Modularization of Machining Graphite Reactor Internals
for
HTR-PM
Guobin Zhan
Dalei Yuan
2014-9-18
SHANGHAI TOYO TANSO Co., Ltd.
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
2
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.
3
SAMPLES OF MACHINED COMPONENTS
4
MACHINING REQUIREMENTS AND CHARACTERISTICS OF
GRAPHITE REACTOR INTERNALS①
Top reflector
Side reflector
15m
Hot chamber
Graphite block
3500 pcs
Small parts 26000pcs
5
MACHINING REQUIREMENTS AND CHARACTERISTICS OF
GRAPHITE REACTOR INTERNALS ②
4.5m
standard of machining
precision:GB/T1800.3-1998
High precision geometric dimension and position dimension
Large number of components
3500 pcs Graphite blocks and , 26000pcs small parts
High precision requirement for pre-assembly
Long processing lead time
Large investment
6
DEVELOP STANDARDIZED AND MODULARIZED MACHINING








A. Requirements
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 preassembly
Standardized pre-assembly
Standardized inspection and
measurement
B. Factor
Material ：about 4000Pcs
Machining equipmentt ：
Sawing machine
2
Precision machining equipment 13
（ Five axis machining center)
CMM
2
Laser tracker 1set
Employees 40
Jig
10set
Assembly platform ：5m*5m 1set
Machining program about 160
Target: develop a kind of standardized and modularized machining model through
reasonable combination of each factor of B to meet the requirements of A.
7
MODULARIZATION OF MATERIALS
IG-110
The material(IG-110)
has been finished. All technical
4-2-1
indexes
satisfied the design requirements ,especially for
4
Impurity content ,Boron equivalent, Strength and
4-2-1-4
Uniformity. This is a good base for machining and preassemble.
Design 12 kinds of standardized material ,according to the drawings,
to improve the machining efficiency and material utilization 8
MODULARIZED MACHINING PROGRAM
All the machining programs
are made in advance
9
MODULARIZED MACHINING PROGRAM
10
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 .
11
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
MODULARIZED MACHINING JIGS
13
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.
14
STANDARDIZED CMM INSPECTION
More than 170 CMM inspection
programs are prepared in advance
15
MODULARIZED MACHINING
HAF003 quality system， standard procedure
3-4-1
3-4-1
Modularized machining of
small parts
Library
automation
Machine
library
Machine
tool library
Machining
program
library
3-4
3-4
Modularized machining
of graphite block
Cutter
library
Inspection
program
library
16
MODULARIZED MACHINING
Material library
Machine library
A
D
B
E
C
A
B
C
Machine tool library
D
E
…...
B
D
E
B
D
E
C
…...
C
…...
…...
CMM program library
Machining program
library
A
A
A
B
D
E
C
Cutter library
A
B
D
E
C
…...
…...
17
PRE-ASSEMBLY
2：clockwise assembly
StepStep
3: counterclockwise
assembly
Step1 ：assemble inner ring
Step 4:Assemble final 4 components
18
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.
19
Thanks for your attention.
20