Costing of Test Articles Ancillary Equipment and Costing Methodology

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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 First Wall Assembly Center Divider Plate Assembly Top Plate Assembly He Inlet/Outlet Pipe Assembly Bottom Plate UCLA July 26, 2005, Assembly CW Outer back Plate Assembly Pb-Li Inlet/Outlet Pipe Assembly

4 SiC Inserts Top Assembly Install SiC inserts Front View Back View SiC Inserts Front Upper Assembly Divider / Grid Plate Assembly SiC Inserts Rear Assembly SiC Inserts Front Lower Assembly UCLA July 26, 2005, CW SiC Inserts Bottom Assembly SiC inserts shown assembled with the first wall module removed SiC inserts shown fully assembled in first wall module

5 Install Inner Back Plate Assembly Inner Back Plate Structure Make Internal Seal Welds (shown in yellow) Inner Back Plate Cover First Wall Grid Plates UCLA July 26, 2005, CW Divider Plates

6 Install top and bottom plate assemblies Top Plate Cover Top Plate Structure Make internal seal welds to top and bottom of the grid plates Make external seal welds to top and bottom plate assemblies Bottom Plate Structure UCLA July 26, 2005, CW Bottom Plate Cover

7 DCLL Test Article and Ancillary Equipment Schedule, team review Items in red are to be costed

8 HCLL From sub-components testing up to integral functional tests Sub-components qualif. Fabrication Test/qualification Functional test (prototypical mock-ups) 1:4-1:3 mock-ups fabricat. (Industry + Associations) 1:4-1:3 mock-ups tests 1:1 mock-ups fabrication (Industry) 1:1 mock-ups tests TBM acceptance tests 1st TBM fabrication (Industry) 1st TBM acceptance tests UCLA July 26, 2005, CW

9 Blanket R&D and Manufacturing Schedule for ITER ID ID Task Name 1 1 ILE establishment 2 2 VV call for tender 3 3 VV contract award 4 4 T=0 Regulatory approval 5 5 Start of excavation at site & building construc 6 6 Start of VV material procurement 7 7 Start of VV fabrication 8 8 First sets ov VV sectors, TF coils and VVTS d 9 9 Start of tokamak assembly Completion of VV torus and start of in-vessel Complete & close cryostat First plasma (Dec 2015) Blanket Detailed design Development of blanket TSD (Technical sp Development of FW qualification criteria Blanket R&D Base blanket R&D Fabrication of mock-ups for qualificatio Prototype fabrication and tests ITER FW/blanket manufacturing FW/blanket call for tender FW/blanket contract award FW/blanket manufacturing design FW/blanket material procurement FW/blanket fabrication and tests FW/blanket delivery to the ITER site UCLA July 26, 2005, CW '03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '14 27/02/2006 ILE establishment 17/07/ /02/2007 VV contract award 07/01/2008 T=0 Regulatory approval 04/02/2008 Start of excavation at site & building construction 07/01/2008 Start of VV material procurement 07/07/2008 Start of VV fabrication 03/10/2011 First sets ov VV sectors, T 07/11/2011 Start of tokamak assembl Completion of VV torus and start of in-vessel components installation 07/04 14/07/ /01/2009

10 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 X 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 X 1 TBD TBD L-13 Po extraction system X 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

11 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

12 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

13 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 (15%) 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 MA (For T3) Materials for these personnel are code MA. 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.

14 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 Kurtz T1 T2 T3 manhr Hard manhr Hard manhr Hard ware ware ware X X X Thermofluid MHD Analysis Smolentsev X X X FCI material development, Katoh Design limits and procurement X Compatibility of SiC/PbLi/FS system Design limits Structural analysis and failure modes Analysis Sharafat X X X Neutronics Analysis Sawan X X X Safety Merrill 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 (Ulrickson) Mechanical Design Design. fabrication and procurement (?) Dagher? -- X -- X -- X X X X X Thermofluid He Design input, analysis (Wong) 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

15 DCLL Special Components 2 mm thick Be coating on FS, Ulrickson PbLi pump, Willms SiC/SiC FCI, Katoh Concentric pipes? Dagher Bellows? Dagher Tritium extraction components X Bi and Po control components X PbLi/He heat exchanger?

16 1st Test 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.

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