IPP Annual Report 2007 - Max-Planck-Institut für Plasmaphysik ...

led to the establishment of the department ”Configuration
Control” whose tasks became to ensure collision-free operation
at all times. These two new departments were combined
with the department ”Design Office” under the umbrella of
one subdivision in order to simplify fast and effective collaboration
between departments that naturally interact
strongly with one another. After about a half year of operation
this organisation has shown its effectiveness in supporting
the device assembly on all aspects by implementing well
defined fast and transparent work flows with a clear distribution
of responsibilities and comprehensive and up-to-date
documentation.
5.1 Configuration Management
The department Configuration Management (DC-CM) plans,
implements and leads the processes that are required to
ensure permanent consistency between the requirements of
the W7-X system specification and the performance attributes
of its components throughout the life time of the
project. The detailed tasks of DC-CM are oriented at the
common standards of configuration management (CM).
CM for W7-X is being implemented with most efficient use
and interlink of existing processes (change request, nonconformances,
interface control, collision control) and tools
(KKS project structure, the PLM-system, data bases).
5.1.1 Change Management
Change Management (CM) controls all change processes,
preserves configuration control at the interfaces, ensures
documentation and consistent implementation in the configuration
of all changes and variances, and provides orderly
communication of change information within the project.
This includes that CM enables change and non-conformance
decisions to be based on the knowledge of complete
change impact. Processes are controlled via a data base.
Highest priority is given to fast handling of change and
non-conformance processes which are time-critical and
might affect the schedule of device assembly. These are
actively guided and driven by CM and thus accelerated.
CM supports preparation and documentation of the configuration
control board (CCB) meetings and the implementation
of its decisions.
5.1.2 Configuration Status Accounting
A PLM-based concept for the W7-X system documentation
has been implemented. It will give access to the complete
configuration information and finally replace the previous
system specification. A central master document for each
W7-X component, the so called loose leaf book, provides
the description of the function of a component and its positioning
in the project structure and the CAD assembly.
Additionally, the loose leaf book is a navigation tool (via
references in the document and links in the PLM system)
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to access specifications, data sheets, interface descriptions,
design changes, and variances that result from non-conformances.
Provision of interface descriptions and accounting
for change impacts across the interfaces is coordinated by
CM. Masses, materials and their composition are documented
for all components within the torus hall in a material
data base. Additionally, the data base documents the certified
relative magnetic permeability of the materials used and
their certified cobalt content as a basis for assessment of
magnetic field errors and to keep track of the amount of
cobalt, which is limited by the authorities due to its high
neutron activation rate.
5.2 Configuration Control
The main missions of the department Configuration
Control (CC) are to ensure collision-free operation of W7-X
for all modes of operation and to coordinate the space
requests of peripheral components in the torus hall and
adjacent buildings. This is being accomplished by developing
the required tools for generating and book-keeping of
the CAD models of the relevant components by performing
the collision checks and finally by initiating and leading the
processes required to eliminate detected conflicts in collaboration
with CM. W7-X is undoubtedly a device with
high geometrical complexity. Especially in the cryostat one
has to deal with three-dimensional free-form shapes of the
coils snugly located between the heat shields of the thermal
insulation of the plasma vessel and the ports, the coil support
structure the meandering lines of the bus-bars and the cryogenic
helium supply, the diagnostic and quench detection
cables and all the required supports and additional components.
Figure 19 illustrates this situation in the cryostat.
Figure 19: Module 5 of the cryostat (outer vessel shell omitted)