Summary Technical Specification. In-vessel Survey Development

Transcription

1 Version 1.3 Summary Technical Specification In-vessel Survey Development Page 1 of 8

2 BACKGROUND Background ITER is a joint international research and development project that aims to demonstrate the scientific and technical feasibility of fusion power. The partners in the project - the ITER Parties - are the European Union (represented by EURATOM), Japan, the People s Republic of China, India, the Republic of Korea, the Russian Federation and the USA. ITER will be constructed in Europe, at Cadarache in the South of France. The Machine Assembly and Installation (MAI) section is responsible for all aspects of dimensional control from acceptance testing of the constituent parts through to their final operational alignment. The ITER device consists of many components, assemblies and associated systems which must be accurately and precisely aligned for the machine to operate. This will require meticulous planning and qualification followed by precise and controlled implementation. One such area is the inside of the vacuum vessel where several thousand components shall be custom machined to provide the alignment references for in-vessel systems. This summary technical specification provides an overview of the requirements for a contract to develop the in-vessel survey, analyses, optimisation and custom machining definition process. OBJECTIVES The purpose of this Call for Nomination is to identify potential companies or consortia wishing to tender for the In-vessel Survey Development contract. The company or consortia of companies selected shall be recognised for their knowledge and expertise in Alignment and Metrology (A&M) and will have extensive experience in software development and qualification for metrology applications. The survey shall include several thousand interfaces which need to be measured in an efficient manner to achieve the challenging programme therefore photogrammetry is the system of choice for this survey. The objectives of this contract are to study the survey requirements for in-vessel component interfaces and develop a measurement scheme to meet them. This will include camera locations and positioning strategy, online process monitoring, target designs, data alignment processes, analysis and reporting, virtual assembly qualification, and customisation definition. Software shall need to be developed, to manage the complete process from survey through conditional logic to the delivery of the definition of customisation parameters. The contract shall focus on the requirements for alignment of 440 blanket modules (BMs) which consist of Shield Blocks (SBs) which carry the First Wall Panels (FWPs) lining the inside of the vacuum vessel, figure 1. The alignment is to be achieved by customising approximately 4000 interfacing components however; the system developed shall need to Page 2 of 8

3 be expandable with generic functionality enabling the addition of further component types once their design is finalised. First Wall Panels mounted on Shield Blocks Fig 1: 440 Blanket Shield Blocks carry first wall panels which line the inside of the vacuum vessel Each inner wall SB is aligned by a combination of 4 flexible cartridges and 2 intermodular keys (with nominal gaps) shared between adjacent modules. A centring key is also present however; this does not contact the SB during assembly, its purpose being to resist forces during operation. The customisation process will involve machining the end faces of the flexible cartridges to the correct planar angle and height then boring an access hole and location face to receive fixation bolts. Pads located in the SB will need their interfacing profiles machined to provide the desired interface with the centring and intermodular keys, figure 2. Page 3 of 8

4 Flexible Cartridges Intermodular Key Pads SB Insert Centring Key Pads Figure 2: Ghosted view of Inner SB with interfacing components The outer wall modules are aligned with a similar system however; in this case the keys locate on the stub keys carrying the flexible cartridges, 4 keys per blanket module, figure 3. Flexible Cartridges Key Pads Stub Keys Figure 3: Ghosted views of Outer SB with interfacing components Page 4 of 8

5 ESTIMATED DURATION It is estimated that the contract duration shall be 12 months from receipt of the ITER Organization (IO) order with deliverables as detailed below: Quality Plan Manufacturing and Inspection Plan (MIP) Survey Strategy Report Software Development Plan Software development (interim reviews) In-vessel survey data processing Data alignment and Analysis Customisation Definition Final software release inclusive of operating instructions and qualification report 2 weeks after contract signed by both parties 2 weeks after contract signed by both parties 13 weeks after contract signed by both parties 16 weeks after contract signed by both parties 26 weeks after contract signed by both parties 34 weeks after contract signed by both parties 40 weeks after contract signed by both parties 52 weeks after contract signed by both parties WORK DESCRIPTION The Contractor will be requested to cover areas such as: MEASUREMENT SYSTEM SELECTION AND JUSTIFICATION The contractor shall consider and make recommendations regarding: Hardware and software for data capture Hardware and software for data processing TARGETING METHODOLOGY The contractor shall consider and make recommendations on the most appropriate way to target the features of interest within the survey. Where necessary feature targets / target carriers shall be conceptually designed and their calibration procedures defined. MEASUREMENT GEOMETRY The contractor shall propose measurement geometry for the survey detailing camera locations, target locations and measurements. Proposals shall be included on how to scale the measurement data identify the location of scale distances within the measurement volume and how to achieve them. UNCERTAINTY ANALYSIS THROUGH SIMULATION The contractor shall determine the measurement uncertainty for the proposed geometry using a qualified simulation process. Page 5 of 8

6 ASSESSMENT OF TASK DURATION The survey needs to be carried out in an efficient manner to meet the demanding schedule for the project. The data processing needs to be automated with the end result being a complete set of machining data for customisation. The contractor shall assess the durations and provide a schedule within a clearly defined basis of estimate. BLANKET MODULE ASSEMBLY SURVEY A first wall panel shall be fitted to each blanket shield module and its plasma facing surface and edge faces scanned or digitised, figure 4. The FWPs shall be uniquely matched to their corresponding shield block (SB) to enable optimised alignment in the vacuum vessel. The equipment used for the digitisation process is not yet defined and is outside of the scope of this specification however, it is important that the software developed for manipulating the data can work with the scan data provided. Data import formats shall be specified together with any restrictions applicable to the data import i.e. file type and size. Digital representation of FWP surface in the form of a point cloud Portable Laser scanner Figure 4: Laser scan of FWP surfaces A survey at the rear of the SB will determine the position of its interface features with respect to the FWP, figure 5. Page 6 of 8

7 FWP Portable measurement arm SB Figure 9: Portable arm SB interface measurement IN-VESSEL SURVEY The contractor shall develop the in-vessel survey technique together with measurement plans to assist the survey with its implementation DATA MANAGEMENT AND ANALYSIS On completion of the in-vessel survey, the data shall be aligned to the Tokamak Assembly Datum realised via a control file supplied by the IO. For each blanket module position, the digitised FWP data shall be fitted to the CAD model taking with it the as-built geometry of the interfaces. Combining this data set with the in-vessel survey data will enable all the customisation parameters to be determined. Before producing CAD models for customisation of the interfacing components, a full analysis of the customisation range shall be carried out. The software developed by the contractor shall report all variations from the nominal fit at each interface and flag up any areas where the tolerance is exceeded. The report shall detail the magnitude and direction of all non-compliant locations. Page 7 of 8

8 If the tolerance range is exceeded the offending SBs will need to be moved from their nominal position as per parameters defined by the IO. CUSTOMISATION DEFINITION The contractor shall provide a software solution to calculate the machining requirements for all interfacing components. Parametric models shall be used for this process which is envisaged to take approximately 24 hours. QUALIFICATION To qualify the complete process the contractor shall construct a simulation model with representative measurement uncertainty and defined manufacturing and assembly variation. The model shall then be used to qualify the software functionality and will be the basis for its acceptance. During this process, representative reports shall be output clearly defining the variation to be managed and indicating areas of non-compliance as applicable to the data. The total run time for the adjustment process is envisaged to be 24 hours excluding the time required to review generated reports and to make user defined decisions. QUALITY ASSURANCE REQUIREMENTS The organisation conducting these activities should have an ITER approved QA Program or an ISO 9001 accredited quality system. Any subcontractor(s) shall not be considered to be members of a consortium and the experience and capacity of subcontractors will not be taken into account during the prequalification procedure. TENTATIVE SCHEDULE The tentative schedule is as follows: - Prequalification submission: November Tender submission: January Contracts signature: April 2013 Page 8 of 8