Electrical, Cabling, I&C Works Contract Assembly and Installation Industry Information Day Electrical, Cabling, I&C Works Contract by Sergio Orlandi & Federico Fortunato 21 May 2015 Disclaimer: The views and opinions expressed herein do not necessarily reflect those of the ITER Organization

Construction Manager-as-Agent Contract Map ITER Organization Construction Manager-as-Agent Domestic Agency Works Contractors Machine Assembly Works Mechanical & Piping Works Specialized Works Super Conducting Joints Special Techniques Lifting & Handling Tokamak Works Contracts Support Contracts Access, Plant Hire Civils & Finishing Balance of Plant Electrical, I&C Works Scaffolding CMA ASY MCP EIC SPx LFT SCF APH CIV

Electrical, Cabling, I&C Works Contract ITER Organization Construction Manager-as-Agent Domestic Agency Works Contractors Machine Assembly Works Mechanical & Piping Works Specialized Works Super Conducting Joints Special Techniques Lifting & Handling Tokamak Works Contracts Support Contracts Access, Plant Hire Civils & Finishing Balance of Plant Electrical, I&C Works Scaffolding CMA ASY MCP EIC SPx LFT SCF APH CIV

Table of Contents Scope Role and Responsibilities Interfaces with other companies Works Schedule IO Expectations Procurement schedule

Location of main Electrical Distribution components 1. SCOPE Location of main Electrical Distribution components 400 kV switchyard Coil Power Converters Reactive Power Compensators Switching Networks and Fast Discharge Units 66 kV switchyard

1. SCOPE Summary of components to be installed: DC busbar and switching network (RUDA Supply) Tokamak in-vessel coil busbars and switches (KODA Supply) Access Control and Security Equipment (IO Supply) Distribution and Control Boards (DA’s Supply) Power and Control Cables (IO or Construction Contractor) Cable Tray and Conduit (Construction Contractor) Process Instrumentation and Connections (DA’s Supply) Quantity and technical characteristics of all the equipment to be installed will be described in the technical specification for tendering process.

Summary of components to be procured: 1. SCOPE Summary of components to be procured: Supply of Power Cables (as an Option) Supply of Signal Cables (as an Option) Cable Trays Electrical Conduit Consumables Quantity and technical characteristics of all the equipment to be procured will be described in the technical specification for tendering process.

DC busbar and switching network Water cooled busbars: Capable to carry up to 70 kA dc; Max. cross-section: 425*690 mm. 1.5 m

DC Busbar General Layout Building 11, B2 Building 74, B2 Building 74, L3 Building 74, vertical busbars Bridge 2 Building 33 Building 32 Bridge 1 Building 11, L3

Tokamak machine, busbars and switches layout TF FDU switch (9 units, SIC) CS/PF SN and FDU switch DC Busbars 120 switches up to 70 kA rating Total length of busbars: 10 km Max. cross-section: 425*690 mm 90 m

Tokamak building: layout integration and installation

DC busbar and switching network Switches capable to carry and break or make, up to 70 kA dc. Explosively actuated circuit breaker Discharge Resistor Counter-pulse circuit Bypass Switch and Vacuum Circuit Breaker

(cables not available on the market) Power cables for discharge resistors. FDU Power cables (400mm2, F 63mm) will connect the FDU circuit breakers located in the Tokamak building (#11) and Diagnostic building (#74) with the discharge resistors (FDR) located in the FD&SN Resistors building (#75). Special, very large, coaxial cables, specifically manufactured for the project : In case of damage of cable during cable pulling there will be a considerable delay in the activity (cables not available on the market) 13

FD and Switching Network Resistor Building Discharge Resistor each Module weight 4.5 Ton

In-Vessel Coil (IVC) Power Supply (PS) Busbar The main Installation Issue is the management of the interface with the other contractors. These Busbar will be installed in a very crowded area. Total Length of the The IVC Busbar is 1200 meter

Tokamak Building Level L2 An example of very crowded area. In-Vessel Coil (IVC) Power Supply (PS) Busbar Tokamak Building Level L2 An example of very crowded area.

Access Control and Security Equipment CCTV Cameras (Internal and External including Infra-red) Access Control devices Telephones (Mobile & Fixed) Emergency Devices Sounders / Semaphores Public Address speakers Motion detectors Site wide system with ~200 controlled doors and associated devices

Quantity of Distribution and Control Board is ~ 4 000 Special Skill for re-engineering and re-works inside distribution and control board to manage possible field change Quantity of Distribution and Control Board is ~ 4 000

Example of Distribution and Control Board Layout

Power Cables LV and MV Quantity and technical characteristics of all the Power Cables to be procured (as an Option) will be described in the technical specification for tendering process. All the cable to be installed are Industry Standard cable The most used type of cables are: Single Conductor Overall Shield or Unshielded, Typical Sections from 120mm2 up to 400mm2 Multiwire Overall Shield or Multiwire Unshielded, Typical Sections from 1.5mm2 up to 120mm2 Will be IO-CT responsibility provide to contractors: Production of Cable procurement Specification Cable BOM Cable Routing Cards (for cable pulling activities) Cable Termination Cards

Control and Instrumentation Cables Ethernet, FiledBUS, Thermocouple, Coaxial and Fibre Optic cables All the cable to be installed are Industry Standard cable Quantity and technical characteristics of all the Control Cables to be procured (as an Option) will be described in the technical specification for tendering process. All the cable to be installed are Industry Standard cable The most used type of cables are: Individually Shielded Twisted Pairs / Overall Shield Thermocouple Compensating Cable Ethernet Cable / Fieldbus cable Fiber Optic Single Mode / Multimode Will be IO-CT responsibility provide to contractors: Production of Cable procurement Specification Cable BOM Cable Routing Cards (for cable pulling activities) Cable Termination Cards

Quantity of Power and Control Cables to be Installed ITER Cables Number of cables Power Cables 22000 Instrumentation and control Cables 83000 Fiber Optic Cable 15000 Average length of cable 100 m Estimated cable length 12 000 km Estimated cable tray length 40 km Procurement of cables as Option with quantities to be fixed

Cable routing inside the Tokamak building The Integrated Installation Sequences will be defined by IO/CMA

Cable routing outside the Tokamak building The Integrated Installation Sequences will be defined by IO/CMA

Functionality for PIC Cables After the cable pulling, all the Cable Tray with PIC (Protection Important Components) cables shall be added with FIRE-Wrapping Add fire-wrapping to all cable trays, in critical rooms The overall quantity of cable trays with fire-wrapping is around 10 km The fire-wrapping material will be specified in the technical specification for tendering process. Detailed Definition of PIC Equipment will be specified in the technical specification for tendering process

~72000 Digital and ~32000 Analog Signal Connection of Process Instrument Instrument Panel/Rack Flow Instruments/Switch Pressure Instruments/Switch Temperature Instrument/Switch Level Instruments/Switch Others Instruments ON/OFF Valves Control Valve ~72000 Digital and ~32000 Analog Signal Will be IO-CT responsibility provide to contractors: Instrument BOM Installation Specification Typical Installation Drawing For each kind of Instrument to be installed

2. Role and Responsibilities The Contractor shall be responsible for the following activities: Provide temporary systems (Utilities and Facilities) Install new Systems & Components Install I&C Components Pull cables Perform cable connection including head preparation and tagging Procure necessary consumables Perform own QC, final installation tests and verification Issue as-built documentation

Contract Functional Interfaces Management Support Co-activity ITER Organization Construction Manager-as-Agent Machine Assembly Works Mechanical & Piping Works Electrical, I&C Works Specialized Works Super Conducting Joints Cryogenics Special Techniques Lifting & Handling Domestic Agency Works Contractors Scaffolding Access, Plant Hire Civils & Finishing Tokamak Balance of Plant Works Contracts Support Contracts

3. Interfaces with other companies All works managed by IO and CMA Main Domestic Agency Installation Contracts: PPEN HV, SSEN HV substations and Main AC Distribution Building (EUDA) May 2016 – March 2020 Building Emergency Power Supply Buildings (EUDA) May 2016 – October 2019 Magnet Power Converter (CNDA and KODA) December 2016 – September 2020 Reactive Power Compensators Area (CNDA) April 2017 – October 2019 Mechanical & Piping Contract For scope see related presentation and next slide. Supplied Services, Facilities and Utilities See presentation on site organization

Process Instrument connection Scope of electrical works for instrument will be to the nipple on the root valves located on the process line installed by the mechanical contractor.

5. Contractor Furnished Equipment and Material Option for procurement of cables The contract will include an option to supply part of the cabling to be installed as part of a centralized procurement strategy. This will include: Low voltage power Instrumentation and control cables Network cables (including fiber optic) Terminations for above 400/230 V Power Socket panel Lights Lighting Panels Terminals and Connections Cable/Wiring Core Ferruling Labels Flexible Conduit Cable Glands Anti-corrosive paste for busbars/converters connection interface Cable Tray/Conduit/Trunking (limited) Earthing and Bonding

Towards Zero Accidents IO Requirements Safety Requirements ITER is submitted to Nuclear Licensing process. For Protection Important Components, the French Nuclear Regulation must be observed. Contractors and Subcontractors must comply with : Order 7th February 2012 for protection important components (PIC) and protection important activities (PIA). Compliance must be demonstrated in the chain of subcontractors. All activities are subject to supervision by the Nuclear Operator. Quality Assurance (QA) Contractors shall have an ITER approved QA Program or ISO 9001 accredited quality system. Towards Zero Accidents

Time Distribution of Works by Contract

Assembly and Installation Industry Information Day Please send all questions to: assemblyinfoday@iter.org Replies to all questions received within 2 weeks shall be published on the ITER web site and notified to all attendees Thank you for your attention