R. Gallix

The ITER Magnet System

Procurement of the ITER magnets is due to start at the end of 2007/early 2008, with the launch of the longest lead time items, the conductor and the TF coil windings. The base design for procurement was established in 2001, and the build up of the Cadarache ITER team has been accompanied by a review of the most critical, or controversial, features of the 2001 design. At the same time, an urgent R&D program has been launched to complete the necessary verification of the design solutions that are proposed. In this paper an overview will be presented of the main design features and drivers, and some of the recent issues and R&D results will be summarized.

Overview of the ITER Correction Coils Design

The Correction Coils (CC) of the ITER Tokamak are developed to reduce the range of magnetic error fields created by imperfections in the location and geometry of the other coils used to confine, heat, and shape the plasma. The proposed system consists of three sets of 6 coils each, located at the top (TCC), side (SCC) and bottom (BCC) of the Tokamak device and using a NbTi cable-in-conduit superconducting conductor (CICC). Within each set, the coils are connected in pairs to produce a toroidal field to reduce the most troublesome, lower order, poloidal mode number fields (m = 1,2,3) in order to operate below the locked mode threshold. The conductor is designed to operate up to 6 T. The winding uses pancakes of one-in-hand conductor (quadpancakes for SCC, octopancakes for TCC and BCC), thus avoiding internal joints. The winding-pack is enclosed inside a 20 mm thick stainless steel casing. The coils are supported by rigid connections to the Toroidal Field (TF) coils. The structural design of the CC is mainly driven by the allowable fatigue stress levels in the conductor jacket, in the case material and in the glass-polyimide electrical insulation system. The boundary conditions on the CC are imposed by the TF coils deformation and the electromagnetic interactions with the PF coils system. The thermo-hydraulic and electrical performance of the CICC is also addressed.

Design and Specifications of the ITER TF Coils

The current design of the ITER Toroidal Field coils and structures, the main critical design and manufacturing issues, and the status of the procurement arrangements for these components, which will be released to the ITER parties in early 2008 to start the manufacturing contracts, are described. Some qualification and R&D work still required in preparation for the manufacture are also mentioned.

Status Report on the Toroidal Field Coils for the ITER Project

The magnet system for ITER comprises 18 Toroidal Field (TF) Coils using Nb3Sn cable-in-conduit superconductor, which operate at 4.5 K in supercritical helium. The procurement of the TF Coils and Structures is amongst the first which have been launched following the creation of the ITER Organization (IO). It is organized in 4 phases. A Procurement Design Readiness Review held in April 2008 confirmed the readiness of the design to proceed with Phases I and II. Procurement Arrangements (PA) were signed with the European and Japanese Domestic Agencies (DA) respectively in June and November 2008. After a brief description of the TF Coils and Structures, the paper gives an overview of the PA showing the milestones towards series production. The procurement strategy of both DA involved is described, in particular the first step which covers pre-production activities: qualification of raw materials, manufacturing trials, mock-ups and full-scale prototype radial plates, impregnation tests and, possibly, winding trials. The work carried out by IO is also presented: optimization of the cover plate welding to satisfy the allowable stress criteria while minimizing the associated distortions, qualification of blends of cyanate ester with epoxy resin for the impregnation of the winding packs and design of the coil terminal region including integration of the needed instrumentation.

The Insertion of the WP in the Structural Casing of the TF Coils of ITER

The ITER TF Coils will consist of two main components; the WP which is formed by the assembly of seven double pancakes, superconducting windings inserted into stainless steel radial plates and the stainless steel structural casing which forms the mechanical interface between TF coils and the remainder of the ITER machine. The final step in assembly of the TF Coils will be the insertion of the WP into the structural casing. The insertion procedure must achieve two critical objectives; accurate geometric location, 1 mm, of the WP current center line with respect to the casing reference faces and the full mechanical location of the WP within the casing to facilitate the uniform transfer of the electromagnetic forces to the casing and the ITER TF keystone structure.

The Toroidal Field Coils for the ITER Project

The ITER Magnet System contains 18 Toroidal Field Coils (TFC). These are large D-shaped coils of about 300 t, 17.5-m height and 9-m width. They consist of a Winding Pack (WP) enclosed in a rigid structural steel case, the Toroidal Field Coil Case (TFCC). The WP is a bonded structure of 7 Double Pancakes (DP), each made up of a radial plate (RP) housing the reacted cable-in-conduit superconductor (CICC), which operate at 4.5 K in supercritical helium. The conductor carries a current of 68 kA in operation to produce a nominal peak field of 11.8 T. The total stored magnetic energy in the 18 TFCs is 41 GJ. While the Japanese and European Domestic Agencies that are in charge of the procurement of the TFCs are progressing with the manufacturing design and the fabrication trials prior to launch the production of the real coils, the ITER Organization (IO) is completing the development and qualification of the most critical items, e.g. cyanate ester and resin blends for the conductor and WP insulation system, the terminal region, the helium inlet, a charged resin system for the filling of the gap between the WP and the TFCC and the general tolerancing especially at the interfaces between the neighboring systems. This paper presents the final design of the TFCs and the results of the developments carried out in the aforementioned areas in the last 2 years.

The Development of Fabrication Technologies for ITER Magnet Supports

The R&D of the manufacture related technology for ITER magnet supports is one of the tasks for construction. In this paper, we report the recent progress on alternative design for the Toroidal Field Support (TFS) manufacture without welding and its related structural analysis; the engineering test of the prototype TFS mock-up under various load combinations; the arc-brazing of cooling pipe to supports technology and its result; the ion implantation for improving the wear resistance of strut dowel in the Poloidal Field (PF) coils PF3-4 support system and the plasma spray insulation coating for correction coil support (CCS).

Design Optimization of the ITER TF Coil Structure for Manufacturing and Assembly

This paper presents some of the design features of the ITER toroidal field coil structure that are being modified to minimize anticipated problems with manufacturing, and assembly, while satisfying their functional design criteria.

Overview of the ITER Toroidal Field Magnet System Integration

The first series components of large D-shaped toroidal field coils (TFC) on the ITER Tokamak project are being fabricated and assembled at European Fusion for Energy (F4E) and Japanese Domestic Agency (JADA) premises since 2013. The TF magnet system consists of 18 individual coils connected in series based on a Nb3Sn cable-in-conduit conductors supplied by a 68-kA rated current with an overall 41-GJ stored energy and a peak magnetic field of 11.8 T. One of the key challenges of the construction of the 18 TFCs and their assembly resides in the control of the integration of the large individually manufactured coil components and in the ultimate management of tolerances on the final assembly into the Tokamak pit. This paper presents the integration aspects related to main TFCs subcomponents under fabrication starting from the TF conductor production, the winding of individual double pancakes, and their heat treatment and impregnation. This includes the fabrication of key prototypes for qualification purpose such as helium supply inlets, the electrical joints, and the design of the winding pack insertion into the structural TFC case during the final welding enclosure. Each preassembled 40° sector of a TFCs pair is then integrated into the torus according to tight tolerance requirements to provide both the so-called TF magnetic center line data and to guarantee the final operating wedged design into the inner leg region. The assembly of the coils terminal is then completed by connecting services through the power feeder busbars, the quench detection high voltage cables and the cryogenics interfaces pipe system.

Development of the ITER Superconducting Magnet Manufacturing Database

The ITER Superconducting Magnet Manufacturing Database, MMD, is not only a data archive, but also a common communication platform, on which contributors to magnet manufacturing collaborate and take coordinated actions. In-kind procurement is a feature of the ITER construction. The magnet system construction involves six Domestic Agencies (DAs) plus contractors in these DAs. The six DAs are EU, Japan, Russia, the USA, Korea and China. The magnet system consists of many components like TF coils and current feeders. The ITER Organization (IO) monitors and controls quality throughout the manufacturing process. This is fundamental because the IO takes responsibility for the ITER machine even though not all large components can be tested under nominal conditions before their acceptance. For many contributors though (who have different cultures, quality assurance systems and languages), quality monitoring and control (QA/QC) represent big challenges. MMD is the web-based application that gives all contributors access to the IO server computer according to deflned privileges. Users can upload and consult updated manufacturing processes, associated drawings, procedures, inspection reports, etc.; more over, they can communicate internationally and visualize identical, updated and systematically stored datasets. The data stored in the database will be available in future site assembling and operation phases. Technically, the database is an application of ICP (ITER Collaborative Platform). ICP is a software framework for implementing database-driven applications for the ITER project. It provides a standardized web browser interface and data storage. This paper presents the design and functionality of MMD.