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Assembly Sequence Plan

NCSX Lehman ReviewPrinceton Plasma Physics Laboratory

Princeton, NJAugust 15-17, 2007

T. Brown

Princeton Plasma Physics Laboratory Oak Ridge National Laboratory

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Assembly Sequence Plan

Summarize the overall machine assembly steps

Provide a background of the key assembly elements.

- Basis for assembly cost estimates.

Briefly review and status the assembly sequence plan

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• Stage 1 – vacuum vessel period preparation• Stage 2 – Modular Coil Half Period assembly• Stage 3 – MCHP assembled over a VV period• Stage 4 – no longer used (old TF half period

assembly)• Stage 5 – final field period assembly• Stage 6 – final machine assembly

NCSX device assembly

The NCSX device is assembled in five stages:

Each stage now corresponds to an assembly Station where installation sequences will take place.

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Type A

Type-B

Type C

The MCHP is assembled at Station 2

The completed assembled tolerance for the MCHP is ± 0.010”.

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The design intent for Station 3 is pass two MCHP assemblies over the VV (without hitting it) and accurately position mating flange. The tolerance for the assembled period is ± 0.020”.

Vacuum Vessel Period

Module Coil Half Period

Module Coil Half Period

MCHP installed over the VV occurs at Station 3

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The assembly path is mounted on screens in Station 3 to guide the motion of a MCHP over the VV period

The MCHP must follow a prescribed path

A 1” stand-off to vessel surface components

The assembly approach being used has been successfully demonstrated

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Within the MCHP assembly path minimum clearances between the MC and VV shell components are encountered.

1.528”

MCHP assembly clearances

.45” clearance in wing region

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FPA on support stand VV ports installed TF temporarily positioned

TF final fit-up

The field period is completed in Station 5

Completed period assembly

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Permanent machine supports

Temporary FPA supports

The NCSX device is completed in Station 6

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Each of the three field periods are assembled concurrently to join Type-C flanges

Type-C flange interfaces

Type-C modular coil interface

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VV spool pieces interface

As the Type-C flanges come together VV flanges will begin to mate with the adjoining spool pieces.

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Each FPA will be properly oriented in their final position using the same technique that has been developed in assembling the MCHP’s and then pulled back to a pre-fit position.

Station 6 incorporates Station 2 positioning techniques

TF coils at the Period ends

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Rev 7 of the assembly sequence plan issued June 6th provides the bases for the FPA and machine assembly cost estimates and schedules.

Detailed assembly steps for Stations 2, 3, 5 and 6 are detailed in ~ 28 pages of an Excel spreadsheet document.

Assembly Sequence Plan

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The sequence plan structure

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The sequence plan structure (cont.)

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Summary

The Rev 7 release of the assembly plan provides the basis for FPA and machine assembly providing far greater detail than was available at the December Lehman review.