Costing of Test Articles Ancillary Equipment and Costing Methodology 0.504 m x 1.71 m x 0.413 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
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 0.504 m x 1.71 m x 0.413 m W x H x D
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
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
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
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
DCLL Test Article and Ancillary Equipment Schedule, team review Items in red are to be costed
HCLL From sub-components testing up to integral functional tests 05 06 07 08 09 10 11 12 13 14 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
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 10 10 Completion of VV torus and start of in-vessel 11 11 Complete & close cryostat 12 12 First plasma (Dec 2015) 13 13 14 14 Blanket 15 15 Detailed design 16 16 Development of blanket TSD (Technical sp 17 17 Development of FW qualification criteria 18 18 Blanket R&D 19 19 Base blanket R&D 20 20 Fabrication of mock-ups for qualificatio 21 21 Prototype fabrication and tests 22 22 ITER FW/blanket manufacturing 23 23 FW/blanket call for tender 24 24 FW/blanket contract award 25 25 FW/blanket manufacturing design 26 26 FW/blanket material procurement 27 27 FW/blanket fabrication and tests 28 28 FW/blanket delivery to the ITER site UCLA July 26, 2005, CW 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 '03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '14 27/02/2006 ILE establishment 17/07/2006 05/02/2007 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 14/07/2008 05/01/2009
DCLL Ancillary Equipment Pb-Li loop Pb-Li system: Dia. m Length, m Weight, kg Cost, $ L-1 Pb-Li pump 1 0.25 1 TBD L-2 Pump housing and expansion tank 1 0.25 1 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 1 0.37 2.4 TBD L-6 Pb-Li tritiume extraction X 1 1 2 TBD L-7 Pb-Li dump tank 1 1 x 1 0.5 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
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 1 0.233 0.63 45.7 TBD FW-2 Electrical heater 1 0.35 1.65 287 TBD FW-3 He circulator 1 1.54 0.3 1979 TBD FW-4 Circulator motor 1 0.88 1.46 1670 TBD FW-5 He storage tanks 9 0.4 2.6 4808 TBD FW-6 He dump tanks 4 0.4 2.6 2137 TBD FW-7 Buffer tank 1 0.4 2.6 534 TBD FW-8 Pipework 1 0.1023 180 2959 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
He-loop 2 PbLi-He systems: PbLi @ 2 MPa Dia. m Length, m Weight, kg Cost, $ He @ 8 MPa, 180 C to 300 C He-1 He/water heat exchanger U tube bundle 300 C to 70 C 1 0.22 0.63 45.7 TBD He-2 Electrical heater 1 0.35 1.65 287 TBD He-3 He circulator 1 1.8 0.35 2868 TBD He-4 Circulator motor 1 1 1.66 2452 TBD He-8 Pipework (including bypass) 1 0.1023 180 2959 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
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.
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
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?
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.