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Assembly and Installation Information Day – 21st May 2015
© 2015, ITER OrganizationPage 1IDM UID: XXXXXX
Keynoteson
Assembly and Installation of ITER
Industry Information Day
St. Paul-lez-Durance, 21st May 2015
Joo-Shik BakActing Head - Construction Department
Disclaimer: The views and opinions expressed herein do not necessarily reflect those of the ITER Organization
Assembly and Installation Information Day – 21st May 2015
© 2015, ITER OrganizationPage 2IDM UID: XXXXXX
Briefing of ITER Project
Understanding of ITER Construction Work
Special Features of Tokamak Assembly Work
Division of Roles and Responsibilities
Approach to Construction Works
Contract Strategy
Overall Schedule
Key Success Factor for ITER Construction
What We are Expecting from Industry
Table of Contents
Assembly and Installation Information Day – 21st May 2015
© 2015, ITER OrganizationPage 3IDM UID: XXXXXX
Briefing of ITER Project(1) Brief History and Current Status
• The ITER Agreement was officially signed at the Elysée Palace in Paris on 21st Nov 2006by Ministers from the seven ITER Members, EU, China, India, Japan, Korea, Russia and US to build the ITER facility and the ITER Organization was established on 24th Oct 2007.
• Over the last 7 years, IO-CT(Central Team) and IO-DA (Domestic Agency) have been focusing on the design, engineering and procurement work of its components/systems.
• The building construction work by EU-DA have been started from beginning of site preparation work in January 2007 and are currently in full swing stage.
• ITER project is now entering into construction phase. Very recently, a dedicated Construction Department has been established to plan and carry out Assembly and Installation work.
• IO is now making every efforts to establish an effective and efficient construction management plan.
Assembly and Installation Information Day – 21st May 2015
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Briefing of ITER Project(2) Project Mission
• ITER is a large-scale nuclear facility that aims to demonstrate the technological and scientific feasibility of fusion energy which is the most probable sustainable energy source in the future.
• It cannot be overstated the importance of the success of ITER construction since the ITER is the starting point of the realization of fusion as an innovative energy source.
Specific Characters of ITER Project:• Large scale in-kind contributed international cooperation project;
• 1st of a kind project to realize futuristic innovative technology;
• R&D based EPC(Engineering, Procurement and Construction) project;
• a typical “Owner Design and Industry Built” project;• and subject to ‘INB’ per French Laws and Regulations.
Assembly and Installation Information Day – 21st May 2015
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Delivery from In-kind Contribution (7 Members)
TF Coils (18)
Feeders (31)
CC Coils (18)
PF Coils (6)
CS Coils (6) Divertor Blanket
Vacuum Vessel
Thermal Shield
Cryostat
Feeders (31)
Assembly and Installation Information Day – 21st May 2015
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Technical ChallengesChallenging size and weight but fine tolerances for major systems
• Tokamak weight: ~ 23,000 tons• SC Magnet: 48 coils, ~ 9,800 tons, 51 GJ stored energy
(TF Coil: ~ 6,540 t, PF Coil: ~ 1,845 t, CS Coil: ~ 1,040 t)• Vacuum Vessel: 19.4 m OD ×11.3 m H, ~ 8,000 t (VV, Ports & components)• Thermal Shield: 1,920 m2, 376 t for VVTS and 1,990 m2, 474 t for CTS and MFs• Cryostat: 28.5 m D × 29.3 m H, ~ 3,536 tons
Tight schedule for assembly and installation (until First Plasma):• KSTAR: ~ 40 Months (~ 300 t), W7-X: ~ 100 Months (~ 425 t), • ITER: ~ 110 Months (with 2 shifts + night shift for NDT)
Extremely large scale UHV vacuum space: (No leak)• Total volume: 1,400 m3 for VV, 8,500 m3 for Cryostat• Number of in-situ installation welds in cryostat: ~ 15,000
Extremely large capacity cryogenic environment: (No cold leak)• Cold mass: ~ 11,000 tons (KSTAR: ~300 tons, W7-X: ~ 425 tons)• Total cryogenic power: 75 kW @ 4.5 K (3 units of 25 kW)
Assembly and Installation Information Day – 21st May 2015
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Understanding of ITER Construction Work ITER facility is subject to Nuclear Licensing.
• QA requirement in accordance with French Nuclear Law is applicable• Constructors are required to have nuclear QA program and working system
ITER construction works include two different kinds of works.• Tokamak assembly: Many specific knowledge which are not available from industry are
required. Assembly of ultra heavy and extremely sophisticated machine with very severe tolerances.
• Plant installation: similar to industry plant but related to special technologies such as high capacity electrical power supply, large scale tritium plant, large capacity cryogenic-plant, custom made special diagnostics, etc.
DAs have their own assembly and installation works at ITER worksite.• For some systems the DA’s manufacturer will perform installation works at the ITER Site
as well as component delivery. (Examples, IN-DA: Cryostat, Cryogenic Lines, KO-DA: AC/DC Convertor)
Scale of works: more than 9 years, workforce up to 2,500
Assembly and Installation Information Day – 21st May 2015
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First of a kind plant• Fusion oriented specific technology, such as specialized work related to superconducting
magnet and extreme technology• No standardized proven assembly processes and methodologies, thus need to develop
appropriate processes innovatively• Large amount of in-situ engineering works necessary
Heavily depended on assembly tools and/or equipment• Various special tools required for assembly works• Handling of huge and heavy components at the limited space
Non-reversible assembly process• Repairs and/or reworks are fundamentally difficult, almost out of the question in most cases.
Others:• In many cases, work spaces are limited and accessibility is poor because of the complexity
of the machine and tight building space• Specific assembly and test scenarios are required accordingly
Special Features of Tokamak Assembly Work
Assembly and Installation Information Day – 21st May 2015
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Organization Structure for Construction
DG and EPB (IO)
Tokamak Assembly
Head of Construction Dep.
IO Worksite Managers
Machine Assembly Work Contractor
CMA
DG and EPB (IO)
Plant Installation
Head of Construction Dep.
CMA Worksite Managers
Plant Work Contractors
IO Technical Experts
Assembly and Installation Information Day – 21st May 2015
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Division of Roles and Responsibilities(1) IO-CT takes full responsibility as the Owner and Design Authority.
• Responsible for compliance with all nuclear safety requirements by supervising the entire construction process and all sub-contractors
• Leads the management of all construction activities with support from Construction Manager-as-Agent (CMA)
IO-DAs shares the responsibility for the Project, and work collaboratively with IO-CT as component suppliers and/or plant installers in the areas of their PAs.
• Responsible for provision of in-kind components on time as defined in Procurement Arrangements (PA).
• Working with IO-CT to provide technical supervisory and assistant services for their component installation
Assembly and Installation Information Day – 21st May 2015
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Mission of Construction Manager-as-Agent (CMA) is to support IO in ensuring that the assembly and installation works are performed in accordance with IO requirements.
• Supports IO for the Tokamak Assembly by supplying the necessary industrial know how, processes, construction workforce management and resources
• In addition, responsible for the planning, supervision, testing and completion of works in auxiliary buildings
IO and DA works contractors:• Execute works under the coordination of the IO and the CMA, in compliance with
specifications, schedule and approved quality plans. • Perform quality controls to demonstrate completion of works according to instructions,
requirements and construction specifications.
Division of Roles and Responsibilities(2)
Assembly and Installation Information Day – 21st May 2015
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Approach to Construction Works General:
• Divide contract packages by disciplines and physical areas (work sites) with minimum interfaces.
• Launch contracting process considering the project schedule
Execution management:• Manage construction works with strong support from CMA in a systematic manner based on
efficient management/control procedures and tools• Exert strong and on time coordination efforts to eliminate conflicts / delays from contractors• Closely support to technical matters and solve technical issues without delay• Pursue to make more efforts for preventive actions than remedial actions• Strictly surveil the quality control process and results to secure required quality• Closely monitor and control the schedule performance in detail
Assembly and Installation Information Day – 21st May 2015
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Division of Construction Worksites
1
2
3
4
5
6
Assembly and Installation Information Day – 21st May 2015
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Worksite Operational Structure For each worksite, a delegated Worksite Construction Manager will be appointed who is a
specialist in that area of works Worksite Construction Teams will be established to assist in the coordination and supervision
of the work – include CMA and relevant experts.
Site Construction Manager
Worksite Construction Team
Overall Daily Site Coordination. Management of Interfaces
MA Contractor Works Contractors
Worksite Construction Team
Worksite Construction Team
Worksite Construction Team
Worksite Construction Team
Worksite Construction Team
Site Works and Coordination
Electrical Buildings
Machine Assembly
Cooling Water and CryogenicControl Buildings
Tokamak Complex
Assembly and Installation Information Day – 21st May 2015
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CMA Contract Roles of IO and CMA by service missions:
Outline of CMA contract and control: • CMA contractor carries out tasks and services under the direction of IO.• CMA shall not self-perform installation work in order to prevent conflicts of interest. • Effective assessment process for each consultant or expert is to be stipulated.• Mechanisms for incentivizing and/or penalizing are to be provided.
Mission IO CMA Remarks
Planning & Management CMA performs under the supervision of IO
Tokamak Assembly IO plays major roles with technology driven initiatives. CMA provides industrial support, know-how, and detailed planning/organizing of the work crews, equipment and tools
Plant Installation CMA largely performs under the supervision of IO and with IO technical expertise
: Major Role
Assembly and Installation Information Day – 21st May 2015
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Work Packaging Basic considerations:
• Physical and functional boundaries;• Minimized interfaces among organizations;• Work sequence, process and maturity of component designs.
Tokamak Assembly:• Sector sub-assembly;• Sector assembly;• Ex-vessel components including ports;• In-vessel components.
Plant in Tokamak Complex• Divided by building floor vertically, by 2 concentric circles horizontally (Port cell and Gallery)• Maximum parallel works based on installation order per building/area and not per system
Plant in Auxiliary Building• Split for each building and area based on installation order and not per system
Assembly and Installation Information Day – 21st May 2015
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5 × 5 Circular Matrix (5 concentric circles x 5 layers)
Segmentation of Tokamak Pit and Complex
Bio-shieldPort CellGallery
In-vessel
In-cryostat
Port & Cryostat
B1 Port Cell
L1 Port Cell
L2 Port Cell
L3
L4
L5
B2 Tokamak interfaceB2
B1
L1
L2
①
②③
④⑤
❶
❷
❸
❹
❺
Cryostat GalleryPort CellBio-shield
Assembly and Installation Information Day – 21st May 2015
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Contract Strategy Two major categories:
• Construction Manager-as-Agent• Works Contracts
Works contracts divided by discipline Specialty contracts:
• Highly specialised and beyond the required capabilities of the general Machine Assembly Works Contractor (VVFJ, SC jointing, HV insulations, etc.)
Transverse support contracts: provided centrally for use by all site contractors• Storage, lifting and handling,
scaffolding, standard tools, etc.
ITER Organization
Construction Manager-as-Agent
Domestic Agency Works
Contractors
Machine Assembly
Works
Mechanical & PipingWorks
Specialized Works
Support Contracts
Tokamak
Electrical, I&C Works
Balance of Plant
Before launching tenders, IO will continue to seek industry feedback.
Assembly and Installation Information Day – 21st May 2015
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Overall Schedule IO is currently elaborating an Updated Long-Term Project Schedule
• Presented to ITER Council in November 2015 for consideration Updated long term schedule information available to bidders in early 2016 Limited works expected to start in the year 2017
Target milestones for construction contracts (subject to change):• CMA contract: Award in spring 2016 • Machine and Piping: Award in autumn 2016 • Electrical and I&C: Award in autumn 2016• Machine Assembly: Award in autumn 2016
Assembly and Installation Information Day – 21st May 2015
© 2015, ITER OrganizationPage 20IDM UID: XXXXXX
Key Success Factor for ITER Construction From IO side:
• Ensuring to meet nuclear quality and licensing requirements• Effective and efficient interface coordination among project stakeholders and integration of
components and systems from different members• Quality of technical specifications, drawings and documentation (Engineering Department)
• No major changes during assembly and installation• Selection of fully capable contractors and maintaining win-win relations
From contractor side:• Company visions and management capability• Correct understanding of ITER facility characteristics and technical requirements• Effective and efficient construction work processes and systems based on lessons learned
from construction of various similar plants• Assignment of sufficiently capable manpower recourses, and motivation and encouragement• Selection of capable sub-contractors and efficient control
Assembly and Installation Information Day – 21st May 2015
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What We are Expecting from Contractors To be win-win partners
• Win-win relationship through mutual trust, rule based on collaboration, efficient communication, etc.
• Right quality by contractors and right price by IO • Ready to share the fruits of the success of ITER with contractors as continuous partners of
global fusion society for the future projects
To meet requirements• Technical requirements as well as project schedule • Nuclear regulations(French laws) as well as code & standards
To perform work safely and protecting environment• ‘Safety First’ should be maintained all the time• Environmental protection is another importance for the construction work
Especially for CMA contractor:• Assignment of best qualified experts to ITER project and keeping continuity of staff,
since the success of CMA contract highly depends on human resources.
Assembly and Installation Information Day – 21st May 2015
© 2015, ITER OrganizationPage 22IDM UID: XXXXXX
Thank you for your attention