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ForewordThis brochure introduces the ITER project(International Thermonuclear ExperimentalReactor) from the point of viewof the industrial partners interested to take partin its construction.ITER will be one of the most challenging scientificand engineering enterprises of the 21st century.For the engineering companies and manufacturingindustries that will take part in ITERconstruction, it will be not only an opportunityto develop and establish, at industrial level, cutting-edgenew technologies relevant for the futurereactor and beyond, but, more importantly, an occasionto grow within an international endeavourwhich will set a new standard for the technicalmanagement of complex engineering projects.The extensive design work, the detailed costand schedule evaluation and the massive R&Deffort, give confidence that the project starts ona sound financial and technical basis, assuringto companies a stable environment for a rewardingparticipation.On the other hand, participation in ITER willimply, especially for those companies that want toplay a major role, a proactive attitude to contributeto this success investing in human resources,technical tools and management approaches.Dr. A. Airaghi Chairman Committee Fusion-Industry3

The ITER ProjectThe ITER programme began in 1985 as acollaboration between the former SovietUnion, the United States, the EuropeanUnion and Japan under the auspices of the InternationalAtomic Energy Agency (IAEA) withthe objective to “demonstrate the scientific andtechnological feasibility of fusion energy for peacefulpurposes”.• The European Union (formally the EuropeanAtomic Energy Community)• Japan,• The People’s Republic of China,• The Republic of Korea,• The Russian Federation (replacing theSoviet Union in 1992),• The United States of America (opting outthe project between 1998 and 2003).Figure 1 -R&D projects insupport of ITERfeasibilityConceptual and engineering design phases led, in2001, to a commonly agreed detailed design of afusion device capable of generating 500 MW offusion power for about 50 minutes, developed ata cost of about 300 million euros of engineeringdesign effort, much of which came from industry.This was underpinned by 600 million eurosworth of research and development by the ITERparties to establish its practical feasibility primarilythrough the construction of full-scale prototypesof key components (Figure 1).The current parties, that have joined the negotiationson the future construction, operation andeventual decommissioning of ITER, are:Canada participated actively in the project, butwithdrew its participation at the end 2003. Othercountries have expressed interest in joining theproject, for example, India.The project is expected to cost around 10 billioneuros over its complete lifetime of 35 years.While the final negotiations among the partiesare still on-going, a major milestone was reachedon June 28 th , 2005, when in Moscow the Partiesagreed to select the EU proposed site of Cadarache,in Provence (south of France) as the sitewhere the reactor will be built (figure 2).4

Figure 2 -Cadarache, the ITERconstruction siteThe Tokamak ConceptITER is based on the tokamak concept. A tokamakis a device able to produce and confinea large volume of high temperature plasma -amixture of electrons and ions- in a toroidal shapeby means of strong magnetic fields. Under theseconditions, a mixture of ions of deuterium (anisotope of hydrogen largely available in nature)and tritium (another hydrogen isotope that needsto be artificially produced) can collide with sufficientenergy to result in the fusion of their nuclei.The resulting products are helium ions and highenergyneutrons. The basic idea is to slow-downthese neutrons recovering their energy to heat-upa thermodynamic vector fluid (water or a gas) thatcan then be used according to close-to-conventionaltechnologies for electrical power generation(heat exchangers, turbines, etc..).The original principle of the tokamak was developedat the Kurchatov Institute in Moscow in the1960s and, due to its ability to maintain the temperaturein a confined plasma, the tokamak hasbecome the most advanced magnetically confinedfusion concept in the world.Fusion plasmas are extremely hot – above 100million degrees – and it is necessary to keep theplasma particles away from the walls of the confinementdevice as much as possible. This is achievedwith a combination of magnetic fields, generatedthrough external coils, and by the currentthat flows in the plasma itself.This “magnetic cage” (Figure 3) creates helicalfield lines inside the machine around which thecharged particles of the plasma gyrate and arekept confined.The plasma current is primarily driven by the voltageinduced by the rapid ramp of current in a transformercoil. Thus, in its basic form, a tokamak works ina pulsed mode. In order to achieve steady state operation,in a future power plant based on the tokamakprinciple, at least part of the current has to be drivencontinuously by means of high-frequency waves orthe injection of fast particles. A thermo-magneticeffect, naturallyoccurring underopportuneplasma parameters- the so-called„bootstrap“current – canthen provide theremaining part ofthe current.Figure 3 -Schematic of thetokamak magneticfields and plasmaconfinement.5

The ITER PlantThe overall ITER plant comprises the tokamak,its auxiliaries and supporting plantfacilities. ITER (Figure 4) has a vertically‘D’ shaped plasma and a lower divertor. The divertoris the main area of contact of the plasmaand is one of the most critical components inthe machine as it controls the amount of impuritiesin the plasma and has to withstand highFigure 4 - ITER Tokamak Assembly - Main Components and ParametersITER Main Design ParametersTotal fusion power500 MWEnergy multiplicationfactor (Q)* ≥ 10Plasma major radius6.2 mPlasma minor radius2.0 mPlasma current15 MAPlasma volume 850 m 3On-axis toroidal field5.3 T* Ratio between the generated fusion power and the power injectedinto the plasmasurface heat loads of up to 10 MW/m 2 . The volumeof the plasma (850 m 3 ) and the thermal insulatingor confinement properties give an energymultiplication factor Q ~10, the factor by whichthe fusion power exceeds the input heating power(50MW) to the plasma (for a future reactor thisfactor will be typically 30 to 40). External heatingcan also be used to drive the plasma current, extendingthe nominal inductive burn of 5 minutesup to about 50 minutes or longer. Plasma controlis provided by the poloidal field coils, pumpingand fuelling and heating systems interlocked withfeedback from diagnostic sensors.ITER uses low-temperature superconducting magnetsfor both the toroidal and the poloidal coils.These coils, which can generate a magnetic fieldof 5.3 Tesla on plasma axis, hold the plasma insidethe vacuum chamber and limit contact with thechamber walls. Access for the heating systems,diagnostics and equipment to be used during theremote maintenance of the machine are provided6

ITER Construction Schedule and CostsAsimplified construction schedule is shownin Figure 6. The ITER Organizationshould be established in 2006. Two yearslater, in 2008, the grant of the Construction Licenseis expected. The actual construction of safetyrelevant parts of the plant cannot start beforethis date. After seven-years construction (expec-ted completion within 2015) and one-year integratedcommissioning, the first plasma operationis expected within 2016). It must be noted thatlong-lead items have to be sent out for tender andprocurement started before the license is granted.The installation of some auxiliary componentssystems extends to 2020.Figure 6 - ITER Construction Schedule(TFC = Toroidal Field Coils, CS= Central Solenoid, PFC= Poloidal Field Coils, VV= Vacuum Vessel)8

The total estimated constructioncosts amount to about3800 M€ (at year2000 currency value).Operation,maintenance, deactivation,decommissioning,spares not includedin this estimate.This cost estimate wasdeveloped in 2000 withinput from all ITER Parties.For the purpose of costestimation the overall ITERPlant procurement was subdividedinto a total of 85 ‘ProcurementPackages’.Each procurement package is describedby a draft specification and definesa set of components, a system or a subsystem,which shall be provided within its scope ofsupply. A list of the procurement packages is givenin the Annex 1. In Figure 7, the sharing of ITERvalue among large areas of procurement is shown.As recognised also in independent reviews of theITER project, the ITER budget cost and scheduleestimate for construction is based on a levelof technical detail and of supporting R&D thathas rarely been achieved by a project prior to itsrelease for construction. This gives a substantialconfidence that the construction can be completedon time and within budget.The procurement packages also form the basis forthe sharing of the contribution of the Parties toITER Construction.To facilitate the negotiation the procurementshave been subdivided in two large classes,• Non-common: to be provided by the HostParty (EU) and corresponding to the procurementsthat are strongly associated with thesite (mainly building and large componentsto be manufactured on-site);• Common: components and systems thatcan be provided by any of the ITER Partiesand shipped to the site for assembly.Figure 7 -Percentage Valueof ProcurementAreas9

ITER ProcurementThe ITER Parties have reached a preliminaryconsensus on the overall managementsystem of the ITER Project duringthe construction phase (in Figure 8 a simplifiedrepresentation of the management structure).According to this scheme the ITER Organisationis subdivided in a Central Team, located on theconstruction site, and a number of Field Teamsthat take care of the technical interface for theprocurements placed in each of the Parties andare located in the Parties territories. Each of theParties will establish a Domestic Agency actingas the project interface for industrial contracts inthe Party’s territory.A broad, though not final, consensus has beenreached among the parties on the subdivision ofthe procurement packages for contributions ‘inkind’.The total share of in-kind procurement is 90%of ITER Construction Cost. The EU as the hostparty will contribute about 50% of such procurements.It is the duty of the Parties to comply with theirobligation to provide the in-kind share of ITERthat they agreed to supply. For this purpose, eachof the Parties shall create a so-called DomesticAgency whose primary duty will be the tenderingand contract placement for the procurement ofcomponents and systems for ITER,on the basis of the specifications.For this purpose the EU Commissionis defining the organisation and regulationsof an ad-hoc organisation,under the provisional name of EuropeanLegal Entity (ELE), which willhandle all the contracts forming theEU in-kind contribution to ITER.This organisation shall have its seatin Barcelona (Spain).Given the large and competitivemarket existing in the EU, both inconventional and high-tech supplies,it is expected that the large majorityof the contracts related to EU ‘inkindcontribution’ will actually beassigned to EU companies.Figure 8 -Management of the ITER Projectduring the construction phaseDuring the negotiations the Parties have reachedmoreover a consensus on the subdivision of theParties contributions to ITER in two classes:• ‘In-kind’ contributions and• ‘In-cash’ contributions.The ‘in-kind’ contributions are those systemsand components that each of the ITER Party iscommitted to procure and deliver to ITER.The ‘in-cash’ procurements are those procurementsthat for various reasons, mainly related tosimplicity of interfaces and integration of the machine,are directly managed, both from a technicaland administrative/financial point of view, by theITER Team. In general these components and systemsshall be procured according to the ITER FinancialRegulations through tenders open to qualifiedsuppliers selected via worldwide competition.10

Under any arrangement for the procurement ofcomponents and services, the ITER Organisationand its Director General, as the prime responsiblefor the implementation and success of the ITERproject, shall retain the full technical control andresponsibility. In particular, the ITER DirectorGeneral and its deputies shall exert a strong controland monitoring on all aspects related to thecontracts for the supply of components or serviceswhich have an impact on safety.The EU contribution, as Host Party, covers quitenaturally a large scope of supply including:The subdivision of the procurements among Partiesis being negotiated taking into account theinterest of each Party to promote industrial developmentand technology in fusion relevant areas.This has been done having care to preserve theoverall integrity of the project. Nevertheless, inorder to promote the consolidation of the procurementactivities in some areas (primarily magnetsand vacuum vessel) the possibility to resortto international consortia/joint ventures is considered.• All the procurements that are for reasonsrelated to obvious manufacturing convenienceand logistics reserved exclusively to theHost Party (non-common part);• Part of the procurements open to the contributionof all Parties (common-part).Contracts for ITER Procurement in the EUThe actual procurement policy will be definedin agreement between the ITER Organisationand the EU Domestic Agency(the ELE).The Committee on Fusion-Industry has beenactively analysing with the technical support ofEFDA 1 , the most efficient way to facilitate theprocess of tendering for contracts related to theprocurement of EU in-kind contribution and hassubmitted to the CCE-FU 2 the document ‘Recommendationsfor consideration in the ELE ProcurementProcedures - Report from the Committee onFusion Industry (CFI)’.Given the wish to keep the ITER and ELE Organisationas ‘lean’ as possible, it is anticipated thatthe EU share of the ITER procurement will besubdivided in a limited number of relatively large,self-consistent contracts still complying withthe schedule constraints and with technical andfinancial limits.In addition to the contracts that are necessary toimplement the ‘in-kind’ contributions, it is anticipatedthat the EU will contribute, through theELE, to the engineering support to the ITER Organisationduring construction.The present analyses show that the full scope ofEU contribution, over the full duration of theITER construction, will be covered by about 220contracts, of which, about 130 contracts for fabrication/supplyand 90 service contracts for engineeringsupport (the number of service contractscan be reduced, if so decided, by ‘grouping’ similarservices).The value of the fabrication/supply contracts rangesbetween a minimum of 2 M€ and a maximumof 60 M€ (12 M€ in average). The value of servicecontracts is about 2 M€ in average.1 European Fusion Development Agreement2 Consultative Committee for the EURATOM Specific Research and Training Programme in the Field of Nuclear Energy (Fusion)11

EU Industrial Involvement in ITER ProcurementThe analyses of the perspective sharing ofITER construction and a rational subdivisionof contracts indicates that ITERprocurement in the EU, will be, in general, anopportunity for a large spectrum of companiesranging from main contractors to qualified companiesof small-medium size.Beyond the direct contribution to fabrication andsupply, the analyses performed by the IndustrialMembers of the CFI have identified an importantrole for engineering companies as ‘engineeringsupport’ to ITER.From experience and analyses of the ITER schedule,it is expected that the spectrum of industrialcontractors involved in ITER construction willevolve in time.Figure 10 -TF Magnets AssemblyFigure 9 - Toroidal Field Model CoilNb 3 Sn ConductorIn a first phase (extending from 2006 to 2010) anumber of procurements for long-lead items onthe critical path, shall be released. The first contractsto be released are for the fabrication of thesuperconducting cables (Figure 9) and magnets(Figure 10, 11), for the vacuum vessel (Figure12) and the detailed design and construction oftime-critical buildings. These contracts are to betendered among companies that have the financialand personnel capabilities, and the largescope of technical competenciesto face this challenge. Thanksto the extensive R&Dperformed during thedesign phase, technologiesare well establishedand a suitablenumber of companiesable to supply, individuallyand or in jointventuresare available,and a healthy level ofcompetition is expected.It is not expected that asubstantial share of thesefirst group of fabricationcontracts will be directly12

awarded to SMEs. Nevertheless, also in this caseit can be anticipated that there will be a substantialinvolvement of SMEs as sub-suppliersFor this purpose the CCE-FU has endorsed theCFI proposal for the establishment ofan Industrial Suppliers Database,the goals of which are to allow toSMEs and main contractors tocome into contact and for SMEsto come into contact with eachother and, when practical toform joint-ventures to reach thecritical size, from a financial andtechnical point of view, so as tobe able to tender also for large procurements.As soon as the on-site constructionhas started a second phase will be initiated(extending from 2010 to 2015), in which anumber of medium size contracts will be placedfor which the participation of SMEs, either aloneor in joint-ventures will be possible and desirable.The third phase will commence as soon as the facilitiesbecome operational and the componentswill be assembled on site (starting from 2010 andextending for the full durationof theproject).At this point a large number of opportunities willarise, not only for SMEs but also for small firms,in the areas of specialized services (both high-techand conventional), maintenance and repair. It isat this point that the Industrial Suppliers Database,which will be maintained throughout theconstruction’, shall become the primary source ofinformation to identify the large variety of contractorsneeded to support the installation, commissioningand the operation and maintenance ofa complex plant like ITER.Figure 12 -Vacuum Vessel andPorts AssemblyFigure 11 - TFMC being inserted inTOSKA Facility (FZK laboratory)13

Engineering ServicesThe CFI analyses have highlighted theimportance of an early definition of engineeringservices procurement packages,which are of similar importance to the hardwarepackages.For the ITER engineering design, EFDA has beenactually utilising the services of a number of qualifiedindustries in the nuclear field grouped underthe EVIW-EFET consortium for several years.The new phase of fusion research and theconstruction of ITER require a wider spectrumof competences to proceed to the final detailingof the design prior to call-for-tender. For thispurpose the EU Commission with the technicalsupport of EFDA has just completed the tenderprocess for a set of new contracts for engineeringsupport.These contracts, which are planned to be signedby the end of 2005 are intended to cover primarilythe needs of EFDA, but they are conceived insuch a way that they can be utilised in an interimphaseof ITER Project implementation.The Industrial Suppliers DatabaseOne of the indications contained in therecommendations of the CFI to theCCE-FU has been the opportunity tocreate a relational database of potential suppliers.As outlined above, the number of contracts requiredto cover the EU contribution is expected tobe about 220 over a period of more than ten years.This number of contracts would not justify specialprovisions for companies’ selection. The list of qualifiedcompanies to be called to tender can be easilyformed combining the proposals of the ITER/ELEtechnical responsible persons, with further proposalsfrom Member States representatives in the EuropeanLegal Entity Council. A similar method wassuccessfully used in the EU fusion programme, e.g.for the JET 3 Joint Undertaking.Nevertheless the CFI, based on a detailed reviewof the experience of CERN and ESA, considersthe establishment of an Industrial Suppliers Databasewould be advisable for the following reasons:• To allow smaller companies to make themselves known as potential sub-suppliers forITER;• To facilitate the ‘main contractors’ identifyingqualified (specialty) companies (inparticular those which have already workedor are working for ITER related supplies);• To facilitate the grouping of smaller companieswith the purpose to create consortiafor specific tenders;• To have a source (not exclusive) of companiesto be invited to tender for the supplyofo Spare partso Maintenance and repairo Industrial Services;• To allow fusion research laboratories toutilise the database to identify supplier forthe parts (Additional Heating and Diagnostics)of ITER supply in which theymay be responsible.14

In order to evaluate the technical difficulties andthe practical implementation of such a database,EFDA has developed, with the support of CERN,a preliminary version of the database soon accessiblethrough the EFDA web page of EFDA(www.efda.org), where an online help providesguidance for the registration of interested firms.The web-based database gives access to a range oftechnical background documentation, includingdetails of the ITER procurement packages and alist of “Activity Codes” detailing the technologyareas contained in each package.This database is therefore a tool to facilitate theidentification of sub-suppliers and partners and willnot be used, for the moment, as a tool to produceshort lists for tender. Until the ELE managementhas endorsed the use of this database for its ownpurposes, this tool shall be used as a mailing list forcompanies that want to be kept up-to-date on thedevelopment of ITER procurement in the EU.3 JET, Joint European Torus, the largest and most successfu tokamakfusion device to date built with the common funding of theEU members states in the frame of EURATOM TreatyQuality AssuranceFor companies that wish to be involved inITER procurement, Quality Assuranceand Quality Management will be keywords.ITER is a quantum leap from experimentaldevices in plasma physics to the real issues ofa reactor plant with specific safety, capital investmentprotection, and reliability /availability requirements.The required quality standards will be set by theITER organisation as specific part of the ‘in kind’procurement packages specifications. The reviewof the matter performed at negotiation level hasidentified the ISO 9001:2000 as an adequategeneral standard for the procurement of ITERcomponents.It is important to note that for those systems andcomponents having a safety classification (SICSafety-Importance Classified, according to ITERdefinition) the rules established for the ‘InstallationNucléaire de Base’ (INB) in France shall apply.A review of the available standards has indicatedthat Quality Assurance Programme described inthe IAEA Safety Series (including the code onquality assurance, 50-C-Q, and the related SafetyGuides, 50-SG-Q1 to Q14) satisfies such requirements.On the other hand, it is not expected that the useof such rules will result in a restriction of competitionor in a substantial overhead on procurementcost and schedule. In reality ISO 9001:2000forms a good basis and a number of well-definedintegrations allow bringing an ISO 9001:2000certified organisation to compliance with IAEAstandards. For those interested, the matter is dealtin detail in the IAEA publication ‘Safety ReportsSeries No.22 Quality Standards: Comparison betweenIAEA50-C/SG-Q and ISO9001:2000’.15

Standards and CodesNo significant problems are envisaged as faras codes and standards are concerned forthe construction of ITER at Cadarache.The important aspect of the structural codes forthe reactor safety boundary, that is the ITER vacuumvessel and its ancillaries, has been analysedin detail reaching the conclusion that it would beopportune to utilise the RCC-MR, 2002 version(Règles de Conception et Construction – MécaniqueRapide) with a number of minor integrationsand deviations required by the specificity ofITER vessel structure and design criteria. Thisstandard does not require a specific certification(like the ‘N stamp’ foreseen by ASME) and leavesopen the competition to all companies that havean organisation and QA suitable for the constructionof large pressure vessel for nuclear or relevantchemical applications. The standards recalled inthe RCC-MR have been systematically updated,moving from French AFNOR to equivalent ENstandards.Working in an Integrated Design EnvironmentThe design of ITER has been possible thanksonly to the use, throughout its development,from conceptual to detailed engineering,of an advanced CAD tool, CATIA TMdeveloped by Dassault Systems in collaborationwith IBM. CATIA Version 4 has beenused to prepare the design of theoverall load assembly of the machineand the design ofthe buildings andservices (Figure13). Recentlythe ITER Team has started an upgrade toCATIA Version 5 and the introduction of a datamanagement system for CAD models (the VPMVirtual Product Management) which allows toguarantee the integration of the overalldesign, a clear management of interfaces(e.g. by the use of theDMU Digital Mock-Up,a tool that allows theverification ofphysicalFigure 13 -Tokamak Building-Plants and servicesat divertor level16

Figure 14 -Digital Mock of ITER(inside the Cryostat)space allocation and clash detection, Figure 14),the possibility to have ‘concurrent engineering’and ‘design in context’, the integration of standardcomponent libraries, advanced tools forplants space allocation and pipe/electrical wiringrooting. Even more important, the VPMallows a web-based access to the database fromengineering units external to ITER, both forexport and import of CAD models. Modules,which allow the simulation of assembly and remoteand manual maintenance operations, arealso available.For those companies who wish to take part inITER procurement it would be ideal to share thesame CAD and VPM system. Of course this requirementis stronger for those companies thatwill have design responsibility within their contractsand a strong integration with the plant.For suppliers working on a ‘build-to-print basis’this requirement is less stringent and the softwaretools available for 3-D model conversion allowan adequate level of bi-directional exchange ofthe models with all the most popular CAD systemson the market.17

Collaborating with EURATOM Associations on Diagnosticsand Additional Heating Systems ProcurementsTwo specific areas of the in-kind procurementfor ITER have a special ‘status’ and they arenamely the Additional Heating Systems(Ion Cyclotron, Electron Cyclotron and NeutralBeams) and the large set of diagnostics to monitorand measure plasma performance and other physicsand engineering parameters of the machine.or diagnostic systems, in a fashion that can becompared to the scientific payload of a satellite.A number of EU fusion laboratories (co-ordinatedby the EU Commission, in the frame ofEURATOM, through the so called AssociationContracts, and so frequently referred to as theFigure 15 -Main PortDiagostics SystemsThe design of systems and components in thisarea is based on specific expertise and specialisedR&D, which, in general, only highly qualifiedlaboratories with a strong background in plasmaphysics can provide.The peculiar feature of almost all diagnostics andall the additional heating systems is to be hostedin well-defined ad-hoc structures, the ‘port plugs’which are introduced in a number of dedicatedports in the vacuum vessel and provide the properinterface in terms of access to the areas of plasmato be measured, protection from plasma radiationand neutrons shielding (Figure 15).Each of the port plugs carries a number of highlyspecialised components of the additional heatingEURATOM Associations) will take the responsibilityof specific diagnostics and will act as ‘maincontractors’ with respect to the ELE and ITEROrganisation. On the other hand laboratories willneed to resort to engineering and manufacturingcompanies for all parts that are beyond the coreknowledge of the diagnostics itself, and also forthe production of parts of diagnostics, movingfrom laboratory development to industrial levelcomponents and spare parts.Here there will be a large amount of opportunitiesopen for SMEs with an agile structure, ableto integrate themselves with laboratories sharingdevelopment and manufacturing. In this area theIndustrial Suppliers Database will facilitate thelink between laboratories and industry.18

Annex 1 - List of ITER Procurement Packages / I19

20Annex 1 - List of ITER Procurement Packages / II

Annex 1 - List of ITER Procurement Packages / III21

22Annex 1 - List of ITER Procurement Packages / IV

EFDA Close Support Unit - GarchingBoltzmannstr. 2D-85748 Garching / Munich - Germany© Prof. M.Q. Tran (EFDA Leader) 2005This report, supported by the European Communities,was carried out within the framework of theEuropean Fusion Development Agreement.The views and opinions expressed herein do notnecessarily reflect those of the European Commission.phone: +49-89-3299-4201fax: +49-89-3299-4197e-mail: minhquang.tran@efda.orghttp://www.efda.orgEditor: Dr Enrico Di PietroGrafic design: Karen JensPrint: Druckerei Steinmeier, Nördlingen, Germany23