Pascal CHAMP, CEGELEC

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


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


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 %


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.


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


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


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


ENGINEERING

Keypoints to success

• Design Engineering

• Manufacturing Engineering

• Integration Engineering


Integration Engineering -> Workshop and Toolings on customer site, designed by Cegelec

14 Septembre 2004


Forming

Press forming 3D

Rolling, folding


Welding

Different methods

• Electron Beam (crossbeams)

• MIG process, adapted to thick filler wire

• Development of dedicated welding toolings


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


Machining


Tests

Welding tests

Leakage tests

Geometric tests


Vacuum Technics

Design, manufacturing and controls -> vacuum target constraints


Handling and Transport


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.


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


Time history of Assembly


ASSEMBLY of 1st Sector on tooling

18 A

oût 2

004


ASSEMBLY of 3rd – 4th – 5th sectors

16 Septembre 2004

29 Septembre 2004

11 Octobre 2004


Sectors welding

14 Janvier 2005


Welding edges machining

9 Février 2005


NORTH POLE ASSEMBLY

14 Février 2005

14 Février 2005

14 Février 2005


SOUTH POLE ASSEMBLY

24 Mars 2005


ULTRASONIC TESTING of WELDINGS

2 Février 2005


GROSS MACHINING of CROSSBEAMS HOLES

12 Décembre 2005


STRENTGH RELAXATION after MACHINING

27 Mai 2005

5 Juin 2005


Positioning rods implant for machine tools support –Laser tracking system

24 Juin 2005


FINAL CROSSBEAMS HOLES MACHINING

1er Août 2005 – 30%

11 Août 2005 – 50%

28 Août 2005 – 100%


CROSSBEAMS ASSEMBLY

7 Octobre 2005


CROSSBEAMS WELDING

20 S

epte

mbr

e 20

05


CLEANING and TAPPING of the VV

Juin 2006

Juin 2006


CROSSBEAMS LEAKAGE TESTS

Juin-Juillet 2006


GLOBAL LEAKAGE TEST OF VV

30 A

oût

2006


TRANSFERT from SITE WORKSHOP to FINAL EXPERIENCE HALL

November 2006


HANDLING into EXPERIENCE HALL

Documents

Pascal CHAMP, CEGELEC