# Presentation: 800764

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_**October 31, 2007 **_
- Mike Viola
- Field Period Assembly Manager

## FPA is Accomplished in Four Stages

**Station 1 – ****Vacuum Vessel (VV) Prep**

**Station** **2 – ****Modular Coil Half Period (MCHP) Assembly**

**Station** **3 - MCHP installation over VV Period**

**Station** **5 - Final Assembly in NCSX Test Cell**

**Station** **6 – Final Machine Assembly – Erik Perry**

## FPA Process Definitions

- FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) Complete
- Input (Station specific):
- Dimensional Control Plan (Art Brooks)
- FPA Assembly Sequence Plan (Tom Brown)
- FPA Specification and Assembly Drawings (Mike Cole)
- MIT/QA Plan provides basis for individual procedures to perform tasks then revised to include developed improvements.
- FPA Procedures
- FPA station 1 procedure is complete and active
- FPA station 2 trials are providing input to procedure development

## Design Philosophy

- We carefully assure that our designs are adequate.
- Utilize outside reviewers to participate in design reviews
- Complete designs early to minimize configuration changes
- not rely on concurrent engineering as much during assembly phase
- We schedule time to test the designs in advance.
- Added trials to discover problems BEFORE the critical path.
- E.g. Added stud tension, bushing, and nose weld trials
- Measure all modular coils in advance of assembly
- developed new alignment techniques
- We allow time to reinforce tooling or make adjustments as needed.

## NCSX Vacuum Vessel Station 1 97% Complete

**NCSX Vacuum Vessel Station 1 ****97% Complete**

- VV #1 and VV #2 98% Complete
- VV #3 95% Complete
- Cooling tube testing and final scans remain

**VVSA with ports welded**

- VV #1

- VV #2

**VV #3 complete**

## Station 2 Trials are Successful 

- Station 2 FPA trials were enhanced and are well in progress:
- Gross fit individual mating coils
- found a few minor interferences
- Joint design trials for Station 2 (useful for Station 3 also):
- Install and torque bolts – assess accessibility **SUCCESSFUL**
- Develop shim technique **SUCCESSFUL**
- Pillow shims **SUCCESSFUL**
- New welded design for inboard interface (nose) **SUCCESSFUL**
- Install Alumina coated metal shims
**Shims on order**

## Station 2 Assembly Sequence

_**Preparation Steps/ Major Activities**_
**MC Fit-up Check **
**Verify will come together (Gross Fit-ups)**
**Pre-Measurement of MHCP Type A/B/C Coil Flanges & Interfacing Type A Coil Flange**
**Individual coils have been racked into proper shape. (within +/- .005”)**
**Alumina Shim Sizing & Preparation**
**Measure shim thicknesses to arrive at a satisfactory shim set for MCHP assembly.**

_**Potential Issues**_** **_**and**_** **_**Mitigation Plans**__** **__** **_
**Tooling not rigid enough – *****RETIRED***
**wedges determined to be adequate**
**Coils still too flexible –***** ******RETIRED***
**physically racked (twisted) coils to re-establish their coordinate system**
**Alignment not within tolerances bars- *****RETIRED***
**successfully met requirements**

**Nose**

## Station 2 Assembly Sequence

_**A-B Modular Coil Assembly Steps/Major Activities**_
**Rack A coil & measure fiducials. **
**lower B coil into place onto outboard shims**
**Measure shim puck height with bore gauge**
**Install nose shear plates & lightly tack weld **
**Lift B & flip to ready for nose welding.**
**Establish A & B coil fiducials – weld flex shims to plasma side both coils, recheck fiducials. Back Office assess part for compliance.**
**Place B coil back on A coil and align**
**Install alumina shims and bushings**
**Weld A/B nose region solenoid side & re-measure.**
**REPEAT FOR C TO A-B ASSEMBLY**

## Station 2 Assembly Sequence

**A-B Modular Coil Assembly**
_**Potential Issues**_** **_**and**_** **_**Mitigation Plans**_
**Alignment not within tolerances ****- *****RETIRED***
**Able to achieve +/- .005” lock-in**
**Weld distortion excessive**
**Install wing chairs to offset distortions**
**If required, coil welds can be ground out & coil separated **

## Station 2 Assembly Sequence

_**Final Assembly Steps/Major Activities**_
**Inflate All Shim Bags**
**Complete Local Services  & Interface Details**
**Install sealant to fill all shim spaces to trap VV/MC insulation.**
**Final Measurements and transfer to MCHP holding area.**

## Station 3 Assembly Sequence

_**Potential Issues**_** **_**and**_** **_**Mitigation Plans**_
**Tooling not rigid enough**
**Reinforce/redesign tooling if necessary**
**Left or Right MCHP changes shape**
**Back Office review changes & provides new left to right MCHP orientation**

_**Pre-Assembly Steps/Major Activities**_
**Pre-Installation Set-Up **
**Install monuments, floor mounted tracks & Vacuum Vessel base support, measure MCHP CG **
**Anchor tooling (floor mounted tracks, support carts, adjuster bar, temporary scaffolding, etc. **
**Pre-Assembly of Left MCHP **
**Establish global coordinate system and install laser screens. **
**Measure MCHP in vertical orientation, including A-A flange **
**Perform Metrology and align**

**MCHP support cart assembly**

**MCHP Left side**

**Vacuum Vessel Support**

## Station 3 Assembly Sequence

_**Pre-Assembly Steps/Major Activities**_
**Install Laser Screens**
**Perform Dry Runs with MCHPs**** **

## Station 3 Assembly Sequence

_**Assembly Steps/Major Activities**_
**Install VV NBI support stand & install VVSA to base support structure.**
**Using metrology, take tooling ball readings to properly position VVSA to global coordinate system.**** **

## Station 3 Assembly Sequence

_**Potential Issues **__**and**__** **__**Mitigation Plans**_
**Components damaged during assembly *****(highly unlikely due to very slow motion)*****.**
**remove MCHP from vessel & repair damaged component with existing spare component e.g. cooling tube or clamp.**
**Weld distortion excessive**
**Install wing chairs to offset distortions**
**If required, coil welds can be ground out & coil separated **

_**Assembly Steps/Major Activities**_
**Install Left then Right MCHP over VVSA**
**Weld Inboard Shims and re-measure alignment**

## Station 5 Assembly Sequence

_**Potential Issues **__**and**__** **__**Mitigation Plans**_
**Floor not stiff enough**** **
**Will be tested in advance with a concrete block; reinforcing can be added to substructure**
**Photogrammetry will allow a bundle adjustment independent of the floor.**

_**Pre-Assembly Steps/Major Activities**_
**Pre-Installation Set-Up**** **
**Install period support fixture**
**Install FPA on support stand & engage base of MC. **
**Install internal & external working platforms**

**FPA lowered onto support stand**

**FPA support stand with lower trim coil**

## Station 5 Assembly Sequence

_**Potential Issues **__**and**__** **__**Mitigation Plans**_
**Difficulty of welders working inside VV in contorted positions may pose ergonomic & confined space hazards**
**Ergonomic / confined space hazards – prior Job Hazard Analysis (JHA) will consider all hazards****	**
**Leak check fails on one or more ports**
**Identify leak point (s), repair weld and re-test**

_**Assembly Steps/Major Activities**_
**VV Port Installation**** **
**Install circular ports. **
**Install domes, inserting the long port through the MC hole opening & weld dome shell to VV. **
**Leak check all port welds.**** **

**1” – 2” clearance around all ports**

## Station 5 Assembly Sequence

_**Assembly Steps/Major Activities**_
**Trim Coil Installation**** **
**Install trim coils - mounted to the MC shells using local field fit support brackets**

**There are four different trim coil sizes.  **

## Station 5 Assembly Sequence

_**Right & Left TF Coil Assembly Steps/Major Activities**_
**Attach temporary supports, disengage base of MC, & ****install TF support brackets **
**Slide TF assemblies against TF support brackets one at a time **
**Install machine support plates & re-engage base of MC**

**Temporary end support  simplified with two TF coils)**

**Right side leveler pad with intermediate support removed**

## Station 5 Assembly Sequence

_**Assembly Steps/Major Activities**_
**Advanced TF Fit-Up Checks**** **

**Install TF support brackets on the sides of the coils, both on the top of the MC and on the bottom.  **

## Station 5 Assembly Sequence

_**Final Assembly Steps/Major Activities**_
**Tack Weld Ports 4’s**
**Install PF Structural Members**
**Route MC leads and coolant lines**
**Install MC Coolant Manifold**
**Install Rogowski Coils on end of VV**

## Station 5 Assembly Sequence

_**Potential Issues**_** **_**and **__**Mitigation Plans**_
**Final measurements not within tolerances**
**Project assess steps necessary if unable to accept out-of-tolerance conditions**

_**Final Assembly Steps/Major Activities**_
**Final Measurements**
**Obtain set of Period 1 alignment fiducials for locating VV within the MC **
**Using monuments on VV for alignment, perform trial VV alignment, adjusting VV supports as necessary. **
**Make final measurement of all fiducials, VV end flanges, & Type C end flanges **
_**REPEAT FOR PERIODS 2 & 3**_

## Summary

- Station 1 vacuum vessel segments are nearly complete.
- Station 2 modular coil assembly trials are well underway, most risks are retired, and assembly steps are well defined.
- Station 3 installing the modular coil half period assembly over the vacuum vessel and Station 5 final field period assembly sequence plans have been developed in detail and include the necessary metrology and trial elements.
- We have a credible plan to assemble the field periods to the accuracy required.
- I have confidence in successfully performing the Field Period Assembly activities.