HCCB Engineering, Fabrication and Procurement, Ancillary Equipment, Interface and System Integration

Transcription

1 HCCB Engineering, Fabrication and Procurement, Ancillary Equipment, Interface and System Integration WBS Engineering Fabrication/Procurement Ancillary Equipment Prepared by A. Ying/P. Calderoni TBM Conference Call Oct. 27,

2 US ITER HCCB Test Submodule Schedule ITER Director appointed First plasma Project Support TBWG activities and ITER/parties interface Qualification and Safety Report HCCB Test Submodule Administraion R&D Helium flow distribution and manifold testing Pebble bed thermomechanics and T recovery RAFS fabrication development T-control and predictive capability Development of FS & SS transition element Diagnostics and instrumentation 1/2 scale mockup and qualification tests In-pile pebble bed assembly test Engineering Preliminary Design Detailed Design Ttitle III Fabrication/procurement Call for Tender (Issue RFP and Fabrication order) Manufacturing Preparation Material procurement Fabrication and QA testing at Mock-up testing site Assembly, Integration and testing at Host Party's site Delivery to ITER site installation Oct

3 Ceramic Breeder Test Submodule WBS Inserting US unit cells into the EU HCPB structural box Neutonics Submodule Operating Conditions Helium Coolant Pressure 8 MPa Temperature, In/Out 100/250 C Helium Purge Pressure 0.1 MPa Temperature, average 225 C Breeder Min/Max 100/350 C Beryllium Min/Max 100/350 C FS Min/Max 100/300 C Electromagnetics/Neutronics unit cell design Unit (mm) 3

4 This submodule approach shares the test space with Japan, which features designing the US blanket configurations into one of the three Japan s submodules 2 of 3 of JA Submodules WBS An example submodule design combines layer and edge-on configurations in one physical unit with its own first wall structural box x 350 x 600 mm 3 each Helium manifold (to be designed) Ceramic breeder: Li 4 SiO 4-40% 6 Li enriched (single size ~0.4 mm) Li 2 TiO 3-70% 6 Li enriched (single size ~ mm) Beryllium (~ 1mm pebble) 4

5 WBS ( ) Title I: Preliminary Design Deliverable: an EM test submodule design, which embodies the general geometrical configurations of the HCCB ITER test submodules The objective of this WBS is to develop a test submodule design representing the helium-cooled ceramic breeder blanket concepts that satisfies a matrix of technical specifications and has a high possibility ready to proceed to detailed design development. The % complete is about 30-35% of the total design effort. The preliminary design will be developed from the existing conceptual designs and engage the following activities: 1. Develop HCCB project definition. ( ) Define the top-level functional needs; Develop a list of approaches for each functional needs; Define performance metrics for the design; Define the design parameters that most directly determine the design (e.g. material selection, structural configuration), Establish the driving design considerations (technical specifications, qualifications, etc.), Perform parametric analyses that quantify the performance metrics for a given design, Develop Draft Bilateral/multi-lateral International Collaborative Agreements 2. Finalize Design-To Specifications (2007) 3. Assess Design Issues and Risks (2008) 4. Finalize Project Management Plan and Conduct the Preliminary Design Review (July, 2008) 5

6 Schedule for WBS Preliminary Design Item # WBS: Title I: Preliminary Design Activity ID Project Definition Define functional Needs Define Performance Matrices Define Design Parameters Establish Driving Design Considerations Perform Parametric Analyses Perform neutronics analysis to identify a technically meaningful test submodule configuration Perform design analysis for structural mechanics and electromagnetics 3.3 Identify reference test submodule design Develop International Collaborative Agreements 4 4 (Initial) 5 5 Finalize Design to Specifications 6 6 Assess Design Issues and Risks Finalize Project Management Plan (including final 7 7 international collaborative agreements) 8 8 Preliminary Design Review Overlapping in schedule implies that an iteration process is taking place 6

7 Cost Estimate for Preliminary Design TBM Costing Input Table WBS Title: Preliminary Design ( ) Scheduled Activity Item # ID Description QTY Units $/unit 1 1 Project Definition Define functional Needs Define Performance Matrices Define Design Parameters 2 2 Establish Design Specifications 3 3 Perform Parametric Analyses Perform neutronics analysis to identify a technically meaningful 3.1 test submodule configuration 3.2 Perform design analysis for structural mechanics, thermal and electromagnetics 3 Identify reference test submodule design Material/Equipment Shippin g/tax Total $ HRS $/HR Total $ ANSYS /CFX, SolidW ork Travel 160 (M)+ 160 (PC) Comments/Assump tions Combined university and Laboratory FTE hourly rate 480 (M)+ 480 (PC) foreign trips 480(PC)+ 1920(G) 480(M)+ 160(PC)+ 1920(G) 480(PC)+ 1920(G) 130 (PC) Graduate student +42(G) hourly rate: $42 170(M)+ 130 (PC) +42(G) (PC)+ 5 peopes 3 days 42(G) domestic trip 3.3 Develop International Collaborative 4 4 Agreements foreign trips 960(M+S) 170(M/S) +480(PC) + 130(PC) 5 peopes 3 days 5 5 Finalize Design to Specifications +1920(G) +42(G) domestic trip 6 6 Assess Design Issues and Risks Finalize Project Management Plan foreign trips 8 8 Preliminary Design Review peopes 3 days domestic trip Subtotal Labor 7

8 WBS ( ) Title II: Detailed Design (specifically for EM test submodule) The scope of this WBS is the detail engineering and design of the reference test submodule concept and its supporting subsystems that developed within the preliminary design phase. It includes validation tests of a ½ scale mockup to confirm that the design is proceeding with the right choice (cost included in R&D). The detailed design package includes technical specifications and requirements, fabrication drawings and procedures, material specifications, quality assurance requirements, testing specifications and requirements, and instrument schematics and wiring diagrams. The technical specification document (TSD) should cover the general requirements and technical requirements, and will include at least (i) contract stages and schedule, (ii) responsibilities, (iii) QA basic requirements, (iv) applicable codes and standards, (v) acceptance criteria, and (vi) detailed technical specifications and requirements unique to TBMs, such as materials, design, fabrication (including welding), examination and testing, maintenance and inspection, and packaging and transportation. Note that specific requirements such as tolerances, surface roughness and outgas rate should be also included in the technical requirements. 8

9 Schedule for WBS Detailed Design Item # WBS: Title II: Detailed Design Activity ID 1 1 Description Complete Design and Design Analysis Develop Technical Specification Documents Establish Qualification Criteria and Non- Destructive Testing Methods Establish Material Specifications Develop Fabrication Drawings Develop Instrumentation Specifics and Wiring Diagram Develop Contract Agreement and Detailed Design Review 9

10 Cost Estimate for Detailed Design TBM Costing Input Table WBS Title: Detailed Design ( ) Scheduled Material/Equipment Labor Travel Item # Activity ID Description QTY Units $/unit Complete Design and Design Analysis 1 1 (EM, Structural Thermomechanics) 3 Shippin g/tax Total $ HRS $/HR Total $ ANSYS /CFX Develop Technical Specification 2 2 Documents Establish Qualification Criteria and Non- 3 3 Destructive Testing Methods Comments/Assump tions 1/2 FTE/ 1 foreign trip and 1 domestic meeting (5) 1/3 FTE / 1 foreign trip and 1 domestic meeting (5) 1/3 FTE /1 foreign trip 4 4 Establish Material Specifications /4 FTE /1 foreign 5000 trip 5 5 Develop Fabrication Drawings CARTIA 3 /ProE /4 FTE Develop Instrumentation Specifics and 6 6 Wiring Diagram /6 FTE Develop Contract Agreement and Detailed 2x 1/4 FTE + 5x 1/52 FTE for review Design Review foreign trip Subtotal

11 WBS ( ) Title III This WBS includes supervision and technical support for procurement, fabrication, inspection, testing, as-built drawings, and other technical activities for the HCCB test blanket submodule. Cost estimate: ½ FTE per year for 3 years : $ 11

12 WBS : Fabrication/Procurement This WBS includes material procurement and fabrication of the reference HCCB test submodule to be tested on day-one of ITER operation and its shipment to Host Party for integration and testing ( ) This WBS includes preparation of documents for the announcement of the contracts, and to provide project and award specifications. This WBS also includes the organization, evaluation and selection of proposals for all fabrication and procurement of components for the HCCB test submodule design. This WBS includes purchasing the necessary tooling and processing by the vender for the fabrication of the TBM, the procurement of all principle materials necessary for the fabrication and assembly of the TBM, and labor needed for components and fabrication of the HCCB test submodule and the packing and shipping to the Host Party. This WBS includes the administration, vendor oversight of installation and on-site acceptance tests of the HCCB test submodule at the Host Party. 12

13 DRAFT Cost Estimates for Unit Cell and Submodule Parameters Unit Cell Submodule (TM) Size, m x x x 0.71 x 0.6 Total breeding volume (0.4 m) Number of units 3 1 Breeder volume per unit, m Beryllium volume, m Total ferritic steel volume, m Total breeder weight, kg (Li 2 TiO 3 ) 3450 x 0.9 x 0.62 x x3= x 0.9 x 0.62 x 0.035= 67 Total beryllium weight, kg 1850 x 0.62 x x 3 = x0.62 x =60 Total ferritic steel weight, kg 7700 x x 3= Breeder cost 1 $ 378 K $ 670 k Beryllium cost 2 $ 189 K $ 540 k Breeder + Beryllium cost $ 567 K $ 1210 K Total estimated cost 1 millions 1.7 millions Li 2 TiO 3 Li 4 SiO 4 Be Ferritic Steel TD kg/m Fabricated density 90% 98% 100% 100% Cost /kg $ 10K 1 $ 10K $ 9K 2 1. CEA price if purchasing 1 kg. The price per kg may increase for a higher 6 Li enrichment and decrease for a large purchase. 2. NGK beryllium pebble price. The price per kg may decrease for a large quantity. 13

14 Base Cost Estimate for Fabrication/Procurement TBM Costing Input Table WBS Title: Fabrication/Procurement ( ) Schedule Material/Equipment Labor Travel Item # Activity ID Description QTY Units $/unit Shipping /Tax Total $ HRS $/HR Total $ Comments/As sumptions 1 1 Call for Tender Issue RFP Issue Fabrication Order 2 2 Manufacturing preparation 100, Material procurement 1,700,000 Fabrication and QA testing at Mockup 4 4 testing site 50, Assembly, integration and testing at 5 5 Host Party's site 1 10, ,000 Subtotal 2,155,000 10,000 1,715, ,000 14

15 WBS Interface Issues and System Integration What ITER will Provide Electric power De-mineralized water (for filling coolant loops) Standard VV equatorial port interface including cooling of flange Heat rejection (from weld preparation on valves on intermediate HX placed in the TCWS vault - note two valves in series required for redundancy) Standard port handling and transfer from and to the hot cell facility Standard loading and unloading at the hot cell ports and standard RH tools for maintenance & refurbishment in the hot cell Acceptance of any tritium bred (interface to be clarified) Interface with ITER control room 15

16 WBS item HCCB submodule ancillary equipment Responsible TBM contact: P. Calderoni 16

17 The ancillary equipment for the HCCB-TBM must be integrated with the equipment already present in Port A (#16) as detailed by EU and Japan preliminary design and finalized by port coordinator HCCB submodule is housed in one of Port 16 TBM Example of integrated scheme proposed by the EU in July

18 Structural components and interfaces in the port cell are common to all programs housed in Port 16 Structure components of PIC: pallet system mech. support for pipes mech. Support for HEX mech. Support for valves Bioshield: concrete wall penetration for pipes tool access corridor Interfaces: Port plug / PIC Helium system Tritium system Instrumentation Main ancillary equipment systems (helium cooling, tritium extraction and coolant purification) are designed, fabricated and assembled by the Program responsible for the TBM in which the HCCB submodule is inserted 18

19 The US TBM program is participating to Port A ancillary equipment system design and procurement through international collaboration and contributing to the fabrication and assembly of the shared equipment in terms of a percentage of the total cost that has to be defined by an international agreement. We currently estimate a share between 10% (same as US contribution to ITER) and 17% (equally sharing the cost among the 6 parties developing a helium cooled ceramic breeder blanket concept) of the total ancillary equipment cost. HCCB ancillary equipment wbs structure Ancillary equipment Administration Engineering Port A interfaces and shared equipment Design of HCCB specific components Title III for HCCB specific components Fabrication/procurement Port A interfaces and shared equipment HCCB specific components Assembly/Installation Port A interfaces and shared equipment HCCB specific components 19

20 EM HCCB submodule Item # Design of HCCB specific components Inside TCWS Inside the Pipe Integration Cask Shared ancillary equipment Interface components HCCB specific components Helium purification system Chemistry control system (He make-up unit) US EU?? H 2? H 2 O 300 Pa H 2 35 Pa H 2 O Bypass for flow control Electric heater for temperature control Helium cooling system Recuperative HEX HCCB submodule 20

21 Item # Port A interfaces and shared equipment EU Helium cooling system EU Coolant purification system EU and Japan preliminary design can be used as reference for preliminary cost assessment of collaboration for ancillary equipment procurement and fabrication once an agreement is reached on the amount of the total cost share for each party 21

22 Preliminary component list for cost estimate Tritium extraction system Cooler Port A shared Helium cooling system Heat exchanger Circulator Electrical heater Dust filter Pipework Valves Pressure control unit Coolant purification system Water separator Electrical heaters Catalytic oxidizer Cooler Blower Molecular sieve adsorber Relief tank Helium make up unit US HCCB specific Coolant purification system Hydrogen and water mixer Flow bypass Valves Pipework Electric heater Interface components Particle filter Tritium monitors Cold trap Recuperative HEX Low Temperature adsorpber Electric heater Compressor Helium make-up unit Water collector Blower Relief tank Diffusor Getter beds Helium buffer vessel LN 2 supply tank Gas chromatograph Glove box Inlet from He cooling system is max of desired operative range of submodule 22