EU TF coils status A.Bonito Oliva F4E Magnets Project Manager Slide 1
Presentation Outline TF coils Main Manufacture Steps Procurement strategy Status of the production Contracts and industries involved One of main challenges: interfaces management Slide 2
The TF coils: main parameters 16500mm 10 TF Coils produced in Europe 9TF coils Produced in Japan Weight : 300t/coil!
EU TF coils: Composed by 2 main components COIL CASES from Japan The TF coils is composed by the winding pack inside a stainless coil case. WINDING PACK: Composed by 7 Double Pancakes staked and impregnated together
EU TF coils: Manufacture of a double pancake (DP) RP manufacture DP Heat treatment (650 C) Winding Conductor Transfer conductor into radial plate RP grooves Conductor insulation CP laser welding Impregnation Ground insulation
g EU TF coils procurement split in 3 contracts Completion of 10 TF coils Manufacture of 10 Winding Packs Winding Pack s main components Coil Case from JAEA Conductor from EU,RF,CN & US Manufacture of 70 Radial Plates Radial Plate
Contracts for EU TF coils Manufacture of 70 Radial Plates Contract placed on December 2012 Consortium CNIM - SIMIC (50-50 production) Main sub-suppliers: 3 Portal Machines: CRENAU, INNSE-Berardi (twin PM), PAMA Forged sectors (50-50): Thyssen-Grodtiz & Forgiatura Vienna Cover plate suppliers: Calvi for cold drawing, Kersten for bending.
Contracts for EU TF coils Manufacture of 70 Double Pancakes and 10 Winding Packs Contract placed on July 2010 Consortium ASG-Iberdrola-Elytt Main place of production : ASG La Spezia Main tooling suppliers: Winding tooling, Insertion tooling, WP impregnation tooling: TPA Brianza Turn Insulation and DP VPI: Elytt Furnace: Terruzzi Laser welding: TTM group
Contracts for EU TF coils Cold test and Insertion of 10 Winding Packs Contract Placed in May 2014 Main suppliers: SIMIC BNG Main Place of production: Porto Marghera, Italy Main Tooling: Cryoplant: BNG-Messer Gap Filling: Hedrich
Main challenge: Interfaces between suppliers Many supplier and sub-suppliers involved High level of technical risks: never done before on this scale and very complex technology! Very complex interfaces: An example: Radial Plate and Double Pancake RP and DP are produced by 2 different suppliers In order to be able to fit the conductor inside the radial plate groove, the double spiral trajectory of the DP and of the RP groove must match perfectly (within tenths of mm) over a length of about 700m!
DP vs RP interface This is interface is very delicate to manage due to the combination of the demanding requirement on both suppliers and to the potential financial consequences in case one DP cannot fit the RP groove ( up to 10MEuros if we have to throw away both!) How did we manage it? 1. R&D: In order to reduce technical uncertainty F4E placed initially 2 contracts to manufacture 2 RP prototypes: finally a mix of the 2 technology was selected. This R&D also gave an indication of the achievable tolerances.
DP vs RP interface (II) 2. Initial Risk mitigation Initially in order to reduce risks for the industries (and for us ), we selected a conservative route where RP groove is machined only after as-built DP conductor trajectory is known. 3. Rigorous quality control In order to master the technology we introduced many intermediate quality controls which gave the capability to detect and correct issues at an early stage 4. Adaptation of strategy to learning curve Once technology reached a comfortable level we moved to parallel production of RP and DP, saving several months on the schedule. This gives benefit to ITER schedule and to the suppliers reducing waiting time.
So in summary our recipe has been: R&D to select best technology Initial conservative approach to minimize initial risks Rigorous intermediate quality to master better technology Flexibility to adapt manufacturing strategy to learning curve Did we succeed in mastering this interface?
TF coils Series Production Status Process No. units completed Notes Radial Plates fabrication Double Pancakes Winding 14 (2 TF coils) 25 (more than 3 TF Coils!) Production rate: 1 every 13 days Production rate >1/2 weeks DP Heat Treatment 15 HT cycle ~1 month DP Transfer & Insertion 11 Process time ~1 week DP Conductor Insulation DP Cover Plate Laser Welding 8 Process time ~3-4 weeks 4
Successfully completion superconducting full size Prototype Double Pancake! The first-ever Double Pancake prototype has been successfully completed and passed all acceptance tests! 15
Thanks Slide 16