1page # machine assembly wbs 700 by: james h. chrzanowski january 24, 2001

1Page #

Machine AssemblyWBS 700

By: James H. Chrzanowski

January 24, 2001

J.H. Chrzanowski 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”

J.H. Chrzanowski 3


• 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

J.H. Chrzanowski 4


• 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

J.H. Chrzanowski 5


• 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)

J.H. Chrzanowski 6


• 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

J.H. Chrzanowski 7


• 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

J.H. Chrzanowski 8


NCSX Pre-Assy. Area

J.H. Chrzanowski 9


• 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

J.H. Chrzanowski 10


• 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

J.H. Chrzanowski 11


• 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

J.H. Chrzanowski 12


• 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

J.H. Chrzanowski 13


• 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

J.H. Chrzanowski 14


• 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)

J.H. Chrzanowski 15


• Machine components will be assembled in the PLT/PBX Test Cell

• 25 Ton Overhead Crane will be used to assemble components

J.H. Chrzanowski 16


Remove walls during assembly

NCSX TEST CELL

J.H. Chrzanowski 17


– 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)

J.H. Chrzanowski 18


– 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

J.H. Chrzanowski 19


• 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

J.H. Chrzanowski 20


Install 1st. Field Period

Install 2nd. Field Period

Install 3rd. Field Period

J.H. Chrzanowski 21


• Install Vacuum pump system– (WBS 200)

• Pump down & Leak check Vacuum vessel

• Complete installation Bakeout connections (WBS 600)

J.H. Chrzanowski 22


• Raise into position Lower PF 3 & 4

• Install Upper PF-3 & 4

• Install PF-1 & 2 Solenoid

PF4

PF3

J.H. Chrzanowski 23


• 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

J.H. Chrzanowski 24


• 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)

J.H. Chrzanowski 25


• Install Cryostat walls and ceiling– Install collars and

boots around feedthru’s

J.H. Chrzanowski 26

WBS 700 Machine AssemblyAct. ID Activity Description DURATION EMEM EMSM EMTB EADM

(Engr.) No. of Tech. Supt.) No. of (Tech.) No. of (Cad Des.) No. of Weeks Hours Personnel Hours Personnel Hours Personnel Hours Personnel

700 Machine Assembly710 Planning and Oversight Activities711 Planning Activities

Construction/ Systems Integration LOE 843 1 0 0 0Prepare Machine Assembly Layout Drawings LOE 0 0 0 290 1

712 Maintaining General Arrangement Drawing LOE 0 0 0 448 1

713 NCSX Platform DesignDesign & fabricate platform components 144 90 1000 240

714 Tooling Design and FabricationTooling procurement and fabrication 432 864Design special tooling 144 288General procurements (mat'ls, safety, hardware,etc.)

715 Oversight ActivitiesConstruction Manager LOE 1726 1

Engr. Support/Lift Engineer LOE 1726 1Construction Safety LOE 1726 1Industrial Hygienst LOE 863 1

Quality Control LOE 863 1720 On- site Pre-assembly Activities

Prepare pre-assembly area 4 144 1 576 4Receive, inspect and test TF & Modular coils 144 1 144 4Assemble TF/Modular coils 10 368 1 1472 4Receive and inspect vacuum vessel segments 72 1 144 4Assemble 1st. Field Period 4 152 1 608 4Position and weld (22) port assemblies 3 224 2 112 1Perform vacuum leak check of welded assemblies 2 80 1 160 2Install Trim coils inside of vacuum vessel 8 288 1 864 3Transport to Test Cell 1 8 1 32 4Assemble 2nd. Field Period 4 152 1 608 4Position and weld (22) port assemblies 3 224 2 112 1Perform vacuum leak check of welded assemblies 2 80 1 160 2Install Trim coils inside of vacuum vessel 8 288 1 864 3Transport to Test Cell 1 8 1 32 4Assemble 3rd. Field Period 4 152 1 608 4Position and weld (22) port assemblies 3 224 2 112 1Perform vacuum leak check of welded assemblies 2 80 1 160 2Install Trim coils inside of vacuum vessel 8 288 1 864 3Transport to Test Cell 1 8 1 32 4

J.H. Chrzanowski 27


Act. ID Activity Description DURATION EMEM EMSM EMTB EADM(Engr.) No. of Tech. Supt.) No. of (Tech.) No. of (Cad Des.) No. of

Weeks Hours Personnel Hours Personnel Hours Personnel Hours Personnel

730 Test Cell and Basement Assembly ActivitiesInstall/ level machine support columns 3 144 1 432 3Install lower support ring plates w/ fiberslip 2 72 1 288 5Install lower cryostat floor 1 40 1 80 2Install lower PF 3 & 4 coils into preliminary position 0.2 8 1 32 4Install 1st. Field Period Assembly 0.6 24 1 96 4Install 2nd. Field Period Assembly 1 40 1 160 4Install 3rd. Field Period Assembly 2 56 1 264 4Install vacuum pump system Responsibility of WBS 200Pumpdown & leak check VV 2 100 120Install PFC's and Internal Diagnostics 24 288 3456Raise lower PF-3 and 4 coils into final position 0.4 16 1 64 4Install upper PF-3 and 4 coils 0.4 16 1 64 4Install PF-1/2 Solenoid into position 0.8 20 1 80 4Install Bus connections to coil systems Responsibility of WBS 400Connect Bakeout System Responsibility of WBS 600Connect Cryo Systems Responsibility of WBS 600Connect cooling Systems Responsibility of WBS 600Install external cryostat walls and Ceiling 2 80 1 240 3Assist external Diagnostic Installations LOE 0 40 1 160 1Install Platform

Complete installation of Platform Structure LOE 24 40 448 80 1Install platform decking LOE 16 24 1 240 0

Install lighting LOE 0 8 1 80 0Install fire detection LOE 24 1 0 80 0

Install fire supression LOE 40 1 0 320 0

740 In-Vessel Measurement System

EM hrs. $ SM hrs $ TB hrs $ DM hrs $

ESTIMATES 4687 $609.3 K 4542 $363.40 16232 $1299. K 1266 $101.3 K3452 $ 276.2 K

Total $2875.3 K

J.H. Chrzanowski 28


• Estimated cost excluding WBS 740

– $ 2,875 .0 k

J.H. Chrzanowski 29


• 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

1page # machine assembly wbs 700 by: james h. chrzanowski january 24, 2001

Documents

machine assemblywbs

ncsx machine

assembly safety

machine assemblyncsx

assembly issuesinitiating

final assembly

machine assemblytooling

test tf