11 ASSEMBLY – Pascal CHAMP / Cegelec
Nice � France10-12 December 2007
Acropolis Congress Centre
LMJ VV Assembly – Experience of the Industryby Cegelec
ASSEMBLY
Pascal CHAMP
Cegelec
22 ASSEMBLY – Pascal CHAMP / Cegelec
Agenda
Brief Cegelec presentation
Cegelec contribution to LMJ project
Technologies and skills required for VV assembly – example of LMJ VV
LMJ VV Pictures History of Assembly
33 ASSEMBLY – Pascal CHAMP / Cegelec
The Cegelec group, in brief
An integrated global group providing technological services to private companies and public authorities
� 26,000 staff
� Sales = nearly 3,1billion euros
Energy and Electricity
Automation, Instrumentation and Control
Information & Communication Technologies
HVAC, Mechanics, Mechatronics
Long-term service agreements
Sales by business activity
12 %
18 % 56 %
7 %
7 %
44 ASSEMBLY – Pascal CHAMP / Cegelec
Cegelec offers strong assets for the ITER project
� Cegelec CEM
expert in global projects for nuclear and scientific applications
� Cegelec Energy
Real time and safety control and instrumentation in nuclear environment
� Cegelec CNDT
Non destructive testing in nuclear power plant, developing processes and providing multiple services
� Cegelec CFB
expert in electrical power supply, ventilation and site security –strong local presence at Cadarache site.
55 ASSEMBLY – Pascal CHAMP / Cegelec
Cegelec’s contribution to LMJ project
Vacuum Vessel : Design, construction and installation of the test chamber for the LMJ (MegaJoule Laser) project. (completed 2006)
SAHA : Engineering and Assembly of the Amplifying Section (excluding amplifier) and installation of the URL
EMM: Design & construction of assembly and maintenance equipment (20 Transportation & Transfer Vehicles for the LMJ and 7 for the LIL -Travelling Platform to the Support Building - Transfer boxes and containers for the optics). (completed 2007)
Supporting frame : Design & construction of the metallic framework used to support the laser lines.
Electrical installation : Power supply, and low voltage installations
66 ASSEMBLY – Pascal CHAMP / Cegelec
LMJ VACUUM VESSEL
Main steps• Factory pre-fabrication of boilerwork sub-assemblies for the chamber (shaping, machining, welding):
- 140 T of Aluminium (AW 5083)- 12 sectors - 100 mm thick- 2 caps - between 100 and 120 mm thick-203 crossbeams of between 200 and 1950 mm in diameter
• Final assembly of the chamber in a dedicated on-site workshop (machining, welding, testing)
• Handling of the assembled chamber (10 metres in diameter, 110 tonnes) - moving it into the LMJ test room - setting on its pedestal at 12 metres high.
• Installation of the concrete biological shielding. (400 mm – 220 T)
( Global Leakage rate : 10-6 Pa.m3/s - Degazing rate < 2.10-6 Pa.m/s after 4h )
MASTERY of
• Engineering
• Forming
• Welding
• Machining
• Tests
• Vacuum technics
• Handling
Keypoints to success
77 ASSEMBLY – Pascal CHAMP / Cegelec
SHORTCUT of ASSEMBLY
PLANT MANUFACTU
RING
SITE MANUFACTU
RING
Assembly of 6 shell segments
Assembly of northpôle
Assembly of
south pôle
Assembly of shell
Forming / Machining of plates
Building of site workshop and
tools
Assembly of pôles
Assembly and Welding of crossbeams
88 ASSEMBLY – Pascal CHAMP / Cegelec
ENGINEERING
Keypoints to success
• Design Engineering
• Manufacturing Engineering
• Integration Engineering
99 ASSEMBLY – Pascal CHAMP / Cegelec
Integration Engineering -> Workshop and Toolings on customer site, designed by Cegelec
14 Septembre 2004
1010 ASSEMBLY – Pascal CHAMP / Cegelec
Forming
Press forming 3D
Rolling, folding
1111 ASSEMBLY – Pascal CHAMP / Cegelec
Welding
Different methods
• Electron Beam (crossbeams)
• MIG process, adapted to thick filler wire
• Development of dedicated welding toolings
1212 ASSEMBLY – Pascal CHAMP / Cegelec
Machining
Several stages,
• Welding edges machining
• Sectors rings assembly
• Crossbeams holes
• Tapping plates surfaces
Gross and final machining,
• Portable machine tools, with displacement controlled in a 3D referential, coupled to Laser tracking system
1313 ASSEMBLY – Pascal CHAMP / Cegelec
Machining
1414 ASSEMBLY – Pascal CHAMP / Cegelec
Tests
Welding tests
Leakage tests
Geometric tests
1515 ASSEMBLY – Pascal CHAMP / Cegelec
Vacuum Technics
Design, manufacturing and controls -> vacuum target constraints
1616 ASSEMBLY – Pascal CHAMP / Cegelec
Handling and Transport
1717 ASSEMBLY – Pascal CHAMP / Cegelec
CEGELEC CEM capabilities summary
Engineering capabilities : Design engineering with Knowledge of Design & Calculation according to CODAP and RCC-MR – Assembly engineering with site works and commissionning
Development of Site Manufacturing methods and tools : Site Welding,
Site machining, Site workshop, specific jigs.
Experience of updating the numerical virtual mock-up : all along the manufacturing of parts & segments, in order to ensure a properfeedback for assembly
Anticipation of assembly troubles
Experience of Clean-up and Ultra vacuum constraints : clean-up ISO 8 level – Global Leakage level 10-6 Pa m3s-1 – Local and global leakage test.
1818 ASSEMBLY – Pascal CHAMP / Cegelec
CONCLUSION
Cegelec’s vision of Key success factors
• Integrated team with a mix design – manufacturing – site works at each stages from early design to integration
• Developments and tests done early before site works ateach stage – allows anticipation and correction of troubles
• Constant questioning : toolings, process modifications, ….
• Keep flexibility to manage interfaces evolutions
• Proper Management of various technologies, in-house or external expertise - Networking
1919 ASSEMBLY – Pascal CHAMP / Cegelec
Time history of Assembly
2020 ASSEMBLY – Pascal CHAMP / Cegelec
ASSEMBLY of 1st Sector on tooling
18 A
oût 2
004
2121 ASSEMBLY – Pascal CHAMP / Cegelec
ASSEMBLY of 3rd – 4th – 5th sectors
16 Septembre 2004
29 Septembre 2004
11 Octobre 2004
2222 ASSEMBLY – Pascal CHAMP / Cegelec
Sectors welding
14 Janvier 2005
2323 ASSEMBLY – Pascal CHAMP / Cegelec
Welding edges machining
9 Février 2005
2424 ASSEMBLY – Pascal CHAMP / Cegelec
NORTH POLE ASSEMBLY
14 Février 2005
14 Février 2005
14 Février 2005
2525 ASSEMBLY – Pascal CHAMP / Cegelec
SOUTH POLE ASSEMBLY
24 Mars 2005
2626 ASSEMBLY – Pascal CHAMP / Cegelec
ULTRASONIC TESTING of WELDINGS
2 Février 2005
2727 ASSEMBLY – Pascal CHAMP / Cegelec
GROSS MACHINING of CROSSBEAMS HOLES
12 Décembre 2005
2828 ASSEMBLY – Pascal CHAMP / Cegelec
STRENTGH RELAXATION after MACHINING
27 Mai 2005
5 Juin 2005
2929 ASSEMBLY – Pascal CHAMP / Cegelec
Positioning rods implant for machine tools support –Laser tracking system
24 Juin 2005
3030 ASSEMBLY – Pascal CHAMP / Cegelec
FINAL CROSSBEAMS HOLES MACHINING
1er Août 2005 – 30%
11 Août 2005 – 50%
28 Août 2005 – 100%
3131 ASSEMBLY – Pascal CHAMP / Cegelec
CROSSBEAMS ASSEMBLY
7 Octobre 2005
3232 ASSEMBLY – Pascal CHAMP / Cegelec
CROSSBEAMS WELDING
20 S
epte
mbr
e 20
05
3333 ASSEMBLY – Pascal CHAMP / Cegelec
CLEANING and TAPPING of the VV
Juin 2006
Juin 2006
3434 ASSEMBLY – Pascal CHAMP / Cegelec
CROSSBEAMS LEAKAGE TESTS
Juin-Juillet 2006
3535 ASSEMBLY – Pascal CHAMP / Cegelec
GLOBAL LEAKAGE TEST OF VV
30 A
oût
2006
3636 ASSEMBLY – Pascal CHAMP / Cegelec
TRANSFERT from SITE WORKSHOP to FINAL EXPERIENCE HALL
November 2006
3737 ASSEMBLY – Pascal CHAMP / Cegelec
HANDLING into EXPERIENCE HALL