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