The ITER Magnet System: Status of Design and · PDF fileThe ITER Magnet System: Status of...

The ITER Magnet System:Status of Design and Procurement

� Introduction� ITER Magnet System Design� ITER Magnet System R&D� Main Manufacturing Challenges� Procurement Sharing and Schedule�Summary

H. Rajainmäki, A. Bonito-Oliva, C. Sborchia and A. VostnerF4E Magnet Group, Barcelona

Hannu Rajainmäki, Summer School, Kullaa, 17 June 2008 Slide 2

Intro – Tokamak

• ITER uses the TOKAMAK magnetic confinement concept:


Intro - The core of ITER

Toroidal Field CoilNb3Sn, 18, wedged

Central SolenoidNb3Sn, 6 modules

Poloidal Field CoilNb-Ti, 6

Vacuum Vessel9 sectors

Port Plugheating/current drive, test blanketslimiters/RHdiagnostics

Cryostat24 m high x 28 m dia.

Blanket440 modules

Torus Cryopumps, 8

Major plasma radius 6.2 m

Plasma Volume: 840 m3

Plasma Current: 15 MA

Typical Density: 1020 m-3

Typical Temperature: 20 keV

Fusion Power: 500 MWMachine mass: 23350 t (cryostat + VV + magnets)- shielding, divertor and manifolds: 7945 t + 1060 port plugs- magnet systems: 10150 t; cryostat: 820 t

Divertor54 cassettes


Intro – ITER in practice

• ITER tokamakbuilding - full of auxiliaries


Intro – Superconducting Magnets

� The development of superconducting magnets for fusion started inthe 1970’s (for example the T-7 and T-15 at Kurchatov Institute with forced flow and flat cable embedded in Cu), in the quest to achieve higher magnetic fields and longer plasma pulses.

� Tore Supra and other superconducting devices with NbTisuperconductors started operation in 1980’s-1990’s.

� Advanced multi-strand Nb3Sn superconductors have been developed to increase the operating magnetic fields.

� Cable-in-conduit conductors (CICC) have been selected due to the large volume, energy and required stability for these magnets.

� The development to magnets for steady-state fusion devices has included the ITER Model Coils in the late 1990’s.



48 superconducting coils:– 18 TF coils– 6 CS modules– 6 PF coils– 9 pairs of CC– Feeders

ITER Magnet System

41 GJ vs. 10.5 GJ magnetic energy in the 27 km Tunnel in the Large Hadron Collider at CERN


Magnet Design Features

� TF & CS Coils use Nb3Sn superconductor due to large operating field (TF 11.8 T, CS 13.0 T)

� TF Coils wound in double pancakes, thin wall circular conductors embedded in stainless steel radial plates

� CS Coils wound in hexa- or quadru-pancakes with thick wall circular-in-square conductors

� PF Coils are manufactured in NbTi, since operating field is < 6.5 T, wound in double pancakes with circular-in-square conductors

� Stainless Steel Jackets are used in the superconducting coils and they are designed to operate at high operating fields and for a large number of cycles (60,000)

� Stainless Steel TF Coil Cases with their intercoil structures form the main support structure of the magnet system

� Composite Pre-compression Rings at the inner leg of the TF coils to relieve tensile stresses and fatigue in the structures

� High Strength Insulated Shear Keys and Bolts for the connection at inner and outer intercoil structures


Main Design Issues

�� Large stored energyLarge stored energy � impact on conductor design and insulation voltages

�� Large current and forces:Large current and forces:� Conductor degradation under electro-magnetic load� Stringent mechanical requirements on conductor jackets� Large steel fabrication (welding, forging, etc.) with tight

tolerance requirements for support structures

�� Large nuclear heatingLarge nuclear heating on conductor � impact on cooling requirements

�� Neutron irradiationNeutron irradiation � impact on insulation selectionimpact on insulation selection

�� High electric voltage (in vacuum)High electric voltage (in vacuum) � impact on insulation selection and quality control procedures


Conductor Concept

� High amperage conductor (large ampere turns and acceptable voltages)

� Large heat removal capability (nuclear heat, AC loss, …)� High stability (local disturbances and peak loads) � High mechanical strength (hoop and out of plane forces)� Quench protection (hot spot limitation)

RequirementsRequirements

SolutionSolution� Large number of parallel superconducting strands to enable high currents� Cabling with ~1/3 void between strands for coolant (supercritical He)� Outer jacket of high strength material to withstand high loads� Flexible design: variable currents by changing size

→→→→ Cable-in-Conduit Conductor


Conductor DesignSub-cable Wrap Central Cooling Channel

Spiral

S/C Strand

Cu Strand

Cable Wrap

Jacket

Sub-cable

• All four magnet systems (CS, TF, PF and CC) are using the same concept • Strand type (NbTi or Nb3Sn) defined by max. field• Number of strands defined by nominal current, typically 1000 strands in 6 bundles• Supercritical He flows in void• Conductor operating conditions:

�� 5K with margin of 0.7K for Nb3Sn @ 11.8-13.0 T�� 5K with margin of 1.5K for NbTi @ 4.0-6.4 T

• Outer conduit material and shape (steel, round) defined by magnet design


CICC is the most used option in CICC is the most used option in fusion magnetsfusion magnets


Toroidal Field (TF) Coils

Nb3SnSuperconductor

5Operating temperature (K)

12.6Height (m)

~310Weight (t)

7Max. voltage (kV)

11Discharge time constant (s)

~400Centering force per coil (MN)

134Number of turns

68Operating current (kA)

11.8Max. conductor field (T)

~41Total stored energy (GJ)

18Number of coils

Design confirmation by Model Coil project launched in 1996


TF Winding Pack

Radial Plate

Cover Plate

Conductor

Holes for VPIDP insulation


TF - Joints and hydraulic connections

Very busy region….insulation must be applied by hand (typically resin wet glass/kapton & pre-made G10 sleeves…high risk area …intermediate Paschen tests

(or equivalent) needed to check quality insulation between assembly steps.

Electrical Joints

High voltage and sensors wiring

Helium inlets/outlets: high voltage

HV breakers


TF - The impact of high voltage: selection of insulation type

0.10.01Co-wound QD tape to conductor

183.5 (7 for a few ms)

WP to ground

2.41.2 (2.4 for a few ms)

DP to DP

1.20.6 (1.2 for a few ms)

Turn to RP

Fault scenarioVf (kV)

Normal Operation (fast discharge) Vn

(kV)

Voltage during TF coil operation

…has driven decision to utilize of Kapton as insulation barrier ….

TF Coil Conductor

17 layers of Glass/Kapton

>3 layers of Glass/Kaptonhalf lapped

For NbSn coils (TF and CS) the insulation must be applied after the heat treatment


TF - The impact of radiation & stress: selection of resin

• Existing industrial epoxies usable for VPI degrade at the design neutron fluence with no margin for operation

• New thermoset material (Cyanate Ester) presents one order of magnitude higher radiation hardness with ultimate far beyond the operational values at the expected fluence

⇓Main issues are:

• Very expensive … but small fraction of overall cost & possible to use blends.

• No experience with such resin on impregnation of (large) superconducting magnets.

Tests on-going at ASG (Genoa) to impregnate a 1m long mock-up with a blend CE-DGEBA (40-60%)

⇓⇓⇓⇓Still very modest compared to TF Still very modest compared to TF

coils !coils !


Electromagnetic Forces on TF coils: – In-plane forces:

• 403 MN centripetal force• Outward forces in the outboard leg

which induce an outwards movement

– Out-of-plane forces:• Overturning moments

⇓⇓⇓⇓

TF -Mechanical Structure

• TF radial extension is mainly determined by the structure• Mostly Stainless Steel cross section• Critical current density of superconductor at operating conditions has only minor impact


TF -The E.M forces are created by

• Friction between coils– Cylindrical closed vaulted shape

formed by the 18 wedged coils at the inner nose

• IIS– 13 shear keys located between

adjacent TF coils

• OIS– Upper and lower OIS– 4 bands of Intermediate OIS

• Pre-compression system reduces the stresses globally, especially the tension loads at the OIS, and reduces fatigue at the IIS shear keys



TF Conductor Development – Stages

Procurement of Advanced StrandProcurement of Advanced Strand

Single StrandsSingle Strands Sub Size SamplesSub Size Samples Full Size SamplesFull Size Samples

Jacketed Jacketed StrandsStrands

Sub Size Sample Sub Size Sample ManufactureManufacture

Full Size Conductor Full Size Conductor ManufactureManufacture

Sub Size Sample Sub Size Sample TestingTesting

Cross Checking Cross Checking and and

Extended TestsExtended TestsFull Size Full Size

Sample TestSample Test

Full Size Sample Full Size Sample ManufactureManufacture

Bending Strain Bending Strain TestsTests

Conductor Procurement Qualification Samples

(CPQS)


SULTAN: Test Facility for Conductors

•SULTAN (SUpraLeiter Test ANlage)

•Split solenoid coil: Allows tests in various magnetic field orientations up to 12 T field and 100 kA current

•Operated by CRPP (Switzerland)

•Unique in the world: All ITER full size conductors are to be qualified using SULTAN test results


EFDA Dipole: Test Facility for Conductors

[A. Portone et al., presented at MT20, Philadelphia, accepted fo[A. Portone et al., presented at MT20, Philadelphia, accepted for publication in IEEE Trans. Appl. Supercond. 18]r publication in IEEE Trans. Appl. Supercond. 18]


LN2-Shield

Current lead80kA - Pole

Current lead80kA + Pole

Bus bar type2

Cold storage vessel

TF-model coil TFMC

Support leg

Inter-coil structure

Auxiliary structure

Safety flap

Vacuum vessel

Bus bar type1

40 mm

80kA

TF Model Coil (TFMC) R&D during ITER-EDA

Conductor (LMI)

Dummy Double Pancake Complete TF Model Coil (AGAN Consortium)

Test in TOSKA (FzK)


TFMC Test Results

ITER TF TFMC Peak field (T) 11.8 9.9 Conductor current (kA) 68 80 Number of turns 134 98 No. of double pancakes 7 5 Stored magnetic energy (MJ) 41,000 337 Coil height (m) 12.6 4.6 Total coil weight 310 40

� TFMC exceeded design values

� No degradation with cycling

� Conductor performance in coil less than expected from short sample tests→ conductor upgraded to recover margin

Tcs at 80 kA

[A. Ulbricht et al., Fus. Eng. Des. 73, 189[A. Ulbricht et al., Fus. Eng. Des. 73, 189--327 (2005)]327 (2005)]


Degradation due to transverse load …

Electromagnetic force(accumulated)

Strand (bent by transverse load)

Strand

Conductor(CS model coil CICC)

Periodic bending deformation of strands in a large CICC

Large strain (low Ic) due to bending�Current transfer among filaments

εLarge strain

Large strain

Strand cross sectionCurrent transfer

Degradation of critical current and n index by strand bending


Improvement of TF Conductor

29Void fraction (%)

10Central channel OD (mm)

43.7Conductor diameter (mm)

2Jacket thickness (mm)

1Cu ratio

0.82Strand diameter (mm)

1422Total number of strands

900Number of Nb3Sn strands

� Transverse load (bending) identified as main cause of degradation � Level of degradation depending on strand type (strain sensitivity)� Updated design with more strands, higher Jc and lower void fraction� First short sample tests in Sultan successful, final qualification in 2008

[P. Bruzzone et al., presented at MT20, Philadelphia, accepted f[P. Bruzzone et al., presented at MT20, Philadelphia, accepted for publication in IEEE Trans. Appl. Supercond. 18]or publication in IEEE Trans. Appl. Supercond. 18]


Central Solenoid (CS) Coils

Nb3SnSuperconductor

5Operating temperature (K)

~980Total weight of all modules (t)

20Max. voltage to ground (kV)

535Turns per module

45Operating current (kA)

13Max. conductor field (T)

~6.4Total stored energy (GJ)

6Number of modules

Design confirmation by Model Coil project launched in 1994

� CS stack composed of 6 independently

powered modules wound in hexa-pancakes


2m

Winding Structure

ConductorStructure

Outer Module(JA)

CS Insert Coil(JA)

Inner Module(US)

Cable (38 mmφ)3x3x4x5x6=1080

Central Tube

Initial Triplex

Nb3Sn Strand

Sub-Cable Lapping

Cable Lapping

Jacke t (Inco loy 908)

Insulation Tape

Model Coils for the CS Coils


CS Model Coil: An International Cooperation

Nominal Operating Conditions- Current 46 kA- Magnetic Field 13 T


CSMC Main Modules

CSMC: Inner module(provided by US)

CSMC: Outer module(produced by Japan)

[H. Tsuji et al., Nuclear Fusion 41, no 5, 645[H. Tsuji et al., Nuclear Fusion 41, no 5, 645--651 (2001)]651 (2001)]


CSMC Results

Small degradation (0.1 to 0.2 K) saturated after a few cycles

CSMC successfully achieved design values

� Differences to present designPancake winding (not layer winding)Jacket material high Mn steel (not Incoloy)[Tsuji et al., ][Tsuji et al., ]


Nb3Al Insert(JA)

TF Insert(RF)

CS Insert(JA)

CSMC Nb3Sn & NbTi Inserts


Poloidal Field (PF) Coils• 6 PF coils independently powered, wound in double pancakes to:

�� Confine and shape the plasma�� PF1 & PF6 control plasma vertical displacement

• Conductor field limited to 6 T: NbTi sufficient• Coils are large (24 m diameter) but use of NbTi simplifies construction

Still open questions:Nb3Sn to gain flexibility ?Increase current in outer PF coils to gain in plasma stabilization ?

PF1

PF2

PF3

PF4

PF5PF6

Three different conductors depending on max. field:

•


PF Conductor

51.9 x 51.951.9 x 51.953.8 x 53.8Circle in square316L jacket (mm)

35.335.337.7Cable diameter (mm)

2.702.85- no -Copper corediameter (mm)

424.7370.5366.8Total copper (mm2)

90.3(before 45.7)

144.5(before 80.5)

229.3Non copper (mm2)

72011521440Nr of sc strands

2.3(before 6.9)

2.3(before 4.4)

1.6Sc strand Cu:nonCu

0.730.730.73Strand diameter (mm)

(2sc+1cu)x3x4x5x63scx4x4x4x63scx4x4x5x6Cable pattern

PF2,3 and 4PF5PF1/6


• Full size conductor (PF1 type) short sample tests in Sultan successful• Target achieved: 52 kA at 6.3 T with margin of 1.2 K• Problem: above 30 kA no transition, just quench

• “Sudden quench” independent from T or B. Originates from local peak fields(R. Wesche et al., Physica C 401, 113-117, 2004)

PF Conductor R&D

Long length performance checked by insert coil →


PF Insert Coil

Coil installation into CSMC facility completedStart of testing in mid June 2008

Upper Terminal

Lower Terminal

NbTi Square Conductor

Precompression System

Intermediate Joint

Coil Design Parameters

PFI

6.3 T

50 kA

2 T/s

49.50 m

Outer Diameter 1.57 m

Inner Diameter 1.39 m

Height 1.40 m

1.40 m

6 t

Height

Weight

Main Winding Envelope

Maximum Field

Maximum Operating Current

Maximum Field Change

Conductor length

[Nunoya et al, presented at ASC 2008][Nunoya et al, presented at ASC 2008][Zanino et al, presented at IAEA 2008][Zanino et al, presented at IAEA 2008]

Cable supplied by RFJacketing and coil manufacture by EU (ASG + Tesla)


Model 1 Forged Model 2 Cast Weld Qualification

Casting

Forgings

Glass-epoxy

GTAW/SAWClosure Welds

EBW/SAW Fabrication Weld

Main Goals

� Qualify manufacturing techniques

for production of base elements

� Qualify welding processes and NDT

methods

� Provide input to the detailed design

GTAW EB+SAW

TF Coil Case R&D


Pre-compression Ring Qualification� R&D work in progress at ENEA Frascati to qualify the base material properties (tensile, ultimate, relaxation, creep, thermal contraction, etc.)

� 1/5 scale mock-ups manufactured and tested at RT under similar static load/hoop stress conditions as in the real rings after pre-loading during assembly

R1_Relaxation test_day 6

0

100

200

300

400

500

600

700

800

900

1000

0 3600 7200

Time [s]

Total radial load RL [ton]

Radial stress RS [MPa]

Hoop stress HS [MPa]

First ring (R1) mock-up

Assembly into test machine

Results of relaxation test after 6 days

Hoop stress distribution during testing

Failure of R1 due to damage in one location


Feeders

• 31 feeders:

– 26 for coils– 3 for structures– 2 for

instrumentation

Required cryogenic power: ~ 64 kW

in-cryostat feeder

cryostat feedthrough

Cold terminal box

safety valves

cubicles

dry box

cryostat wall

TF terminal area


HTS Current Leads� Application of HTS current leads saves ~ 25 % of the total cryogenic power

needed (18 kW at 4.5 K !)� Large R&D program initiated in EU to develop a 70 kA HTS current lead� Program successfully completed in 2005 by test of a 1:1 prototype

(using Bi-2223 tape stacks) in the TOSKA facility

[R. Heller et al., IEEE Trans. Appl. Supercond. 15, 1496[R. Heller et al., IEEE Trans. Appl. Supercond. 15, 1496--1499 (2005)]1499 (2005)]



� Heat treatment, insulation and transfer into RP of reacted double pancakes� Tight tolerances / clearances for insertion of radial plate� Maximum allowable deformation of reacted conductor ~0.1%� Permanent elongation after heat treatment ~0.05%

� Manufacture of radial plates and cover welding�� Extruded profiles laser welded together vs. machined plates�� Control of out-of-plane distortion during laser welding of covers

� Vacuum Pressure Impregnation of turn and double pancake insulation

� Insulation Resistance under Irradiation�� Degradation of inter-laminar shear strength�� Gas evolution during machine life

� Case materials and manufacture/assembly of outer intercoil structures

� Manufacture of pre-compression rings with uni-directional glass (S-2 or ECR)-epoxy composite

Main Manufacturing Issues for TF Coil Procurement


• No prototype for learning & testing of the technology

• Many technological aspects will require additional development compared the model coil

⇓⇓⇓⇓

• Learning to be done directly on final coils (BUT 1 spare coil)

• Very tight schedule

• No full operation cold test of prototype or 1st of series

Main Challenges for TF Coils


TF coils main manufacturing steps

Wind…React…

Insulated and Transfer

Impregnated of moduleStacking of modules

Welding magnet in case

TFMC manufacturing TFMC manufacturing phasesphases


Manufacture of radial plates

Machining Method (M)

Laser Welded Method (LW)

• Use of conventional machine.• Use of welding technique to minimize

deformation after welding between segments

• Use of manufacturing technique to minimize deformation and machining time

Courtesy

JA

Radial Plate

Cover Plate

Holes for VPItion


…compared with the TF model coil…

In the TF model the radial plates were made by machining a single forged plate.

⇓⇓⇓⇓

For TF full size coil, due to the large dimensions, different segments must be welded and machined + groove walls thinner than in TFMC

⇓⇓⇓⇓

Still a lot to explore !Still a lot to explore !


2) Winding

Winding roll

Sand-blasting machine

Straightening toolWinding machine(trial Fabrication)

Traveling direction

Drum

� Automatic three roll bending machine will be used.

� The conductor should be transferred to RP groove after heat treatment. Therefore,1) High accuracy winding,

and2) Accurate prediction of

conductor elongation /shrinkage (JA think thisis not critical issue now)

are key technologies.

Winding R&D at JAEA


Heat Treatment

TF coils TFMC

The experience on heat treatment: gained on TFMC is quite relevant to the full size TF coils


Main issues of length-change

Elongation measurement result of TF coil conductors

-0.02%

+0.03%

Internal tin

SS316LN

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0 100 200 300 400 500 600 700Temperature ( C)

Elo

ngat

ion

(%)

Bronze

-0.02%

+0.03%

-0.02%

+0.03%

-0.02%

+0.03%

Internal tin

SS316LN

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0 100 200 300 400 500 600 700Temperature ( C)

Elo

ngat

ion

(%)

Bronze

Elongation/Shrinkage

Bronze (JASTEC) +0.03%

Internal tin (Mitsubishi) -0.02%

Elongation/Shrinkage

Bronze (JASTEC) +0.03%

Internal tin (Mitsubishi) -0.02%

K. MatsuiITER Superconducting Magnet technology group, JAEA

Progress Meeting between ITER IO, JAPT, and EUPT on the Preparationof the Procurement Specifications for the TF Coil Winding and Structures

27 Sept. 2007Naka, Japan


Radial plate articulated support

Radial plate(under the support)

Support platform

Heat treatment support

Open TF coil double pancake Umbrella

structure

A possible solution for the Transfer process


…then the insulation is relatively straightforward…

DP manufacturing. Insulation · The proposed

insulating machine achieves:

· Minimal deformation of the conductor by minimizing the amplitude of the wave.

· Complete insulation of one layer with one roll in one step.

Controlled Strain <0.1%


…welding of the covers…

Laser welding

Experience on TFMC


…DP insulation and the impregnation of the DP modules…

…this is relatively straightforward operation…

•Main challenge is to impregnate the turns inside the radial plates

•The resin penetrates through holes in the covers. The distance between holes is determined with preliminary R&D

A section of the TFMC Dummy DP

A fully impregnated TFMC DP


DP stacking and WP impregnation

8. Winding Pack8. Winding PackStacking of 7 DP

DP surface 2mm shape tolerance 3mm nominal dry glass shimming between DP absorb lack of planarity of DPJoint connection along the stacking process

7mm ground insulation of WP ensures the feasiblity of the requested 3mm shape tolerance

The main issue if the very tight tolerance required on the planarity of the straight length


� High accuracy required to reduce error fields

� Reduce machining of huge components

� Fitting gaps carry stress penalty

Insertion of Winding into Case

Insertion of WP in the case


The next phases will be:• Phase I (about 2 years, contract begins early 09)

– Manufacture of a full size dummy (with some sc) DP to:• Verify feasibility of manufacturing full size RPs• Gain experience in Impregnating full size DPs with new resin• Qualify full size tooling & processes

• Phase II– Manufacturing of one full size TF coil in EU and one in JA

• Phase III (completion foreseen in 2014)– Manufacture of the series of remaining 9 coils in EU and 8

for JA.

Future steps for TF Coils


� Pre-industrial R&D and qualification tests foreseen in the first two years of the contracts (the same for the PF coils) to finalize tooling and manufacturing procedures of double pancakes

� Several sub-scale and full-scale mock-ups of radial plates and welding of conductor cover plates

� Short-beam impregnation tests with the chosen (advanced) resin system

� One full-scale dummy double pancake each with copper cable to validate the winding, insulation, transfer, cover welding and DP impregnation procedures

� One six-turn full-scale coil each with superconducting cable to validate the heat treatment procedure and assess the effect of heat treatment on WP shape and tolerances

� Full-scale conductor and joint samples to be tested in the Sultan facility

� One case mock-up for closure welding qualification and impregnation tests

Qualification Phase for TF Coil Manufacture (EU and JA)


PF Coil Manufacture on Site

• Large factory needed for the manufacture of PF2 to PF6 coils at Cadarache site

• PF manufacturing building to be available in early 2010


Wound in Wound in DPsDPs……

Sand blast

Calendering

InsulationTurning table


Aligning columns

DPsDPs stackingstacking


� Extensive quality control and quality assurance are foreseen throughout the manufacture of conductors and coils

� Extensive databases for strand and cable properties, winding geometry and all quality control test protocols

� Staged procurement and production-proof samples of the manufactured conductors are required

� A series of leak tests on conductors and coils during different stages of jacketing and winding

� High voltage tests throughout the coil manufacture, also in Paschen-minimum conditions

� Tight control of non-conformities

� Cold testing of all magnets (not yet approved) is proposed down to 4 K to check leak and high voltage integrity and measure joint resistance with moderate current

Quality Assurance Programme



Magnet Procurement Sharing

TF Coils (including radial plates, not cases)Conductors supplied by CN, EU (~20%), KO, JA, RF, USWindings 10 from EU, 9 from JA

TF StructuresBasic structures from JA (cases, shear keys and bolts)Case-winding pack insertion – 10 EU, 9 JAGravity supports from CNPre-compression rings from EU

CS Coil (includes pre-compression structures and supports)Conductors from JA6 modules from US

PF CoilsConductors from CN, except share between EU and RF for PF1 & PF6Windings PF2-PF6 from EU, PF1 from RF

Correction Coils & Feeders (and CTBs including current leads)CN, including conductors and leads

InstrumentationITER Fund


ConductorChinaSouth KoreaJapanRussiaUnited StatesEurope

TF CoilJapan

TF coil casesJapan

Europe

TF Coil Sharing


Magnet Cost SharingRelative Total Contribution of Different Components

Total 802IUA

JA

US

CN

EUKO

RF

Fund 0

50

100

150

200

250

300

350

400

-2 -1 1 2 3 4 5 6 7 8 9 10 11

Yearly Expenditure Plan

Co

st in

IUA

Year relative to January 2009

Total 802 kIUA


Magnet Construction Schedule

Integrated Project Schedule (IPS): the table below shows the current ITER schedule to meet the deadline of first plasma in 2016 and includes fabrication, not development � Starting time too stringent

A new detailed schedule has been developed and the construction requires 2 years extension of the plasma deadline (2018)


Superconducting strand contractsSuperconducting strand contracts�� Scope to supply CrScope to supply Cr--coated Nbcoated Nb33Sn strand, if successfully qualified by CPQS Sn strand, if successfully qualified by CPQS

�� Probably more than one supplier for capacity and risk optimisatProbably more than one supplier for capacity and risk optimisationion

�� SomeSome Parties (CN, RF, KO) have only one qualified supplierParties (CN, RF, KO) have only one qualified supplier

Cu strand contractCu strand contract�� Scope to supply CrScope to supply Cr--coated Cu strandcoated Cu strand

�� Relatively simple specification and tender process Relatively simple specification and tender process

�� EU CallEU Call--forfor--Tender launched on 17 March 2008Tender launched on 17 March 2008

Cabling & jacketing contractCabling & jacketing contract�� Scope: Cabling, installation of jacketing line, welding of tubesScope: Cabling, installation of jacketing line, welding of tubes

Procurement of jacket, wrap, spiralProcurement of jacket, wrap, spiralJacketing and compactionJacketing and compaction

� Probably several contracts with specialized laboratories and companies�� sharing/splitting difficult, but enables fast reaction in case of problems

Quality control for strand and conductor testsQuality control for strand and conductor tests

F4E TF ConductorProcurement


F4E TF Coil Procurement

Raw material for RPs : 5 x10=50 central +

2 x 10 =20 side plates

Radial plate and cover machining: 50 central + 20

side plates

Conductor FROM ITER

Case sections = 4 x 10 = 40 FROM ITER Quality Control

Risk Management

Planning and schedule

Wind 7 x DPs modules

Main tooling (e.g. winding machine, heat treatment oven, etc.)

Assembly 5+2 DP modules to create TF winding pack

(WP)

Heat treat 7 x DPs modules

Transfer and Insulate & Impregnate 7 x DPs modules

X 10 coils

Cold test WP

Assembly in the final case, final impregnation and machining

Packaging and transport

X 10 coils

Manufacturing drawings and procedures

Fabrication of the Full-Size Double-Pancake Prototype

Pre-qualification tests Qualification

phase

Full Production

phase

Transversal activities

Supply may be organized in one single contract or multiple contrSupply may be organized in one single contract or multiple contracts acts �� Procurement Procurement Arrangement to be signed in June 2008 (?), detailed strategy to Arrangement to be signed in June 2008 (?), detailed strategy to be developedbe developed

� Introduction� ITER Magnet System Design�ITER Magnet System R&D� Main Manufacturing Challenges� Procurement Sharing and Schedule�Summary


Summary

� The ITER procurement phase started at the end of 2007 with the signature of the first Procurement Arrangements for the TF Conductors

� This is supported by many years of design and R&D work and the production of several Model Coils and Insert Coils

� Several technical issues related to the large size of the coils and lack of experience in some areas - not covered by the Model Coils - are still open and must be tackled in the first stages of the manufacture

� Big challenges are the organization of the in-kind contribution from seven Parties and the management of the procurement contracts

� The foreseen schedule is very tight, especially for the start-up and preparation periods before the full-scale production, and does not take into account learning curves, delays or “force majeure”.


Acknowledgement

� E. Salpietro, W. Baker (EFDA Garching), A. Portone (F4E)

� N. Mitchell, A. Devred, J. Knaster (ITER IO Cadarache)

� H. Fillunger, R. Maix (ATI Vienna)

� K. Okuno, N. Koizumi and the JADA Team

� All the Colleagues in the EU Associations

� The members of the Magnet Design Review and TF Conductor & Coil Procurement Review Groups

� EU Industrial Partners

Date post:	30-Mar-2018
Category:	Documents
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