Conceptual Design Requirements for FIRE

John A. Schmidt

FIRE PVR

March 31, 2004

Outline

• Conceptual Design Requirements• History• Issues to be addressed during Conceptual

Design• Conclusions

Requirements for Conceptual Design

• The two sources of requirements for completion of conceptual design are:

– The DOE Critical Decision process

– Engineering requirement to initiate Preliminary Design

Schedule of FIRE Activities to Prepare for Construction

USFY 2002 USFY 2003 USFY 2004 USFY 2005 USFY 2006

BPSchedule_Construct

USFY 2007

Technical Assessment of FIRE (Snowmass July 2002)

Strategic Assessment of FIRE (FESAC Sep 2002)

Approve Mission Need and Initiate Preproject planning activities.

Conceptual Design of FIRE

Preliminary Design

Final Design

Physics Validation of FIRE (OFES Requirement)

Approve Performance Baseline

Approve Preliminary Range

(Baseline cost and schedule are “locked.” Project included in budget submission.)

CD-2

CD-1

CD-0

FIRE PreConceptual Design Activities

July 2004

Critical Decisions CD are DOE requirements and follow from DOE Order O 413.3

site selection

Mission Need Review (CD-0)

• Key review elements for a Mission Need Review are:– Mission Need Statement. Assess adequacy of documentation

confirming that the new project provides a specific capability that the Department currently lacks to meet its assigned mission.

– Program/Mission Requirements. Assess whether high-level requirements are sufficiently defined to identify potential alternatives (to be analyzed in the next phase) that are both applicable and capable of meeting project goals.

– Total Project Cost and Schedule Ranges. Review basis of the rough order of magnitude cost range and provide an assessment of whether this range reasonably bounds the cost and schedule of alternatives to be analyzed in the next project phase. Review basis of schedule range and assess whether the schedule is consistent with strategic requirements for when this project is required. Also, for projects closely linked to other projects, assess whether schedule results in appropriate integration.

CD-1 Documentation

• Conceptual Design Report - Alternative Analysis, Hazard Analysis, Site Selection Criteria, NEPA Documentation, Systems Requirements, cost and schedule estimates

• Risk Management Assessment

• Safety Documentation

• Acquisition strategy

Requirements to Initiate Preliminary Design

• Subsystem Requirements

• Feasibility– Is there a design solution within the allotted

envelopes?

• Cost (range)

• Schedule

Sliding Joint

PF Coils

OH Coil

Vacuum Vessel

TF Coil Inner Leg Assembly

TF Coil and Case

Dewar

Conceptual Design Issues - Magnets

• Solenoid leads

• Elbrodur fatigue

• Welding R&D

• Insulation R&D

Conceptual Design Issues - PFC’s

• Time dependent forces

• With transient thermal

• Connected to the vessel

• Startup with passive plates

• Magnetic detectors with passive plates

• First wall cooling for AT operation

Conceptual Design Analysis - VV

• Plastic analysis

• Limit analysis

• Optimized geometry and refined FEA models

• Dynamic analysis

• Fatigue analysis, including plastic effects

• Seismic analysis

Conceptual Design - VV

– Develop design of generic port plug

– Optimize divertor attachments for

stress, remote handling

– Design internal plumbing and

shielding

– Re-design / optimize gravity supports

Conceptual Design R&D - VV

– Select/verify method for bonding of copper cladding to vessel skin

– Select/verify method for routing of cooling passages into and out of cladding

– Develop fabrication technique for in-wall active control coils

– Perform thermal and structural tests of prototype vessel wall, with cladding, tubes, tiles, etc. (need test facility)

– Verify assembly welding of octants and tooling for remote disassembly/reassembly (need test facility)

Remote Maintenance Conceptual Design

• Many in-vessel remote handling system designs and procedures remain to be developed in concert with components– Divertor module remote attachment and handling interface– FW tile and limiter module attachment, handling end-effector and

interface– Standardized midplane port assemblies and handling systems– Upper and lower auxiliary port assemblies and handling systems– In-vessel inspection (metrology & viewing) system deployed via

midplane port

• Ex-vessel and hot cell remote handling systems have less design development– Component transfer casks, transport and positioning at ports (crane vs

air cushion, how are casks positioned at upper auxiliary ports?)– Upper and lower vertical ports are currently being fitted with diagnostics

but can they be maintained?– Hot cell layouts, remote handling systems and component repair stations

Conclusions

• The FIRE design is well positioned to complete the engineering required for Conceptual Design.

• The biggest effort will be in Remote Maintenance - both design and initiating R&D.

• It should be relatively straight forward to complete Conceptual Design in about nine months given approval of CD-0 and adequate funding.