Notes
Outline
Machine Assembly
WBS 700
By:  James H. Chrzanowski
January 24, 2001
                      WBS 700 Machine Assembly
WBS 710  “Planning and Oversight”
WBS 720  “On Site Pre-Assembly Activities”
WBS 730  “Test Cell & Basement Assembly              Activities”
WBS 740  “Measurement Systems”
WBS 700 Machine Assembly
WBS 710  “Planning and Oversight”
Includes costs associated with planning and overseeing the assembly of the Vacuum Vessel /Coil Field Periods, plus the final assembly of the NCSX machine in the C-site Test Cell.
Responsible for coordinating all NCSX Test Cell activities including those Pre-assembly activities in the TFTR Test Cell
WBS 700 Machine Assembly
WBS 710  “Planning and Oversight”
Developing plan for assembly of machine components
Integration between WBS elements involving assembly issues
Initiating and maintaining General Arrangement Drawing of Test Cell
Designing tooling required for component assembly
Design and fabrication of machine platform
WBS 700 Machine Assembly
Tooling Design and Material Procurements
Special assembly and lifting fixtures and tooling
$100.0 k ~ $125.0 k (w/25% G&A)
General procurements ( miscellaneous items required for assembly- safety, tools, disposable items, etc.)
$ 20.0 k ~ $ $25.0 k (w/25% G&A)
Platform Materials
$35.0 k ~ $ 44.0 k (w/25% G&A)
WBS 700 Machine Assembly
Labor Requirements:
Construction Manager  (1726 mhrs)
Engineering support (2857 mhrs)
Construction Safety Representative ( 1726 mhrs)
Industrial Hygiene  (863 mhrs)
Quality Control (863 mhrs)
Cadd Designer  (1295 mhrs)
Technician/ Monthly Support: (2386 mhrs)
Material & Supplies: $155.0 k ~ $194.0 k (w G&A)
Estimated Cost: $1,360 k
WBS 700 Machine Assembly
WBS 720  “On Site Pre-Assembly Activities”
This WBS section includes the costs associated with the receipt, assembly, alignment and vacuum leak testing of the (3) field periods
WBS 700 Machine Assembly
WBS 700 Machine Assembly
WBS 720  “On Site Pre-Assembly Activities”
The assembly of the VV/Coil Modules will occur in the abandoned TFTR Test Cell located at D-site
Area Preparation: $57.6 k (720 mhrs technician and  monthly support)
Sufficient floor space and crane capacity available (110 Ton capacity)
Manpower dependent-  Multiple segments could be assembled simultaneously
WBS 700 Machine Assembly
Assumptions
The vacuum vessel will be delivered to the TFTR Test Cell in three sections
The TF coils and Modular coils will be  delivered to the TFTR Test Cell as separate components
WBS 700 Machine Assembly
TF Coil Systems
Receive, inspect and test TF and Modular coils
$23.1 k  (288 mhrs Tech. & Monthly Support)
Assemble all of the TF/Modular coils together for fit up and alignment
Components may have to be  match reamed
Alignment equipment will be required (laser or “Faro” measuring arm required)
$147.2 k (1840 mhrs)  approx. 2.5 months
WBS 700 Machine Assembly
Assemble Field Period Components
Assemble each of the three Field Periods
TF coils/Modular coils/vacuum vessel and Trim coils
Slide TF/ Module coil assemblies onto the vacuum vessel and align/fasten coil structures together
Hang Vacuum vessel from Coil support structure
MIG weld port extensions to the vacuum vessel
(22) extensions per field period
WBS 700 Machine Assembly
Assemble Field Period Components-continued
Vacuum leak Field Period segment
Install Trim coils inside of the vacuum vessel
PFC’s to be installed after final assembly of all three periods in the NCSX Test Cell (welded scenario)
Transport “Field Period” to the NCSX Test Cell
Cost per field period assembly  $ 167.7 k
Approximately 16 weeks per assembly
WBS 700 Machine Assembly
WBS 73 “Test Cell & Basement Assembly”
This WBS section includes the assembly of all the NCSX Torus components in the Test Cell including:
All support structure
Vacuum vessel & coil systems
Cryostat
Test Cell Platform (inc. lighting, fire detection, suppression system under platform)
WBS 700 Machine Assembly
Machine components will be assembled in the PLT/PBX Test Cell
25 Ton Overhead Crane will be used to assemble components
WBS 700 Machine Assembly
WBS 700 Machine Assembly
Activities not included in this WBS :
Bus runs to the coils (WBS  400)
Cryo-line connections (WBS  600)
Bakeout system installation & connections (WBS  600)
Water system connections (WBS  600)
Neutral Beam Installations (WBS  200)
External Diagnostic Installations (WBS  300)
Shield wall modification & installation (WBS 600)
Vacuum pump system (WBS 200)
External Diagnostics (WBS 300)
WBS 700 Machine Assembly
Activities not included in this WBS :
GPP Activities
Lighting Upgrade
Test Cell Roof upgrade ??
Dew Point Control needs repair
C-site Cooling Tower Upgrade
Upgrade Central Chilled Water Plant
WBS 700 Machine Assembly
Machine Assembly Sequence
Install/align machine support columns
Install lower support rings
Install lower cryostat floor
Position lower PF-3 & 4 coils in support Rings
Pump down & Leak Check Vacuum Vessel
WBS 700 Machine Assembly
Install 1st. Field Period
Install 2nd. Field Period
Install 3rd. Field Period
WBS 700 Machine Assembly
Install Vacuum pump system
(WBS 200)
Pump down & Leak check Vacuum vessel
Complete installation Bakeout connections (WBS 600)
WBS 700 Machine Assembly
Raise into position Lower PF 3 & 4
Install Upper PF-3 & 4
Install PF-1 & 2 Solenoid
WBS 700 Machine Assembly
Machine Assembly Sequence- continued
Installation of PFC’s and Internal Diagnostics
Weld support hardware and plumbing
Approximately 2 months x 3 men
Assemble tile subassemblies (outside VV)
Approximately 2 months x 2 men
Install Internal PFC’s & Diagnostics
Approximately 4 months x 4 men
Estimated Cost $300.0k
WBS 700 Machine Assembly
Machine Assembly Sequence- continued
Install Bus connections to coil systems (WBS 400)
Connect Cryostat and water lines (WBS 600)
Install Platform around machine
Install external diagnostics (WBS 300)
WBS 700 Machine Assembly
Install Cryostat walls and ceiling
Install collars and boots around feedthru’s
WBS 700 Machine Assembly
WBS 700 Machine Assembly
WBS 700 Machine Assembly
Estimated cost excluding WBS 740
$ 2,875 .0 k
 WBS 70 Machine Assembly
Rates Used For Estimating
Engineering -mechanical & electrical (EM)
$130.00 per hour
Senior lab (SM)/Technicians (TB) and              Cad Designers(DM)
$80.00 per hour
Material & Supplies
Cost plus 25% G&A
No contingency included in estimates