Fusion Engineering and Design 98–99 (2015) 1432–1436
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Metrology for WEST components design and integration optimization C. Brun ∗ , G. Archambeau 1 , L. Blanc 1 , J. Bucalossi, M. Chantant, L. Gargiulo, A. Hermenier 2 , R. Le, A. Pilia CEA, IRFM, F-13108 Saint-Paul-lez-Durance, France
h i g h l i g h t s • • • •
Metrology methods. Interests of metrology campaign to optimize margins by reducing uncertainties. Assembly problems are solved and validated on a numerical mock up. Post treatment of full 3DScan of the vacuum vessel.
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Article history: Received 18 September 2014 Received in revised form 28 May 2015 Accepted 3 June 2015 Available online 2 July 2015 Keywords: WEST Metrology Plasma facing components Integration Assembly Software Leica Laser tracker
a b s t r a c t On WEST new components will be implemented in an existing environment, emphasis has to be put on the metrology to optimize the design and the assembly. Hence, at a particular stage of the project, several components have to coexist in the limited vessel. Therefore, all the difficulty consists in validating the mechanical interfaces between existing components and new one; minimize the risk of the assembling and to maximize the plasma volume. The CEA/IRFM takes the opportunity of the ambitious project to sign a partnership with an industrial specialized in multipurpose metrology domains. To optimize the assembly procedure, the IRFM Assembly group works in strong collaboration with its industrial, to define and plan the campaigns of metrology. The paper will illustrate the organization, methods and results of the dedicated metrology campaigns have been defined and carried out in the WEST dis/assembly phase. To conclude, the future needs of metrology at CEA/IRFM will be exposed to define the next steps. © 2015 Elsevier B.V. All rights reserved.
1. Introduction Tore Supra tokamak is currently turning to WEST platform (Tungsten (W) Environment in Steady-state Tokamak) and will become a test bench for ITER divertor target in order to minimize manufacture and operation risks [1]. To be relevant for ITER, high flux components have to be tested during long pulses and on X point plasma configuration. Thus, the main transformation of the platform consists to install 2 new poloidal field coils inside the vacuum vessel name “Divertor” [2]. This implementation requires the total removal of existing Plasma Facing Components (PFC), as well as the magnetic instrumentation and the inner baking system. Fig. 1
∗ Corresponding author. Tel.: +33 442257200. E-mail address:
[email protected] (C. Brun). 1 Address: SETIS – GROUPE DEGAUD, F-38100 Grenoble, France. 2 Address: HEXAGON METROLOGY, F-91978 Courtaboeuf, France. http://dx.doi.org/10.1016/j.fusengdes.2015.06.005 0920-3796/© 2015 Elsevier B.V. All rights reserved.
presents the final PFCs configuration layout when it will be fully achieved. During the components design phase, real geometry of the inner vessel and ports has to be considered scrupulously to take account of real geometric dispersion. Tore Supra vessel has been built in the 80s and disparities up to some centimeters could be measured between real environment and theoretical CAD models. In this context, the assembly group has to assure the mechanical interfaces between all designs data, which are constitute a batch of 200 complex components have to be assembled. This is achieved by a permanent exchange and check of the whole Tokamak numerical mock-up used by the Design Office (DO). In a first time, all the interfaces had to be checked to qualify components integration and, based on this result, a second metrology phase must be considered to optimize inner configuration. Thus, before WEST assembly, Tore Supra vessel real geometry was checked to validate conceptual margins. Then, with the goal to maximize the plasma volume,
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Fig. 2. Leica TM5100A Theodolite used in Tore Supra in 2000. Fig. 1. WEST inner components configuration.
the two divertors will be set up with a minimum distance from the existing wall. To achieve the metrology campaigns using edge technology, save time, money, effort and enhancing the quality of the measurements, the CEA/IRFM thanks to a partnership with companies skilled in the metrology techniques, metrology tools and having a good practice of their implementation.
2. Industrial partnership for metrology For WEST components integration, a partnership between CEA and 2 expert companies has been signed. In this way, metrology equipment and software platform will be provided by Hexagon Metrology [3], the world leader manufacturer for metrology solutions. Metrology campaigns are defined and carried out by SETIS [4], a Degaud group company based in Grenoble (France) and expert for industrial measurement (EPR reactor, Jules Horowitz, LMJ chamber, CERN). This partnership agreement started in the same phase than WEST components final design. Main objectives were to select the most convenient techniques and processes for all components integration and assembly phases. Industrials are fully involved in WEST sequences and offer assistance during metrology campaigns and data analysis. During the previous Tore Supra assembly from eighties to 2000s the techniques used for positioning the components were mainly based on tapes and on theodolites [5]. A Leica theodolite was used to assemble and measure the position of the inner components in order to achieve 0.5 mm positioning accuracy (see Fig. 2). The theodolite has been used to adjust the nominal required position (radius, azimuth and height) of the main components toward the magnetic wall reference. The magnetic wall reference was defined in 1998 through a measurement of the magnetic field using MNR probes [6]. Thanks to the partnership, new metrology techniques have been implemented, such as tracking and scanning. Laser trackers (LT) are the most frequently used metrology tools. They are used for characterization of surfaces, metrology guided assembly, final (recording) measurements, comparisons of as built and CAD model, etc.. . . LTs are very flexible in use, and show a very high accuracy at the same time. Typical targets for LTs are 1.5 and 0.5 in corner cube reflectors (CCRs). A scanner system can be associated to the LT to digitize the area with a great accuracy <0.1 mm (Figs. 3 and 4).
Fig. 3. Leica Corner Cube Reflector 0.5 .
3. Metrology campaigns planned for WEST For WEST transformation achievement, more than 24 metrology campaigns were defined and started in 2013. Associated with the Tore Supra dismantling phase, firsts campaigns were dedicated on the comparison between the vacuum vessel As-Built geometry and the 3D CAD models (see Fig. 5). Metrology operations were also performed in the same time to keep the measurement referential witch was defined by metrology target placed on removed element. A temporary measurement referential has been built
Fig. 4. Leica AT901 laser tracker during disassembly work in 2013.
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Fig. 5. example of difference between Tore Supra CAD model and the As-Built configuration; the port normally center around the components is hugely “shifted” on the right.
with new metrology target implemented on the inner vessel wall, which represent 126 referential points wisely installed. Definitive measurement referential will be implemented later on WEST components after their assembly. During WEST assembly, about two hundreds batch of components will be set up in the vacuum vessel. It is of paramount importance to set up the components with the scope to minimize gaps with to the inner vessel wall. Thus the WEST project requires to have a thorough knowledge of the vessel geometry and tokamak ports. Results will, in the first time, qualify gaps defined between elements and offer, in a second analysis, opportunity to optimize distances. Each metrology campaign is associated and planned to an assembly sequence. However, in WEST assembly, the metrology campaigns are dissociated to assembly phase Thus, in order to reduce co-activity in this confined environment. The metrology process is composed by five steps as presented below:
Fig. 6. Measurements of vertical ports to validate the interfaces between the inner vessel and divertor supporting structure.
dynamic mode with a pitch of 15 mm (see Fig. 6). A maximal dispersion of 10 mm on the VV vertical ports has been determined after post-processing the data. This result allows us to validate the interfaces and start the manufacturing of the divertor supporting structures. 4.2. Characterization of the VV walls restricting elements
1. Laser tracker installation 2. Laser tracker “orientation” by measurement of the position of the object or component in the basis made of reference points; 3. Characterization of the elements (point measurement); 4. Post-treatment on portable metrology software (modeling surface); 5. Analysis of results.
VV wall prominent parts limit the position of the divertor structure inside the VV. Following a first analysis, the welds in the inner VV wall junction planes were identified as the restricting elements (see Fig. 7). A dedicated metrology campaign using a laser tracker technique was performed which shows that the minimum gap between the divertor structure at its nominal position and the most prominent weld is 16 mm. Thus, data analyses have highlighted an optimization of the divertor position about 12 mm from its nominal position. However, a safety margin from 3 to 4 mm between each divertor and the inner wall keep clear to compensate the machining uncertainties and assembly tolerances.
4. Measurements performed and results
4.3. For vacuum vessel inner walls scanning
The main issue of WEST project metrology phase is to maximize the plasma volume and so to position as close as possible the divertor structure from the vessel. For reach this request from the head of the WEST project without any possibilities to adjustments of the divertor structure after assembly, the mechanical interfaces must be check with a great accuracy. Thus, for divertor integration qualification and position optimization, 2 main metrology campaigns were performed.
In 2014 the opportunity to get access at the inner wall, comes to a decision to scan the VV in order to get an As-built model and
4.1. For ports position and geometry measurement The divertor supporting structure will be attached on the magnetic arms, and it penetrates into the vacuum vessel through the lower and upper vertical ports. As, it cannot be adjusted horizontally, the question of its interfaces with the lower port walls was raised during the design phase for its optimization. A first metrology campaign was devoted to check this interface. The theoretical gap between the lower ports plugs walls and the divertor supporting structure is 16 mm. The laser tracker was used to perform this measurement. The geometry of the wall is measured in
Fig. 7. Measurement of welding edge, VV restricting element.
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Fig. 8. VV scanning material – Leica AT901 with T-Scan.
to improve a reverse engineering study in order to reduce assembly uncertainties. 80% of the inner wall has been scanned in 5 days with an accuracy of 0.1 mm, which represents the measurements of more than 500 million points. The measurement has been made with the laser tracker technique associated to a scanning system (see Fig. 8). This metrology campaign complements the previous ones exposed in Section 4.2 to focus on the areas in comparison with the divertor structure with the objective to maximize the plasma volume. The CAD geometry will be compare with the AS-built environment gets by the scan. This method, permit us to optimize the new interfaces with the AS-built VV geometry including safety margins, to insure the WEST components assembly. As a reminder, the welds in the inner VV wall junction planes were identified as the restricting elements. But, after the disassembly phase of the existing PFCs components in 2013, some others elements in the inner vessel can be considered as the restricting elements. A reverse engineering has been implemented in first to check the interfaces with the WEST components, and in a second time to optimize the position of the divertor. A first post-treatment on the measured datasets is achieved with the metrology software platform Polyworks® (see Fig. 9). The laser tracker technique connected to Polyworks® compute the measures
Fig. 9. View for Tore Supra VV modeling.
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Fig. 10. Distance analyzing between the As-built VV & 3D CAD model of divertor with Polyworks® .
in real time and generates a 3D mesh model will be used to analysis. This model was then used to check the minimum distance of the divertor beam and to get data for the optimization of the design of the pipes, cables and diagnostics integration in the vertical observation ports and in the junction plane exits. In addition, the VV modeling showed that other elements non available in the theoretical CAD models were as prominent as the junction plane welds rims. Fig. 10 presents the distance between the VV modeling datasets and the divertor structure in a color scale from 0 mm (red) to 50 mm (green). With the reverse engineering method, we were able to optimize the position of the divertor closer to VV from 3.5 mm for the lower divertor and 6.5 mm for the upper, without change the design of it. That mean increase the plasma volume to 1%. Moreover, the design on-going of the pipes, cables and diagnostics integration can be improve using a reverse engineering.
5. Conclusion and perspectives The metrology on WEST project is an integral part of the assembly and the Laser tracker techniques are the most frequently used in metrology tools. To help the assembly group, a reverse engineering starts to be used to the integration of the batch of two hundreds components. A daily work between the DO and the assembly group is an ongoing task to achieve the common aim: “WEST assembly”. On the 24 metrology campaigns planned, 4 have been carried out with a support of our partnership. Their know-how and edge technology use, were able to save time, money, effort and enhancing the quality of the measurements. The two first metrology aims planned for the WEST assembly in 2013–2014 have been achieved with the divertor integration and optimization position inside the VV. Thanks to those metrology campaigns, the manufacturing of the divertor has been started with an optimize design for its integration. Now, the metrology continues to help the conception and assembly of WEST components. In the future, a metrology on vacuum and temperature 70◦ should be considered to monitor the divertor during plasma operation. In the second part of the 2014, 3 metrology campaigns are planned to assemble the first WEST components (Magnetic diagnostics, VV protection panels, lower ports,. . .).
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References [1] “The WEST Project,” [Online]. Available: http://west.cea.fr [2] L. Doceul, et al., Design, integration and feasibility studies of the Tore-Supra divertor structure, in: Proceeding of the 27th Symposium on Fusion Technology (SOFT-27), vol. 88, 24–28 September 2012, LIège, Belgium, 2012, pp. 814–817. [3] “HEXAGON METROLOGY,” [Online]. Available: http://www.hexagonmetrology. com
[4] “Groupe DEGAUD,” [Online]. Available: http://www.groupe-degaud.com [5] F. Samaille, J. Cordier, L. Gargiulo, Assembly and set-up of the CIEL project plasma facing components on Tore Supra, in: Proceeding of the 22nd Symposium of Fusion Technology (SOFT), Vols. 66–68, September 2003, Helsinki, Finland, Elsevier, 2003, pp. 335–339. [6] J. Cordier, Determinationof the Tore Supra magnetic axis using MNR probes, in: Proceeding of the Twentieth Symposium on Fusion Technology (SOFT), 7–11 September, Marseille, France, 1998.