Costing of Test Articles Ancillary Equipment and Costing Methodology

Transcription

1 Costing of Test Articles Ancillary Equipment and Costing Methodology m x 1.71 m x m C. Wong, S. Malang, M. Youssef, N. Morley, M. Ulrickson and the TBM design team US ITER-TBM Meeting August 10-12, Idaho Falls

2 DCLL TBM Design and Costing General Observations 1. We have completed the conceptual design of our integrated DCLL test module 2. Our first DCLL design could be similar to the last integrated module design 3. All DCLL module designs could be similar with the exception of diagnostics and FCI 4. Impacts from costing details, ITER construction schedule and sharing of ancillary equipment will determine the final schedule, installation and costing of ancillary equipment. FCI m x 1.71 m x m W x H x D

3 Costing Methodology With initial focus on the 1 st DCLL module A task schedule is developed US-ITER Resource code and TBM program technical groups are used to organize labor and hardware costs Ancillary equipment detailed Gathering costing information on special components: Be coated wall, SiC/SiC FCI, PbLi pump Module diagnostics Initial attempt on the DCLL module box cost estimate Beyond the 1 st TBM module Continue to work on costing details with costing professionals on ancillary equipment and with technical team support.

4 DCLL Test Article and Ancillary Equipment Schedule Items in red are to be costed

5 Resource Code (Res. Code): A code used for resource loading the project schedule and indicating the type of resources (R&D, materials, equipment, project management, design, etc.) to be used. (Indicated in red items that we will have to include) Resource Resource Name Definition Code RD R&D All labor (technician, crafts, engineering, physics, etc.) cost. Note: Material and equipment funded for R&D should use code MA or EQ as appropriate. PM Project Management The cost of personnel performing and support activities. These activities include physics management support, WBS managers, systems engineering, procurement, QA and ES&H personnel Note: Travel is code T; computers, materials and supplies for these personnel are code MA. MA Materials The cost of procured materials. This includes computers, supplies and raw materials for equipment fabrication LA Labor Other than R&D, the cost of technician and craft labor used by laboratories for shop labor, inspection, testing, etc., at the labs. The cost for technician and craft labor to perform installation activities at the US ITER site is code IN. EQ Equipment The cost of procured equipment. Note: The cost of equipment fabricated in-house will be included as the material (MA) and labor (LA) used to fabricate the equipment. T1 Title 1 Design The cost of personnel performing Title I (preliminary design) T2 Title II Design The cost of personnel performing Title II (detail design) T3 SW Title III Design and fabrication Software Development The cost of personnel providing technical support to procurement, installation, fabrication, inspection, testing, as-built drawings and other technical activities. The cost of custom software application development, including the cost of subcontractors used for software development services. This includes custom PLC software but not software provided by equipment suppliers. Note: The cost or travel (T), computer hardware, workstations, office supplies (MA) is not to be included in software. IN Installation The cost of technicians and/or crafts labor to perform installation of components and equipment at the US ITER site. Note: Materials and equipment needed to support installation are resources MA and EQ respectively. TX Sales and Tax The cost of sales and use tax on materials and equipment. SP Spares The cost of spare equipment. T Travel The cost of travel, domestic and foreign.

6 DCLL Design Technical Support Group and Functions For the first DCLL test module design With costing impacts FS engineering and fabrication Recommend method(s) of fabrication T1 T2 T3 manhr Hard manhr Hard manhr Hard ware ware ware X X X Thermofluid MHD Analysis X X X FCI material development Design limits and procurement X Compatibility of SiC/PbLi/FS system Design limits Structural analysis and failure modes Analysis X X X Neutronics Analysis X X X Safety Design input and analysis X X X Tritium Extraction and Control Systems Later Design input and analysis Diagnostics/Instrumentation/Control Design input and procurement X X X X TBM interface with plasma Be: Design input, procurement Disruption: Analysis Mechanical Design Design. fabrication and procurement -- X -- X -- X X X X X Thermofluid He Design input, analysis X X X Ancillary equipment: PbLi system Design and procurement X X X X Ancillary equipment: He system Design and procurement X X X X X

7 DCLL Ancillary Equipment Pb-Li loop Pb-Li system: Dia. m Length, m Weight, kg Cost, $ L-1 Pb-Li pump TBD L-2 Pump housing and expansion tank TBD L-3 Pump motor 1 TBD TBD L-4 Pb-Li mixed tank for the bypass loop 1 TBD TBD L-5 Pb-Li/He heat exchanger, bypass loop TBD L-6 Pb-Li tritiume extraction TBD L-7 Pb-Li dump tank 1 1 x TBD L-8 Dump tank heater 1 TBD L-9 Pressure control unit 1 TBD L-10 Cold trap for PbLi 1 TBD TBD L-11 Cold trap coolant 1 TBD TBD L-12 Bi extraction system 1 TBD TBD L-13 Po extraction system 1 TBD TBD L-14 Concentric PbLi pipe 1 TBD L-15 Pipings 1 TBD L-16 Trace heaters TBD L-17 Valves TBD TBD L-18 Pressure transducers TBD TBD L-19 Temp. sensors TBD TBD L-20 Rupture disk TBD TBD L-21 Programmable logic control system 1 TBD

8 He-loop 1 First wall He System: 8 MPa, 380 C to 440 C Dia. m Length, m Weight, kg Cost, $ FW-1 He/water heat exchanger U tube bundle 440 C to 43 C TBD FW-2 Electrical heater TBD FW-3 He circulator TBD FW-4 Circulator motor TBD FW-5 He storage tanks TBD FW-6 He dump tanks TBD FW-7 Buffer tank TBD FW-8 Pipework TBD FW-9 Pressure control subsystem 1 TBD TBD FW-10 Tritium extraction system 1 TBD TBD FW-11 Helium purification system 1 TBD TBD FW-12 Flow meters TBD TBD FW-13 Temperature sensor TBD TBD FW-14 Pressure transducer TBD TBD FW-15 Valves TBD TBD FW-16 Programmable logic control system 1 TBD

9 He-loop 2 PbLi-He systems: 2 MPa Dia. m Length, m Weight, kg Cost, $ 8 MPa, 180 C to 300 C He-1 He/water heat exchanger U tube bundle 300 C to 70 C TBD He-2 Electrical heater TBD He-3 He circulator TBD He-4 Circulator motor TBD He-8 Pipework (including bypass) TBD He-9 Pressure control subsystem 1 TBD TBD He-10 Tritium extraction system 1 TBD TBD He-11 Helium purification system 1 TBD TBD He-12 Flow meters TBD TBD He-13 Temperature sensor TBD TBD He-14 Pressure transducer TBD TBD He-15 Valves TBD TBD He-16 Programmable logic control system 1 TBD

10 DCLL Special Components 2 mm thick Be coating on FS PbLi pump SiC/SiC FCI Concentric pipes Bellows Tritium extraction components Bi and Po control components PbLi/He heat exchanger

11 Be (2 mm) on FS wall (From M. Ulrickson) ITER shield: The Be on the first wall is 10 mm thick. For TBM: The cost of the Be is trivial compared to the cost of the attachment because Be forms brittle beryllides with most materials. There must be either a diffusion barrier Between the Be and the ferritic or an interlayer of a material that does not form beryllides but bonds to both Be and ferritic. For the first wall Be joint to CuCrZr the preferred options are Ti layers (some concern about H embrittlement due to hydride formation), Al or Al-Si alloys (concerns about low melting point but very compliant), and complex brazes that contain CuSnInNi (the Russians propose substituting Ce for Ni). The joining is done by either hot-isostatic pressing at C or brazing at about 800C. For the higher temperatures the FW panel must be quickly quenched to prevent overaging of the Cu alloy. For ferritic this probably won't be necessary. For the FW the Cu is joined to steel before the Be is joined. The Cu to SS joint is quite straight forward. I don't know of any work on joining Be to ferritic. Assuming one of the above joining methods works on Ferritic, I think the cost of just the joining step would be $200K to $600K per square meter of surface. R&D costs are going to be significant. How can we piggyback this item on the international program?

12 PbLi Pump (From S. Malang) FZK has experience with small pump for PbBi. A large pump was modified for the use of PbBi in the composition Pb45Bi55. The rotor material was modified in the critical part (where a high Nickel-content in the steel is present) using the GESA treatment, which is in principle an alumina melting into the surface and the formation of alumina oxide. This large pump is capable of attaining a pressure head of 0.69MPa at a flow rate of 47m 3 /h (135kg/s) at a temperature of 350 C, which is below the promises of KSB which claimed a flow rate of 80m 3 /h at the same conditions. The KSB pump is not completely leak tight and requires a lot of effort of the gas management at and near the free surface. A new much cheaper and much more reliable option for building a pump is offered by Hermetic in Gundelfingen. They developed a pump for mercury (Hg) for BASF operating at 400 C, which requires a complete leak tightness with losses of a few ml gas per year. This is in principle a centrifugal pump, in which the operating liquid is also used as a lubricant for the rotor of the AC motor they account also for the MHD losses. The price of a unit with 1MPa at 60m3/h operating with PbBi is related to the last quotation around 60KEuro all included. We had identified possibly suitable centrifugal pumps in the US, but design/coating modifications will be needed.

13 Hyper-Therm High-Temperature Composites, Inc Gothard Street, Units A, B & C Tel: (714) Huntington Beach, CA Fax: (714) July 26, 2005 Neil B. MORLEY, Adj. Associate Professor Mechanical and Aerospace Engineering Department University of California, Los Angeles Engineering-IV, Los Angeles, CA, USA Neil, Re: ROM Quote for SiC/SiC square tube fabrication Hyper-Therm High-Temperature Composites, Inc. is pleased to provide a rough order of magnitude cost for fabricating square tube 5cm wide and 5 mm thick. Lengths are specified in the second table below. The square tube will be fabricated from CG-Nicalon fabric and a CVI SiC matrix. A multilayer SiC fiber coating will be utilized. A layer of CG-Nicalon mat will be placed at the mid-plane of the thickness to provide internal porosity that will reduce the through thickness conductivity. After densification the tube ends will be machined with a step and cut to length. A CVD SiC seal coat will then be applied to eliminate any open porosity on the part. The following Table provide estimated costs per tube for a several quantities and several lengths. Fiber Architecture Interphase Matrix CG-Nicalon 0/90 fabric faces with a layer mat at the core Mulilayered SiC interphase:20 nm PyC/ 4 x [100 nm SiC/20 nm PyC] CVI SiC to no open porosity Qty 25 cm long 50 cm long 75 cm long 100 cm long 2 $6,500-7,500/tube $10,000-11,000/tube $16,000-17,000/tube $18,000-20,000/tube 4 $5,000-6,000/tube $7,500-8,500/tube $10,000-12,000/tube $12,000-14,000/tube Sincerely, Robert J. Shinavski, PhD Page 1 of 1

14 Module Diagnostics T: On TBM, BT: Behind TBM, A: Transporter, R: Remote area We will need to identify specific diagnostics and designs at different stages of testing.

15 Cost Estimate for DCLL module box by M. Di Martino of GA (Assuming all Design, R&D are completed and fabricated panels provided) Allocated assembly time with the fabricated panels: Prepare material cutting list 6h Material cutting 8h Tack weld 6h Inspect 2h Weld per specifications 24h? Stress relieve 4h Labor $80.00 = $ Cleaning cost: Sand blasting 4h Passivate 4h Rinse 2h Alcohol rinse 4h Package 6h Labor m x 1.71 m x m W x H x D Fabricated panel cost: kg@ $62.33/Kg = $ % (waste)= Kg@ $62.33/Kg = $ Tot material cost $ Total cost for one unit $ (Fabricated material costing from ARIES-ST $1992)

16 Estimated cost for SiC f /SiC FCI Protective package: Labor $ 80.00/h = $ Fabricated material cost: 86 $ 1000/kg = $ % (waste) 21.5 $ 1000/kg = $21500 Total fabricated material cost = $ Labor cost = $ 640 Total cost for one unit = $ (Fabricated material SIC f >$ 1000/kg from ARIES-ST 1992) $ 80.00/h labor for 2004 Or: From Hyper-Therm 6 channels x $14000=$84000

17 Cost estimate for Breeder Pb-17Li and Be-coating PbLi: $11.85/Kg = 60% enriched Total material cost $26344 (Material costing from ARIES-ST $1992) Be-coating: 0.86 m $200k/m 2 = $ (Low estimate from M. Ulrickson)

18 Estimated total cost for one half-port DCLL test module box FS FW/blanket $62.33/kg SiC f /SiC FCI insert $1000/kg Pb-17Li* $62.33/kg (Li 6 60%) Be-wall $ Total $ Observations: Accurate cost estimate is not possible at this time. Cost of test module will be dominated by fabricated unit cost of SiC f /SiC FCI and joining cost of Be onto FS first wall. * Note: We will need to include PbLi in the PbLi loop

19 Dear Neil and Clement, I m attempting in this to address some of your request both for the required R&D and the cost of hardware needed to construct a neutronics TBM (NT-TBM). First I m addressing in Fig. 1 a proposed design for the NT-TBM. The idea is not new but was modified from previous thoughts of the EU community. This could be the design basis for both the HCPB and DCLL blanket concepts (of course with some not big changes.) GENERAL Fluence requirements: 1. Neutronics measurements (except activation and damage parameter) require one of two fluence levels namely: low fluence level (~1 W.s/m 2 ) and very-low fluence level ( ~1 mw.s/ m 2 ). 2. These levels are the minimum fluence requirements, but higher levels are generally desirable for improving measuring statistics. 3. The low fluence level could be realized, for example, with a wall load of MW/ m 2 and 400 s pulse, as is the case in ITER. 4. THe NWL of ~0.78 MW/ m 2 at the TBM is much larger than the MW/ m 2 needed and therefore, most of these measurements can be made within the duration of a single pulse. Type of measurements (in-pile Measurements): 1. 1st Measuring Campaign: Neutron and gamma Spectra, Neutron fluence (use of multi-foil activation method, MFA, or NE213 detectors) 2. 2nd Measuring Campaign Local (and if possible zonal) tritium production rates and profile. (using Li-pellets, Li-glass detectors) 3. 3rd Measuring Campaign 4. Neutron and gamma heating rates. Out of-pile- measurements such as dose behind test module and at cryostat, neutron yield from plasma and source characterization (part of plasma diagnostics.

20 SPECIFIC Design Features to accommodate these measurements (see attached figue) (dimensions were checked with Mo Dagher this morning to ensure consistency) Two or three measurement tubes are inserted from behind (starting from the transport container wall) all the way to the front of the TBM. The OD. Is cm. We place the MFA foils (micro cm thick-1 cm OD) in train (many of them are required, each is intended to measure a particular reaction in for a particular Threshold energy: e.g.: Au-197(n,g)Au-198: thermal neutrons In-115(n,n )In-115m: Fast neutrons. Ni-58(n,p)Co-58: and Ni-58(n,2n)Ni-57: En>2.9 and 13.4 MeV, respectively Al-27(n,a)Na-24: En>8.5 MeV Nb-93(n,2n)Nb-92: En>10.8 MeV Since measurements can be performed in a fraction of a pulse, we need to retrieve these foils, either mechanically as show in the figure, or by a rabbit system. Shown on the figure two position for these MFA foils: One when it is at the tip of the measurement tube and one where they are pulled to a pre-determined inner position. (to measure flux, spectra at various locations) R&D issues: 1. Can we design these tubes of with this OD dimension?. Its length could be ~60 cm TBM (with Manifold)+110 cm shield+ 250cm service area cm frame+240 service are mc biological shield+ 50 cm to the transport container =830 cm? 2. How reliable the mechanical system will be? 3. Can these tubes take inside other measuring teqchiques for TPR, heating rates or bigger sizes are needed? 4. How much flux disturbance these tubes can impart on neutron and gamma spectrum (they at least should be modeled in the 3- D calculation). This requires analysis and possibly sensitivity/and uncertainty approach using perturbation codes. 5. If we pull the MFA foils to the back, a vacuum zone could be created ahead of them. May be a filler zone could be placed in the void areas after fully retrieving the foils and putting the filler for another separate pulse (i.e. different arrangement).

21 6. Do these measuring tubes need to be cooled (shown in the figure that we can do that by a He-cooling station located in the transport container area. Also MO Dahger suggested routing some of the helium used to cool the FW to at least cool the front part of these tubes where heating rates are the highest. 7. It is not sure that each pulse during the early D-T operation (~750 pulse) will have the same incident neutron spectra (in absolute value, spatial shape and spectrum). The question is: if we leave these foils inside the TBM for several pulses (or even for a year before the scheduled maintenance in ITER is performed), how useful the activation data will be and what correction factor we need to apply to account for the decay of the transmuted material?. It is possible to make a replica of the NT-TMB and use it in an existing 14.1 MeV facility (FNS, FNG), apply many pulses and come up with a correction factor. This may also be necessary to undertake prior to inserting the TBM in ITER. (This by the way was done to the Lithium Breeder Module, LBM, when it was tested at LOTUS facility in Switzerland and at TFTR back in 1983.) 8. Can we plug these measurement tubes during the EM-TBM tests and use them latter on?. 9. Can other measurements be performed (e.g some themo-mechanical measurements during the NT-TBM tests. These are just a few. Hardware requirement. 1. WE need to know the number of foils requires for flux measurement at each location, how many number of time this should be repeated and the cost of each folis. 2. For TPR measurement, how meany l=li-pellet, Li-glass or any other techniques (NE-230 small counter) would be needed. What is the cost of each. 3. How many measuring tubes are needed for each blanket concept tested (at least 3). What is the length of each tube (~830 cm) what is the cost? At present, I acquiring the above hardware estimates from Dr. Nishitani (FNS, JP) and DR. Paola Batistoni, GNF, Italy)

22 Schematic of Neutronics TBM and Instrumentation

23 What to do next? Continue to work on more costing details: Work with technical support groups and others on the costing for T1, T2 and T3 including labor and hardware. Work with costing professionals to estimate cost for ancillary equipment. We will need to add the design and cost of the TBM shield and pipings. Estimate costs for special components. Provide estimated budget and schedule. N-stamped not needed, good news!

24 Comments and Discussions