The ITER toroidal field model coil project

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200 A. Ulbricht et al. / Fusion Engineering and Design 73 (2005) 189–327 Fig. 3.10. The impregnated winding pack. The Helium outlet tubes protrude and the outer joint area is still left free. adjacent terminations and protruding into both copper soles. These pins were electron beam welded in such a way that the bulk temperature of the terminations did not reach more than 60 ◦ C. This method has been validated with a full-size joint sample as described in Section 7. 3.4.3. Ground insulation and impregnation After having provided the outer joints with welded clamps of aluminium alloy they were wrapped by the required sliding layer (Tedlar tape) and a combined glass–Kapton insulation. Then 8 mm of combined glass–Kapton insulation was built up on the whole surface in order to form the ground insulation, which was then impregnated with DGEBA epoxy resin. After impregnation and before assembly with the coil case dielectric tests (10 kV DC and ACpeak-to-peak) and flow/pressure/leak tests were performed successfully. 3.4.4. Stainless steel case The case of the TFMC was made of 70–90 mm thick 316LN stainless steel sheet. The thickness was defined after FE calculations for the worst load case. The pieces were MAG welded together by qualified procedures to a U-shaped structure. All welds were ultrasonically tested. Defects had to be repaired, which were unacceptable according standards for highly loaded austenitic welds. The tightly toleranced shape was obtained by machining and local heating, partially in combination with the applied force of hydraulic jacks. Fig. 3.11. The winding pack in the stainless steel case. After filling the gap between the two with silica sand the cover was placed on top and subsequently welded. The welding chamfers on top of the U-shape and on the cover plate were copy milled. A fit within a few tenth of mm was achieved. 3.4.5. Winding pack/case assembly For the winding pack/case assembly, both were in reversed position (i.e., bottom up). After having brought up the glass felt layers on the bottom of the winding pack the case was put on. A special tool fixed the assembly and allowed a turn over without slipping out of place. After having the gap filled with silica sand and placing glass felt on top, the case cover was positioned on top (Fig. 3.11). The first three passes of the root were TIG welded and inspected using dye penetrant. The remaining 70–90 mm deep seam was MAG welded. Ultrasonic testing on all welding seams was performed by the French Institut de Soudure. All located defects larger than those agreed had to be repaired, particularly in highly stressed areas of the case. After cover welding the case openings were sealed to make it vacuum tight for impregnation with the same type of epoxy resin and the same curing procedure, as used for the previous impregnations (see Section 3.3.7). For impregnation, the same mould was used again as a heating vessel. 3.4.6. Final machining and surface finish The final machining of the interfaces and cooling channels on the outer circumference was done after
impregnation of the coil in the case and sand blasting of the outer surface. After the final machining the covers were welded on the cooling channels of the outer circumference and pressure and leak tested. The final surface finish was achieved by degreasing with agreed solvents. 3.4.7. Headers and bus bars The inlet and outlet header assemblies have been built up on assembly frames. After having been pressure and leak tested they were transferred onto the TFMC. A number of sensors (strain gauges, rosettes, displacement, temperature, etc.) as described in Section 3.7 were mounted onto the TFMC. The Kapton insulated high voltage cables have been equipped with the warm vacuum tight feed throughs by FZK and provided by industry with the cold end pieces that were connected with the voltage taps coming from the pancakes and the radial plates. The bus bars have been manufactured from a CS1 type conductor using NbTi strands and a stainless steel square jacket. The bus bar terminations are of the same type as the EU FSJS’s [40,38]. Two types of bus bars were manufactured: Bus bars type 1 were mounted on the TFMC connected to the coil terminations (see Fig. 3.12). After assembly in the TOSKA facility they were connected to the terminations of bus bars type 2 forming part of the TOSKA current lead system (so-called cryostat extension). The busbars were insulated by multi-layer wrapping with glass-Mica tapes wetted with ambient temperature curing epoxy resin. 3.4.8. Intermediate and final tests at suppliers works Intermediate tests (dielectric, pressure/flow/leak, geometrical, etc.) were performed on DP modules, winding pack in different stages and subassemblies. A final 30 bar helium internal pressure and leak test of the TFMC with all headers and instrumentation was carried out in a vacuum tank built by modifying the impregnation mould. The total leak rate had to be:
Page 1 and 2: Fusion Engineering and Design 73 (2
Page 3 and 4: The application and continuation of
Page 5 and 6: 3.2. Conductor manufacture 3.2.1. S
Page 7 and 8: A. Ulbricht et al. / Fusion Enginee
Page 9 and 10: Table 3.5 TFMC double pancake data
Page 11: 3.3.7. Module ground insulation and
Page 17 and 18: trial consortium AGAN and the Europ
Page 23 and 24: ˙Q ICS [W] ˙Q case [W] ˙Q bus ba
Page 29 and 30: 4.3.2.4. Standby operation over nig
Page 35 and 36: 2 weeks (JAERI method); for joint 1
Page 37 and 38: Table 4.5 Main operation parameters
Page 45 and 46: Fig. 4.35. Computed TFMC windings c
Page 49 and 50: the quench detection system. The lo
Page 55 and 56: ply current regulation. This situat
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Fig. 5.18. Summary of performance a
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filaments in the TFMC (and similar)
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Symbols Explanation C00 Coefficient
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A. Ulbricht et al. / Fusion Enginee
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the outer joint outlet. This heat e
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Fig. 6.9. Loss energy of the TFMC w
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Fig. 6.13. Evolution of the couplin
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and during Phase 2 (within 6%). The
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other hand, if using the central ch
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Fig. 6.20. Top: quench propagation
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Fig. 6.23. Measured (multi star) an
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fB Friction factor of the bundle re
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surement with voltage taps located
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Table 7.3 TFMC pancake (joint) resi
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Table 7.8 Values of TFMC and FSJS j
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Fig. 7.7. The insulated bus bar typ
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Rneg, 1[nΩ] = 1.77 [n�] + 3.75
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law actually is good (better than
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Fig. 7.16. Current in the petals re
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ence may exceed the inaccuracy of t
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provided support to the coil and th
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(c) The best fit in relation to the
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8.5. Comparison to ITER TF coil str
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Fig. 9.7. Partial discharge activit
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circular cross-section and central
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two different sets of Hall probe ar
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equation: dx = Ax + Bu dt y = Cx +
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[34] E. Salpietro, R. Maix, G. Bevi
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[86] R. Heller, D. Ciazynski, J.L.
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ple for ITER, IEEE Trans. Appl. Sup
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PSB: Power System Blockset is a MAT
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The ITER toroidal field model coil project

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