L. Poncet

Status of the F4E Procurement of the EU ITER TF Coils

The ITER magnetic system includes 18 Toroidal Field (TF) Coils using Nb3Sn cable-in-conduit superconductor. Each TF coil, about 300-t in weight, is made by a Winding Pack (WP) composed by 7 Double Pancakes (DP) modules stacked together, impregnated and inserted in stainless steel coil case. Each DP is made by a Radial Plate (RP), a very large D-shaped stainless steel plate with grooves machined on a spiral path on both sides, in which the insulated conductor is inserted after the heat treatment. The procurement of the TF coils will be carried out by Fusion for Energy (the European Domestic Agency (DA)), responsible for 10 coils (including 1 spare coil) and the Japanese DA, responsible for 9 coils. The conductors will be produced by 6 different DAs, while the coil cases only by the Japanese DA. In July 2008 the Procurement Arrangement was signed between the ITER Organization (IO) and F4E defining the scope, technical and management requirements for the procurement of such coils. F4E has developed a procurement strategy aimed to minimize costs and risks, consisting of subdividing the procurement into three main procurement packages, each foreseeing an initial R&D qualification phase. One procurement package is related to the construction of 72 RP (including 2 prototypes), another to the fabrication of the 10 WP and a third to the cold test and coil-case insertion of 10 WP. So far F4E has signed 5 contracts. In 2009, we placed 2 contracts for the procurement of RP prototypes and 1 contract for the development and qualification of the welding and the Ultrasonic Test technologies for the coil case welding. In 2010 1 contract has been placed for the construction of 10 WP and 1 contract for the engineering optimization of the cold test and coil insertion.

Progress in the F4E Procurement of the EU ITER TF Coils

The ITER magnetic system includes 18 Toroidal Field (TF) Coils constructed using Nb3Sn cable-in-conduit superconductor. Each TF coil comprises a Winding Pack (WP) composed of 7 Double Pancake (DP) modules stacked together, impregnated and inserted into a stainless steel coil case. Fusion for Energy [the European Domestic Agency (DA)] is responsible for the procurement of the ten while the Japanese DA is responsible for remaining nine coils. The conductors are being produced by 6 different DAs, while the coil cases only by the Japanese DA. F4E has implemented a procurement strategy aimed to minimize costs and risks, consisting of subdividing the procurement into three main procurement packages, each foreseeing first an R&D and qualification phase. One procurement package is related to the construction of 72 radial plates (RP), another to the fabrication of the ten WP, and a third to the cold test and coil-case insertion of ten WP. In collaboration with industry, F4E has successfully produced two RP prototypes. Regarding the DP, the construction of the first DP prototype has started. In this paper, we will report on the results achieved so far and the status of each of the procurement packages.

Status of the F4E Procurement of Radial Plate Prototypes for the EU ITER TF Coils

This paper reflects the status of the manufacturing of 2 Radial Plate prototypes for the EU ITER TF Coils. The production of these prototypes will supply valuable information for the manufacturing of the total required number of 70 Radial Plates, in terms of manufacturing technologies, optimization of cost, manufacturing time and risks.

The European Procurement of Cold Test and Case Insertion of the ITER Toroidal Field Coils

The International Thermonuclear Experimental Reactor is an international scientific project with the aim of building a tokamak fusion reactor capable of producing at least 10 times more energy than that spent to sustain the reaction. In a tokamak the fusion reaction is magnetically confined and the toroidal field coil system plays a primary role in this confinement. Fusion for Energy, the European Domestic Agency for ITER, is responsible for the supply of 10 out the 19 toroidal field coils. Their procurement has been subdivided in three main work packages: the production of 70 radial plates (the structural components which will house the conductors), the manufacture of 10 winding packs (the core of the magnet) and cold test and insertion into the coil cases of 10 winding packs. The cold test/insertion work package presents significant technological challenges. These include the cold test of the winding packs 14 m high, 9 m wide and weighing 110 t, the welding and inspection of the 316 LN stainless steel coil case, with welded thicknesses of up to 144 mm accessible only from one side combined with the need to minimize the deformation during the welding process (more than 70 m of weld per coil and up to 90 passes to fill the chamfer) and the resin filling of the coil case after insertion of the winding pack (the total volume to be filled up is about one cubic meter per coil). From 2009 up to mid 2011, F4E has carried out an R&D program in order to investigate the most challenging steps of the manufacturing processes associated to this work package, both to meet the demands of the ITER schedule and to minimize technological risks; in this paper an overview of the results obtained is presented.

Progress in Europe of the Procurement of the EU ITER TF Coils

The ITER magnetic system includes 18 toroidal field (TF) coils constructed using a Nb3Sn cable-in-conduit superconductor. Each TF coil comprises a winding pack (WP) composed of seven double pancake (DP) modules stacked together, impregnated, and inserted into a stainless steel coil case. Ten TF coils are being produced in Europe, under the responsibility of Fusion for Energy (F4E) (the European Domestic Agency), whereas the remaining nine TF coils are being produced in Japan. F4E has implemented a procurement strategy aimed to minimize costs and risks by subdividing the procurement into three main packages, each foreseeing first an R&D and a qualification phase. One procurement package is related to the construction of 72 radial plates (RP), another to the fabrication of the ten WPs, and a third to the cold test and coil-case insertion of ten WPs. All industrial contracts have now been signed and are running. The situation as of September 2015 is as follows: 2 RP prototypes and 32 production RPs (enough for four TF coils) have been successfully (enough for four TF coils) produced and delivered to the winding pack supplier. A full-size superconducting DP prototype has been successfully fabricated and subjected to a thermal cycle at 80 K. So far, 33 DPs have been wound, 27 DPs have been heat treated, and 26 DPs have been successfully transferred into the RP grooves. The cover plate welding has been successfully completed on 18 DPs. Regarding the insertion contract, an alternative way to insert the WP inside the coil case has been devised, and the corresponding transfer tooling is being procured. The qualification for the most important manufacturing processes is underway.

He-Inlet of the Toroidal Field Coil: Qualification and Manufacturing Status

In this paper, we will report on the manufacturing of 6 helium inlet mock-ups for the EU ITER TF coils, and on the results of the mock-up tests and other qualification activities carried out in the European industry on this subject.

F4E Procurement of Radial Plates for the EU ITER TF Coils (October 2015)

This paper reflects the status of the manufacturing of 70 radial plates (RPs) for the EU ITER TF Coils. About 3700 t of stainless steel 316 LN have been forged and 240 t of cover plate (CP) raw material bars have been procured for the procurement of the RPs. Each RP is composed of six forged segments welded using local vacuum EB Welding technology for 35 RPs and narrow-gap TIG for the other 35 RPs. All RP plates are finally machined to final dimensions (9 m × 14 m) and tolerances using large portal milling machines. The groove length, planarity, and D-shape form tolerances are the most challenging required tolerances: ±30 ppm for the groove length and 1 mm for both planarity and D-shape form. The main challenges faced and results achieved so far are presented and improvements with respect to the prototype phase are described.