VV procurement by the EU

Transcription

1 ITER Business Forum Meeting Nice, December 13, 2007 VV procurement by the EU L. Jones, EFDA 1

2 CONTENTS 1. VV Sharing and EU Scope 2. VV Contract Requirements 3. VV Specification 4. EU companies and Institutes involved in the ITER/EU VV Sector Manufacture Design and R&D 5. ITER/EU VV Sector Manufacture Design and R&D 6. VV Sector Construction Stages 7. Proposed EU VV Sector Manufacture Schedule 2

3 The VV is shared between 4 Parties Korea 2 Sectors, Equatorial and Lower ports, Vessel Supports) Russia Upper Ports India In-wall shielding EU 7 Sectors The EU contract will be to make 7 D-shaped Sectors and then weld the upper and lower ports to them The VV Sector Assembly is to be carried out by the EU under a different contract and will not be presented here 3

4 VV Contract Requirements The VV Sector Tender for 7 ITER VV Sectors will be for firms or consortia which have the capabilities as follows: Large assembly workshop with 600 Ton crane and height access of 15 m Facilities for machining large and heavy components Experience in quality welding of stainless steel thick sections Access to deliver the 13m x 7m x 7m Sectors to a sea port High level of Quality Assurance Certification Highly qualified engineering personnel for CAD design, analysis, inspection, programme management and QA Access to advanced computer engineering calculation facilities and programs A project management team with considerable experience in procurement and subcontracting of large stainless steel components Advanced NDT (Ultrasonic and X-ray Inspection) experience and facilities Tender Issue September, 2008 Contract Start May,

5 EU companies and Institutes involved in the ITER/EU VV Sector Manufacture Design and R&D 19 Companies and Institutes in 9 Countries have contributed to the work shown in this presentation Czech Republic 1. Institute of Applied Mechanics, Brno Finland 1. Hollming Works, Kankaanpää Works Oy 2. Univ. of Tampere France 1. AREVA, Lyon 2. DCNS, Nantes 3. CEA, Arceuil 4. CEA, Saclay Germany 1. AREVA, Erlangen 2. MAN-DWE, Deggendorf 3. Pro-Beam, Burg Holland 1. NRG, Petten 2. Exploform, Rijswijk Italy 1. Ansaldo Ricerche, Genoa 2. SIMIC, Camerana Slovenia 1. Univ. of Ljubiana Spain 1. Iberdrola, Madrid 2. Technatom, Madrid UK 1. Phoenix Inspection Systems, Warrington 2. TWI, Abington 5

6 EU VV Sector Manufacture Design and R&D Sector Manufacturing Possible Manufacturing Routes No-Segments With Segments Biggest problem is the tight tolerances, +-10 mm and +-5 mm at the edges Finished Segments Semi-Finished Segments Finished Segments E-Beam Welded Finished Segments Arc Welded Semi-Finished Segments Arc Welded 6

7 No-Segments VV Construction Method The Inner shell is first completed with a jig with large hydraulic jacks, which can force correct shape. The inner segment is completed with the outer shell by EB welding A local E-Beam welding system is used to weld the inner shell to the housings Advantage is that the shape can be very well controlled Disadvantage is that all the work is done in a large facility 7

8 Semi-Finished Segments VV Construction Method The Segments are completed apart from the outer shell, with heavy jigs welded to the inner shell to prevent distortion The Segments are joined and then the outer shell added Advantage is that the Segment joining can be made without undue distortion Disadvantage is that the jigs are expensive to make and remove 8

9 Finished Segments VV Construction Method The Sector is divided Poloidally into 4 Segments Inboard (shown here) - Upper - Equatorial - Lower Each Segment is finished before being welded to the others There is a problem with the joining of the segments to maintain the shape Disadvantage is that the segment joining may lead to distortion Advantage is that each Segment can be made is a smaller facility 9

10 Finished Segments VV Construction Method R&D Sector Model (1) A ful-sized part of a poloidal sector, weighing 20 Tons, was constructed by Ansaldo/SIMIC Italy, including the Segment joint between the inboard and upper Segment. A frame was included to replace the stiffness of the rest of the Sector and obtain realistic distortion results 10

11 Finished Segments VV Construction Method R&D Sector Model (2) WELD DISTORTION PREDICTION To gain information on welds shrinkage and deformations, all types of welded joints were reproduced, simulating their constraints, by validation mock-ups with temperature and distortion measurements Housing Outer Shell The structure was built up on heavy 80 mm thick jigs, welded to the inner shell Inner Shell Rib JIG Two Segments were finished separately on the jigs. The cylindrical parts welded with EB welding 11

12 Finished Segments VV Construction Method R&D Sector Model (3) WELD DISTORTION PREDICTION The joint between the two segments was welded. The distortion were measured by 3D Laser Scan with a grid spacing 70x70 mm 85% of the surface (blue points) complies with the target fabrication tolerances (± 5 mm) All surfacesare within the 10 mm required tolerance 12

13 Finished Segments VV Construction Method R&D Sector Model (4) SYSWELD Weld Distortion Analysis The complete assembly process was simulated with computer analysis by IAM, Brno 34 weld joints with 1970 beads were used in a Local-Global method There was very good agreement between measurement and calculation This method can (and will) be used to predict the distortion for the complete VV Sector fabrication 13

14 Finished Segments VV Construction Method Using E Beam Welding only (1) With the conventional fabrication method, the structure is built starting with the inner shell, adding ribs and cylindrical features, and then carrying out the closure weld The disadvantage is that the arc welding produces large distortions unless controlled In this all-eb welded method, the box structure is first produced, then the cylindrical features stepwise added Thus all welds may be inspected through the access holes 14

15 Finished Segments VV Construction Method Using E Beam Welding only (2) This all-eb welded method is possible due to the existence of very large EB chambers at Pro- Beam, Germany, and DCNS and CNIM, France 15

16 Finished Segments VV Construction Method Using E Beam Welding only (3) First at DCNS, Nantes, a smaller validation mock-up has been constructed to verify the techniques and welding processes The shells are held by clamps and machined so that the precise fit-up with the ribs is achieved 16

17 Finished Segments VV Construction Method Using E Beam Welding only (4) The manufacture of the full-size inboard segment is proceeding. The shielding blocks can be easily lowered from above and secured through the access holes to be used later for cylindrical features 17

18 VV Sector R&D UT Inspection (1) Technatom, Spain: Use of existing scanning device to Sector mock-up for UT inspection 18

19 VV Sector R&D UT Inspection (2) At Phoenix Inspection and CEA Saclay (with phased array), specialised UT techniques have been developed to reliably inspect the one sided closure welds of the outer shell, where no access to the root side is possible 19

20 VV Specification The Appendices form the bulk of the Specification and include: 14 Mandatory Technical Appendices 6 Informative Technical Appendices MANDATORY Manufacturing Requirements Welding Procedures Specifications 2-D Drawings NDE Methods Dimensional Inspection APPENDICES Additional Testing Packing, shipping and handling Supplier structural verification Final Acceptance Validation Mock-ups INFORMATIVE APPENDICES Vacuum Vessel Description Possible Manufacturing Routes ITER Structural Calculations Previous VV R&D 3-D CATIA models Vacuum Requirements Engineering Analysis Pressure, Flow Testing Information required for Tender Information valid only for Tender 20

21 VV Sector Construction 1 Pre-Procurement Procurement of Stainless Steel Base Material by F4E Forgings produced for EB welded VV Prototype The ITER Grade 316 (N) material has up to a 15 month delivery period, so to avoid schedule delays, F4E will purchase about 40% of this material for freeissue to the Supplier 21

22 VV Sector Construction 2 Design Studies Mock up Designs Design Calculations + SYSWELD Manufacturing Procedures Intermediate Design Review Manufacturing Drawings Documentation for the Notified Body The first design activity is to complete the concept of the assembly method and design the Validation Mock-Ups An important milestone after 5 months is the ITER design review to include calculation and French Authority acceptance of design, before the manufacturing drawings and material procurement can proceed 22

23 Manufacturing Development VV Sector Construction 3 Validation Mock-Ups and Studies are required to ensure that the ITER specification is achieved. A. Large Mock-ups, Machines and Studies to ensure manufacturing tolerances A1. Segment joining - inboard and outboard welding access and distortion A2. SYSWELD calculations and validation of model of assembly method with instrumented welding coupons A3. Development of special machines for manufacture, e.g for local machining of FH bores and Sector Edges and EB local welding of Housings to Inner Shell B. Smaller Mock-ups to validate special ITER requirements B1. One sided welding issues Gas protection and UT Inspection B2. Shell Surface Water channels Cleaning, Corrosion, Cleaniness B3. Shell Surface Vacuum facing High Vacuum performance, Emissivity B4. Shielding Plates Assembly, especially at segment joints 23

24 Tooling Fabrication VV Sector Construction 4 Procurement of machining device Jig Fabrication Jig-Supports Erection Frames Upending Frame Vertical Support Transportation frame The assembly method assumed here uses steel jigs which must have a greater stiffness than the VV in order to suppress most of the welding distortion 80 mm thickness plate with a total weight the same as the finished VV construction is used The jigs are not re-useable as they have to be massively welded to the inner shell 24

25 The duration of the most complicated and largest (36% of total) segment is 1 year and 2 months. The triangular section introduces severe complications VV Sector Construction 5 Lower Segment Production Triangular Support Fabrication Welding to Inner Shell Pieces Inner Shell Pieces welding Ribs to Inner Shell Welding Port Stub Welding Housings m/c+ EB Weld Outer Shell welding 25

26 VV Sector Construction 6 Auxiliary Items Production The manufacture of Blanket Manifolds, brackets and splice plates does not lie on the critical path 26

27 Assembly to form Sector VV Sector Construction 7 Bring in the segments in sequence Lower-Inboard- Equatorial-Upper Ports Welding Cutting, Surface Cleaning Removal of Jigs The Finishing Frame works, required to achieve the tolerances includes: the machining of each flexible housing bore > 200 per Sector the machining of the thread of each flexible housing the machining of each key facing surface the machining of the edges of the Sector with a J welding preparation 27

28 VV Sector Construction 8 Testing, Assembly of Auxiliary Items and Delivery Vacuum Leak Tests Pressure Test Installation of Blanket Manifolds, Diagnostics Dimensional and Final Acceptance Packing Shipping to Cadarache The execution of the Vacuum Leak testing involves the construction of a temporary enclosure for the Helium gas and pumping of the VV interspace. Should any leaks occur, there may be considerable delays before the leak is localised 28

29 VV Sector Schedule 29