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1 MC Assembly over the VV FPA Station 3 FDR Review July 17, 2007 T. Brown.

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  • MC Assembly over the VVFPA Station 3FDR Review July 17, 2007T. Brown

  • Are the requirements well defined?Does the design meet the requirements?Do the drawings define the design adequately to be used as the sole basis for fabrication and acceptance of the support fixture?Does the analysis adequately underpin the design and have they been checked?Has safety been adequately addressed in the design of the support fixture?Can the support fixture be fabricated and installed within the budget and schedule identified in the project baseline?Have all relevant chits from previous design reviews been adequately addressed?

  • This review covers the general arrangement of the Station 3 assembly components, the support fixtures for the MCs and VV and the laser screens. The local alignment fixtures used to provide added positional adjustments of the MCHP and the lift fixture is not covered. This will be reviewed at a later date.

  • Assembly Position the VV to allow installation of the MCHPsProvide movement of left MCHP support to allow final installation of right side MCHPProvide an accurate mounting for the laser path tracingsProvide a method for installing the MCHP over the VV without interferencesAllow access area to install Type-A flange hardwareThe goal for the final tolerance for the completed assembled MC period is 0.020.

    Structural Provide a stable support for the VV to allow installation of the MCHPsProvide a stable support for each MCHP that minimizes deflection of the interfacing MC Type-A flangesProvide a stable laser path tracing support frame

  • Vacuum Vessel is supported and is in position to receive left MCHPTake metrology measurementsDefine VV positionAdjustable VV base supportAdjustable VV lateral support

  • Peer reviewTwo bolts were added since peer review

  • A clearance space of 1.5 exists between the top of the junction box and the surface of the support structure.

  • 8.75 ksi VM stress with on 1.25 bolt0.0030 peak deflection3,629 lb VV load

  • Laser screens have been sized for laser tracings.Tracks have been extended to remove MC supports during coil installation.

  • The MCHP is support off a base structure attached to the MC shell feet.The base structure rolls on rails which were extended because of assembly interferences.Support railsBase support structure

  • 8 ton Hilman RollerGuide RollerA local channel is used to lock the structure in place.The support beam was extended on the one side.

  • Support and leveler system pre-attached to MC.Local hold down support.

  • Metrology measurements taken to establish left MCHP positionThe right MCHP position set to spherical seats using the crane/mechanized screw system The deflection of the flange A surface when supported off he base was evaluated.

  • CG location

    CAD weight of MCHP with support is 21,933 lbs

  • VV motion over the MCHP

  • VVSA1 metrology measured surface points added to VV1.38The Type-B MC winding form comes within 1.38 to the CAD defined VV surface.

  • There are no out-of tolerance points in the tightest region on VVSA1. Local measurement were made to confirm that all added surface components did not extend more than 1 off the surface.

  • 0.384 minimum clearance to surface componentsStep 0 defines the final assembled position1 limit of surface components above vessel surface.In general there is 2 assembly space above the VV CAD surface. With 1 surface components, leaves a min. 1 assembly gap.

    Chart2

    1.6192890698

    1.6001960755

    1.5207045857

    1.3840617215

    1.6115103971

    1.7490654795

    1.9271248361

    2.1019242648

    2.273225313

    2.3125607181

    2.3361507614

    2.1634684868

    2.1622793527

    2.4888259809

    2.5023309739

    2.4510075381

    2.3959926945

    2.3368966331

    2.257495835

    2.186626678

    2.213486007

    2.1219194647

    2.1932481135

    2.1097034227

    2.209244733

    2.1155676111

    2.1114786455

    2.116174537

    2.1136560392

    2.1112007776

    2.1114356607

    2.1067867496

    2.1022638535

    2.0970919067

    2.0917145997

    2.0867807889

    2.1193690243

    2.1235941209

    2.1341863066

    2.1233427762

    2.1166007323

    2.1098606732

    2.1012560825

    2.1142576091

    2.127545933

    2.140371465

    2.0867963915

    2.1513305912

    2.1621046305

    2.0998969971

    2.0700086089

    2.020673956

    2.0733782974

    2.1285770936

    2.1861639854

    2.2042410072

    2.2052049253

    2.2069115893

    2.1617790233

    2.1779978365

    2.1953185793

    2.1778793128

    2.0676804195

    2.0035033006

    2.0318137281

    2.0609171732

    2.1028457388

    2.1133986614

    2.122645478

    2.1369989368

    2.112944524

    2.0893282078

    2.0649151667

    2.0537564559

    2.0788278739

    2.0549945085

    2.0334700413

    1.9990534848

    1.9725820003

    1.9512063451

    1.9834240682

    2.0123644159

    2.037895988

    2.0600175471

    2.0786898051

    2.0938756303

    2.1055292907

    2.1136194331

    2.1181431339

    2.1190540731

    2.1163044184

    2.109881487

    2.1039860792

    2.0951478257

    2.0862869233

    2.07553161

    2.066857803

    2.0581578811

    2.0494187881

    2.0406539355

    2.031857485

    2.1029124614

    2.1060991531

    2.2156059555

    2.1224609191

    2.2414369141

    2.1531182808

    2.1588596928

    2.1685137404

    2.2052178879

    2.2356746106

    2.2328397695

    2.2332547594

    2.1828940453

    2.1718143352

    2.1659420657

    2.1786588476

    2.2213311429

    2.1757349321

    2.2515137856

    2.3270365175

    2.277613433

    2.2742948108

    2.1907724336

    2.2517865537

    2.3131853881

    2.2351247182

    2.272254495

    2.2052499314

    2.188039692

    2.2043364182

    2.24591615

    2.2157669835

    2.1980722124

    2.2001102934

    2.2303808212

    2.197830265

    2.2000892084

    2.1747072785

    2.2362849573

    2.2975876114

    2.2715385729

    2.2474772512

    2.2401479146

    2.2814895053

    2.3583219947

    2.4408537724

    2.511992459

    2.5852335946

    2.6253500322

    2.6631659341

    Step Interval

    Distance to VV Surface

    arts_011807::VV_MCWF_DISTANCE

    Sheet1

    Time

    (Sec)Dist (in)

    01.619

    0.011.600

    0.021.521

    0.031.384

    0.041.612

    0.051.749

    0.061.927

    0.072.102

    0.082.273

    0.092.313

    0.12.336

    0.112.163

    0.122.162

    0.132.489

    0.142.502

    0.152.451

    0.162.396

    0.172.337

    0.182.257

    0.192.187

    0.22.213

    0.212.122

    0.222.193

    0.232.110

    0.242.209

    0.252.116

    0.262.111

    0.272.116

    0.282.114

    0.292.111

    0.32.111

    0.312.107

    0.322.102

    0.332.097

    0.342.092

    0.352.087

    0.362.119

    0.372.124

    0.382.134

    0.392.123

    0.42.117

    0.412.110

    0.422.101

    0.432.114

    0.442.128

    0.452.140

    0.462.087

    0.472.151

    0.482.162

    0.492.100

    0.52.070

    0.512.021

    0.522.073

    0.532.129

    0.542.186

    0.552.204

    0.562.205

    0.572.207

    0.582.162

    0.592.178

    0.62.195

    0.612.178

    0.622.068

    0.632.004

    0.642.032

    0.652.061

    0.662.103

    0.672.113

    0.682.123

    0.692.137

    0.72.113

    0.712.089

    0.722.065

    0.732.054

    0.742.079

    0.752.055

    0.762.033

    0.771.999

    0.781.973

    0.791.951

    0.81.983

    0.812.012

    0.822.038

    0.832.060

    0.842.079

    0.852.094

    0.862.106

    0.872.114

    0.882.118

    0.892.119

    0.92.116

    0.912.110

    0.922.104

    0.932.095

    0.942.086

    0.952.076

    0.962.067

    0.972.058

    0.982.049

    0.992.041

    12.032

    1.012.103

    1.022.106

    1.032.216

    1.042.122

    1.052.241

    1.062.153

    1.072.159

    1.082.169

    1.092.205

    1.12.236

    1.112.233

    1.122.233

    1.132.183

    1.142.172

    1.152.166

    1.162.179

    1.172.221

    1.182.176

    1.192.252

    1.22.327

    1.212.278

    1.222.274

    1.232.191

    1.242.252

    1.252.313

    1.262.235

    1.272.272

    1.282.205

    1.292.188

    1.32.204

    1.312.246

    1.322.216

    1.332.198

    1.342.200

    1.352.230

    1.362.198

    1.372.200

    1.382.175

    1.392.236

    1.42.298

    1.412.272

    1.422.247

    1.432.240

    1.442.281

    1.452.358

    1.462.441

    1.472.512

    1.482.585

    1.492.625

    1.52.663

    1.512.615

    1.522.565

    1.532.746

    1.542.714

    1.552.787

    1.562.861

    1.572.936

    1.583.011

    1.593.087

    1.63.170

    1.613.249

    1.623.333

    1.633.414

    1.643.502

    1.653.585

    1.663.675

    1.673.761

    1.683.853

    1.693.940

    1.74.034

    1.714.123

    1.724.219

    1.734.309

    1.744.407

    1.754.499

    1.764.598

    1.774.691

    1.784.791

    1.794.886

    1.84.986

    1.815.082

    1.825.183

    1.835.281

    1.845.384

    1.855.481

    1.865.584

    1.875.682

    1.885.785

    1.895.882

    1.95.984

    1.916.081

    1.926.133

    1.936.185

    1.946.281

    1.956.332

    1.966.383

    1.976.478

    1.986.528

    1.996.578

    26.671

    2.016.720

    2.026.768

    2.036.858

    2.046.904

    2.056.950

    2.067.030

    2.077.107

    2.087.179

    2.097.250

    2.17.321

    2.117.400

    2.127.486

    2.137.579

    2.147.680

    2.157.787

    2.167.901

    2.178.023

    2.188.154

    2.198.277

    2.28.392

    2.218.515

    2.228.645

    2.238.782

    2.248.927

    2.259.079

    2.269.239

    2.279.406

    2.289.580

    2.299.762

    2.39.951

    2.3110.146

    2.3210.348

    2.3310.557

    2.3410.772

    2.3510.993

    2.3611.220

    2.3711.452

    2.3811.690

    2.3911.933

    2.412.181

    2.4112.433

    2.4212.690

    2.4312.951

    2.4413.216

    2.4513.485

    2.4613.758

    Sheet1

    Time (Sec)

    Measure

    arts_011807::VV_MCWF_DISTANCE

    Sheet2

    Step Interval

    Distance to VV Surface

    arts_011807::VV_MCWF_DISTANCE

    Sheet3

    Time (Sec)

    Measure

    arts_011807::VV_MCWF_DISTANCE

  • FEM Analysis of the Stage3 Support FrameH.M. FanMarch 14, 2007

  • Shell-support interfacesInboard shell type COutboard shell type COutboard shell type AFEA ModelSupport frame

  • FEA Assumptions Linear analysis Not including clamps in the model Weight of clamp was added to the weight of modular coil Constraints at four bottom pads of the support frame Material properties:

  • Un-deformed shape with scale of deformation = 468Total Displacement The inboard displacements are higher than the outboard displacements.Unit of Displacement is meter(0.015)(0.0034)(0.0051)

  • Vertical Displacement The maximum downward displacement occurs at the inboard region of the shell type A.Unit of Displacement is meter(0.001)

  • Scale of Displacement = 400Vertical Displacement of Support FrameIt is better to rotate the column 90 or to add stiffeners below the beam.add a stiffener here- The plots show the deformed and un-deformed shapes

  • Maximum stressvon Mises Stress Stresses in the MCWF are small. The peak stress (~2 ksi) occurs at the outboard leg of the shell type A. The max. von mises stress in the support frame (9.98 ksi) locates in the horizontal frame underneath the inboard column.Unit of stress is pascal

  • Inboard shell type COutboard shell type AOutboard shell type CContact Pressure at Shell-Support Interfaces Unit of stress is pascal- The contact pressures are not uniform on the contact surfaces(877 psi)

  • Forces on Top of Column Supports Forces and moments are shown in the global coordinate system: The calculated dead weight of MC and MCWF is 19.52 kips. If the actual measured dead weight is greater than that, all the calculated stresses, forces, and displacements can be reasonably increased by the same ratio. Inboard column under shell type C has the highest axial load and the bending moments.

  • W6X25Ix = 53.3 in^4 Sx = 16.7 in^3 rx = 2.67 inIy = 17.1 in^4 Sy = 5.62 in^3 ry = 1.53 in

    Column stress criteria are checked as follows:Column Design where:Fa is the allowable axial stress in the absence of bending momentfa is the computed axial stress

  • Summation of total forces and moments at the base of the inboard column in the global coordinate system are:

    FX = - 445 N FY = - 233 N FZ = 44405 N MX = -332 m-N MY = 31 m-N MZ = -22 m-N

    orFX = - 100 lb FY = - 52 lb FZ = 9980 lb MX = -2.94 in-k MY = 0.27 in-k MZ = -0.20 in-k

    For -13 UNC A307 bolt, Fy = 33 ksi, the allowable single shear load is 1.96 kip.

    Allowable tensile area is 0.1419 in2 and the allowable bolt tension is 2.81 kip.Bolt stress With bolt group as shown on the right, the maximum shear in the bolt is 0.03 kip, which is much smaller than the allowable shear 1.96 kip.

    The maximum tension in the bolt is 0.64 kips that also smaller than allowable tension.

  • FEM Analysis of the Stage3 Support FrameFollow-up

  • HM loading were applied to each support, ignoring the MCHP movement constraints at the top of the posts. 0.148 max deflection

  • Incorporating square tubes and local stiffeners reduced the peak deflection from 0.148 to 0.009 (also excluding MCHP moment constraints).

  • Deflected surface of Type-A flange shown is from HMs original analysis. With additional stiffness added to base structure the Type-A flange deflection should be reduced.

  • Review of earlier chits Oct 06, external peer review

    # Chit/Audit Finding [Originator]Review Board RecommendationResponsibility41Need 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. ReiersenConcurBrown42Consider coil-to-coil interferences that might result from the coolant tubes on the modular coils - W. Reiersen ConcurBrown51Has 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. PerryProject should evaluateBrown50The 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. ChipleyConcurBrown52Who is designing and fabricating the VV/MC standoffs for use during the assembly? How are they attached to the vacuum vessel? - E. PerryProject should evaluateBrown57Trials need to be completed promptly so adjustments can be made without affecting overall schedule. - E. PerryConcurBrown

  • Are the requirements well defined?Does the design meet the requirements?Do the drawings define the design adequately to be used as the sole basis for fabrication and acceptance of the support fixture?Does the analysis adequately underpin the design and have they been checked?Has safety been adequately addressed in the design of the support fixture?Can the support fixture be fabricated and installed within the budget and schedule identified in the project baseline?Have all relevant chits from previous design reviews been adequately addressed?

  • VV weight assumed was 3736 lbs.(Half VV period with no ports plus services)1000 lb lateral + gravity load1-3/4 bolt at base14.3 ksi peak VM stress

  • 10.3 ksi1000 lb lateral load + gravity load1-3/4 bolt at base

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1 MC Assembly over the VV FPA Station 3 FDR Review July 17, 2007 T. Brown
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