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Bonito Oliva A.,Fusion for Energy F4E | Batista R.,Fusion for Energy F4E | Bellesia B.,Fusion for Energy F4E | Boter Robello E.,Fusion for Energy F4E | And 27 more authors.
IEEE Transactions on Applied Superconductivity | Year: 2016

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 RD 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. © 2002-2011 IEEE. Source


Poncet L.,Fusion for Energy F4E | Bellesia B.,Fusion for Energy F4E | Oliva A.B.,Fusion for Energy F4E | Boter Rebollo E.,Fusion for Energy F4E | And 16 more authors.
Fusion Engineering and Design | Year: 2015

The ITER Toroidal Field (TF) magnet system consists of 18 "D" shaped coils. Fusion for Energy (F4E), the European Domestic Agency for ITER, is responsible for the supply of 10 out the 19 TF coils (18 installed plus one spare coil). Each TF coil, about 300 t in weight, is made of a stainless steel case containing a Winding Pack (WP).The European manufacturing of the Radial Plates (RPs) and WPs has been awarded to two different industrial partners, whose activities are strongly linked with each other. In order to manufacture a Double Pancake (DP), first, the conductor has to be bent onto a D-shaped double spiral trajectory, then heat treated and inserted in the grooves of the RP. This represents the most challenging manufacturing step: in order to fit inside the groove, the double spiral trajectory of the conductor must match almost perfectly the trajectory of the groove, over a length above 700. m. In order to achieve this, the conductor trajectory length must be controlled with an accuracy of 1. mm over a length of 350. m while the radial plate groove has to be machined with tolerances of ±0.2. mm over dimensions of more than 10. m. In order to succeed, it has been essential to develop a metrology process capable to control with high accuracy both the DP conductor and the RP groove trajectories.This paper reports on the work carried out on the development and qualification of the dimensional metrology to monitor the manufacturing of the conductor. Reference is made to the final dimensional check of the RP focusing on the groove centreline length. In addition the results obtained on the one to one scaled prototype DP are described. Finally, the strategy and foreseen improvements for the production of DPs are discussed. © 2015 Elsevier B.V. Source


News Article
Site: http://phys.org/physics-news/

One of the biggest and most complex magnets in history is being manufactured at the ASG facilities, Italy. This gigantic "D" shaped coil will be form part of the system that will confine ITER's super-hot plasma which is expected to reach 150 million ˚C. Basically, an impressive magnetic shield will entrap the hot gas and keep it away from the walls of the vessel of the world's biggest fusion machine. F4E is responsible for the supply of 10 out of the 18 TF coils that ITER will need to operate. Witnessing the first TF coil taking shape is a turning point for the project and the 600 people having contributed to this milestone from at least 26 companies. This is the result of various contracts starting in 2008 when F4E started its collaboration with several suppliers for the production of Europe's TF conductor, which reached a length of 20 km. Iberdrola, ASG and Elytt Energy, have used parts of this conductor to manufacture Europe's first TF coil. Winding, sandblasting and heat treatment have been some of the main steps taken in order to fit the conductor into stainless steel plates, known as radial plates, manufactured by CNIM and SIMIC. Piece by piece the conductor had to be lifted, wrapped, insulated and placed back in the grooves of the plates before it got covered. Then, the structure containing the conductor has been laser welded and wrapped with insulating material, before going through impregnation. To create the inner-core of the TF coil, a pack of seven of these structures had to be stacked, electrically jointed, wrapped, insulated and impregnated. Pipes through which cold liquid helium will circulate inside the magnet to help it reach a superconducting state and instruments to measure its performance have also been added. Each of these packs, known as a winding pack in the ITER jargon, is 14 m high, 9 m wide and 1 m thick. Its weight is approximately 110 tonnes which compares to that of a Boeing 747! For Alessandro Bonito-Oliva, F4E's Manager for Magnets, and his team, this has been an accomplishment of significant importance. "Thanks to our determination to meet the tight planning for magnets and the excellent collaboration between F4E and its suppliers we are heading towards Europe's first TF coil, which also happens to be a first for ITER. Seeing a magnet of such complexity taking shape suggests that we can deliver some of the most technically challenging systems of ITER. Sharing expertise and good communication between F4E, ITER International Organization and Japan's Domestic Agency for ITER have been fundamentally important for the achievement of this milestone and will continue to be as production is still ongoing. So what are the next stages for the inner-core of the first TF coil? The stacking of the first pack has been completed and the electrical insulation material is being applied. When its vacuum-pressure insulation is concluded it will be transferred to SIMIC to conduct a series of tests. Then, it will be inserted in the massive case of the coil and in the end the final casting process will be performed, during which additional epoxy resin will be injected to fill in any remaining gaps. And what about the progress of the other TF components? In March the production of radial plates for which F4E is responsible has accelerated reaching 45 out of a total of 70. Meanwhile, the manufacturing of the components of the second TF coil have been completed paving the way for its assembly.


Poncet L.,Fusion for Energy F4E | Bellesia B.,Fusion for Energy F4E | Oliva A.B.,Fusion for Energy F4E | Boter Rebollo E.,Fusion for Energy F4E | And 16 more authors.
Fusion Engineering and Design | Year: 2015

The ITER Toroidal Field (TF) magnet system consists of 18 "D" shaped coils. Fusion for Energy (F4E), the European Domestic Agency for ITER, is responsible for the supply of 10 out the 19 TF coils (18 installed plus one spare coil). Each TF coil, about 300 t in weight, is made of a stainless steel case containing a Winding Pack (WP). The European manufacturing of the Radial Plates (RPs) and WPs has been awarded to two different industrial partners, whose activities are strongly linked with each other. In order to manufacture a Double Pancake (DP), first, the conductor has to be bent onto a D-shaped double spiral trajectory, then heat treated and inserted in the grooves of the RP. This represents the most challenging manufacturing step: in order to fit inside the groove, the double spiral trajectory of the conductor must match almost perfectly the trajectory of the groove, over a length above 700 m. In order to achieve this, the conductor trajectory length must be controlled with an accuracy of 1 mm over a length of 350 m while the radial plate groove has to be machined with tolerances of ±0.2 mm over dimensions of more than 10 m. In order to succeed, it has been essential to develop a metrology process capable to control with high accuracy both the DP conductor and the RP groove trajectories. This paper reports on the work carried out on the development and qualification of the dimensional metrology to monitor the manufacturing of the conductor. Reference is made to the final dimensional check of the RP focusing on the groove centreline length. In addition the results obtained on the one to one scaled prototype DP are described. Finally, the strategy and foreseen improvements for the production of DPs are discussed. © 2015 Elsevier B.V. All rights reserved. Source

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