Transcript DCLL ITER-TBM Plan and Cost Summary US DCLL TBM – and PbLi Loop

DCLL ITER-TBM Plan and Cost Summary
US ITER TBM
PbLi Flow
Channels
US DCLL TBM
and PbLi Loop –
Port Cell View
PbLi
He-cooled
First Wall
484 mm
SiC FCI
He
US DCLL TBM –
Cutaway Views
2 mm gap
He
A US TBM Technical Plan and Cost Estimate
has been developed and reviewed
 A technical plan for US ITER TBM has
already been developed.
– A good cost estimate was generated
through the combined efforts of the
technical experts from:
• Plasma Chamber
• Materials,
• PFC, and
• Safety Programs
• Plus ORNL costing &
management professionals
– An external review by US DOE
technical and project experts found the
cost and plan “complete and credible”
 The costs depend strongly on the level of
international collaboration and timing
– IF US is “going it alone”, R&D costs
are likely to be larger than that given
in this estimate.
– Some tritium extraction R&D and
fabrication delayed till 2nd module
2
DCLL TBM Deliverables:
Hardware for 1st TBM experiments during H-H
1.6 m
A full size, vertical
half-port, DCLL
test blanket
module
3m
Primary and secondary DCLL helium
coolant flow loops
2m
A DCLL PbLi coolant flow loop
and HXs
TBM Deliverables:
Software and Specifications needed for 2nd
TBM and TBM experiment operations
He
T2
.
Permeator
Component specifications
sufficient to fabricate the
tritium processing systems
He, T2
Breeder, T2, He
T2, He
T2
Breeding
Dual Coolant
Blanket
To Tritium
Plant
T2/Breeder
Separator
He
Heat
Exchanger
He
To Tritium
Plant
Breeder, T2
Breeder
He, T2
Preliminary T
Processing
Systems Flow
Chart
HCCB thermofluid and
DCLL MHD flow
simulations
T2
Heat
Exchanger
Permeator
He
A verified predictive capability
sufficient to design, qualify,
operate, and interpret data for
the H-H phase TBMs, and to
design later D-D and D-T phase
TBMs and ancillary systems and
diagnostic systems;
Breakdown of DCLL TBM Program Cost Estimate
by Major Categories
US ITER TBM
Category
Basic R&D
Examples of Activities
•
•
•
•
•
Joining technologies for RAFS
SiC FCI development
LM MHD flow behavior experiments
Tritium control and extraction
Advanced predictive capabilities
Design and
Development
Activities
• TBM design and analysis
• Safety analysis and support
• Testing of scaled mockups in non-fusion
facilities
TBM & Ancillary
Equipment
Fabrication
• TBM fabrication & acceptance tests
• Ancillary coolant loops and support systems
fabrication and acceptance tests
“Project” Costs
• Administration and management for US share
• Integration with ITER and Partner systems
• Contingency
Total US Costs (over the next 10 years)
Reference
$37M
Comment
Needed
before either
TBM or CTF
testing
$32M
2007-2016
timeframe
$7M
2012-2015
timeframe
$17M
2007-2016
$93M
Including
escalation and
contingency
5
R&D tasks must directly contribute to satisfying design,
qualification, safety, and operation requirements
US ITER TBM
TBM R&D tasks have been
reviewed based on the
minimum necessary to:
ITER TBM
Acceptance Requirements
(still being quantitatively defined)
– Form the basis for important
design, material, and
fabrication decisions
– address safety issues and
reliability risks that must be
resolved for qualification of the
first TBMs
– plann operate and analyze US
TBM experiments in ITER
At a minimum, this same
R&D will be needed before
testing the DCLL in any
US FNS device
TBMs must not interfere with
ITER operation or safety
Ancillary systems must be
licensed as safety grade
TBMs must be DEMO
Relevant
DCLL R&D Tasks
affect a variety of systems
US ITER TBM
DCLL R&D tasks vary
considerably in cost and scope
1. US ITER Proj.
1.8 US ITER TBM
1.8.1 DCLL
1.8.1.1 Test Module
1.
2.
3.
4.
5.
6.
7.
8.
9.
Thermofluid MHD
SiC FCI Fabrication and Properties
SiC/FS/PbLi Compatibility & Chemistry
FM Steel Fabrication & Materials Prop.
Helium System Subcomponents Tests
PbLi/H2O Hydrogen Production
Be Joining to FS
TBM Diagnostics
Partially Integrated Mockups Testing
1.8.1.4 Tritium Systems
1.
2.
3.
4.
Model Development and Testing
Fate of Tritium in PbLi
Tritium Extraction from PbLi
Tritium Extraction from He
1.8.1.5 Design Integration
1.
2.
3.
He and PbLi Pipe Joints
VV Plug Bellows Design
Chemistry control
Main contributors to DCLL R&D Costs
US ITER TBM
• RAFS fabrication and Partially-integrated Mockup Testing make up >50%
of projected costs
• FCI development and MHD database
are also an appreciable
portion of total R&D
• Other smaller activities:
diagnostics,
helium thermofluid,
PbLi compatibility,
tritium, etc.
RAFS Fab. Devel,
$12,243, 30%
Total $39,964 k
FCI Fabrication,
$3,060, 8%
Thermofluid MHD,
$7,040, 18%
Escalated cost over Period: FY06-FY15
Percentages refer to fraction of total DCLL R&D
Partially-Integrated
Mockup Testing,
$8,297, 21%
DCLL TBM Development Milestones
US ITER TBM
 Significant up-front R&D on ferritic steel fabrication technologies and
simulation code QA
 Progressive mockups and testing required for qualification
Approve 1st TBM
fabrication
Key early design
decisions
Approve Prototype
Fabrication
International R&D efforts can save the US
significant time and money
US ITER TBM
 RAFS Fabrication, Properties, Irradiation database
– All parties interested in HIP and welding techniques, but some
proprietary issues
– EU and JA programs have considerable investment
 NDE of RAFS components
– All parties interested, fewer proprietary issues
 Be joining to RAFS
– All parties interested, no research underway
 PbLi MHD and Heat transfer
– 3 or 4 Parties interested, Common operational and safety database
 PbLi/H20 reaction
– 3 or 4 Parties interested, Common safety database
~ $10M savings assumed in current cost estimate
Extrapolation of DCLL TBM costs to FNF Testing
 DCLL TBM Program costs are to deliver the first DCLL module and
support systems, So for several modules:
– the TBM & ancillary equipment cost needs to be multiplied by number of
modules (~6-12 modules PER ONE Concept)
– R&D and Design and Development costs will increase (but perhaps
modestly ) to account for number of modules for the same DCLL to consider
variations in: conditions, design, materials, fabrications, etc.
– Project Cost will increase with number of modules , but < linear
– Accounting for installation, operation, decommissioning, PIE must be
included
 Each other concept to be tested will have its own R&D, fabrication and
project costs, although some synergy is expected in:
– Test facilities
– RAFS fabrication technology
– Diagnostics/PIE facilities
Backup slides
TBM Testing in ITER (Phase I), combined with FNF, is
the most effective development path for FNT



US ITER TBM
FNT/Blanket development is critical to fusion
A strong base FNT R&D program, together with fusion environment testing is
essential
ITER is a unique, unparalleled and “real” opportunity to begin stage I fusion
break-in and scientific exploration
 ITER will provide the first, and likely the only, opportunity to explore the fusion
environment for many years


Low fusion power CTF is required for stage II engineering feasibility, and stage
III reliability growth phases of FNT development
Even if CTF exists parallel to ITER, you still do TBM in addition to CTF
– If we do CTF and invest billions to test and develop FNT, this means we are serious.
The cost of experiments in ITER is very small and cuts years and huge costs from
the required CTF operation
– TBM tests in ITER will have prototypical Interactions between the FW/Blanket and
Plasma, thus complementing tests in CTF (if CTF plasma and environment are not
exactly prototypical, e.g. highly driven with different sensitivity to field ripple, low
outboard field with different gradients)
– Testing in any fusion environment will require same R&D, qualification, mockup
testing, testing systems, licensing as for ITER TBM, none of this effort for ITER
TBM is wasted
13
Summary of TBM Safety & Licensing
US ITER TBM
The Safety and Licensing benefits to US Fusion program are:
–
–
–
A licensed-prototypical breeding blanket module that has demonstrated safe and
reliable operation in a D-T fusion reactor environment, which would be very
valuable in licensing of FNF or DEMO
Developed and demonstrated maintenance techniques plus approaches for
reducing worker exposure for DEMO relevant blankets
R&D on tritium safety and accountancy for future fusion reactors that produce
tritium
The Safety and Licensing requirements from ITER on TBMs require that
–
–
–
–
TBM Equipment be on site prior to first plasma in ITER for acceptance testing
The TBMs and AEUs will be built to the highest standards for any ITER system and
should therefore be just as reliable; the best time to demonstrate and improve the
TBM reliability is during the non-nuclear phase of ITER operation
Concepts that are not covered by ITER’s RPrS will not be licensed with ITER and
the PT proposing these concepts will have to deal directly with the French
Authorities to license their TBM
TBMs will be required to present a minimal risk to ITER safety and operation, or
they will not be accepted
14
Evaluating R&D Tasks
US ITER TBM
 A system has been established to evaluated R&D tasks
 E = Essential for the qualification of TBM deliverable and
successful execution of the TBM experiments, and no other party
is doing it
 I = Important for the qualification of TBM deliverables and
successful execution of the TBM experiment, or Essential but is
definitely being done by another party
 D = Desirable but the risk may be acceptable if not performed
 R&D subtasks are evaluated separately, if a task
includes many subtasks.
 R&D lower than desirable has already been eliminated
DCLL R&D Breakdown and Evaluation
US ITER TBM
Baseline Cost
(esc. K$)
Evaluation
Rating
WBS#
WBS Description
1.8.1.1.2
TBM Research and Development
1.8.1.1.2.01
Thermofluid MHD
$7,040
1.8.1.1.2.01.01
Modeling Tool Development
$2,668
Essential
1.8.1.1.2.01.02
Flow Channel Inserts Experiments & Modeling
$1,873
Essential
1.8.1.1.2.01.03
TBM Manifold Experiments & Modeling
$958
Essential
1.8.1.1.2.01.04
Thermofluid MHD Integrated Code Improvement
$1,542
Important
1.8.1.1.2.02
SiC/SiC FCI Fabrication and Properties
$3,060
1.8.1.1.2.02.00
SiC/SiC FCI Fabrication and Properties - Admin
$391
-
1.8.1.1.2.02.01
Technical Planning
$381
Essential
1.8.1.1.2.02.02
1st Generation FCI SiC/SiC
$363
Essential
1.8.1.1.2.02.03
2nd Generation FCI SiC/SiC
$589
Important
1.8.1.1.2.02.04
Low Dose Irradiation Effects
$1,335
Essential
1.8.1.1.2.03
SiC/FS/PbLi Compatibility & Chemistry
1.8.1.1.2.03.01
Technical Planning and Detailed Data Analysis
$35
Essential
1.8.1.1.2.03.02
Capsule Tests for Dissimilar Material Effects
$88
Important
1.8.1.1.2.03.03
Testing/Analysis of 1st-Gen Reference SiC Samples
$370
Important
1.8.1.1.2.03.04
Testing/Analysis of 2nd-Gen & MHD Exp. SiC Samples
$449
Important
$37,968
$942
DCLL R&D Breakdown and Evaluation (Cont.)
US ITER TBM
Baseline Cost
(esc. K$)
Evaluation
Rating
WBS#
WBS Description
1.8.1.1.2
TBM Research and Development (cont.)
1.8.1.1.2.04
FM Steel Fabrication Development and Mat Properties
1.8.1.1.2.04.01
Fabrication Technology for Mock-ups
$862
Essential
1.8.1.1.2.04.02
Investment Casting Feasibility Assessment
$564
Important
1.8.1.1.2.04.03
FW Investment Casting Development
$2,715
Important
1.8.1.1.2.04.04
Grid Plate/Manifold Investment Casting Tech Devel
$1,227
Important
1.8.1.1.2.04.05
First-Wall HIP Technology Development
$2,206
Important
1.8.1.1.2.04.06
Grid Plate/Manifold HIP Technology Development
$991
Important
1.8.1.1.2.04.07
Weld Procedure Development
$850
Important
1.8.1.1.2.04.08
Test Methods Development and ITER SDC & DB
$820
Important
1.8.1.1.2.04.09
Irradiated Properties Database
$973
Important
1.8.1.1.2.04.10
Non-Destructive Examination Methods
$1,034
Important
1.8.1.1.2.05
Helium System Subcomponents Analyses and Tests
$923
1.8.1.1.2.05.01
Helium Cooled First Wall Heat Transfer Enhancement
$483
Important
1.8.1.1.2.05.02
Helium Coolant Flow Distribution
$439
Important
$37,968
$12,243
DCLL R&D Breakdown and Evaluation (Cont.)
US ITER TBM
Baseline Cost
(esc. K$)
Evaluation
Rating
WBS#
WBS Description
1.8.1.1.2
TBM Research and Development (cont.)
1.8.1.1.2.06
PbLi/H2O Hydrogen Production
1.8.1.1.2.07
Be Joining to FS
1.8.1.1.2.07.01
Joining Research, Small Mock Fab, Strength Testing
$211
Important
1.8.1.1.2.07.02
Small HHF Test Mockups and NDE
$548
Important
1.8.1.1.2.07.03
Prototype PFC mockup
$429
Important
1.8.1.1.2.07.04
Irradiation of TBM PFC joints
$290
Important
1.8.1.1.2.08
Advanced Diagnostics
1.8.1.1.2.08.01
Participation in International Diagnostics
$721
Important
1.8.1.1.2.08.02
Testing H-H TBM Diagnostics on Mockups
$619
Important
1.8.1.1.2.08.03
Diagnostics Development for Nuclear Parameters
$1,766
Important
1.8.1.1.2.09
Partially Integrated Mockups Testing
$8,297
1.8.1.1.2.09.01
FW Heat Flux tests
$3,938
Essential
1.8.1.1.2.09.02
PbLi Flow and Heat Transfer Tests
$3,342
Essential
1.8.1.1.2.09.03
Pressurization and Internal LOCA Tests
$1,017
Essential
$37,968
$880
Important
$1,478
$3,106
DCLL R&D Breakdown and Evaluation (Cont.)
US ITER TBM
Baseline Cost
(esc. K$)
Evaluation
Rating
WBS#
WBS Description
1.8.1.4.2
Tritium Processing Systems R&D
1.8.1.4.2.01
Model Development and Testing
$213
Essential
1.8.1.4.2.02
Fate of Tritium in PbLi
$577
Important
1.8.1.4.2.03
Tritium Extraction from PbLi
$621
Essential
1.8.1.4.2.04
Tritium Extraction from He
$238
Important
1.8.1.5.2
DCLL/ITER System Integration R&D
1.8.1.5.2.01
He and PbLi Concentric Pipe Joints
-
Essential
1.8.1.5.2.02
VV Plug Bellows Design
-
Essential
1.8.3.3
Data / Codes Integration
1.8.3.3.1
Integrated Strategy Development
$256
Important
1.8.3.3.2
Executive Routines & Data Structure
$938
Important
1.8.3.3.3
Integration of Simulation Capabilities & Data
$1,237
Important
1.8.3.3.4
Integrated Code Benchmarking & Application
$837
Important
$1,649
$347
$3,268