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FIP/1-3 Full-scale trial results to qualify optimized manufacturing plan for ITER Toroidal Field coil winding pack in Japan N. Koizumi, M. Nakahira, K. Matsui, T. Hemmi, H. Kajitani, M. Iguchi and T. Sakurai Superconducting Coil Technology Group, Japan Atomic Energy Agency (JAEA) 25 th Fusion Energy Conference (FEC 2014) St. Petersburg, 13 th October 2014 1

Outline 1. ITER Toroidal Field (TF) coil and its procurement in Japan 2. Technical issues and optimized manufacturing plan 3. Full scale trials for TF coil winding pack manufacture 4. Progress in TF coil series production 5. Summary 2

ITER magnet system Correction coil (18 coils) PF coil (6 coils) TF coil (18 coils) 16.5m CS (6 modules) 3

ITER TF Coil Coil case (200 tons) Outboard Winding Nominal field Inboard pack = 11.8T 16.5m (110 tons) Nominal current = 68kA 9m Cross-sectional view of a TF winding pack (WP) (Inboard) Side DP(2) Regular double Cover plate (CP) Laser welding pancake (DP) (5) between RP and CP Turn insulation Insulation around DP RP groove to insert conductor TF conductor (Nb 3 Sn CICC) 4

Scheme of TF coil procurement in Japan  To recover from delay by disaster in Japan in 2011 and to meet ITER schedule, JADA is building two lines for manufacturing 9 TF coils. JAEA MHI (Melco & HHI) Toshiba Full-scale trials Full-scale trials 5 TF coils 4 TF coils 5

Outline 1. ITER TF coil and its procurement in Japan 2. Technical issues and optimized manufacturing plan 3. Full scale trials for TF coil winding pack manufacture 4. Progress in TF coil series production 5. Summary 6

Challenge in TF coil WP manufacture  Basic technique of TF coil manufacture was demonstrated by TF model coil (TFMC) development during ITER-EDA.  Although TF coil ≈ 3.5 X TFMC, 16.5m 4m tolerances of TF coil ≈ those of TFMC.  Allowable strain of TF superconductor <0.1% 3m  Tight tolerance is challenging. TFMC （ EDA, 2001 ） Most critical challenge (Transfer) 9m  TF conductor elongation after heat treatment ITER-TF coil ≈ 0.05% Conductor with  Other sources originating error; turn insulation Winding, RP and dimension measurement  Gap between conductor turn insulation and RP 110mm groove surfaces = 1mm or 1.5mm  Original tolerance ≈  0.02% in length RP Transfer 7

Solution of challenge in transfer CCD camera  To enable transfer, Laser marker Encoder Winding head manufacturing plan is optimized. 3m 1. High accuracy winding technique using optical Conductor Thin scratch measurement system. To winding (Target accuracy =  0.01% ) Optical measurement system during winding table 2. Highly accurate prediction of conductor elongation by heat treatment (HT). +/-2.7mm After (Target accuracy =  0.02% ) HT 3. 4 RP sub-assemblies are Machined 10 RP sections after assembled to fit RP groove (Machined in +/-2.8mm welding parallel) length to heat-treated winding 4 RP sub- length. assemblies (Relaxed tolerance in conductor length ≈  0.04% ) New RP manufacturing procedure 8

Optimized TF coil manufacture procedure 4 RP sub- RP 10 RP assemblies sections Elongation by hat treatment RP Pancake TF conductor: CN, JA, KO Transfer (RP insertion) Heat treatment (650 o C, >100h) (EU, RF, US) Winding RP AP BP Turn insulation Winding pack (WP) Assembly of WP & coil case Transfer (Turn insulation) TF coil case: 9

Outline 1. ITER TF coil and its procurement in Japan 2. Technical issues and optimized manufacturing plan 3. Full scale trials for TF coil winding pack manufacture 4. Progress in TF coil series production 5. Summary 10

Strategy to accelerate full-scale trials to start series production Existing regular RP (Tolerance of conductor transfer to RP is  0.02%) 1 st full-scale trial Achieved tolerance RP dimension measurement (  0.01%) Winding & Dummy rDP dimension Transfer winding measurement (  0.02%) TF coil manufacture until transfer Start of Winding Heat treatment (HT) Transfer winding of (  0.02%) (  0.01%) 1 st TF coil Proto sDP HT of sDP Transfer Prediction of winding (Final confirmation) conductor Good uniformity of elongation elongation (  0.01%) (  0.02%) 2 nd full-scale trial 11

Winding machine qualification Winding head Uncoiler Optical system Winding table Movable Rotation  Commissioning was completed in September 2013. 12

Winding by new winding machine 13

Dummy regular DP (rDP) winding  Dummy regular DP (rDP) winding was successfully completed at beginning of November 2013. 14

Dummy side DP (sDP) winding  Proto sDP winding was also successfully completed at end of November 2013. 15

Accuracy of winding dimension 100 100 Deviation of condutor length in each turn (ppm) Deviation of condutor length in each turn (ppm) 80 80 60 60 40 40 Conductor N11 N1 20 20 0 0 P11 P1 -20 -20 -40 -40 -60 -60 -80 -80 -100 -100 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2 P10 P11 N10 N9 N8 N7 N6 N5 N4 N3 Turn number Turn number Dummy rDP (1 st trial) Proto sDP (2 nd trial) Accuracy of winding <  0.01% 16

RP transfer (RP insertion between pancakes) Upper pancake winding Lower pancake winding Radial plate 17

Turn insulation and insertion of conductor in RP groove 18

Dummy rDP transfer  Dummy conductor was inserted in RP groove after turn insulation. Taping heads 19

Heat treatment of proto sDP Conductor elongation Heat treatment oven 0.10 Elomgation of condutor length in each turn (%) 0.08 0.06 0.04 0.02 0.00 N10 N9 N8 N7 N6 N5 N4 N3 N2 N1 Turn number  Dedicated oven was fabricated.  Conductor elongation by heat treatment   5 o C at 650 o C was demonstrated. =0.061 % +0.007 /- 0.005%. 20

Outline 1. ITER TF coil and its procurement in Japan 2. Technical issues and optimized manufacturing plan 3. Full scale trials for TF coil winding pack manufacture 4. Progress in TF coil series production 5. Summary 21

TF coil winding and heat treatment  Winding of 5 DPs for the 1 st TF coil was completed.  1 st DP was heat treated. Winding of 1 st DP of JA 1 st TF Coil 100 Deviation of condutor length (ppm) 80 60 40 20 0 -20 1st DP -40 2nd DP 3rd DP -60 4th DP -80 5th DP Heat treatment of 1 st DP of JA 1 st TF coil -100 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 N10 N9 N8 N7 N6 N5 N4 N3 N2 (Elongation = 0.07% +0.006/-0.008%) Turn number  Elongation < Prediction(0.06%)  0.02%  Winding accuracy <  0.01% 22

Summary Full-scale trials are performed to qualify the optimized manufacturing plan of ITER TF coil WP manufacture in Japan. The major achievements and progress are as follows:  High accuracy of winding to control conductor length with  0.01% was demonstrated.  Heat treatment oven was developed with highly accurate temperature control and conductor elongation is predicted to be 0.06%  0.02%. From these successful achievements, JADA started series production of TF coil. The present achievements are as follows:  5 DP winding was completed with satisfying target accuracy of  0.01%.  1 st DP was heat treated and elongation of conductor is within target accuracy of  0.02%. In addition, the delay from 2011 is being recovered. 23

Dummy sRP trial manufacture Final assembly Welding between RP sections Machining RP section Completed RP Flatness of RP sections After welding (RP sub-assembly) for dummy sRP 24