Field Period Assembly Wayne Reiersen SC Project Review PPPL May 2006

Reiersen / 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

Reiersen / 3 Field period assembly process

Reiersen / 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

Reiersen / 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

Reiersen / 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

Reiersen / 7 6-pack completed using magnetic alignment in 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

Reiersen / 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

Reiersen / 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

Reiersen / 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

Reiersen / 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 PPPL’s Hoisting and Rigging Program (ENG-021) Two turning fixtures have been fabricated The first VVSA has arrived

Reiersen / 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

Reiersen / 13 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