PF Coils Manufacturing and Cold test contract (MFR) Face to face meetings July 2014 Kevin SMITH Pierre GAVOUYERE LASSERRE

Transcription

1 PF Coils Manufacturing and Cold test contract (MFR) Face to face meetings July 2014 Kevin SMITH Pierre GAVOUYERE LASSERRE 1

2 Summary of the presentation PF Coils Project PF Coils Schedule PF Coil Manufacturing Process (general presentation) MFR Scope of Supply (WBS) Contractual Arrangements Definition of the contract type main features Contractual liability and Interface Agreement Main inputs provided by F4E Main outputs expected from the candidate (offer) 2

3 PF Coils Project PF6 Manufacture : done by ASIPP PF2 to 5 Manufacture : 6 main contracts 1. Engineering Integrator (ASG) 2. Winding Tooling (SEA ALP) Russian Domestic Agency 3. Impregnation/Additional Tooling 4. Site & Infrastructure 5. PF Coils Manufacturing & Cold Test ASIPP 6. Cold Test Facility 3

4 PF Coils Schedule Contracts Call for tender Publication Expected Contract signature Duration Procurement procedure Engineering Jan 2013 Aug years Negotiated Integrator Winding Tools Jul 2013 Apr years Negotiated Contract signed Site & Infrastructure Impregnation and Additional Tools Manufacturer (MFR) May 2014 Oct years Open Market Survey Completed June 2014 Dec years Open Market Survey Completed Jul 2014 Apr years Negotiated Market Survey Completed Cold Test facility Sep 2014 Apr years Restricted PF6 ASIPP Oct years Co operation Agreement 4

5 PF Coils Manufacturing Process Superconductor (supplied by IO) Winding & Insulation Double Pancake (DP) Preparation (insulation, joint box & termination) Double pancake (DP) Impregnation Cold Test Final Coil Assembly Winding pack (WP) Impregnation DP Stacking & Winding Pack (WP) Ground Insulation 5

6 PF Coils Manufacturing Process Workflow goes from left to right : WP Impregnation DP Preparation & Impregnation DP Stacking & WP Insulation Storage area Winding & Insulation Conductor spool Storage Cold Test Clean Areas (ISO Class 9) PF Coil working stations 6

7 MFR Scope of Supply (WBS) Level 1 Level 2 Level 3 Manufacturing & Cold Testing Contract Components Qualification Dummy DP Fabrication PF Coils Manufacturing PF Cold Testing Logistics Management & Administration Staff training Access & EHS Management Procurement for component qualification Component fabrication QC Tests, QC reports, recommendations for modifications Procurement for dummy DP s PF4 & PF5 dummy DP fabrication Winding Pack mock up fabrication QC Tests, QC reports, recommendations for modifications Procurement for PF coils PF coils fabrication QC Tests, QC reports, final acceptance tests at room temperature Procurement for cold testing PF coils Cold testing QC Tests, QC reports, final acceptance tests at 80K Preparation for transportation to Tokamak site Takeover of the PF facility Witness installation and commissioning of special tooling Procurement, installation and commissioning of standard tooling Day by day maintenance of special tooling Storehouse procurement and management Working areas cleaning Handover: dismantling of standard tooling Workshop coordination Cost control / procurement activities Reporting to EI and to F4E / Participation to coordination meetings Administration staff Participation to the EI training courses Participation to the Tooling Contractors training courses Participation to the EHS training courses MFR Training for his staff Access control formalities OHS risk analysis Monitoring of the EHS regulations & standards 7

8 Contractual Arrangements Main aims (Reminder Info Days, Cadarache, April 2014): Appropriate allocation of risks Reasonable final price Alignment of contractor s and F4E s interests Possibility to adjust the resources estimate following the learning curve Definition of the contractual arrangements: Firm Price defined by the MFR contractor for: Tools (based on the Technical specifications provided by EI) Materials (based on the BoM provided by EI) Productive staff (based on EI s estimate) Non productive staff (supervision, workshop coordination, management, administration ) entirely defined by MFR Bonus for the completion of the first 2 coils based on milestone achievement Re assessment of the manpower estimate at the end of (or during) the manufacturing of the 2 nd coil MFR's performance measured during the manufacturing of PF2 is used as a basis to define a Final Price Liquidated damages related to the manufacturing of the last two coils (PF4 and PF3) 8

9 Contractual Arrangements Re assessment of the manpower estimate Main tools: MFR s Reporting (e.g. monthly meetings): Actual progress vs. Manufacturing Schedule Actual resources vs. EI s estimates Non productive time Ways to adjust/improve performance (workshop coordination, reorganization, trainings ) Lower threshold: Re assessment to be considered if the productive working hours exceed x% (e.g. 10%) of the ASG's estimate. An estimation of a "normal" non productive time (machine setting, waiting time during conductor handling, machine downtime ) will have to be agreed during the negotiation phase. Relationships" between the PF coils (coefficients): Estimation of the working hours needed for the last two coils (PF4 and 3) by extrapolating from the working hours needed to manufacture 2 nd coil (PF2). 9

10 Contractual Arrangements Interface Agreement The Interface Agreement regulates cooperation between the contractors during the project execution. EI drives the project and gives instructions to the contractors Project Coordination Committee conducts a regular follow up of the Project Interface obligations: definition of the scope of work and the responsibilities of each contractor Dispute resolution procedure: 1.EI 2.F4E 3.Mediator 4.Competent court CEAR Insurance: Cover: material damages (e.g. coils) arising from any causes (unless excluded) Contractor s exposure: 1.deductibles 2.what is not covered For example damage to a coil during impregnation: Insurance? MFR correctly followed procedures? Tools functioned correctly? Procedure provided by EI correct? External cause? 10

11 Main inputs provided by F4E Drawings, BoM, Technical Specifications Control Plans, Manufacturing methods, QC procedures Manufacturing schedule (from components' qualification to the acceptance tests of the last coil) Definition of Worker profiles using International and European standard frameworks: ISCO International Standard Classification of Occupations ESCO European classification of Skills/Competences, Qualifications and Occupations EQF European Qualifications Framework Manpower estimate (productive staff) for each manufacturing phase and each profile of worker (mechanical fitters, electricians, TIG welders, etc ) Manpower estimate = Task duration + Number of workers Example for station A (winding): Winding of 1 DP = 5 weeks Workers = 2.7 Mechanical Fitters + 2 Winders TIG welder 11

12 Main outputs expected from the candidate (offer) Main content of the candidate s Technical Offer: Structure of the MFR s organization: Productive staff (including Logistics) Management and Administration (including EHS management) Strategy and plan to resource the facility during the whole manufacturing process (according to the EI s schedule) Structure of the MFR s supply chain Tools which will be provided by MFR 12

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