Field Period Assembly

1
Field Period Assembly
Wayne Reiersen SC Project Review PPPL May 2006
2
Preparations for FPA have been going well

• FPA processes have been defined in the MIT/QA
  Plan
• Magnetic alignment of coils into field periods
  has been adopted
• Facility-level planning and safety documentation
  is in place
• Manufacturing Facility Operations Plan updated to
  include FPA activities
• Project Hazard Analysis approved by the PPPL
  Safety Review Committee
• The firs VVSA has arrived
• We are ready for the ACC review of Station 1
• MIT/QA Plan is being signed
• Receipt inspection and assembly procedures
  written
• Turning fixtures fabricated
• Preparations for subsequent stations are on track

3
Field period assembly process
4
Turning fixtures fabricated for Station 1

• Two turning fixtures fabricated to allow parallel
  operations
• Provide easy access for installation of components

A ratchet locking system has been added to
enhance safety
5
Assembly procedure written for Station 1

• Magnetic loops (65-80 flux loops, 4 toroidal
  loops), coolant lines (64), heater tapes, and
  thermocouples will be installed

6
Modular coils assembled into 3-packs in Station
2a

• The coils will be positioned based on inspection
  data using three adjustable spherical seats
• Custom shims will be placed between the flanges
• Coils will be secured with insulated bolts

Adjustable support stand
Type-C assembly being lowered in place
Completed half-period assembly
7
6-pack completed using magnetic alignmentin
Station 2b

• Second support fixture allows assembly of the
  mating half-period using magnetic alignment
• Magnetic alignment involves nulling symmetric
  differences in mutual inductances
• Requires an array of pick-up coils symmetrically
  placed about the symmetry plane
• Reduces the risk of unacceptable field errors
  relative to using physical measurements alone
• 6-pack disassembled into two 3-packs for
  installation over the VV

Fiberglass tube with 20 wire loops on each side
of the parting plane.
Symmetric alignment of Type A coils
8
Modular coils installed over VV in Station 3

• The use of the overhead crane for rotating the
  modular coils over the VV described at previous
  SC review
• After installation with overhead crane, modular
  coils are supported by a rolling ground support
  system
• The interfacing Type-A flanges are then shimmed
  and bolted together into a full field period and
  VV support hardware installed

9
TF coils are assembled into 3-packs in Station 4

• TF coils wedged together in an accurately
  machined fixture
• TF coils retracted slightly in the radial
  direction (1/4 in) to provide clearance during
  the final machine assembly
• Temporary structures are needed for upper and
  lower structure for TF half-period assembly and
  final field period assembly

10
Final field period assembly in Station 5

• Two stations planned for final field period
  assembly provide schedule robustness
• Assembly sequence
• Weld ports on MC/VVSA subassembly
• Rotate TF coil half-period assemblies into
  position
• Install external trim coils
• Install temporary blocking around vacuum vessel
  to inhibit movement during transport
• Completed field periods transported to the NCSX
  Test Cell at C-site for final assembly

Ports welded on
TF coils rotated into position
Completed field period
11
Station 1 is ready for the ACC review

• The MIT/QA Plan is out for signature - it
  provides
• A description of the FPA sequence including a
  process outline
• A description of each station including tooling
  and fixtures
• A listing of specifications (which identify
  applicable drawings and models, define
  requirements, and verifications) for each station
• A listing of procedures and documentation
  requirements for each station
• The procedure for material receipt and
  verification is approved
• The assembly procedure for installing the
  magnetic diagnostics, coolant tubes, heater
  tapes, and thermocouples has been drafted
• Installation of the flux loops has been
  prototyped on the PVVS
• Hoisting and rigging will be performed per PPPLs
  Hoisting and Rigging Program (ENG-021)
• Two turning fixtures have been fabricated
• The first VVSA has arrived

12
Preparations for other stations are on track

• Tooling is being designed for Stations 2 and 3
• Models have been completed for tooling required
  on Stations 2 and 3
• A magnetic alignment system is being designed for
  assembling modular coils into 6-packs
• The design of the coil-to-coil interface hardware
  (a WBS 14 activity) is also planned for this FY
• Detailed design of tooling for Stations 4 and 5
  will begin after design activities on Stations 2
  and 3 are completed

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Next steps

• ACC will review readiness of Station 1 for
  operation and provide a report which addresses
  the charge questions
• Have the facility hazards for the work on Station
  1 been appropriately identified, e.g. in the
  Manufacturing Facility PHA?
• Have appropriate safety controls, e.g. those
  identified in the identified in the Manufacturing
  Facility Operations Plan, been implemented for
  the work on Station 1? 
• Has personnel safety been adequately addressed in
  the design of the turning fixture?
• Has adequate training been provided (or planned
  to be provided in a timely manner) for the work
  to be conducted safely?
• NCSX will respond to any issues raised by ACC
• When issues have been resolved to the
  satisfaction of the Project Manager (Neilson) and
  RLM (Dudek), the RLM will provide authorization
  to the ATI (Viola) to commence operations on
  Station 1