Modularization of Machining Graphite Reactor Internalsfor

HTR-PM

2014-9-18

SHANGHAI TOYO TANSO Co., Ltd.

Guobin Zhan

Dalei Yuan

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CONTENT

★Shanghai Toyo Tanso Profile

★Machining requirements and characteristics of machining of graphite reactor internals

★Develop standardized and modularized machining Modularization of materials Modularized machining program Standardization of machining jig Standardized machining internal test Standardized CMM inspection Modularized machining Pre-assembly

★Summary and Subject

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SHANGHAI TOYO TANSO PROFILE

Shanghai Toyo Tanso(STT) which was found by Toyo Tanso Co., ltd in Japan, is one of the four subsidiaries in China. Shanghai Toyo Tanso was established in August 1994, the registered capital is 17.4 million dollars

• Address: No. 486, XinFei Road, Songjiang, Shanghai, China• Gross area: 66000M2

• Buliding area: 20000M2

• Employee:240 STT is mainly specialized in the manufacturing, processing and distribution of various special

graphite products which are widely used in many industrial fields such as semiconductor, photovoltaic, optical fiber, metallurgy, non-ferrous metal, molds, etc.

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SAMPLES OF MACHINED COMPONENTS

15m

Graphite block 3500 pcs

Small parts 26000pcs

MACHINING REQUIREMENTS AND CHARACTERISTICS OF GRAPHITE REACTOR INTERNALS ①

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Top reflector

Side reflector

Hot chamber

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MACHINING REQUIREMENTS AND CHARACTERISTICS OF GRAPHITE REACTOR INTERNALS ②

2m

standard of machining precision:GB/T1800.3-1998

4.5m

High precision geometric dimension and position dimensionLarge number of components3500 pcs Graphite blocks and , 26000pcs small parts High precision 　 requirement for pre-assemblyLong processing lead timeLarge investment

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Standardized quality and size of material

Reasonable machining program High machining precision equipment,

with positioning jigs and tooling Management of machining

environment and Collecting dust Management of processing time Design of lifting tools for pre-

assembly Standardized pre-assembly Standardized inspection and

measurement

Material ： about 4000PcsMachining equipmentt ： Sawing machine 2 Precision machining equipment 13 （ Five axis machining center) CMM 2 Laser tracker 1setEmployees 40 Jig 10setAssembly platform ： 5m*5m 1setMachining program about 160

DEVELOP STANDARDIZED AND MODULARIZED MACHINING

Target: develop a kind of standardized and modularized machining model through reasonable combination of each factor of B to meet the requirements of A.

A. Requirements B. Factor

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Design 12 kinds of standardized material ,according to the drawings, to improve the machining efficiency and material utilization

MODULARIZATION OF MATERIALS

IG-110

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4-2-1

4-2-1-4

The material(IG-110) has been finished. All technical indexes satisfied the design requirements ,especially for Impurity content ,Boron equivalent, Strength and Uniformity. This is a good base for machining and pre-assemble.

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MODULARIZED MACHINING PROGRAM

About 30 kinds

of basic program

combine

Top reflector product

program(about 20)

combineBottom reflector

product

program(about 30)

combine

Hot chamber product

program(about 50)

combine

Side reflector product

program(about 60)

All the machining programs are made in advance

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MODULARIZED MACHINING PROGRAM

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MODULARIZED MACHINING PROGRAM

STT select the most effective processing technology based on lots of validation for typical characteristic of graphite brick, such as mortise and keyslot ,compare the distinction for different processing parameter and technology .

STANDARDIZATION OF MACHINING JIGS

Design modular jig according to the drawings help to reduce time of locating jig , ensure the precision, be convenient operation. 12

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MODULARIZED MACHINING JIGS

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STANDARDIZED MACHINING INTERNAL TEST

The processing equipment is able to check all the key dimension and key structure automatically at every operating station, that means the geometric dimension of component can be checked during machining process.

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STANDARDIZED CMM INSPECTION

More than 170 CMM inspection programs are prepared in advance

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MODULARIZED MACHINING

Machine library

Machine tool library

Machining program library

Cutter library

Inspection program library

HAF003 quality system ， standard procedure

Modularized machining of graphite block

Modularized machining of small parts

Library automation

3-4

3-4-1

3-4-1

3-4

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MODULARIZED MACHINING

Material library

A B

D E …...

C

Machining program library

A B

D E …...

C

Machine library

A B

D E …...

C

Cutter library

A B

D E …...

C

CMM program library

A B

D E …...

C

Machine tool library

A B

D E …...

C

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Step1 ： assemble inner ring

PRE-ASSEMBLY

Step 2 ： clockwise assembly Step 3: counterclockwise assembly

Step 4:Assemble final 4 components

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SUMMARY AND SUBJECT

• It is difficult to satisfy the requirement of the quality and delivery time with traditional machining mode. Making process easy to handle, STT is developing an efficient way which can make the task can be done by a style of standardization and modularization. That means we arrange and organize 4M1E (Man, Machine, Material, Method and Environment) based on standardized or modularized processes. STT have confidence that we can deliver qualified graphite reactor internal to client according to the contract .STT will make contribution to HTR-PM.

• The machining process has already started from this month, will be completed in July 2017. The overall processing time is over 50,000 hours! The subject to be discussed for the next coming HTR projects is how to improve the machining efficiency further more based on the practice in STT this time, for example, how to shorten processing time from 22 months to 12 months.

• Hereby, thanks our client, Chinergy ,Tsinghua University and Huaneng group, they offer great support and help for the machining project, also thanks our talent staffs, T.Imamura, G.Hatou, Jian Liang, Gang Hu, Dalei Yuan, and others, they contribute their wisdom and effort which could be make the machining process in a kind of modular style.

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Thanks for your attention.