1. 1 Stage 3 Peer Review October 26, 2006 T. Brown

2. 2 Field Period Assembly (FPA) – Stage 3 1.Make sure the requirements for the tooling is well defined (including dimensional control requirements) 2.Make sure we have a design which functionally meets those requirements (including a credible metrology approach) 3.Make sure that the tooling meets structural design criteria 4.Make sure that all chits from the Station 2 tooling have been addressed and relevant chits from the FPA Peer Review have been dispositioned and are being addressed Charge:

3. 3 MCHP installation over VV period – Stage 3  Provide a stable VV support system.  Provide a method for rotating a MCHP over the VV without interferences.  Provide for temporary support for each MCHP to set Type-A flange and VV interfacing components.  The goal for the final tolerance for the completed assembled MC period is ± 0.020”. BASIC REQUIREMENTS:

4. 4 The MCHP must follow a prescribed path The 24,000 lb MCHP must move over the VV field period within a prescribed assembly path. Some history here…. Assume a 1” stand-off to vessel surface components

5. 5 step 3 clearance to the shell has dropped slightly from 1.35" to 1.34“ step 60 clearance to the OOT points drops from 1.53" to 1.40“ as-built data from the Modular Coils not folded in yet Clearances from the new clamp envelope (for the 7" clamp with the bolt head protruding) to the OOT points for VVSA3 and to the Shell

6. 6 A 0.45” minimum clearance exists between wing region of Type A’s as the two half period MC shells comes together. MC to MC Clearance Wing region

7. 7 R&D activities were used to help develop the Stage 3 assembly approach. Crane Supported – hand assisted assembly

8. 8 The path traveled by each laser was plotted on sheets of velum and mounted to the screens, aligning pre-marked crosshairs located on the screen with marks on the printed paper One-quarter inch circles were used to define the required laser positions along the curve path. The block was manipulated to follow the sequential points with an occasional maximum deviation of about ¾” to 1”, all within our allowed assembly tolerances. Improvements will be made using motor driven mechanical screws with in-line encoder.

9. 9 To improve the accuracy of moving the MCHP we will be replacing the chain falls with mechanized screw systems with inline encoders. Crane system updated with mechanized screws

10. 10 Laser system is used to follow the assembly path

11. 11 Pre-fit flange shim installation at Type-A interface Metrology measurements taken to establish left MCHP position The right MCHP position set to spherical seats using the crane/mechanized screw system All shims are installed once alignment is set. Will this be done in the horizontal position?

12. 12 Final Stage 3 fixture details and assembly sequence. Vacuum Vessel supported and in position to receive left MCWF Take metrology measurements Define VV position

13. 13 Lower support bracket attached at Station 1.

14. 14 4.5” VV weight with ports shown is 3629 lbs.

15. 15 Diagnostic junction box geometry 4.5 A clearance space of 1.5” exists between the top of the junction box and support structure.

16. 16 VV is positioned using the Lica, viewing probes on the NBI port flange and the vessel end flange.

17. 17 The best position of the laser tracker to accurately define the MC position needs to be defined as well as fixed floor mounting locations.

18. 18 Stage 3 fixture details and assembly sequence (cont). Left MCWF moved into position by overhead crane Left support cart moved into position. Load supported and crane removed The left side is rotated over the VV and placed ¾” from its final position and supported from the roller system below.

19. 19 Stage 3 fixture details and assembly sequence (cont). Right MCWF moved into position by overhead crane Right support cart moved into position. Load supported and crane removed. Metrology measurements taken. The right side is rotated to within ~1/2” of its final position and held by the crane. The left side is then moved to its final position via rollers and the right side mates with the spring loaded spherical seats via the crane system.

20. 20 The base support structure connects with the lower TF/MC shell structure interface.

21. 21 Hilman Roller Guide Roller A roller system is used to guide support cart

22. 22 A high load leveler system supports the MCHP AirLoc Wedgemount bolt on spherical seat precision leveler Support and leveler system pre-attached to MC.

23. 23 8.75 ksi VM stress with on 1.25” bolt 0.0030” peak deflection 3,629 lb VV load

24. 24 # Chit/Audit Finding [Originator] (Continued) 7 Vessel - are the fiducials accessible to both the Romer and the Leica after the coils are assembled around it, or are the reference points then transferred to the port extrusions - which are welded on ater ? ! It would seem that the vessel fiducials become buried at coil and period assembly time. - S. Anderson 16 Machine tolerance and Assembly and Alignment - the trick with machine assembly is to get a reliable and reproducible set up on a basic coordinate system, and then align each part, and sub assembly to this master coordinate system. In doing this, one needs to minimize the leap-frogs or movements of the measurement system, which will accumulate some error each time, and to take great care to allow for and add up the accumulated errors, from positioning a coil in a winding form, from assembling a half-period and a period, from joining periods, etc. And ultimately one needs to have this coordinate system throughout the life of the device, as diagnostics need to be aligned to it to permit them to be correlated to the magnetic structure. So the fiducials need to be accessible at all times. - S. Anderson 5 It appears that some measurements, such as coil to coil, will be taken with equipment that does not have the 10x “rule of thumb” accuracy needed. - F. Malinowski 44 Consider providing a fixed location for the laser tracker at Station 3 and beyond. - W. Reiersen 41 Need to establish revised envelopes for the coil clamps, thermal insulation, and as-built (out-of-tolerance) VV including appropriate envelope for VV clamps. Need to reassess minimum clearances. Document results with assumptions clearly identified. - W. Reiersen 42 Consider coil-to-coil interferences that might result from the coolant tubes on the modular coils - W. Reiersen 51 Has the reduction in clearance between VV and MC during assembly due to as-built dimensions of VV and MC been evaluated? Does this include the new clamps? What is the minimum clearance when all of this is taken into account? 0.4”? - E. Perry 50 The stage 3 assembly will be tedious but doing this with crane and rigging hardware is probably the correct approach. I would encourage the team to continue to prototype this approach with the “mechanized screw with inline encoders” as soon as practical. - K. Chipley

25. 25 52 Who is designing and fabricating the VV/MC standoffs for use during the assembly? How are they attached to the vacuum vessel? - E. Perry 57 Trials need to be completed promptly so adjustments can be made without affecting overall schedule. - E. Perry 8 Vessel - How is the vessel manipulated to be in the right place - with just the vertical supports? And is the adjustment aimed to optimize the coil to vessel clearance, or to enable the vessel sectors to meet at full assembly? What 'slop' in vessel location is allowable? - S. Anderson 24 How do you engage vacuum vessel vertical support threads when you can’t see the initial installation? Cross threading is a very real possibility. How is rod end held in position until the rod is threaded in? Would it rotate in the clevis? - E. Perry 46 The problem of the attaching the support rods to the threaded bosses on the vacuum vessel is similar to several situations at SNS. We found a commercial company Fastorq (http://www.fastorq.com/zipnut.htm) that sells a unique product that overcomes the dreaded first thread engagement problem. We have incorporated their technology into some special spherical inserts and into some grapple lifting fixtures. This may not be applicable to the NCSX situation since the vessel parts are already fabricated. - K. Chipley 53 What precision handling equipment (hydroset, chain falls with mechanized screws, alignment lasers, etc) is required, does PPPL have these items and what is the current status of this equipment? - E. Perry 40 Assure that the type and number of metrology rigs and qualified staffing are understood well in advance. - G. Gettelfinger 59 The Leica seems to be on the critical path for many tasks. Is there a schedule for the use of the Leica? Shouldn’t a second Leica be obtained (rented)? - E. Perry # Chit/Audit Finding [Originator]

26. 26 Summary 1.Make sure the requirements for the tooling is well defined (including dimensional control requirements) 2.Make sure we have a design which functionally meets those requirements (including a credible metrology approach) 3.Make sure that the tooling meets structural design criteria 4.Make sure that all chits from the Station 2 tooling have been addressed and relevant chits from the FPA Peer Review have been dispositioned and are being addressed Charge: