Assembly and Installation Information Day – 21st May 2015

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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

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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

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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.

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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.

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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)

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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)

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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

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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

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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

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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

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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)

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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

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Division of Construction Worksites

1

2

3

4

5

6

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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

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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

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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

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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

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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.

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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

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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

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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.

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Thank you for your attention