Manufacture of the poloidal field conductor insert coil (PFCI)

Abstract

Within the framework of the R&D programme for international thermonuclear experimental reactor (ITER) the European team European Fusion Development Agreement (EFDA) has been charged with the design and manufacture of the poloidal field conductor insert coil (PFCI). The purpose of the PFCI is to test and demonstrate the performance of long-length full-scale NbTi conductors in ITER-relevant conditions. The PFCI will be tested in the central solenoid model coil test facility at the JAEA, Naka, Japan. This paper details the complete manufacturing of the PFCI including development, forming machining, pre-assembly, impregnation, final assembly and testing. The PFCI is a single-layered wound solenoid of nine turns with a transition joggle in the centre section of the winding and an intermediate joint connection between the upper termination and the main coil winding. To give the required overall dimensions to fit in the testing facility, preformed and machined glass resin composite filler pieces are assembled with the winding and is finally vacuum pressure impregnated (VPI) to create a single assembly unit. The PFCI is enclosed for assembly in a support structure, which consists of an upper and lower flange, each made up of four electrically insulated machined stainless steel castings, and 12 tie rods preloading the complete assembly in the vertical direction. The upper flange is equipped with four radial restraining jacks and the lower flange is equipped with four sets of studs and shear keys to withstand the net vertical and lateral electromagnetic forces. The PFCI is equipped with inductive heaters, voltage taps, temperature transducers, strain gauges and other instrumentation as diagnostics to monitor the performance. The current status of the manufacture is that the coil has passed the final acceptance tests and it is in the support structure assembly stage.