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WP7 Plan – Pilot TSS Cost – Risks Linda R. Coney Group Leader – Target Safety and Controls www.europeanspallationsource.se 15 – 16 February 2016.

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Presentation on theme: "WP7 Plan – Pilot TSS Cost – Risks Linda R. Coney Group Leader – Target Safety and Controls www.europeanspallationsource.se 15 – 16 February 2016."— Presentation transcript:

1 WP7 Plan – Pilot TSS Cost – Risks Linda R. Coney Group Leader – Target Safety and Controls www.europeanspallationsource.se 15 – 16 February 2016

2 Outline WP7 Project Plan for TSS – P6 Pilot TSS Cost Estimate Project Risks – Exonaut Conclusions 2

3 WP7 Scope 3 WP7 covers the tasks and activities needed to design, procure, install, test, and commission the Target Safety System (TSS). WP7 leads the Hazard Analysis process for the Target Station to identify events leading to a risk of release of radioactive material – this defines requirements for the TSS & other target systems. WP7 provides support for the development of process controls for target station systems.

4 Plan for TSS Development Accident Analyses Q2 2015 – Q1 2016 Pilot TSS Design – logic, architecture, interfaces Q1 2015 – Q1 2016 – MS: PDR of Pilot TSS February 2016 Test Stand 2015 – Oct 2016 Design of TSS Architecture – Includes documentation, interface finalization, & safety analysis of system – MS: CDR of TSS System Q1 2017 Manufacturing Sept 2017  July 2018 – Supplier chosen Sept 2017 – Factory acceptance test May 2018 – Delivery to site July 2018 Installation July 2018  Oct 2018 Testing Oct 2018  Jan 2019 Integrated testing Jan 2019  Aug 2019  then beam commissioning 4

5 Schedule 5 Concept PhaseFinal Design Make Phase PDRPDR PDRPDR 2014 Q4 2015 Q1 Q2 Q3 Q4 2016 Q1 Q2 Q3 Q4 2017 Q1 Q2 Q3 Q4 2018 Q1 Q2 Q3 Q4 Installation & Testing 2019 Q1 Q2 Q3 PDRPDR PDRPDR PDR PDRPDR PDRPDR Site Inst. & Testing CDR PDRPDR PDRPDR Delivery to ESS PDRPDR PDRPDR PDRPDR PDRPDR PDRPDR PDRPDR Target Safety System

6 Schedule – Milestones First milestone – Pilot-TSS design PDR Current forecast dates for all milestones shown below YTD actuals (Dec 2015): 0.91 M€ SPI: EV/PV = 0.97 (aim > 1; Nov 0.95) CPI: EV/AC = 0.98 (aim >1; Nov 0.98) 6 IDName Current Date A77370PDR – Pilot TSS designFeb 2016 A53380Hazard Analysis for TSS CompletedApr 2016 A53480TSS Logic description completeMay 2016 A53560CDR for TSSFeb 2017 A63480Acceptance of Factory Test for TSSMay 2018 A20156030Delivery to siteJuly 2018 A77850On-site TSS Testing Starts (end of Installation)Oct 2018 A63560On-site tests complete (TSS system tests)Jan 2019 A63580End integrated tests with Target systems and AcceleratorAug 2019

7 Schedule Performance – EVM Graph 7 Accumulated Scheduled Variance (EV-PV) -22,986 € -25,547 € -8,818 € -38,213 € -57,080 € -46,205 € -29,066 € Accumulated Cost Variance: (EV - AV) -35,150 € -26,028 € -11,857 € -28,917 € -25,608 € -13,982 € -17,570 € Last Month's Scheduled Variance (EV-PV) -14,970 € -2,560 € 13,418 € -29,394 € -18,867 € 10,876 € 17,139 € Last Month's Cost Variance: (EV – AV) -9,929 € 9,122 € 14,219 € -17,060 € 3309 € 11,626 € -3,557 € Controls 30/06/201531/07/201531/08/201530/09/201531/10/201530/11/201531/12/2015 Earned 652,092670,929718 417756 563798 438852 232889 043 Actuals 687,242696,957730 274785 480824 046866 214906 583 Scheduled 705,657696,475727 235794 776855 518898 436918 109 June JulySeptAugOctNovDec

8 CPI & SPI Trends 8

9 Major Procurements Safety system cost in P6 Hardware and software for Target Safety System 4.7 M€ Not in-kind contribution Cost estimate 2 train system 1 with PLC, distributed I/O and fiber cables 1 with relay and copper cables 15 shared instruments (9 helium + 6 shaft rotation) Process instruments – based on SNS TPS and discussion with Emerson Control hardware & programming – based on Siemens products. ESS has agreement with Siemens for safety/standard control equipment Racks and Cabinets – based on Rittal Cables – based on web search & internal ESS experience Documentation – based on SNS considering 15 instruments Work – based on SNS proposal & ICS proposal for Pcool control equipment 9

10 Pilot TSS cost estimate EquipmentSiemens refrenceQnt Price per unit Price (€) Instrument in Utility room 1 235000 1Safety Process instrumentation 915000135000 2Motor and shaft monitoring 61500090000 3other material (small parts, wires,connector,..) 110000 10 Train 1 – sensors, utility room equipment Input cabinet in Utility Room_Train 1 1 6757 1Cabinet 450*450*300 mm (W*H*D) 1400 2Simatic F-digital input6ES7136-6BA00-0CA04188752 3SIMATIC PROFINET INTERFACE IM155-6PN6ES7155-6AU00-0CN01255 4BUSADAPTER BA 2XSCRJ6ES7193-6AP00-0AA01256 5SIMATIC ET 200SP, BASEUNIT6ES7193-6BP00-0DA032472 6Mounting rail sectional railwidth 35MM6ES5710-8MA11127 7Simatic HMI 7"6AV2123-2GA03-0AX01600 8Power supply SITOP 24V/10 A6EP3334-8SB00-0AY02156312 9Redundancy module for power supply6EP1961-3BA21183 10 other material (small parts, wires, bolts, circuit breakers,.. 12000 11Work (Mounting,..) 12000

11 Pilot TSS cost estimate 2 11 Main Rack_Train 1 1 15423 1Rack Rital 600/1800/600 11050 2Mounting rail 160 mm6ES7590-1AB60-0AA0118 3CPU 1516F-3 PN/DP6ES7516-3FN00-0AB013760 4Memory Card 24 MB6ES7954-8LF02-0AA01255 5Comunication processor6GK7543-1AX00-0XE01400 6Profinet switch SCALANS X204-26GK5204-2BB10-2AA31845 7Simatic HMI 12"6AV2123-2MA03-0AX011500 8Power supply SITOP 24V/10 A6EP3334-8SB00-0AY02156312 9Redundancy module for power supply6EP1961-3BA21183 10PC 11200 11 other material (small parts, wires, bolts, circuit breakers,.. 12000 12Work (Mounting,..) 14000 Fiber optic-Train 1 1 444000 1fiber optic cable 1500 m to FEB 172000 2Conduit 1500 m to FEB 172000 3Fiber Optic cable 3500 m to control room 1150000 4Conduit 3500 m to control room 1150000 Cabinet in Control room 1 104400 1Cabinet 400*800*300 mm (W*H*D) 1400 2Trapped Key System ??? 1100000 3 other material (small parts, wires, bolts, circuit breakers,.. 12000 4Work (Mounting,..) 12000 Train 1 – rack in room#1, fiber optic cables, MCR cabinet

12 Pilot TSS cost estimate 3 Output cabinet in FEB_Train 1 1 7009 1Cabinet 450*450*300 mm (W*H*D) 1400 2Simatic F-digital output relay type6ES7136-6RA00-0BF0196 3Simatic F-digital output6ES7136-6DB00-0CA01218 4Simatic digital Input6ES7131-6BF00-0CA0196 5BUSADAPTER BA 2XSCRJ6ES7193-6AP00-0AA01256 6SIMATIC ET 200SP, BASEUNIT6ES7193-6BP00-0DA022448 7Base Unit type F06ES7193-6BP20-0BF0118 8SIMATIC PROFINET INTERFACE IM155-6PN6ES7155-6AU00-0CN01255 9Mounting rail sectional railwidth 35MM6ES5710-8MA11127 10Simatic HMI 7"6AV2123-2GA03-0AX011200 11Power supply SITOP 24V/10 A6EP3334-8SB00-0AY02156312 12Redundancy module for power supply6EP1961-3BA21183 13 other material (small parts, wires, bolts, circuit breakers,.. 12000 14Work (Mounting,..) 12000 Cabinet for the contactors in FEB 1 5400 1Cabinet 400*800*300 mm (W*H*D) 1400 2Safety Contactor 25001000 3 other material (small parts, wires, bolts, circuit breakers,.. 12000 4Work (Mounting,..) 12000 12 Train 1 – cabinet in FEB, contactors for ion source

13 Cost Estimate Total Cost €Total Cost Train 1 HW shown817,989 Cabling – 1300013,000 PLC coding and validation – 7000070,000 Spare parts – 4000040,000 Documentation – 8900089,000 Validation/verification/test – 4950049,500 Train 11.08 M€ Train 2 (sensors and contactors already included in cost for Train 1) 0.35 M€ Total1.43 M€ 13 Cost for complete TSS depends on results of AA and new safety functions to be implemented within the TSS

14 Risks and Issues Biggest risk for Pilot TSS – definition of requirements – Finalization system requirements and design depends on completion of accident analysis scenarios – Allocation of safety functions from ESS facility to Target Station to Target systems – SSM requirements applicable to Pilot TSS 14 IDRiskTreatmentStatus 3 Licensing framework for ESS target station is not well defined, or is changed Work with ES&H division to understand SSM documentation and expectations Participate in Safety Advisory Group (SAG) Complete hazards analysis in a timely manner and perform design basis accident analysis Target division engagement in the development of an ESS-wide safety classification methodology Attend SAG meetings Progressing with Accident Analyses Documenting Target hazard analysis process Reviewed and applied ESS safety classification scheme Reviewed proposed content for license 2 SSM application 43 Design and interface information given to CF too late Use the formal documents ICD and ICD-R to communicate the requirements TSS-CF ICD written & reviewed for PDR Regularly meet with CF re. TSS

15 Summary WP7 developing Pilot-TSS design Timely completion of accident analyses critical for establishing TSS requirements and identifying additional target station SSCs – Analyses depend on effort within all Target system groups, in-kind partners, and ES&H – Accident analyses results will impact safety requirements for Target systems including TSS – Results from accident analyses are likely to require new interfaces between TSS and additional target systems Cost estimate will be affected when additional requirements for TSS come out of the accident analyses 15

16 Concluding Remarks This concludes the material we have to present Thank you for your time and participation in the review We welcome your comments and advice to help us complete this effort in the best possible way 16

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