Costing of Test ArticlesAncillary Equipment and Costing Methodology

C. Wong, S. Malang, M. Youssef, N. Morley, M. Ulrickson

and the TBM design team

US ITER-TBM MeetingAugust 10-12, Idaho Falls

0.504 m x 1.71 m x 0.413 m

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

DCLL TBM Design and Costing General Observations

0.504 m x 1.71 m x 0.413 mW x H x D

UCLA July 26, 2005, CW

Top Plate AssemblyFirst Wall

Assembly

Bottom Plate Assembly

Outer back Plate Assembly

He Inlet/Outlet Pipe AssemblyCenter Divider

Plate Assembly

Pb-Li Inlet/Outlet Pipe Assembly

UCLA July 26, 2005, CW

SiC InsertsFront Upper

Assembly

SiC InsertsRear Assembly

SiC InsertsBottom Assembly

SiC InsertsTop Assembly

Divider / Grid PlateAssembly

Install SiC inserts

SiC InsertsFront Lower

Assembly

SiC inserts shownassembled with the

first wall module removed

SiC inserts shownfully assembled infirst wall module

Front View Back View

UCLA July 26, 2005, CW

First Wall

Grid Plates

Divider Plates

Inner Back PlateStructure

Inner Back PlateCover

Install Inner Back PlateAssembly Make Internal

Seal Welds(shown in yellow)

UCLA July 26, 2005, CW

Install top and bottomplate assemblies Top Plate Cover

Top Plate Structure

BottomPlate Cover

BottomPlate

Structure

Make internal seal weldsto top and bottom of

the grid plates

Make external seal welds to

top and bottom plate assemblies

DCLL Test Article and Ancillary Equipment Schedule, team review

Items in red are to be costed

UCLA July 26, 2005, CW

HCLL From sub-components testing up to integral functional tests

1st TBM acceptance tests

1st TBM fabrication(Industry)

TBM acceptance tests

1:1 mock-ups tests

1:1 mock-ups fabrication(Industry)

1:4-1:3 mock-ups tests

1:4-1:3 mock-ups fabricat.(Industry + Associations)

Functional test(prototypical mock-ups)

Test/qualification

Fabrication

Sub-components qualif.

14131211100908070605

UCLA July 26, 2005, CW

ID ID Task Name

1 1 ILE establishment2 2 VV call for tender3 3 VV contract award4 4 T=0 Regulatory approval5 5 Start of excavation at site & building construc6 6 Start of VV material procurement7 7 Start of VV fabrication8 8 First sets ov VV sectors, TF coils and VVTS d9 9 Start of tokamak assembly10 10 Completion of VV torus and start of in-vessel 11 11 Complete & close cryostat12 12 First plasma (Dec 2015)13 1314 14 Blanket15 15 Detailed design16 16 Development of blanket TSD (Technical sp17 17 Development of FW qualification criteria18 18 Blanket R&D19 19 Base blanket R&D20 20 Fabrication of mock-ups for qualificatio21 21 Prototype fabrication and tests22 22 ITER FW/blanket manufacturing23 23 FW/blanket call for tender24 24 FW/blanket contract award25 25 FW/blanket manufacturing design26 26 FW/blanket material procurement27 27 FW/blanket fabrication and tests28 28 FW/blanket delivery to the ITER site

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

'03 '04 '05 '06 '07 '08 '09 '10 '11 '12 '13 '142003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

Blanket R&D and Manufacturing Schedule for ITER

DCLL Ancillary EquipmentPb-Li loop Pb-Li system:

Dia. m Length, m Weight, kg Cost, $

L-1 Pb-Li pump 1 0.25 1 TBDL-2 Pump housing and expansion tank 1 0.25 1 TBDL-3 Pump motor 1 TBD TBD

L-4 Pb-Li mixed tank for the bypass loop 1 TBD TBDL-5 Pb-Li/He heat exchanger, bypass loop 1 0.37 2.4 TBDL-6 Pb-Li tritiume extraction X 1 1 2 TBD

L-7 Pb-Li dump tank 1 1 x 1 0.5 TBDL-8 Dump tank heater 1 TBDL-9 Pressure control unit 1 TBD

L-10 Cold trap for PbLi 1 TBD TBDL-11 Cold trap coolant 1 TBD TBDL-12 Bi extraction system X 1 TBD TBDL-13 Po extraction system X 1 TBD TBD

L-14 Concentric PbLi pipe 1 TBDL-15 Pipings 1 TBDL-16 Trace heaters TBD

L-17 Valves TBD TBDL-18 Pressure transducers TBD TBDL-19 Temp. sensors TBD TBDL-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 TBDFW-2 Electrical heater 1 0.35 1.65 287 TBDFW-3 He circulator 1 1.54 0.3 1979 TBDFW-4 Circulator motor 1 0.88 1.46 1670 TBDFW-5 He storage tanks 9 0.4 2.6 4808 TBDFW-6 He dump tanks 4 0.4 2.6 2137 TBDFW-7 Buffer tank 1 0.4 2.6 534 TBDFW-8 Pipework 1 0.1023 180 2959 TBD

FW-9 Pressure control subsystem 1 TBD TBDFW-10 Tritium extraction system 1 TBD TBDFW-11 Helium purification system 1 TBD TBD

FW-12 Flow meters TBD TBDFW-13 Temperature sensor TBD TBDFW-14 Pressure transducer TBD TBDFW-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 TBDHe-2 Electrical heater 1 0.35 1.65 287 TBDHe-3 He circulator 1 1.8 0.35 2868 TBDHe-4 Circulator motor 1 1 1.66 2452 TBDHe-8 Pipework (including bypass) 1 0.1023 180 2959 TBD

He-9 Pressure control subsystem 1 TBD TBDHe-10 Tritium extraction system 1 TBD TBDHe-11 Helium purification system 1 TBD TBD

He-12 Flow meters TBD TBDHe-13 Temperature sensor TBD TBDHe-14 Pressure transducer TBD TBDHe-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

Code Resource Name Definition

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 for these personnel are code MA.

MA (For T3)

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 Title III Design

and fabrication The cost of personnel providing technical support to procurement, installation, fabrication, inspection, testing, as-built drawings and other technical activities.

SW Software Development

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

T1 T2 T3 manhr Hard

waremanhr Hard

ware manhr Hard

wareFS engineering and fabrication “Recommend method(s) of fabrication” Kurtz

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)

-- X

-- X

-- X

X

Mechanical Design “Design. fabrication and procurement” (?) Dagher?

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

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 areaWe will need to identify specific diagnostics and designs at different stages of testing.