant tritium pressure for an example DCLL case

20. An Idea: Virtual TBM
Better integration and management of codes used for predicting TBM conditions and interpreting TBM experiments
CAD
MCNP
HIMAG
TMAP
ANSYS
RELAP …
Experience with CAD/MCNP should just be the start

21. ORNL

22. Rough DCLL TBM Cost Estimate Summary Covering the next 10 years (Subject to revision in detailed evaluation of costs)
Preliminary DCLL R&D Cost Summary
Tritium Permeation
XXX
Thermofluid MHD
SiC/SiC Fab Process & Properties
SiC/PbLi/FS Compatibility
FS Box Fabrication & Material Issues
Helium Systems Subcomponent Tests
PbLi Hydrogen Production
Be Joining to FS (TBM PFC)
Virtual TBM
Advanced Diagnostics
Integrated mockup tests
Design, analysis and DCLL TBM and systems fabrication
rough cost estimate is XXX
some key costs still not included
Prioritizing and trade-off assessment activity underway
Risk assessment activity underway

23. Ceramic Breeder Test Submodule Inserting “US” unit cells into the EU HCPB structural box
Electromagnetics/Neutronics unit cell design
Unit (mm)

24. Main HCCB Test Sub-Module R&D Areas Identified in the Activity
Test Module R&D
Ying
Helium flow distribution and manifold testing
Calderoni
Pebble bed thermomechanics and T recovery
Calderoni/Katoh
RAFS fabrication development (overlap with US DCLL)
Rowcliffe/Kurtz
T-control and predictive capability
Ying/Merrill
Development of FS & SS transition element
Zinkle/Kurtz
Diagnostics and instrumentation (some overlap with US DCLL)
½ scale mockup and qualification tests (some overlap with US DCLL)
Tanaka
In-pile pebble bed assembly test
Katoh/Calderoni

25. HCCB Test Sub-Module Schedule Summary
(note: schedules and R&D tasks are evolving)

26. Rough HCCB TBM Cost Estimate Summary Covering the next 10 years (Subject to revision in detailed evaluation of costs)
Engineering Design Activities: ~$XXX
Fabrication of 1st series of unit cells ~$XXX

27. Categorizing R&D Tasks
A system needs to be established to categorize R&D tasks to give a cost range
Simple rating system being tried in the US:
E = Essential for the qualification and successful execution of the TBM experiment, and no other party is doing it
I = Important for the qualification and successful execution of the TBM experiment, or Essential but is definitely being done by another party
D = Desirable but the risk is acceptable if not performed
According to this system: International effort affects US prioritization

28. Some initial conclusions (that some have already realized, but all need to face)
TBMs are generally much more expensive than initial estimates might show
Many hidden expenses will continue to be discovered
Undefined elements of ITER QA/licensing requirements can impact cost significantly (~>10%)
R&D efforts are a large portion of costs
They must be scrutinized and prioritized
R&D activities mostly address areas of interest to other Parties
Tested full scale prototypes are likely necessary to avoid failures in first years of operation that jeopardize mission of validating DT phase TBM
There is very little time left if subscale mockups and prototypes are to be attempted.

29. TBWG should identify and coordinate effort on key, common, R&D areas
Suggestion, For each common R&D area, one or two parties (depending on issue difficulty and criticality) should “volunteer” to do the research, and share the results
Be layer joining to FS
Tritium extraction and cleanup in He purge and coolants
Common diagnostic sensors and controllers
Common test and qualification tests and test facilities
Virtual TBM simulation capabilities
FS technology (joining, shaping, in-situ rewelding, irradiation database)
FS to Austenitic Steel Transition Sections
PbLi/Water hydrogen generation (all PbLi systems with volume > 280 liters)
(Another US Presentation will elaborate on practical possibilities…)
Cooperation on R&D issues is the first step to cooperative test programs – once common needs and purposes are clearly evident to the parties