INDUSTRIAL COST ASSESSMENT FOR ITER TRITIUM PLANT …

CA9500431

Canadian Fusion FuelsTechnology Project

INDUSTRIAL COST ASSESSMENT FOR ITER TRITIUMPLANT SYSTEM (WATER DISTILLATION, VPCE AND ISS)

CFFTP G-9501January, 1995

S.K. Sood, K.M. Kalyanam, C. FongOntario Hydro Nuclear

CFFTP GENERAL

The Canadian Fusion Fuels Technology Project represents part of Canada's overall effort in fusion energyresearch. The focus for CFFTP is tritium technology and remote handling. The Project is funded by theGovernment of Canada and Ontario Hydro Technologies. Ontario Hydro Technologies administers theProject.

INDUSTRIAL COST ASSESSMENT FOR ITER TRITIUMPLANT SYSTEM (WATER DISTILLATION, VPCE AND ISS)

CFFTP G-9501January, 1995

S.K. Sood, K.M. Kalyanam, C. FongOntario Hydro Nuclear

'C-Copyright Ontario Hydro, Canada, 1995. Inquiries about copyright andreproduction should be addressed to:

Manager, CFFTP2700 Lakeshore Road WestMississauga, Ontario CanadaL5J 1K3

CFFTP GENERAL

TABLE OF CONTENTS

PAGE

1.0 TASK OBJECTIVE 1

2.0 COST ASSESSMENT METHODOLOGY 1

2.1 Items Included in the Cost estimate 2

2.2 Items Not Included in the Cost Estimate 3

2.3 Licensing and Registration 3

3.0 SYSTEM DESCRIPTION AND COST ESTIMATES 4

3.1 ITER Water Detritiation System Description 4

3.1.1 Water Distillation System Cost Estimate 4

3.1.2 Vapour Phase Catalytic Exchange System CostEstimate 6

3.2 Isotope Separation System Description 8

3.2.1 Isotope Separation System Cost Estimate 9

4.0 COST ESTIMATE FOR COMMISSIONING ANDTESTING 12

4.1 Items Not Included In The CommissioningAnd Testing Cost 13

5.0 COST ESTIMATE FOR ROUTINE INSPECTION 13

6.0 COST ESTIMATE FOR ROUTINE MAINTENANCE 15

7.0 COST ESTIMATE FOR SPARE PARTS 17

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TABLE OF CONTENTS

PAGE

8.0 SPECIAL REQUIREMENTS & SERVICES DURINGCONSTRUCTION 18

8.1 Special Requirements for the Water Distillation System . 18

8.2 Special Requirements for the VPCE System 19

8.3 Special Requirements for the ISS 20

9.0 ESTIMATED SCHEDULE 20

10.0 SUMMARY 22

11.0 REFERENCES 23

APPENDIX A 27

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1.0 TASK OBJECTIVE

The objective of this Industrial Cost Assessment Task for ITER TritiumPlant System consists of providing an order--of-magnitude cost estimatefor the following major subsystems, as outlined in the Scope of TaskAgreement and Work Program111:

* Water Distillation (WD) System,* Vapour Phase Catalytic Exchange (VPCE) System, and* Isotope Separation System (ISS) System.

The order-of-magnitude cost estimate is based on the available EDAFlow Diagrams and Data Sheets provided to us, representing the ITERTritium Plant Systems design as of September 1994 (See Appendix A).

2.0 COST ASSESSMENT METHODOLOGY

The methodology adopted in preparing the order-of-magnitude costestimate for the above three subsystems of the ITER tritium plantsystem is based on building the estimate from the ground up, startingwith equipment cost estimates, and adding labour activities separatelyfor engineering, fabrication, assembly, testing, installation,commissioning, etc. The estimate has been developed assuming thatthe systems are to be engineered, fabricated and constructed inCanada, (to comply with the Codes, Standards, QA and SeismicClassification applicable in Canada) since information on ITER siting isnot currently available.

The estimate is based on Ontario Hydro in-house cost data on similarsystems and equipment, such as the heavy water upgrading plants, theDarlington Tritium Removal Facility, etc. The cost estimates are notbased on quotations from suppliers for specific ITER components, sincethis would require completion of detailed design and specifications.Available costs of components have been escalated to 1994 dollarsusing the Marshall and Swift Equipment Cost Index12-41. Wherenecessary, equipment costs have been estimated based on availablecosts of components of different capacity and size, using typical

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industrially accepted scale-up factors'3-41. Available cost data inCanadian dollars have been converted to U.S. dollars, using theexchange rate of $ 1 U.S. = $ 1.4 Canadian.

2.1 Items Included in the Cost estimate

The order-of-magnitude Total Plant Cost estimate includes thefollowing items:

a) Cost of components such as process and auxiliary equipment,

b) Cost of piping, valves and instrumentation,

c) Cost of foundation and supports, insulation and painting,

d) Cost of Installation,

e) Cost of Engineering and Overheads,

f) Freight, customs and duty,

g) Contingency.

Separate cost estimates have been provided for the following:

1) Commissioning and Testing,

2) Routine Annual Inspection,

3) Routine Annual Maintenance,

4) Spare Parts.

2.2 Items Not Included in the Cost Estimate

The following items are not included in the order-of-magnitude TotalPlant Cost estimate:

a) Cost of Building,

b) Cost of Building Services such as HVAC, Fire Protection etc.,

c) Cost of Utility Services such as cooling water, steam, instrumentair, electric power supply, liquid N2 etc. that interface with theTritium Plant System,

d) Taxes, Insurance and Interest Costs,

e) Cost of Plant Licensing,

f) Central Control System, Data Acquisition System,

g) Additional Feed Water Treatment Systems for Water Detritiation toControl Organics, pH and Oil.

2.3 Licensing and Registration

WD and VPCE systems have been licensed in Canada up to a maximumconcentration in water of 34 Ci/kg, and the Darlington Tritium RemovalFacility, licensed in Canada, has a tritium inventory of about 25 g. Thecost estimate for ITER WD, VPCE and ISS systems is prepared on thebasis of similar Code and Quality levels. However, the concentrationof tritium at the bottom of the ITER WD system and in the VPCE, ismuch higher (300 Ci/kg), and the tritium inventory in the ISS isexpected to be higher than 100 g.

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Should more stringent Code and Quality levels be required for licensingand registration of the ITER systems as a consequence of the higherconcentrations, then the cost estimates prepared in this report will below. If the Codes and QA levels assumed in this report are acceptable,the additional licensing cost is expected to be relatively modest.

3.0

3.1

SYSTEM DESCRIPTION AND COST ESTIMATES

ITER Water Detritiation System Description

The Water Detritiation System detritiates the Heat Transport System(NTS) coolant and waste water streams of the ITER reactor system.The Water Detritiation System consists of a Water Distillation (WD)Unit and a Vapour Phase Catalytic Exchange (VPCE) Unit. The coolantwater at a tritium concentration of about 10 Ci/kg is sent to the WDunit at the rate of 102 kg/h, detritiated to less than 0.5 Ci/kg andreturned to the coolant loop. Waste water at a tritium concentration of0.1 Ci/kg is sent the WD unit at the rate of 20 kg/h, detritiated to lessthan 0.5 mCi/kg and discharged to the environment.

3.1.1 Water Distillation System Cost Estimate

The Water Distillation Unit consists of three vacuum distillationcolumns, pumps, reboilers, condensers and associated lines, valves andcontrols.

The Water Distillation System cost estimate is based on the columnsizes shown in the table below (See Appendix A).

Parameter

Column Dia. (cm)Top/Bottom

Packed Height (m)

No. of Sections

WD COLUMN SIZES

WD1.1

112/112

22.2

11

IL WD1.2

112/112

22.2

11

WD2

50/50

26

13

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The main components included in the cost estimate are as follows:

1) Columns: Columns WD1.1 and WD 1.2 are assumed to have 11flanged sections (3 m high) and Column WD2 is assumed to have12 flanged sections (3 m high). Each section contains phosphor-bronze structured packing (2 m high), liquid distributor, collectorand packing supports. Each column has a sump and a supportskirt.

2) Vacuum Unit: The vacuum unit consists of two liquid-ring typepump/compressor, seal water system and associated piping,valves and controls.

3) Heat Exchangers: Reboilers, condensers, evaporators, coolers andcold traps, as indicated in the ITER drawings.

4) Pumps: Feed and Product transfer pumps and reflux pumps, asindicated in the ITER drawings.

5) Tanks: Surge and drain tanks.

6) Water Treatment System: Water treatment systems for the wasteand coolant water feeds - consisting of degasser, heat exchanger,pump, tank, Ion-Exchange columns and filters.1

7) Chilled Water Package: A packaged chilled water unit to supplychilled water to the cold traps.

8) Instrumentation & Control: All control valves, instrumentation andcontrol, effluent tritium monitors, control panels, and controlcomputer.

'Depending on ITER operating conditions, additional treatment systems tocontrol organics, oil and p" may be required. Since the Reference Design doesnot identify such systems, cost for such systems are not included.

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9) Utility System Components: Piping and valves associated withsteam and cooling water, condensate return, electrical equipmentsuch as transformers, and motor control (up to the WD SystemLimit).

10) Insulation: Thermal insulation for the columns, heat exchangersand piping, as required (up to the WD System Limit).

11 ) Support/Foundation: Equipment foundations and structuralsupports, as required.

In addition, the cost estimate is based on the following assumptions:

a) All components in contact with process water are made ofstainless steel.

b) The components are assumed to be designed, fabricated andtested in accordance with the requirements of ASME Section VIII,Division 1, and in compliance with Canadian StandardsAssociation Quality Assurance Program CSA-Z 299.3.

The estimated cost for the unit including components, installation,engineering, freight, customs, duty and contingency, of the WaterDistillation Unit is shown in Table-1.

3.1.2 Vapour Phase Catalytic Exchange System Cost Estimate

The Vapour Phase Catalytic Exchange (VPCE) System has two stages,each stage consisting of pumps, evaporator, superheater, condenser,and associated lines, valves and controls. The bottom product waterfrom the WD Unit at a tritium concentration of about 300 Ci/kg is fedto the VPCE Unit at the rate of about 4.72 kg/h, detritiated by a factorof about 3 and returned to the WD Unit. In the VPCE Unit, tritium istransferred from the water phase into the hydrogen gas, circulating ata rate of about 1.6 kg/h. The operating pressures and temperatures ofthe WD Unit are 11 to 20 kPa and 320 to 330 K. The operatingpressures and temperatures of the VPCE Unit are 110 to 120 kPa and

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320 to 473 K. The VPCE Unit, the sump and the reboiler of the lastWD column, and the interconnecting lines are assumed to havesecondary containment.


1) VPCE Equipment: Evaporators/Demisters, Superheaters, catalystvessel and condensers, as shown in ITER Drawings.

2) Dryer Package: Two molecular sieve bed dryers with regenerationcircuit, piping, valves and controls, as indicated in the ITERdrawings.

3) Pumps: Feed and Product transfer pumps, as indicated in the ITERdrawings.

4) Tank: Expansion tank for H2 gas.

5) Compressors: Double-containment metal-bellows type gascirculating compressors.

6) Instrumentation & Control: All control valves, instrumentation andcontrol, control panels, control computer.

7) Utility System Components: Piping and valves associated withcooling water, electrical equipment such as transformers, andmotor control {up to the VPCE System Limit).

8) Insulation: Thermal insulation for the VPCE unit, heat exchangersand piping, as required (up to the VPCE System Limit).

9) Support/Foundation: Equipment foundations and structuralsupports, as required.

10) Secondary Containment: Secondary containment for componentscontaining high tritium water.

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a) All components in contact with process water are made ofstainless steel.

b) The components are assumed to be designed, fabricated andtested in accordance with the requirements of ASME Section VIII,Division 1, and in compliance with Canadian StandardsAssociation Quality Assurance Program CSA-Z 299.3.

The estimated cost for the components, including installation,engineering, freight, customs, duty and contingency, of the VPCE Unitis shown in Table-2.

3.2 Isotope Separation System Description

The Isotope Separation System (ISS) is provided for processing thehydrogen isotope faed streams from the Water Detritiation(WD + VPCE) unit, Impurity Treatment, Plasma Exhaust and NBI. TheISS separates the hydrogen isotopes into pure H, D and T products bymeans of cryogenic distillation at about 24 - 30 K. The ISS mainlyconsists of three cryogenic distillation (CD) columns, cryo-adsorbers,equilibrators, overhead condensers, reboilers, heat exchangers, pumps,valves and the associated instrumentation and piping, and cold box .The CD columns, the associated cryo-adsorbers, overhead condenser,reboilers and heat exchangers are located inside a cold box vessel, andthe remaining equipment such as pumps, equilibrators and valves arelocated inside a glovebox. A standard (2.2 kW) helium refrigerator isassumed to provide the required refrigeration load, and it is located inthe adjacent area - outside of the cold box and glovebox.

Based on the current ITER EDA ISS design information, (seeAppendix A), the hydrogen isotope feed streams to be treated by ISSare: 785 mol/h from the VPCE unit, 200 mol/h from the ImpurityTreatment and 80 mol/h from the Plasma Exhaust. Therefore, the totalhydrogen isotope feed rate to be treated by the ISS is about1,065 mol/h.

8

3.2.1 Isotope Separation System Cost Estimate

The ISS cost estimate is based on the information shown in the threeITER EDA ISS flow diagrams and ITER EDA ISS data sheet (SeeAppendix A).


1) CD Columns: Columns CD1 to CDS are fabricated from stainlesssteel pipes. The column diameters are: 12.8/4.4 cm (for CDD,7/3.4 cm (for CD2) and 4.75/3.75 cm (for CDS). The packedheights of columns CD1, CD2 and CDS are 6m, 3.25m and 2m,respectively. Each column is equipped with stainless steelpacking, a reflux liquid distributor, interdistributor screens andpacking supports as well as a support skirt.

2) Cryo-Adsorbers: Two dual-bed cryo-adsorbers, operated at liquidnitrogen temperature of about 77 K, are provided to remove theimpurity gases from the hydrogen isotopes prior to entering theCD columns.

3) Heat Exchangers: Reboilers, overhead condensers and compactgas-to-gas heat exchangers are provided as indicated in the ITERdrawings.

4) Cold Box Assembly: The Cold Box provides vacuum insulation tothe CD columns and serves as secondary containment. All the CDcolumns, cryo-adsorbers, overhead condensers, reboilers andcompact gas-to-gas heat exchangers are contained within the ColdBox. The Cold Box is an upright cylindrical vessel, consisting oftwo sections - an upper 1.52 m diameter section (where cryo-adsorbers, heat exchangers are located) and a lower 0.8mdiameter section. A cold box vacuum unit, consisting of a Varianpump, an ion pump, a vacuum gauge and liquid nitrogen cold trap,is used to maintain the cold box pressure below1.33 x 1CT4Pa.

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5) Pumps: Doubly contained metal bellows pumps are used as feedand product transfer pumps, as indicated in the ITER drawings.

6) Helium Refrigerator: A packaged 2,2 kW helium refrigeration unitis used to keep the CD columns in the operating temperaturerange of about 24 - 30 K.

7) Product Tanks: Two small product tanks are provided, asindicated in the ITER drawings.

8) Equiiibrators: Five catalytic equilibrators are provided, as indicatedin the ITER drawings, to promote the breakdown of theintermediate species HD, HT, a ^d DT, into H2, D2 and T2. Theequilibrators contain Pt-on-alumina catalyst and are operated atroom temperature.

9) Glovebox Assembly: The glovebox provides secondarycontainment for the tritium handling components, such as metalbellows pumps and equilibrators, as indicated in the ITERdrawings.

10) Instrumentation & Coïttrol: All control valves, instrumentation andcontrol devices, feedthroughs, control computers, mass flowcontrollers, control panels and instrument rack.

11) Consumables: Gas supplies, welding machine rental and heliumleak detector.

12) Insulation: Thermal insulation for the CD columns, heatexchangers and piping, as required.

13) Support/Foundation: Equipment foundations and structuralsupports, as required.

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a) All components in contact with hydrogen isotopes are made ofstainless steel.

b) The components are assumed to be designed, fabricated andtested in accordance with the requirements of ASME Section VIII,Division 1 (for pressure vessels), and B31.3 (for piping) and incompliance with Quality Assurance Program ISO-9001, andCanadian Standards Association Quality Assurance ProgramCSA-Z 299.2 (for tritium wetted parts) and Canadian StandardsAssociation Quality Assurance Program CSA-Z299.3 or Z299.4(for standard commercial items), or equivalent.

The estimated cost for the ISS components, including installation,engineering, freight, customs, duty and contingency, is shown inTable-3.

The Cost Estimate does not include the following auxiliaries:

1. Auxiliary systems such as Drain & Purge System and RecombinerSystem (These are- not included in the Reference DesignDrawings). [Note: An "order-of-magnitude" cost estimate for thesetwo auxiliary systems is about $ U.S. 1.5 million.]

2. Sampling and Analysis System including process tritium monitorssuch as ion-chambers and Mass Spectrometers [Note: An "order-of-magnitude" cost estimate for this system is about $U.S.1 Million].

3. Piping, valves, instrumentation and controls associated with utilitysupplies such as liquid nitrogen, argon and helium, andcomponents associated with electricity supply. (These are notincluded in the Reference Design Drawings). [Note: An "order-of-magnitude" cost estimate for the above is about $U.S.0.5 Million].

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4.0 COST ESTIMATE FOR COMMISSIONING AND TESTING

The Commissioning and Testing of Water Detritiation and IsotopeSeparation Systems consist of the following activities:

1. Pre-commissioning inspection, helium leak testing and pressuretesting (hydrostatic or pneumatic testing) of the assembledsystems.

2. Cold commissioning (non-tritium and trace tritium) andperformance testing.

3. Hot commissioning (with tritium) and performance testing.

It is assumed that the system is completely assembled and all interfacesystems such as cooling water, steam, plant air, instrument air andelectric power have been commissioned and tested.

Water Distillation System: Based on Heavy Water Upgrading Plantexperience, it is estimated that the commissioning and testing of theITER Water Distillation System will take about 7 months, with 4 peopleworking full-time for about 40 hours per week, i.e., 40 hours/week x4.3 weeks/month x 7 months x 4 people = 4,816 hours. At $ U.S.70/hour, the estimated cost for the commissioning and testing of theITER Water Distillation System « $ U.S. 0.34 million.

Vapour Phase Catalytic Exchange (VPCE) System: Based on theDarlington Tritium Removal Facility experience, the commissioning andtesting of the ITER VPCE System is estimated to require about 5months, with 3 people working full-time for about 40 hours per week,i.e., 40 hours/week x 4.3 weeks/month x 5 months x 3people = 2,580 hours. At $ U.S. 70/hour, the estimated cost for thecommissioning and testing of the ITER VPCE System ~ $ U.S.0.18 Million.

Isotope Separation System (ISS): Based on the previous experience onDarlington Tritium Removal Facility and the Tritium Purification Systemfor the Princeton University, it is estimated that the commissioning andtesting of the ITER-ISS will take about 9 months, with 5 people

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working full-time for about 40 hours per week, i.e., 40 hours/week x4.3 weeks/month x 9 months x 5 people = 7,740 hours. At $ U.S.70/hour the estimated cost for the commissioning and testing of theITER-ISS « $ U.S. 0.54 million.

4.1 Items Not Included In The Commissioning And Testing Cost

The following items are not included in the above cost estimate forcommissioning and testing of the Water Detritiation and IsotopeSeparation Systems:

1. Cost of registering the assembled process systems with theapplicable jurisdictional authorities.

2. Cost of field modifications that may be necessary duringcommissioning and testing.

5.0 COST ESTIMATE FOR ROUTINE INSPECTION

Routine annual inspection activities are required to ensure that theequipment and components are in good working condition and tocomply with the requirements of jurisdictional Codes, Standards andActs (such as the Boilers and Pressure Vessels Act of Ontario). Thetypical inspection activities and the estimated cost for performing theseactivities are presented below.

Annual Inspection Activities For The Water Distillation System:

(1) Check wear parts on reflux, circulating and product pumps,compressors, and vacuum pumps.

(2) Inspect leak-tightness on columns, evaporators, condensers,valves, equipment sight glasses and secondary containments.

(3) Check surface cleanliness or corrosion on heat exchangers,column packing and liquid distributors.

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(4) Calibrate and verify all flow, level, temperature and pressureinstruments and controls, and tritium monitors.

(5) Inspect and test all equipment relief devices.

It is estimated that routine annual inspection of the ITER WaterDistillation System will take about 4 weeks, with 4 people working full-time for about 40 hours per week, i.e., 40 hours/week x 4 weeks x4 people = 640 hours. At $ U.S. 70/hour, the estimated cost for theannual inspection activities of the ITER Water Distillation System« $ U.S. 45,000/year.

Annual Inspection Activities For The VPCE System:

(1) Check wear parts on gas circulating compressors and waterpumps.

(2) Inspect leak-tightness on evaporators, condensers, secondarycontainments, valves, and sample equipment.

(3) Check electric heaters, filters and dryer desiccant.

(4) Check surface cleanliness or corrosion on evaporators, andcondensers.



It is estimated that routine annual inspection of the ITER VPCE Systemwill take about 4 weeks, with 3 people working full-time for about40 hours per week, i.e., 40 hours/week x 4 weeks x 3 people =480 hours. At $ U.S. 70/hour, the estimated cost for the annualinspection activities of the ITER VPCE System « $ U.S. 34,000/year.

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Annual Inspection Activities For The ISS System:

(1) Check wear parts on Helium Refrigeration System compressorsand expansion turbine, and on ISS feed pumps, process purgevacuum pumps and compressors, cold boxes roughing andvacuum equipment.

(2) Inspect leak-tightness on cold boxes, gloveboxes, cryogenicadsorbers, equilibrators, valves and sample equipment.


(4) Inspect and test all electric heaters.


It is estimated that routine annual inspection of the ITER ISS will takeabout 5 weeks, with 4 people working full-time for about 40 hours perweek, i.e., 40 hours/week x 4 weeks x 4 people = 800 hours. At$ U.S. 70/hour, the estimated cost for the annual inspection activitiesof the ITER ISS = $ U.S. 56,000/year.

6.0 COST ESTIMATE FOR ROUTINE MAINTENANCE

Routine annual maintenance activities are required to ensure that theequipment and components are in good working condition. The typicalmaintenance activities and the estimated cost for performing theseactivities are presented below.

Annual Maintenance Activities For The Water Distillation System:

(1) Replace depleted lubricant on equipment.

(2) Replace worn-down equipment seals, gaskets, and valve seats.

(3) Plug or replace leaking heat exchanger tube bundles.

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(4) Clean distillation column distributors, and heat exchanger surfaces,if necessary.

(5) Conduct maintenance overhaul on major equipment (vacuumpumps, compressors)

(6) Replace IX column resins, filter cartridges.

The planned annual maintenance of the ITER Water Distillation Systemis estimated to take about 6 weeks, with 4 people working full-time forabout 40 hours per week, i.e., 40 hours/week x 6 weeks x 4people = 960 hours. At $ U.S. 70/hour, the estimated labour cost forthe annual maintenance of the ITER Water Distillation System= $ U.S 67,000/year. The annual cost of maintenance materials isassumed to be 100% of the labour cost, or $ U.S 67,000/year.Therefore, the total annual maintenance cost for the ITER WaterDistillation System « $ U.S 134,000/year.

Annual Maintenance Activities For The VPCE System:



(3) Plug or replace leaking heat exchanger tube bundles.

(4) Clean heat exchanger surfaces, if necessary.

(5) Conduct maintenance overhaul on major equipment (water pumps,gas circulating compressors, dryer unit).

The planned annual maintenance of the ITER VPCE System isestimated to take about 4 weeks, with 3 people working full-time forabout 40 hours per week, i.e., 40 hours/week x 4 weeks x 3 people =480 hours. At $ U.S. 70/hour, the estimated labour cost for theannual maintenance of the ITER VPCE System « $ U.S 34,000/year.The annual cost of maintenance materials is assumed to be 100% ofthe labour cost, or $ U.S 34,000/year. Therefore, the total annualmaintenance cost for the ITER VPCE System = $ U.S 68,000/year.

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Annual Maintenance Activities For The ISS:



(3) Conduct maintenance overhaul on major equipment such ascoldbox vacuum pumps, helium refrigeration system compressorsand expanders, metal-bellows pumps, drain & purge systemvacuum pump and compressors.

The planned annual maintenance of the ITER ISS is estimated totake about 6 weeks, with 4 people working full-time for about40 hours per week, i.e., 40 hours/week x 6 weeks x 4 people =960 hours. At $ U.S. 70/hour, the estimated labour cost for theannual maintenance of the ITER ISS = $ U.S 67,000/year. Theannual cost of maintenance materials is assumed to be 100% ofthe labour cost, or $ U.S 67,000/year. Therefore, the total annualmaintenance cost for the ITER ISS = $ U.S 134,000/year.

7.0 COST ESTIMATE FOR SPARE PARTS

The following spare parts are.normally recommended bymanufacturers:

1. Main components on compressors, expanders, vacuumequipment, metal bellows pumps and valves.

2. Heat exchanger tube bundles.

3. Electric heaters.

4. Controls and instruments.

5. Spare WD column distributors.

6. Spare WD system sight glasses.

7. Spare filter cartridges.

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The cost of spares is estimated at about 10% of the plant equipmentcost.

Therefore, the estimated Spare Parts Costs are:

1. Water Distillation System = $ U.S. 9.56 x 106 x 0.10~ $ U.S. 1.0 million.

2. VPCE System = $ U.S. 1.28x 106x0.10« $ U.S. 0.13 million.

3. Isotope Separation System = $ U.S. 3.07 x 106 x 0.10« $ U.S. 0.3 million.

8.0 SPECIAL REQUIREMENTS & SERVICES DURINGCONSTRUCTION

The general requirements during construction are specifications,procedures, quality control and quality assurance programs forcleanliness, welding, non-destructive examination, and pressure andleak testing of assembled components.

8.1 Special Requirements for the Water Distillation System

Some of the special requirements and services during the constructionof the Water Distillation System are:

(1) Lifting devices such as cranes and overhead monorails for liftingthe packed column sections, the head condenser and cold trapsto their installation positions.

(2) Pneumatic pressure testing of the completely erected columns intheir vertical position.

(3) Access platforms at the various levels near the column manholes.

(4) A "clean" room environment for the assembly of the WDcomponents so that dust and dirt particles cannot get into theprocess components.

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(5) Installation procedures to ensure that the column internals(packings, distributors, collectors, hold-down plates) are notcontaminated with oil, grease, dust and debris.

(6) Proper quality assurance program to ensure that the top flangesof the sump and column sections are perfectly level and that thedistributors are perfectly level.

(7) Seal welding of the column section flanges. Nozzles andopenings should be blanked and couplings should be plugged toprevent weld splatters and dirt from entering the column sections.

8.2 Special Requirements for the VPCE System

Some of the special requirements and services during the constructionof the VPCE System are:

(1) Lifting devices such as overhead monorails for lifting the dryerunit skid, VPCE unit skid and the expansion tank to theirinstallation positions.

(2) Leak testing of the secondary containments.

(3) A "clean" room environment for the assembly of the VPCEcomponents so that dust and dirt particles cannot get into theprocess components.

(4) Assembly and installation procedures to ensure that the VPCEcatalyst and the dryer desiccant are not contaminated withmoisture, oil, grease, dust and debris.

(5) Proper quality assurance program to ensure alignment andvibration isolation for the gas circulating compressors.

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8.3 Special Requirements for the 1SS

The special requirements during the construction of the ISS are asfollows:

(1) In general, the maximum permissible leakage for the ISScomponents, including all process connections, is 10"8 std. cc/secHe or better. This requires that all joints be welded or thatspecial high vacuum fittings be utilized. Therefore, specialwelder/brazer qualification is needed to ensure good workmanshipon all welded/brazed joints.

(2) The assembly of the ISS components should bo performed in a"clean" room environment so that foreign dust particles cannotget into the ISS process.

(3) Fingerprints should never be left on the Mylar superinsulation,since they will make the thermal insulation less effective, andthus create heat leak into the CD columns. Clean plastic handgloves should be used vvhile insulating the CD columns.

(4) All cryogenic process and lines must be insulated in order toprevent accidental contact of personnel with extremely coldsurfaces.

(5) Proper Quality Assurance program is needed to ensure that theconstruction of ISS will meet the design requirements.

9.0 ESTIMATED SCHEDULE

The project completion time for the ITER Water Detritiation System andISS from detailed design to installation, commissioning andperformance testing is expected to be of the order 3 to 5 years. Theproject completion time is site specific, and depends on regulatoryrequirements such as Codes and Standards, registration and licensing.

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The following schedule is presented based on a Canadian Site:

ACTIVITIES

Detailed Design, Tendering Documents, Requestfor Bids, Bid Evaluation and Award of Contracts

Fabrication, Assembly, Testing and Delivery ofequipment and components to Site

Site Assembly, Installation, Interface SystemsTie-in

Commissioning and Performance (Cold) Testing

Hot Testing, Operator Training, Operating Licensefrom Regulatory Body

TIME REQUIRED

1 .5 to 2 yearsfrom start date

1 to 1 .5 yearsfrom award ofcontract

0.5 to 1 yearfrom delivery

0.5 year frominstallation

0.5 year fromCold testing

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10.0 SUMMARY

The estimated costs for the WD, VPCE and ISS systems aresummarized below.

ITEM

Total Plant Cost (Order-Of -Magnitude): (Includesequipment & materials, support & foundation, freight,customs & duty, seismic & safety analyses, engineering& overheads, installation and contingency.

ITER WD System Cost

ITER VPCE System Cost

ITER ISS Cost

$ U.S. 1994

(Million)

17.4

3.3

7.4

Cost for Commissioning and Testing

ITER WD System Cost


ITER ISS Cost

0.34

0.18

0.54

Cost for Routine Annual Inspection

ITER WD System Cost


ITER ISS Cost

0.045

0.034

0.056

Cost for Routine Annual Maintenance

ITER WD System Cost


ITER ISS Cost

0.13

0.07

0.13

Cost for Spare parts

ITER WD System Cost


ITER ISS Cost

1.0

0.13

0.3

indu»riaJ.j27 22

11.0 REFERENCES

[1] SCOPE OF TASK AGREEMENT AND TECHNICAL DESCRIPTIONOF THE WORK PROGRAMME, Industrial Cost Assessment for ITERTritium Plant System, ANNEX 1 to N32 TD 01 94-08-26 FE.

[2] Chemical Engineering, McGraw-Hill Publication, McGraw-Hill, Inc.,1981-1994.

[3] Donald S. Remer and Lawrence H. Chai, "Design Cost Factors forScaling-up Engineering Equipment", Chemical EngineeringProgress, August 1990, Page 77-82.

[4] Perry's Chemical Engineers' Handbook, 6th Edition, R.H. Perry andD.W. Green, McGraw Hill Publishing Co., 1984.

industrial .J27 23

Table-1 : ITER WD Unit Cost Estimate

ItemMo.

A)

B)

Description

EQUIPMENT &MATERIALS

INSTRUMENTATION

Total Cost (Eqpt.& Mat.)

C) FREIGHT

Total Delivered Cost

D)

E)

F)

INSTALLATION/FIELDCOST

SUPPORT/FOUNDATION

CUSTOMS/DUTY

Total Installed Cost

G)

H)

1)

J)

ENGINEERINGOVERHEADS,PROCUREMENT, QA,PROJECTMANAGEMENT

SAFETY ANALYSIS

SEISMIC ANALYSIS

CONTINGENCY

TOTAL COST

COSTx 106

$U.S. 1994

8.19

1.00

9.19

0.37

9.56

1.53

0.74

1.84

13.67

1.70

0.25

0.47

1.30

17.39

Comments

4% of Eqpt.& Matl.

20% of Eqpt.&Mat!.

10% of Installed

WiBlri»l.j27 24

Tab!e-2: ITER VPCE Unit Cost Estimate

ItemNo.

A)

B)

Description


INSTALLATION

Total Cost (Eqpt. & Mat.)

C) FREIGHT


D)

E)

F)

INSTALLATION/FIELDCOST

SUPPORT/FOUNDATION

CUSTOMS/DUTY


G)

H)

1)

J)

ENGINEERING,OVERHEADS,PROCUREMENT, Q.A.,PROJECT MANAGEMENT

SAFETY ANALYSIS

SEISMIC ANALYSIS

CONTINGENCY

TOTAL COST

COSTx 106

$ U.S. 1994

0.96

0.27

1.23

0.05

1.28

0.63

0.18

0.25

2.34

0.55

0.1

0.1

0.23

3.32

Comments

4% of Eqpt. &Matl.

20% of Eqpt. &Matl.

5% of Eqpt. &Matl.

2.7% of Eqpt. &Matl.

10% of Installed

industrial .j27 25

Table 3: ITER ISS Cost Estimate

ll»r,iNo.

A)

B)

Description


INSTRUMENTATION

Total Cost (Eqpt.& Mat.)

C) FREIGHT


D)

E)

F)

INSTALLATION/FIELD COST

SUPPORT/FOUNDATION

CUSTOMS/DUTY


G)

H)

1)

J)

ENGINEERING &OVERHEADS,PROCUREMENTQA/PROJECTMANAGEMENT

SAFETY ANALYSIS

SEISMIC ANALYSIS

CONTINGENCY

TOTAL COST

COSTx 106

$U.S. 1994

2.81

0.14

2.95

0.12

3.07

0.25

0.55

0.61

4.48

1.16

0.34

0.26

1.16

7.40

Comments

4% of Eqpt.& Matl.

20% of Eqpt.& Matl.

25% of Installed

indus trial ,j27 26

APPENDIX A

(1) ITER EDA Drawings issue No. 93.09.07.08:

a) Water Detritiation System Flow Sheet

b) Water Detritiation Columns P. & I.D.

c) Feed Evaporators For Isotope Separation P. & I.D.

d) Isotope Separation System Flow Sheet

e) Isotope Separation System Cold Box P. & I.D.

f) Isotope Separation System Secondary Containment P. & I.D,

g) VPCE and Feed Treatment for Isotope Separation P. & I.D.

(2) ITER EDA Data Sheets as of Sept. 1994 (O.K. Kveton, ITERNaka):

a) ITER EDA Water Detritiation System - Pump and Blower Sizes

b) ITER EDA ISS - 2000 sec burn/dwell cycle - rev. Sep. 94 -1000 Ci/h Permeation, 98% T2 Product.

india trial ,J27 27

ITER EDA ISS - 2000 sec burn/dwell cycle - Rev. Sep.94 -1000 Ci/hpermeation, 8.45 mol DT/h impurity from plasma.

Operating mode 98% Ï2 Differences from earlier in BOLDOperating mode - 50% T2 not evaluated

parameternumber of stagespressuretemperature

column diameterpacked heightreflux ratiointermediate, reboilercolumn hold-up

intermediate

total hold-up opermode 98% T2

-

total hoktvp opermode 50% Tg

condenserfeed location

draw off

location dimension

top/bo». ! îkPa]topbottomtop/bott.

staqe/WtopbottomreboilerreboilerH2OH2D20D2T20T2T2T2OT2T2dutystaqe

stage

IK)[K][cm][m]

/IW][mol/stage][mol/stage][mol/stage][mol/stage][mole][mole]

[mole]fmolei[mole][mote][q][mole][mole]M[W]

stream 1stream 2streamsstreamsstreamsstream 10stream 13stream 14stream .16stream 19stream 36stream 18stream 23stream 20stream 22stream 30stream 26stream 34streamsstream 7stream 4stream 3stream 6stream 1 1stream 15stream 17stream 31stream 24stream 25stream 22stream 27stream 32

W0137011/20325 .329.8112/11244.426

391391

3126

1.47*105

2.53*1 02

2£3

13.38

3003652330 .

1370

WD225011/17320.9329.850/502630

7878

625

2.0*104

0.36

0.000487

0.0029

250

180250

CD1120140715021.5525.012.8/4.463.8580/6002.820.38/800.9/120

171

120

2.30513.8

800

451111008111070

175120

C0280125/13024.3824.747/3.4325950/2600.90.222.7/500.6/80

0.013

42.13

12£873.7

400

30423533

13880

CD380100/10323.6725.054.75/3.75222

0.350.22

0.22

2.6*1 rr9

7.5

15.593

120

304555

14280

2000 sec burn cycleITER" EDA Water detritiation system- Pump and Blower sizes

Pump

P-1P-2P-3P-4P-5P-6B-1B-2

Purpose

Waste water -detrit.DW-2toDW-1.2DW-1.2toDW-1.1DW-1.1 toEV-3VPCE-1 feedDetrit. Coolant returnFrom CD to VPCE see ISSFrom VPCE to CD see ISS

water ft.[kg/h]

20540

194420553.33

77

gas flow[mol/h]

552552

inletJkPaJaJl̂

203030

P-4 disch300140140

outlet[kPa(a)]

320+pd320+pd

40+cw+pd250+pd

TBD140+pd140+pd

2000 sec burn cycle

ITER- EDA Water detritiatiom system- Heat exchanger sizes

Exch-angerCON-1CON-2CON-3CON-4EV-1EV-2EV-3VE-1SH-1GS-1VE-2SH-2GS-2CON-5

Purpose

Waste w. feed overhead cond.Coolant feed overhead cond.DW-2 overhead condenserDW-1.2 overhead condenserWaste feed evaporatorCoolant feed evaporatorDW rebilerVPCE-1 evaporatorVPCE-1 superheaterVPCE-1 condenser-gas sep.VPCE-2 evaporatorVPCE-2 superheaterVPCE-2 condenser-gas sep.Chilled water condeser

CON-6 1 Condenser

Hot side[mol/h]

30000114000

737

737550550

cold side[mol/h]

11114000

114000185737

185737

Duty[kW]

13.253

15002.20.32.

2.20.32.5

temp[KJ

330330

473

473

.•P.

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