Transcript NCSX visit - Lutz Wegener.ppt

Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
Assembly Meeting NCSX/W7-X


Organization W7-X Assembly (Responsibilities)
Assembly Similarities NCSX/W7X (pictures taken from
presentations of NCSX and of W7-X)
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
1
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
Organisation
W7-X Assembly Organisation – Departments and Work Packages
On-site co-ordination
TB Montage
W7-X
Simone Gojdka
Lutz Wegener
Secretary: Heike Nothnagel
Cooling
Periphery
Device Assembly
Assembly technology
Krampitz
Karl-Heinz Oelgemöller
Fred Hurd
Specifications, Interfaces
Electric
DC
TD
•
•
•
•
•
•
Cooling system of W7-X
Conceptual design
Routing
Interfaces
Assembly concepts
Procurement, set-up planning, detailed
design
• Management of Assembly/Installation (RLM)
HL
• Instrumentation Cabling Cryostat; design;
routing, procurement, installation
• Instrumentation Cabling in D/T hall, design;
routing, procurement, installation
• Ground system and system voltage in D/T
Hall; design; routing, procurement, installation
• Cable administration
• Assembly concepts and set-up planning
• Procurement, set-up planning, detailed design
• Procurement and installation of support structure
for switch boards for diagnostics
• Management of Assembly/Installation (RLM)
Construction of the Basic Device
- Component preparation
- Pre assembly (Ia, Ib, II, III)
- Final assembly (IV, V)
- Metrology
- Leak testing and vacuum technique
- Welding shop
- In-vessel assembly
- Responsible Line Managers (RLM)
- Service; cleaning and protection
- Documentation and work preparation
- Layout of halls and Workplace design
Technology, design, engineering, procurement
and optimisation of assembly procedures,
equipment, devices, tools...w.r.t.:
- Pre-assembly (coils, vessels, structure)
- Torus-assembly (vessels, ports, magnet system)
- Bus-bar system (FZJ)
- In-vessel components
- Assembly space administration
- Tests and Qualifications
Procurement and installation of:
- Bus-bar system
- Machine base
- Procurement and installation of:
- Vacuum System
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
2
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
Organisation
Assembly Organisation – Device Assembly with Work Packages
On-site co-ordination
TB Montage
W7-X
Simone Gojdka
Lutz Wegener
Secretary: Heike Nothnagel
Periphery
Device assembly
Assembly technology
Rüdiger Krampitz
K.-H. Oelgemöller
Fred Hurd
Assembly control
Shift manager 1
Shift manager 2
Metrology
Welding shop
Vacuum technique
K.-H. Oelgemöller
H. Modrow
NN
Torsten Bräuer
Jens Holluba
Heinz Grote
Welding trials
Qualifications
Welding plans
Welding sequence
Welding supervision
Qualification of
welders
- Equipment
- Consumables
- Leak tests in the
entire W7-X
enterprise
- Leak test
qualifications
- Development and
procurement of test
equipment
- Operation of leak test
facility
- Assistance to
diagnostics
- Design, procurement
and installation of the
vacuum systems of
W7-X
- Process planning
- Scheduling
- Resource planning
- Storage/Magazine
- Procurements
- Consumables
- QAAP, AA, PA
- Workshop assistance
- Process monitoring
(consumption of
resources)
L. Wegener
Service
FDN
- Transport
- Cranes, crane tools
- Scaffolding
- Cleaning
- Hall layout
- Workplace design
- Documentation
- Storage assistance
- Component
preparation
- MST I, II, III
- MST IIIa, IVa, IV, V
- RLM (FBL)
- Component
preparation
- MST I, II, III
- MST IIIa, IVa, IV, V
- RLM (FBL)
- Component alignment
- Metrology inspections
- Survey
- Metrology service
- Photogrammetry
- Laser Scanning
- 3D measurement
machine
- Metrology technique
- Tools & devices
- Special tests
- Investigations
Assembly Meeting NCSX/W7-X, 11./12.10.07
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3
Unternehmung
WENDELSTEIN
7-X
Assembly Similarities NCSX - W7-X
Max-PlanckInstitut für
Plasmaphysik
Cutaway View of Stellarator Core
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
4
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
Cutaway View of W7-X Core
Basic machine
70 super conductive coils,
360 t, 4 K, In = 17,6 kA
Central support structure
(CSS), 60 t
299 Ports
Machine base
Plasma vessel
Plasma
Helically wound plasma axis, Bmax. < 3 T
Divertor
L. Wegener
Outer vessel, cryogenic vacuum < 10-5 mbar, 4 K
Assembly Meeting NCSX/W7-X, 11./12.10.07
5
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: FPA Station 1
W7-X: Preparation of Plasma Vessels and Ports
Add coolant tracing
Port prefit – weld preparation check
Station 1 Laser Tracker setup –
Diagnostic loops & cooling studs
locations
•Incoming inspection
•Geometrical check
•Diagnostics
•Thermal insulation
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
6
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
W7-X: Preparation of components
•Incoming inspection
•Geometrical check
•Diagnostics
•Thermal insulation
•Incoming inspection, metrology
•Instrumentation (100 wires)
•SC welding
•Protection coil connection area
•Incoming inspection
•Installation of supports
•Geometrical check
•Thermal insulation...
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
•Incoming inspection
•Geometrical check
•Instrumentation
•Adaptation of Supports...
•Incoming inspection
•mech. Adaptation...
(external hall)
7
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
W7-X: Preparation of components
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
8
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: FPA Station 2 (M. Viola, M. Cole)
W7-X: none comparable operation
Type B
Toroidal
break
Poloidal
break
Coil Type A
L. Wegener
Coil Type C
Assembly Meeting NCSX/W7-X, 11./12.10.07
9
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
W7-X: Mounting Stand 1
NCSX: Field Period Assembly Station 3
Add first 3-mod-coil set
The pre-assembly hall where two flip
symmetric half-modules are presently
built up in the mounting stands.
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
Add 2nd 3-mod-coil
set
10
Unternehmung
WENDELSTEIN
7-X
NCSX: FPA station 3 (only few operations)
W7-X: Mounting Stand II
Max-PlanckInstitut für
Plasmaphysik
Two flip symmetric half-modules on mounting stand II, positioned together at the stairs-shaped
flange in the middle of the CSS (one fifth of the central support ring); bus-bars and helium pipe
system are mounted.
Coil Type C
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
11
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: FPA station 3 (but only few operations)
W7-X: Mounting Stand II
Trial assembly of two PV half-modules. The contour needs to be adjusted with heavy brackets. The
weld can only be done from the inside since the outer side is covered with thermal insulation. The
outside of the weld seam needs to be covered with protection tubes to avoid heat influence to the TI
and to make possible the gas-backing and the leak-testing.
Coil Type C
Latest assembly
tests at ROVERA
Assembly PIN
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
12
Unternehmung
WENDELSTEIN
7-X
NCSX: none comparable operation
W7-X: Mounting Stand II
25 single bus-bars manufactured and mechanically
mounted by Forschungszentrum Jülich (FZJ)
L. Wegener
Max-PlanckInstitut für
Plasmaphysik
Trial assembly of dummy bus-bars at
the manufacturer in Jülich. Support
ring and coils have been mocked up of
aluminium.
Assembly Meeting NCSX/W7-X, 11./12.10.07
13
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: FPA Station 4
W7-X: none comparable operation
Coil Type C
Add first 3-TF-coil set
L. Wegener
Add 2nd TF-mod-coil set
Assembly Meeting NCSX/W7-X, 11./12.10.07
14
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: partially comparable, FPA Station 5
W7-X: Mounting Stand IVa and IV
Mounting Frame
Entrance to the Pre-Assembly Hall
Machine Base
Platform
Module in
the lower
shell of the
outer vessel
Coil Type C
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
15
Unternehmung
WENDELSTEIN
7-X
NCSX: FPA Station 5
W7-X: Mounting Stand V: Port Installation
Max-PlanckInstitut für
Plasmaphysik
Principle:
•Align able ramps (x, y, z and rot
(x, y, z)) on a movable bridge
•The port is fastened on the ramp
on one side via an interface
flange.
Two ramps are independently
operated; a third one on the floor
The moveable bridge on rails
Machine centre, Laser Tracker
Coil Type C
Add port extensions (weld ports,
install TF coils, leak check, final
metrology)
L. Wegener
Machine Base with rails
Rails on the floor
Assembly Meeting NCSX/W7-X, 11./12.10.07
16
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
Assy Requirements NCSX/W7-X
Position Winding Center within a TP of .020 inch. ~ 0,5mm (W7-X: ~2mm)
FPA tol distribution
Tol for coil to coil
.010 ~ 0,25mm
(W7-X: ~1mm)
Tol for HP assy
.010~0,25mm
W7-X: ~1,5 mm
W7-X:~2 mm
L. Wegener
(W7-X: 0,5mm)
Assembly Meeting NCSX/W7-X, 11./12.10.07
17
Unternehmung
WENDELSTEIN
7-X
NSCX: Shims between coil to coil assy
W7-X: Wedges between modules
Max-PlanckInstitut für
Plasmaphysik
The shims provide the following functions
• Insulate between the coils
• Path for compressive and shear loads
• Adjust coil position during assy
Shims consist of a composite of sstl
and together
Bolting
G11 insulation
both magnet
modules; machined
G11 insulation
shims (red)
sstl shims machined from data obtained during
dimensional inspection of flange surface
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
18
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX: Bladder Installation, W7-X: Narrow Support Elements
Fill access for
expanding bladder
Expandable sstl can
installed in machined
grove of wing
Exploring option for using commercially
available configuration and/or similar to this
design
Commercial steel capsule jack or “flat jack”
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
19
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
W7-X: Narrow Support Element – Detailed Design
Central
Ring
Dust protection
Central Supports
Wave spring
Sliding surface
MoS2 coated
Pad in
Al-Bronze
Pad frame
Narrow Supports
10 cm
Lateral Support
NPC
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
20
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
NCSX and W7-X: Access for reaming and welding
Access for reaming is very important. We are currently
reviewing the configuration to assure adequate access is
available.
3
A-B 3
1.375-6UNC
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
A
B
21
Unternehmung
WENDELSTEIN
7-X
Max-PlanckInstitut für
Plasmaphysik
W7-X: Welding of Lateral Support Elements
NCSX: Welding at inner flanges?
Lateral support elements are welded between neighbouring coils. The weld seam thickness is
between 20 and 30 mm. The shrinkage must remain within an inaccuracy of less than 0,5 mm.
Lateral Support
Element
Lateral
Supports
L. Wegener
Assembly Meeting NCSX/W7-X, 11./12.10.07
22