1 / 16

NCSX Field Period Assembly Operations and Risks

This article discusses the concerns and risks associated with the field period assembly operations of the NCSX project. It covers topics such as staffing, cost and schedule, metrology utilization, and more. The article also highlights the expert work crew assigned to perform first-time tasks and the importance of prototyping each activity.

craigstevens
Download Presentation

NCSX Field Period Assembly Operations and Risks

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Field Period Assembly (FPA) Operations, Cost and Schedule, Staffing, and Metrology Utilization Mike Viola Field Period Assembly Manager NCSX FPA Peer Review October 11-12, 2006 PPPL

  2. FPA Concerns and Risks First article takes longer and procedures cannot be finalized until techniques have been proven. Heavy emphasis on prototyping each activity • Expert Work Crew and Support • Our most highly effective and ingenious technicians assigned to perform first time tasks. More time allocated for first time. John Edwards 30 years experience (Master Support Technician), Mike Duco from Lockheed (simulations, manufacturing, coatings, vibrations), Ed Bush 20+ Quality Assurance then NB Ion Sources. • Augmented as needed by cryogenic operators and NB Technicians • Learning Curve (Extra time included in schedule) • Perform all tasks first with expert crew – Prove principles to mitigate risk!! And then finalize procedures. • Train secondary support crew to perform bulk of work • Tooling • Expert crew perform dry run of tooling NCSX Field Period Assembly Peer Review

  3. FPA Metrology Issues Metrology (Mike Duco with Steve Raftopoulos engineering support) • Available equipment in house • Leica Laser: 0.0005” accuracy • Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available) • Reach/Accessibility • Coils are easy to reach but need high accuracy • VVSA is hard to reach but localized activities can use lower accuracy equipment. • Availability • Hardware/Software is ~80% available. • Have days of crashing and unpredictable operations. • Combination of Windows, Verisurf, MasterCAM, Leica Power Inspect, ROMER… • Repeatability • Datums strategically located to provide individual activity support • May need recommendation for datum locations to be used through final machine assembly if datum shift or tolerance buildup is of concern • Expert metrology support group being considered within Fabrication Division. NCSX Field Period Assembly Peer Review

  4. FPA Activity and Risks – Station 1 • Station 1 (Install VVSA external components diagnostic coils, cooling tubes, thermocouples using Leica laser tracker or Romer arm) • All three VVSA’s received by 9/30/06 • All work performed on station 1 fixture (2 “rotisserie” stations) with Leica laser tracker & 2 men augmented with 3 technicians when needed • Most risks are identified – Installation Progressing • Technique developed to locate diagnostic loop templates • Technique developed to adjust interferences (cooling tube studs and thermocouples) • Technique developed to install diagnostic templates • Technique developed to wind diagnostic loops • Remaining trials: • Technique to connect cooling hoses to vertical risers • Technique to hold heating tapes in place on vertical ports. NCSX Field Period Assembly Peer Review

  5. FPA Activity and Risks – Station 2 • Station 2 (3 coil preassembly – align, shim, and assembly using Leica laser tracker) • Some risks are identified: • Prefit individual mating coils – identify any gross interferences & checkout tooling • Required stiffness of adjustable platform • Remaining trials: • reaming bolts - accessibility • Develop shim technique and use liquid shim • Install liquid shim in vertical orientation • Installing studs for epoxy shim • Installing metal shims (1 hole, 2 hole machined or various thicknesses) • Pillow shims NCSX Field Period Assembly Peer Review

  6. FPA Activity and Risks – Station 3 • Station 3 (install coils onto VVSA using Leica laser tracker) • Align and assemble 2 coil three packs first then onto VVSA • Some risks are identified: • Technique developed to manipulate coils onto VVSA • Remaining trials: • reaming bolts - accessibility • Develop shim technique and use liquid shim • Install liquid shim in vertical orientation • Installing studs for epoxy shim • Installing metal shims (1 hole, 2 hole machined or various thicknesses) • Pillow shims NCSX Field Period Assembly Peer Review

  7. FPA Activity and Risks – Station 4 & 5 in NCSX test cell • Station 4 (install, align and assemble TF Coils using Leica laser tracker) • Trials TBD • Station 5 final assembly in NCSX test cell to enhance efficiency and reduce HP overhead (weld ports, install TF coils, leak check, final metrology) • Leak check moved to final assembly • Trials TBD NCSX Field Period Assembly Peer Review

  8. “SAFELY SAFELY SAFELY” • Documentation and Integrated Safety Management (ISM) Work Plans • Manufacturing Facility Operation Plan (MFOP) covers overall facility conduct using ISM as its basis. • Activities Certification Committee (ACC) independently reviews each station setup, operations, and plans before station is activated. NCSX Field Period Assembly Peer Review

  9. FPA Process Definitions • FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) • Input (Station specific): • Dimensional Control Plan • FPA Assembly Sequence Plan • FPA Specification and Assembly Drawings • MIT/QA provides basis for individual procedures to perform tasks then revised to include developed improvements. NCSX Field Period Assembly Peer Review

  10. FPA Roll up Schedule NCSX Field Period Assembly Peer Review

  11. FPA Manpower Loading Ramp up to full complement beginning FY 08 NCSX Field Period Assembly Peer Review

  12. FPA Metrology Utilization Station 1 FP #3 and Station 2 FP #2 & 3 Station 4 FP #1 & 2 Station 5 FP #1 Station 2 and Station 3 FP #1 and Tooling checks Station 1 and Station 2 FP #1 NCSX Field Period Assembly Peer Review

  13. FPA Station 1 Activity has begun - Metrology Very good agreement. VVSA1_MTM_FINAL_NUMBERS VVSA1_PPPL_BEST_FIT NCSX Field Period Assembly Peer Review

  14. FPA Metrology Metrology is serving appropriate needs. VVSA2_MTM_FINAL_NUMBERS VVSA2_PPPL_BEST_FIT NCSX Field Period Assembly Peer Review

  15. FPA Station 1 Active Station 1 Laser Tracker setup – Diagnostic loops & cooling studs locations Port prefit – weld preparation check NCSX Field Period Assembly Peer Review

  16. FPA Summary • To Conclude • Our best technicians are assigned to the FPA tasks to mitigate risk. • Some assembly operations are still somewhat conceptual and will be tested out prior to actual work is performed. • Reasonable time is allocated to perform FPA including proof of principle. • Open Issues • Some activities are still quite conceptual • Metrology needs further study and augmentation • Datum transferability and tolerance buildup • I invite the review team to offer their concerns and provide advice. NCSX Field Period Assembly Peer Review

More Related