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Machine Assembly WBS 700

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”

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Machine Assembly WBS 700

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  1. Machine AssemblyWBS 700 By: James H. Chrzanowski January 24, 2001

  2. 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”

  3. 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

  4. 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

  5. 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)

  6. 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

  7. 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

  8. WBS 700 Machine Assembly NCSX Pre-Assy. Area

  9. 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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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)

  15. 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

  16. WBS 700 Machine Assembly Remove walls during assembly NCSX TEST CELL

  17. 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)

  18. 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

  19. 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

  20. WBS 700 Machine Assembly Install 1st. Field Period Install 2nd. Field Period Install 3rd. Field Period

  21. WBS 700 Machine Assembly • Install Vacuum pump system • (WBS 200) • Pump down & Leak check Vacuum vessel • Complete installation Bakeout connections (WBS 600)

  22. WBS 700 Machine Assembly • Raise into position Lower PF 3 & 4 • Install Upper PF-3 & 4 • Install PF-1 & 2 Solenoid PF3 PF4

  23. 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

  24. 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)

  25. WBS 700 Machine Assembly • Install Cryostat walls and ceiling • Install collars and boots around feedthru’s

  26. WBS 700 Machine Assembly

  27. WBS 700 Machine Assembly

  28. WBS 700 Machine Assembly • Estimated cost excluding WBS 740 • $ 2,875 .0 k

  29. 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

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