pacific northwest national laboratory u.s. department of energy initial cost estimates for...
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No Slide TitlePacific Northwest National Laboratory U.S. Department of Energy
Initial Cost Estimates for Development of DCLL TBM Ferritic Steel Structural Components
R.J Kurtz1, A.F. Rowcliffe2 and S.J. Zinkle3
1Pacific Northwest National Laboratory
December 12 -14, 2005
DCLL WBS Definitions - R&D
Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints
Rowcliffe,Kurtz
Assess irradiation performance of FM steel/be bonded joints (shared with 1.8.1.1.2.8).
Rowcliffe,Kurtz
Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors
Rowcliffe,Kurtz
1.8.1.1.2.5.6
Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior.
Rowcliffe,Kurtz
1.8.1.1.2.5.5
Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3
Rowcliffe,Kurtz
1.8.1.1.2.5.4
Develop manufacturing technologies through industrial vendors for the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections; develop assembly sequences and post-joining heat treatments
Rowcliffe,Kurtz
1.8.1.1.2.5.3
Develop manufacturing technologies through industrial vendors for the fabrication of FM steel internally cooled plate components (first wall ,top and bottom plate assemblies, back plates etc.)
Rowcliffe,Kurtz
1.8.1.1.2.5.2
Rowcliffe,Kurtz
1.8.1.1.2.5.1
This WBS includes R&D tasks to determine, for all TBM mock-ups and prototypes, the selection of FM steel compositions and the appropriate fabrication and joining technologies and to assess the operational limitations for the TBM box structure including the FW, internal ribs and separators, manifolds, and connections to piping. Emphasis will be placed on evaluating on-going fabrication R&D in EU and Japan. This task will also evaluate the performance of FM steel joints produced by US and international vendors and provide the data needed for US design analysis under 1.8.1.1.3
Rowcliffe,Kurtz
1.8.1.1.2.5
Description
DCLL TBM Fabrication Schedule Summary
*Prototype may or may not be full scale
DCLL Test Article
Partially Integrated Tests
TBM Fabrication
1.8.1.1.2.5.1 - Fabrication Technology for Mockups
Objective: Recommend materials, define fabrication technologies and interface with vendors on the construction of sub-size mock-ups under 1.8.1.1.2.11
Period of Performance: FY06 - FY10
Assumptions: 1900 h/y (same for all tasks), pragmatic approaches to mockup fabrication (e.g., T91, flat plate geometries, non-prototypic fabrication technologies), material supplied by Task 1.8.1.1.2.11.
Cost Basis: 0.50 FTE/y - Scientist
Total Cost: $0.751 M
1.8.1.1.2.5.2 & 1.8.1.1.2.5.3 - Fabrication Tech. for Internally Cooled Plates and TBM Assembly
Objective: Develop manufacturing technologies through industrial vendors for; 1) the fabrication of FM steel internally cooled plate components, 2) the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections, 3) develop assembly sequences, and 4) post-joining heat treatments.
Period of Performance: FY06 - FY10 (may need to extend to FY11)
Assumptions: Industry is used from the beginning to develop fabrication technology, novel fabrication technologies such investment casting and plasma spray approaches, materials science program support for fabrication development is 1.25 FTE/y - Scientist.
Cost Basis: Recent EU experience for development of fabrication and joining technology ($1 M/y + 3% escalation/y), 50% of cost to procure fabricated shapes for entire Japanese TBM used as the basis for fabrication development.
Total Cost: $7.688 M
1.8.1.1.2.5.4 - Properties of FM Steel Joints
Objective: Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3.
Period of Performance: FY06 - FY10
Assumptions: Cost to perform microstructural analysis, mechanical testing (tensile, creep, fatigue, creep-fatigue, fracture toughness) on a range of welded/HIPed products, interfacing with ITER structural design codes and development of joint testing methods.
Cost Basis: 0.50 FTE/y - Scientist, 1.0 FTE - Technician, $0.025 M/y for specimen fabrication
Total Cost: $1.996 M
1.8.1.1.2.5.5 - Irradiated Properties Database
Objective: Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior.
Period of Performance: FY07 - FY08
Assumptions: Use state-of-the-art rabbit capsules, 6 microstructure/weld variants, tensile and fracture, 2 doses, 2 temperatures, 4 multiplicity.
Cost Basis: Recent US/Japan experiments (FY05 dollars):
Design/assembly/specimen fabrication - $0.22 M
Disassembly - $0.10 M
PIE - $0.20 M
0.5 FTE/y Scientist for 2 y, 1 FTE Technician for 1 y, 0.5 FTE Technician (SEM/TEM) for 1 y.
Total Cost: $1.151 M
1.8.1.1.2.5.6 - Effects of Irradiation on Prototypic Joints
Objective: Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors.
Period of Performance: FY08 - FY10
Assumptions: Use one temperature controlled RB capsule with 3 sub-capsules at different temperatures
Cost Basis: Recent US/Japan experiments (FY05 dollars):
Design/assembly - $0.60 M
Surveillance - $0.15 M
Disassembly - $0.15 M
PIE - $0.45 M
0.5 FTE/y Scientist for 3 y, 1 FTE Technician for 2 y, 0.5 FTE Technician (SEM/TEM) for 1 y.
Total Cost: $2.600 M
1.8.1.1.2.5.7 - Irradiated Properties of
Objective: Assess irradiation performance of FM steel/Be bonded joints (shared with 1.8.1.1.2.8).
Period of Performance: FY07 - FY08
Assumptions: The cost of this task is assumed to be 50% of Task 1.8.1.1.2.5.5.
Cost Basis: see Task 1.8.1.1.2.5.5
Total Cost: $0.516 M
1.8.1.1.2.5.8 - Non-Destructive Examination Methods
Objective: Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints
Period of Performance: FY06 - FY10
Assumptions: Development of specialized inspection techniques and probes, effort carried out at national labs/universities, industrial participation may be needed for custom probe fabrication, reliability and effectiveness of NDE techniques will be qualified using prototypic flaws.
Cost Basis: 0.5 FTE/y - Scientist, 0.5 FTE/y - Technician, $0.10 M/y to fabricate qualification specimens.
Total Cost: $1.811 M
DCLL WBS Definitions - Design Engineering
Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5
Rowcliffe,Kurtz
1.8.1.1.3.1.2.1
This WBS includes the administration and R&D for the evaluation and recommendation of fabrication technology, cost estimate and development of structural design code
Rowcliffe,Kurtz
1.8.1.1.3.1.2
Description
1.8.1.1.3.1.2.1 - Materials Properties and Fabrication Technology
Objective: Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5.
Period of Performance: FY06 - FY10
Assumptions: Largely a consulting activity to the design team but also a key interface with ITER structural team.
Cost Basis: 0.50 FTE/y - Scientist
Total Cost: $0.751 M
Pacific Northwest National Laboratory U.S. Department of Energy
Total Costs for Ferritic Steel Structural Component Fabrication R&D + Engineering
17.264
Total
0.751
1.8.1.1.3.1.2.1
1.811
1.8.1.1.2.5.8
0.516
1.8.1.1.2.5.7
2.600
1.8.1.1.2.5.6
1.151
1.8.1.1.2.5.5
1.996
1.8.1.1.2.5.4
7.688
Partially Integrated Tests
TBM Fabrication
Bid Package
Initial Cost Estimates for Development of DCLL TBM Ferritic Steel Structural Components
R.J Kurtz1, A.F. Rowcliffe2 and S.J. Zinkle3
1Pacific Northwest National Laboratory
December 12 -14, 2005
DCLL WBS Definitions - R&D
Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints
Rowcliffe,Kurtz
Assess irradiation performance of FM steel/be bonded joints (shared with 1.8.1.1.2.8).
Rowcliffe,Kurtz
Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors
Rowcliffe,Kurtz
1.8.1.1.2.5.6
Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior.
Rowcliffe,Kurtz
1.8.1.1.2.5.5
Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3
Rowcliffe,Kurtz
1.8.1.1.2.5.4
Develop manufacturing technologies through industrial vendors for the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections; develop assembly sequences and post-joining heat treatments
Rowcliffe,Kurtz
1.8.1.1.2.5.3
Develop manufacturing technologies through industrial vendors for the fabrication of FM steel internally cooled plate components (first wall ,top and bottom plate assemblies, back plates etc.)
Rowcliffe,Kurtz
1.8.1.1.2.5.2
Rowcliffe,Kurtz
1.8.1.1.2.5.1
This WBS includes R&D tasks to determine, for all TBM mock-ups and prototypes, the selection of FM steel compositions and the appropriate fabrication and joining technologies and to assess the operational limitations for the TBM box structure including the FW, internal ribs and separators, manifolds, and connections to piping. Emphasis will be placed on evaluating on-going fabrication R&D in EU and Japan. This task will also evaluate the performance of FM steel joints produced by US and international vendors and provide the data needed for US design analysis under 1.8.1.1.3
Rowcliffe,Kurtz
1.8.1.1.2.5
Description
DCLL TBM Fabrication Schedule Summary
*Prototype may or may not be full scale
DCLL Test Article
Partially Integrated Tests
TBM Fabrication
1.8.1.1.2.5.1 - Fabrication Technology for Mockups
Objective: Recommend materials, define fabrication technologies and interface with vendors on the construction of sub-size mock-ups under 1.8.1.1.2.11
Period of Performance: FY06 - FY10
Assumptions: 1900 h/y (same for all tasks), pragmatic approaches to mockup fabrication (e.g., T91, flat plate geometries, non-prototypic fabrication technologies), material supplied by Task 1.8.1.1.2.11.
Cost Basis: 0.50 FTE/y - Scientist
Total Cost: $0.751 M
1.8.1.1.2.5.2 & 1.8.1.1.2.5.3 - Fabrication Tech. for Internally Cooled Plates and TBM Assembly
Objective: Develop manufacturing technologies through industrial vendors for; 1) the fabrication of FM steel internally cooled plate components, 2) the assembly of TBM box structures, internal ribs, separators, manifolds and piping connections, 3) develop assembly sequences, and 4) post-joining heat treatments.
Period of Performance: FY06 - FY10 (may need to extend to FY11)
Assumptions: Industry is used from the beginning to develop fabrication technology, novel fabrication technologies such investment casting and plasma spray approaches, materials science program support for fabrication development is 1.25 FTE/y - Scientist.
Cost Basis: Recent EU experience for development of fabrication and joining technology ($1 M/y + 3% escalation/y), 50% of cost to procure fabricated shapes for entire Japanese TBM used as the basis for fabrication development.
Total Cost: $7.688 M
1.8.1.1.2.5.4 - Properties of FM Steel Joints
Objective: Determine unirradiated properties of weld and HIP joints produced by US or international vendors. Results will be used to assess viability of various fabrication methods and provide performance data for design analysis under 1.8.1.1.3.
Period of Performance: FY06 - FY10
Assumptions: Cost to perform microstructural analysis, mechanical testing (tensile, creep, fatigue, creep-fatigue, fracture toughness) on a range of welded/HIPed products, interfacing with ITER structural design codes and development of joint testing methods.
Cost Basis: 0.50 FTE/y - Scientist, 1.0 FTE - Technician, $0.025 M/y for specimen fabrication
Total Cost: $1.996 M
1.8.1.1.2.5.5 - Irradiated Properties Database
Objective: Conduct irradiation program to define effects of neutron irradiation under TBM conditions on properties of FM steels with emphasis on HIP and welded joints; establish relationships between as-fabricated hardness and microstructural properties and irradiated mechanical behavior.
Period of Performance: FY07 - FY08
Assumptions: Use state-of-the-art rabbit capsules, 6 microstructure/weld variants, tensile and fracture, 2 doses, 2 temperatures, 4 multiplicity.
Cost Basis: Recent US/Japan experiments (FY05 dollars):
Design/assembly/specimen fabrication - $0.22 M
Disassembly - $0.10 M
PIE - $0.20 M
0.5 FTE/y Scientist for 2 y, 1 FTE Technician for 1 y, 0.5 FTE Technician (SEM/TEM) for 1 y.
Total Cost: $1.151 M
1.8.1.1.2.5.6 - Effects of Irradiation on Prototypic Joints
Objective: Determine irradiated properties for final qualification of prototypic FM steel joints made by US and international vendors.
Period of Performance: FY08 - FY10
Assumptions: Use one temperature controlled RB capsule with 3 sub-capsules at different temperatures
Cost Basis: Recent US/Japan experiments (FY05 dollars):
Design/assembly - $0.60 M
Surveillance - $0.15 M
Disassembly - $0.15 M
PIE - $0.45 M
0.5 FTE/y Scientist for 3 y, 1 FTE Technician for 2 y, 0.5 FTE Technician (SEM/TEM) for 1 y.
Total Cost: $2.600 M
1.8.1.1.2.5.7 - Irradiated Properties of
Objective: Assess irradiation performance of FM steel/Be bonded joints (shared with 1.8.1.1.2.8).
Period of Performance: FY07 - FY08
Assumptions: The cost of this task is assumed to be 50% of Task 1.8.1.1.2.5.5.
Cost Basis: see Task 1.8.1.1.2.5.5
Total Cost: $0.516 M
1.8.1.1.2.5.8 - Non-Destructive Examination Methods
Objective: Evaluation and development of NDE techniques and procedures for flaw detection and sizing in TBM plates and joints
Period of Performance: FY06 - FY10
Assumptions: Development of specialized inspection techniques and probes, effort carried out at national labs/universities, industrial participation may be needed for custom probe fabrication, reliability and effectiveness of NDE techniques will be qualified using prototypic flaws.
Cost Basis: 0.5 FTE/y - Scientist, 0.5 FTE/y - Technician, $0.10 M/y to fabricate qualification specimens.
Total Cost: $1.811 M
DCLL WBS Definitions - Design Engineering
Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5
Rowcliffe,Kurtz
1.8.1.1.3.1.2.1
This WBS includes the administration and R&D for the evaluation and recommendation of fabrication technology, cost estimate and development of structural design code
Rowcliffe,Kurtz
1.8.1.1.3.1.2
Description
1.8.1.1.3.1.2.1 - Materials Properties and Fabrication Technology
Objective: Provide input on materials properties to design analysis tasks, interface with ITER team on MPH activities and development of structural design criteria; provide interface between design and the development of fabrication technologies under 1.8.1.1.2.5.
Period of Performance: FY06 - FY10
Assumptions: Largely a consulting activity to the design team but also a key interface with ITER structural team.
Cost Basis: 0.50 FTE/y - Scientist
Total Cost: $0.751 M
Pacific Northwest National Laboratory U.S. Department of Energy
Total Costs for Ferritic Steel Structural Component Fabrication R&D + Engineering
17.264
Total
0.751
1.8.1.1.3.1.2.1
1.811
1.8.1.1.2.5.8
0.516
1.8.1.1.2.5.7
2.600
1.8.1.1.2.5.6
1.151
1.8.1.1.2.5.5
1.996
1.8.1.1.2.5.4
7.688
Partially Integrated Tests
TBM Fabrication
Bid Package