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Preliminary Failure Modes and Effects Analysis of the US DCLL Test Blanket Module

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Preliminary Failure Modes and Effects Analysis of the US DCLL Test Blanket Module INL/EXT-07-13115 Preliminary Failure Modes and Effects Analysis of the US DCLL Test Blanket Module Lee C. Cadwallader August 2007 The INL is a U.S. Department of Energy National Laboratory operated by Battelle Energy Alliance INL/EXT-07-13115 Preliminary Failure Modes and Effects Analysis of the US DCLL Test Blanket Module Lee C. Cadwallader August 2007 Idaho National Laboratory Advanced Nuclear Energy Systems Department Idaho Falls, Idaho 83415 Prepared for the U.S. Department of Energy Office of Fusion Energy Sciences Under DOE Idaho Operations Office Contract DE-AC07-05ID14517 ABSTRACT This report presents the results of a preliminary failure modes and effects analysis (FMEA) of a small tritium-breeding test blanket module design for the International Thermonuclear Experimental Reactor. The FMEA was quantified with “generic” component failure rate data, and the failure events are binned into postulated initiating event families and frequency categories for safety assessment. An appendix to this report contains repair time data to support an occupational radiation exposure assessment for test blanket module maintenance. iii iv CONTENTS ABSTRACT.................................................................................................................................................iii ACRONYMS................................................................................................................................................ 1 1. INTRODUCTION.............................................................................................................................. 2 1.1 References ............................................................................................................................. 3 2. PRELIMINARY FMEA ON U.S. DCLL TBM PB-17LI FLOW LOOP .......................................... 4 2.1 Pb-17Li Flow Loop Description............................................................................................ 4 2.2 TBM Operation ..................................................................................................................... 6 2.3 Current Design Information on Pb-alloy Fission Reactors.................................................... 7 2.4 Related Operating Experiences Supporting the FMEA......................................................... 9 2.4.1 Sodium Liquid Metal Experiences.................................................................... 14 2.5 FMEA Failure Rate Data..................................................................................................... 16 2.6 TBM Preliminary FMEA Results........................................................................................ 16 2.7 Notes from Similar FMEA Studies ..................................................................................... 20 2.8 References ........................................................................................................................... 21 3. PRELIMINARY FMEA ON U.S. DCLL TBM HELIUM COOLANT LOOP............................... 25 3.1 TBM Helium Coolant System Description ......................................................................... 25 3.2 TBM Operation ................................................................................................................... 27 3.3 Design Information of Interest ............................................................................................ 28 3.4 Related Operating Experiences Supporting the FMEA....................................................... 29 3.5 FMEA Failure Rate Data..................................................................................................... 31 3.6 TBM Preliminary FMEA Results........................................................................................ 34 3.7 Notes from Similar FMEA Studies ..................................................................................... 35 3.8 Conclusions ......................................................................................................................... 35 3.9 References ........................................................................................................................... 36 v 4. PRELIMINARY FMEA ON U.S. DCLL TBM MODULE BOX ................................................... 40 4.1 TBM Module Box Description............................................................................................ 40 4.2 TBM Operation ................................................................................................................... 44 4.3 Design Information of Interest ............................................................................................ 44 4.4 Related Operating Experiences Supporting the FMEA....................................................... 46 4.5 FMEA Failure Rate Data..................................................................................................... 46 4.6 TBM Preliminary FMEA Results........................................................................................ 54 4.7 Conclusions ......................................................................................................................... 55 4.8 References ........................................................................................................................... 57 5. FMEA RESULTS............................................................................................................................. 62 5.1 References ........................................................................................................................... 66 Appendix A. Preliminary Failure Modes and Effects Analysis of the Pb-17Li Flow Loop ....................... 67 Appendix B. Preliminary Failure Modes and Effects Analysis of the Helium Flow Loop ........................ 98 Appendix C. Preliminary Failure Modes and Effects Analysis for the TBM Module Box...................... 111 Appendix D. Active Repair Times for Pb-17Li Components................................................................... 133 FIGURES 2-1. The Pb-17Li flow loop of the U.S. DCLL TBM. .................................................................................. 5 3-1. The helium flow loop of the U.S. DCLL TBM. .................................................................................. 26 4-1. U.S. DCLL TBM module front view................................................................................................... 41 4-2. U.S. DCLL TBM module box exploded view.....................................................................................41 4-3. U.S. DCLL TBM module box rear view showing support elements................................................... 42 4-4. U.S. DCLL TBM module box plan view in cutaway. ......................................................................... 42 4-5. U.S. DCLL TBM module backplates and helium gas routing............................................................. 43 4-6. U.S. DCLL TBM module box rear view with helium manifolds. ....................................................... 43 vi TABLES 2-1. Pb vapor above a liquid Pb pool.......................................................................................................... 15 2-2. Pb-17Li loop FMEA Results for postulated initiating events.............................................................. 18 3-1. Helium loop FMEA results for postulated initiating events. ............................................................... 34 4-1. TBM module box FMEA results for postulated initiating events........................................................ 55 5-1. Event frequency categories.................................................................................................................. 62 vii ACRONYMS ACGIH American Conference of Governmental Industrial Hygienists AGR Advanced Gas Reactor APEX Advanced Power Extraction ASDEX Axi-symmetric Divertor Experiment ASME American Society of Mechanical Engineers ASN Autorite de Surete Nucleaire AVR Arbeitsgemeinschaft Versuchreaktor BWR boiling water reactor CREDO Centralized Reliability Data Organization D-D deuterium-deuterium D-T deuterium-tritium DCLL dual coolant lithium lead DDD design description document EBR Experimental Breeder Reactor EM electromagnetic FCI flow channel insert FMEA failure modes and effects analysis FW first wall GSSR Generic Site Safety Report HCPB helium cooled pebble bed HELOKA Helium Loop Karlsruhe HIP hot isostatic press HPS helium purification system HTTR High Temperature Engineering Test Reactor IDLH immediately dangerous to life or health IEEE Institute of Electrical and Electronics Engineers ITER International Thermonuclear Experimental Reactor JCT Joint Central Team (ITER) JET Joint European Torus LB liquid-breeder-to-helium (heat transport loop) LOCA loss-of-coolant accident MTTF mean time to failure NFPA National Fire Protection Association PIE postulated initiating event PWR pressurized water reactor RAFS reduced activation ferritic steel RPrS Rapport Preliminarie du Surete SG steam generator STP standard temperature and pressure TBM test blanket module TCWS Tokamak Cooling Water System THTR Thorium High Temperature Reactor TLV threshold limit value TRITEX Tritium Experiment TZM titanium zirconium molybdenum vppm volume parts per million VV vacuum vessel 1 Preliminary Failure Modes and Effects Analysis of the US DCLL Test Blanket Module 1. INTRODUCTION This report presents the results of a preliminary failure modes and effects
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