1. US Test Blanket Module Partially Integrated Testing 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. 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 US ITER TBM

2. 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 Outline US ITER TBM

3. R&D progresses in stages Basic Properties Single and Multiple Effects Testing Partially-Integrated Mockup Testing Final Design Fabrication Qualification FY2008 2009 2010 2011 20122013 DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June PrelDesRev July BidPack August FabRoute Dec US ITER TBM

4. R&D stages Title3DesRev StartPrototype June FY2008 2009 2010 2011 20122013 DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June PrelDesRev July BidPack August FabRoute Dec US ITER TBM Partially Integrated Mockup Tests HHF test – DCLL1, HCCB1 MHD test – DCLL2 Pressure test – DCLL-p, HCCB-p Data Fabricate Mockups FW HHF He-cooled mockups PbLi flow mockups, PbLi loop Pressurization mockup Test Facilities FW HHF facility – heat + He loop MHD facility – magnet + LM loop P facility - + burst enclosure Final Design Fabrication Qualification

5. R&D stages Title3DesRev StartPrototype June FY2008 2009 2010 2011 20122013 DetDesFinalRev September PrototypeDone April FinDesChng December StartTBMfab June PrelDesRev July BidPack August FabRoute Dec US ITER TBM Partially Integrated Mockup Tests HHF test – DCLL1, HCCB1 MHD test – DCLL2 Pressure test – DCLL-p, HCCB-p Data Fabricate Mockups FW HHF He-cooled mockups PbLi flow mockups, PbLi loop Pressurization mockup Test Facilities FW HHF facility – heat + He loop MHD facility – magnet + LM loop P facility - + burst enclosure verify predictive capabilities, complex geometry & conditions Final Design Fabrication Qualification *Satisfy ITER qualification assure TBMs will not fail and jeopardize ITER

6. Partially Integrated Test Data Detailed Design Fab Qual Combined Schedule Test Facility DCLL PbLi loop analysisDCLL mockup des/fab MHD test extended operation Pressure Facility HCCB mockup des/fab ship He loop & PbLi mockup FW test He Loop HCCB P test FW test Title3DesRev StartPrototype June FY2008 2009 2010 2011 20122013 DetDesFinalRev September PrototypeDone April FinDesChng December startTBMfab June prototype DCLL analysis DCLL P test HCCB analysis US ITER TBM

7. 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. Three Partially-integrated Tests US ITER TBM

8. 1.FW Heat Flux Testing: Three Partially-integrated Tests - #1 US ITER TBM 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. 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. Three Partially-integrated Tests - #2 US ITER TBM

10. 2. PbLi Flow and Heat Transfer Test (DCLL): Three Partially-integrated Tests - #2 US ITER TBM BOB magnet QTOR magnet and LM Flow Loop FLIHY Electrolyte loop UCLA MTOR Lab UCLA has developed the MTOR lab for liquid metal MHD studies. Use of the MTOR lab would require that the PbLi loop (DCLL test) fit an existing magnet. (also true elswehere)

11. 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) Three Partially-integrated Tests - #3 US ITER TBM

12. Costing Process 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. US ITER TBM

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

14. “Big Ticket Items” 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. 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. He loop for ITER TBM US ITER TBM

15. Concluding Statements 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 US ITER TBM