PFC/RR-89-1
DOE/ET-51013-263
TESTING OF
FULL SCALE ITER
OHMIC HEATING COIL CONDUCTORS
Hoenig, M.O.
January 1989
Plasma Fusion Center
Massachusetts Institute of Technology
Cambridge, Massachusetts 02139 USA
MASSACHUSETTS INSTITUTE OF TECHNOLOGY
Plasma Fusion Center
CAMBRIDGE MASS. 02139 USA
FAX: 617-253-0807
Phone: 617-253-5503
TESTING OF FULL SCALE
ITER OHMIC HEATING COIL CONDUCTORS
Mitchell 0. Hoenig
Jan 19, 1989
INTRODUCTION
ITER requirements call for a superconducting Ohmic
Heating Coil
(OH Coil) with a Local Flux1 of about 200 V-s.
We have performed a scoping study to define an AC, cablein-conduit conductor
[CICC]
design for a 2.5 m bore OH Coil, with a
200 V-s local Flux potential in order to guide our future base
program work on advanced CICC conductors.
In carrying out the scoping study we have also addressed
the classic issue of how one might qualify such a conductor in a
sub scale facility.
We believe it is important to develop a conductor in full
scale in order to fully qualify the processes involved in its
production as well as evaluate its behavior as a full cable. It is
generally difficult to test the full scale conductor to full
operating stress, in anything but a full scale coil, since in a
simple solenoid conductor stress is related not only to field [B],
current [I] but also to Ri, the radius of the inner turn.
We have therefore proposed that the full scale sheathed
conductor be co-wound with an additional inter-turn structural
strip whose thickness can be scaled with the inner radius of the
coil.
In our proposal we have chosen an essentially half scale test
coil (1.3 m vs 2.5 m bore), a coil size which would not require any
structure beyond that of the full scale sheath.
1
Local Flux, (defined here) is based on a free standing O.H. Coil,
with a Flux Density of B+/B- .
1
The 1.3 m scale has also been chosen because it matches
the dimensions of the JAERI DPCF facility, and therefore suggests
an economical, shared undertaking, which we describe.
ABSTRACT
The optimized conductor, "CICC-OH-1" is designed for 12.5
T operation at 30 kA with an I(op)/I(crit) ratio [RI] of 0.5, with
Bmax = 14.7 T at R, = 1.0
To use "CICC-OH-1" in the 2.5 m bore OH Coil, the CICC is
co-wound with a structural band, sized to limit tensile strength to
50% of Yield at 30 kA and 12.5 T.
When wound into a 1.3 m bore test coil, tensile stress in
the "CICC-OH-1" conduit equals 50% of Yield at 30 kA and 12.5 T.
The conductor requires no additional inter-turn structure in this
coil configuration. Conduit thickness of the "CICC-OH-1" permits a
minimum bend radius of 0.5 m.
A 1.3 m bore test coil could be economically produced by
upgrading the JAERI DPCF Test Facility. The DPCF increase in field
would be achieved by the replacement of its 30 kA (7 to 8T 2)
NbTi DPC-U1 & U2 field coils with coils using new 30 kA (12.5 to
14.7 T 3)
Nb 3 Sn conductor.
The upgraded DPCF Coil would consist of three or four 1.3
m bore pairs of coil modules
. Conductor used would be "CICC-OH-1"
or equivalent. Three or four full scale candidate OH Coil
conductors, provided by different sponsors could thus be readily
evaluated as part of the upgraded DPCF Facility.
The proposed test coil could also accommodate test
pancakes or modules of other (for example PF,TF or advanced OH)
conductors
.
We believe that an upgrade of the existing DPCF facility,
with an investment of $M 20 in a new 3-Module-Pair Coil [or $M 25
in a new 4-Module-Pair Coil], is feasible. The investment could
logically be shared by three or four sponsors. The upgrade would
also have to include modifications to the DPCF Cryogenic system to
accommodate higher AC loss.
2
3
8T is peak field attainable with an I(op)/I(crit) ratio of 1.
Bmax = 12.5 and 14.7 T at
I(op)/I(crit) = 0.5 and 1.0 (resp.).
2
The proposed program is designed to accomplish the
following:
Facilitate the simultaneous testing of 3 or more
[ii
full scale OH Coil
(candidate) conductors.
[ii]
Upgrade the DPCF AC Test Facility at JAERI for
the testing of Advanced OH and PF conductors at fields of 12.5 to
14.7 teslas.
[iii]
Accelerate the development of a high-flux ITER
Ohmic Heating Coil. Starting with wire procurement in 1991 and coil
fabrication in 1992, 12.5 T coil tests could be undertaken in 1995.
[iv]
reasonable cost
Accomplish a major ITER/tokamak objective at
[$M 25]. The equivalent cost of a 2.5 m bore OH
Coil prototype would be $M 100 in addition to a new $M
facility investment.
3
150 to 200
SCOPING STUDY SUMMARY
200 V-s [local Flux] requirements can be satisfied by a
solenoid with the following characteristics:
Coil Diameter
3.7
(OD)
Coil Bore
2.5
Coil Height
Coil Bore Flux Density
Peak Ramp Rate
(=/>)
10.
(=/>) 12.5
5.
m
m
m
T
T/s
These coil characteristics, in turn can be satisfied in
a coil fabricated from a force cooled, cable-in-conduit conductor
[CICC],
designated
"CICC-OH-1" (for reference).
As shown in Fig 1, "CICC-OH-1" is co-wound with a shaped
structural band (Fig 2) . Thus reinforced, "CICC-OH-1" is designed
for 30 kA, 12.5 T operation as the sole conductor of a 2.5 m Bore
O.H. Coil.
"CICC-OH-1" Conductor Characteristics:
Superconductor
Ternary Internal Process Tin Nb 3 Sn with
2
Jc(12.5T,4.2K, 0.1 pV/cm) =/> 700 A/mm non-Cu4
Hysteresis Loss (0:7T:0:-7T:0)
=/< 1 j/cc wire.
I(op)/I(crit) = 0.5 at 12.5 T and I(op) = 30 kA
Cu Stabilizer
=/> 50% of Wire Cross Section
Hydraulics
Coolant: Supercritical Helium
Cable Space He Fraction =/> 32 %. Additional,
annular He equal to Cable Space mass flow.
Length of hydraulic path not to exceed 150 m.
Conduit
Incoloy 908, cold worked prior to precipitation
hardening heat treatment in order to provide a
(0.2%) Yield Stress of =/> 1500 MPa at 4.2 K.
Structure
Conduit thickness not exceeding 4.0 mm for ease
of fabrication. Additional structure to be
provided by means of a co-wound, co-heat treated
band, same alloy. Tensile Strength =/< 0.5*(0.2%
Yield) at 12.5 T .
4
Commercially available from TWCA
4
Geometry
Axial Height = 28.85 mm (insulated CICC)
Radial build = 39.28 mm (reinforced & insulated
CICC)
Overall Jc
38.83 A/mmA2 for an insulated "CICC-OH-1"
26.47 A/mmA2 for reinforced, ins."CICC-OH-1"
Illustrations
"CICC-OH-1 ",
"CICC-OH-1",
"CICC-OH-1",
Calculations
reinforced
reinforcement
not reinforced
Fig 1
Fig 2
Fig 3
See Table I, attached.
TEST OPTIONS
Three test options are available
Option
1
The conductor (per Fig 1) could be tested in the form of
a full scale, (2.5 m bore) prototype OH Coil. A substantial coil
would be needed to provide full self field. Prototype coil
characteristics5 are :
Coil
Coil
Coil
Coil
O.D.
height
weight
Cost
3.7
8 to 10
248
103
m
m.
tonnes
$M
Test Facility
Illustration
non existent
Module of OH Coil: Fig 4A
Option 2
The identical CICC conductor,except without its co-wound
structural reinforcing band (ie per Fig 3) could be tested under
identical conditions of field and current in the form of smaller
(1.3 m bore) test coil . The test coil would also provide its own
self field. Test coil characteristics6 are :
Coil O.D.
Coil height
Coil weight
5
6
2.0
2.3
38.2
m
m
tonnes
See Table I, column H.
See Table I, column C
5
Coil Cost
Test Facility
18.2
$M
DPCF at JAERI
Illustrations
[upgraded]
Module of Test Coil: Fig 4B
Test Coil Elevation: Fig 5
Option 3
A much shorter length [150+ m] of the full scale
conductor (per Fig 3) could be wound into a 1.0 to 1.5 m bore test
module (perhaps a unit Double-Pancake). Option 3 requires the use
of a Background Field Coil, such as one proposed in Option 2.
SCOPING STUDY ALTERNATIVES
We have attempted to demonstrate that a superconducting
coil, fabricated from the "CICC-OH-1" conductor uniquely satisfies
the requirements of an Ohmic Heating Coil with a Local Flux of 200
V-s.
[1]
USE OF
"CICC-OH-1" AS FULL SCALE OHMIC HEATING
COIL CONDUCTOR,
Overall Coil Geometry :
Diameter
Bore
Height
(OD)
(=/>)
3.7 m
2.5 m
m
10.
Operating between +/- 30 kA the "CICC-OH-l"
Iop/Icrit
ratio of is 0.5. Ramped between +/- 12.5 T the OH-Coil provides a
Local Flux of 197 V-s.The conductor is illustrated in Figs 1-3.
Co-wound with a structural strip
(Figs 2),the CICC-OH-1
conductor satisfies the following radial design requirements:
Tensile stress
Yield Strength
=/<
50% of alloy (0.2%)
(CICC conduit and structure).
Axial Compressive stress in the CICC-OH-1 Conductor is
minimized by the division of the coil into a number of flanged
Sub-Coils, or Modules
7
(Fig 4A).
See Table I, column H.
6
The unit Module, consisting of Six
(6) Double Pancakes
(or 12 vertical layers) has a net height of 0.39 m and a flanged
height of 0.49 m. 10 module-pairs would be needed to build one 10
m tall, 12.5 T coil.
Operating characteristics of the 12.5 T, 2.5 m Bore, 3.7
m OD OH-Coil are illustrated in Fig 6 for an Ip/Icrit ratio
of <
0.5 to 1.
The same data are tabulated in more detail in Table 1
(Columns H-K).
The shipping weight of a pair of the 3.7 m diameter
Modules is 21 tonnes while their (uninstalled) cost has been
estimated at $M 7.7.
[2]
USE OF THE
"CICC-OH-1" AS CONDUCTOR FOR A 1.3 m
BORE TEST COIL
Overall Coil Geometry8
Diameter
(O.D.)
2.0
Bore
Height
structure,
m
1.3 m
2.33 m
In this configuration "CICC-OH-1" needs no supplementary
(see Fig 3). The 12.5 T, 1.3 m bore coil is assembled
using three
(3)
[or four
(4)] pairs of Unit Modules. A cross-
sectional view of the Module is shown in Fig 4B (for comparison
with Fig 4A, the 2.5 m bore OH Coil Module cross-section). Like
the OH Coil Module the Test Coil Module consists of Six
Pancakes (or 12 vertical layers).
and a flanged height of 0.45 m.
(6) Double
It has a net height of 0.35 m
The 12.5 T, 2 m O.D. Test Coil, illustrated in Fig 5
satisfies the same design constraints for operation at +/- 12.5 T
and +/-
30 kA as the full size OH Coil, namely:
a
b
c
8
See Table I,
Iop/Icrit = 0.5
Tensile stress
=/< 50% of alloy
Yield Strength (CICC Conduit).
Insulated CICC-OH-1 Conductor Overall
Current Density (Jc): 38.8 A/mm2
column C
7
While the 1.3 m bore, 2 m OD Test Coil can be
conservatively operated as a 12.5 T facility magnet at 30 kA, its
"CICC-OH-1" conductor can be pushed to higher current levels. This
is illustrated in Fig 6, the Load Current Plot, with the following
ultimate limit:
a
b
c
Iop/Icrit = 1.0 at 35.2 kA and 14.7 T
CICC tensile stress = 69% of 0.2% Yield
Strength.
Insulated Conductor Overall Current
Density (Jc) would increase from 38.8 to
45.6 A/mm2
The study assumes that Coil Modules are fabricated in
pairs. Three (or four) sets of Module Pairs could thus be
fabricated by 3 or 4 sponsors, each contributing one pair of Coil
Modules. While one pair could be fabricated from the "CICC-OH-1"
conductor, the other Module pairs could represent competing OH Coil
candidate technologies, with matching overall characteristics.
Detailed characteristics of the
12.5 T,
1 m Bore, 2 m OD
Coil are presented in Table 1 (Columns C-F) for comparison with OH
Coil characteristics (Columns H-K). The shipping weight and
(uninstalled) cost of a pair of the Test Coil Modules are 9.3
tonnes and $M 4.1
[3]
(resp.).
DPCF FACILITY UPGRADE
The 2 m O.D. Test Coil brings to mind the operation of
the coil within the DPCF Facility at JAERI in Japan (Fig 7).
Except for its limited field capability, the DPCF Facility already
satisfies most of the required condition. Ramped Fields of the
order of 5 T/s with Peak Fields of 12.5 to 14.7 teslas would be
possible with an upgrade of the Facility.
The Superconducting Magnet Facility, referred to here as
the DPCF Poloidal Coil Test Facility is operated by the Japanese
Atomic Energy Research Institute (JAERI) under the direction of
Dr. S.Shimamoto.
The DPCF upgrade (from a nominal 7.5 to 12.5 teslas)
would be effected by the replacement of the DPCF's 7.5/8 tesla 2 m
OD DPC-U1 and DPC-U2 Coils with the 12.5 tesla 2 m diameter, 2.33
m tall Test Coil (Fig 5).
DPCF is uniquely suited for this task. Its facilities
include an operational (>50+ kA by 5+ kV) A.C. power supply, and
a vacuum vessel with a 4 K shielded inner volume adequate to
8
accommodate a 2 to 2.5 m O.D., 3.5 m high coil. The vacuum vessel
is superbly equipped with 30+ kA current leads as well as all
services required for the support of these operations.
The existing DPCF magnetics system uses a pair of 1 m
I.D. by 2 m O.D. NbTi Background Field Coils (DPC-Ul and DPC-U2),
capable of a 10 T/s ramp rate between 0 and 7.5 to 8 T. The coil
pair has a common vertical axis. Peak field is limited to 7.5 to 8
T. In our current (US-DPC) program we have designed for a peak
field of 9.5 to 10 T by placing our Nb 3 Sn Test Coil in the center
plane between the DPC-Ul and DPC-U2 Coils.
[4]
SELECTION OF DESIGN CURRENT,
The effect of Operating Current
(Iop) on various
conductor characteristics has been summarized in Table II for both
the 2 m OD Test Coil (Table II, Columns C-G)
and the 3.7 m OD
Ohmic Heating Coil (Table II, Columns I-M).
Thus:
The effect of an increase in Iop from 20 to 60
[ii
kA is a negligible (2 %) increase Local Flux [see Table II, line
49, columns I-M] .
[ii]
As illustrated in Fig 8, a major advantage of
higher current is reduced CICC length. Thus a 20 to 60 kA increase
in current represents a 43 % decrease in CICC length from 350 to
200 m.
[iii]
The larger the current
(Iop),
the larger the
9
CICC conductor . While an increase in CICC radial width would not
pose a winding problem for even a 0.5 m 1.R. test coil,
fabricating a conduit from a 5.2 mm (or even > 4 mm) thick Incoloy
strip most likely would.
[iv]
The effect on cost could also be significant. As
illustrated in Fig 8, a design change from 20 kA to 60 kA,
represents a 17 % cost reduction.
[vI
The larger the operating current, the more
complex the termination, joint and current lead.
9
See Table II, lines 31 and 32.
9
While these parameters deserve further study, we have
selected 30 kA as the recommended nominal operating current for
the "CICC-OH-1" conductor (Iop/Icrit = 0.5) . Peak operating
current
(at Iop/Icrit=
1) would be 35 kA
SELECTION OF FLUX DENSITY.
[5]
Using 12.5 T as reference, we have evaluated the effect
10
of 14.5 and 15.5 T Flux Densities [B] on Local Flux1. We have
assumed a constant B within the coil bore, a coil O.D. of 3.7 m
and an Iop of 30 kA [at Iop/Icrit = 0.5].
Coil I.D.(bore),
Flux,
coil weight and cost are dependent variables. The effect of the
flux density increase on these variables is shown in Fig 9 and has
been tabulated below:
LOCAL FLUX OH.Coil I.D.
[V.s]
[ratio]
[im]
Bmax
[T]
Module Height
WEIGHT 11
[m]
COST 12
[$M] [ratio]
12.5T
196.7
1.00
2.52
0.35
20.7
3.85
1.0
14.5T
15.5T
206.1
203.7
1.05
1.04
2.10
1.74
0.39
0.44
30.6
44.3
6.47
9.79
1.7
2.5
Thus an increase in B from 12.5 to 14.5 T represents
only a 5% increase in Flux, while the cost increase is 70%. There
appears to be a maximum in the Flux vs. B plot (see Fig 12)
indicating a higher Flux at 14.5 than 15.5 T. Hence, based of
Flux, there appears to be no reason to increase B above 12.5 T.
Fig 10 compares 12.5 and 14.5 T CICC characteristics,
comparable Coil Modules are illustrated in Fig 11.
while
10
11
12
Local Flux, (defined here) is based on a free standing O.H. Coil,
with a Flux Density of B+/B- .
Tonnes per Unit OH Coil Module.
$M per Unit OH Coil Module.
10
It should be noted that the 14.5 T OH Coil design has a
Critical Peak Field of 15.75 T
[at Iop/Icrit = 1.0],
while the
equivalent Critical Peak Field for the 12.5 T OH Coil is 14.6 T.
This is illustrated in Fig 12, entitled "Coil Bore Flux Density
for 12.5 and 14.5 T OH Coils".
CONCLUSIONS
We believe that our "Scoping Study" demonstrates the
feasibility and cost effectiveness of the following:
(1)
The testing of full scale, sheathed OH Coil
conductors in an essentially half-scale A.C.
test facility under severe operating conditions
of current density, flux density and stress.
(2)
An upgrade and use of the Japanese DPCF Test
Facility at JAERI for the testing of ITER OH
Coils at a nominal flux density of 12.5 T.
(3)
The replacement of the DPC-Ul and U2 coils in
the upgraded DPCF Facility with 12.5 T
replacement coils.
(3)
The assembly of the new DPCF replacement coils
using 3 (or 4) pairs of 1.3 m bore, 2 m
diameter, series connected coil modules.
(4)
The coil modules to be built in pairs, by 3 or 4
different sponsors, using full scale OH Coil
conductors.
(5)
The difference between a conductor tested in the
12.5 T DPCF and the full scale ITER OH Coil
would be the co-wound structure, which would be
added to the conductor in order to limit tensile
stress, generated by the higher forces of the
larger OH Coil.
(6)
Test operations of the Upgraded DPCF Test
Facility to be initiated in 1995.
We recommended a 30 kA current level for the upgraded
DPCF Coil, when operating as a Test Facility, (at Iop/Icrit= 0.5).
Peak field at the conductor at this current level to be 12.5 T.
current
It should then be possible to increase the
level to 35 kA (Iop/Icrit = 1) in order to subject the (3 or 4)
candidate conductors to more severe testing.
11
The nominal peak field of 12.5 T (at Iop/Icrit= 0.5) is
adequate. A design based on 14.5 T would not be cost effective.
Gain, in Flux is negligible.
The 1.3 m scale has also been chosen because it is cost
effective, since it matches the dimensions of the JAERI DPCF
facility, and therefore suggests an economical, shared undertaking,
described above.
12
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I [crit]=f (B [bore])
for OH COIL
0
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FIG 6
12.0
[max]
13.0
14.0
15.0
16
(T)
LOAD LINE PLOTS FOR 12.5T
O.H.COIL and TEST COIL.
18
M.O.Hoenig MIT
Jan1989
12.5+T I(op)=f (B) 890111
Ul BACKGROUND
FIELD COIL
.
I
CONDUCTOR TEST CO
US-DPC OR DPC-EX
U2 BACKGROUND
FIELD COIL
2
FIG 7
m DIAMETER
DEMONSTRATION POLOIDAL
19
COIL TEST FACILITY
n~pci;
0
0
I
I
I
*
-
U
U
U
H
U
0
0U-
1
U
,.004
U
KWJ4
cv~
0
0 - 5'-
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ON N
I -4
4
000 TF1
&
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I
H
43
H
0
1--i
0
x
in
to 0
V1
0
z
urn
I
E-4
0
H
0
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0
0
0
U')
0
E4
V')
0
u.
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LI
1iI
0
11D
OPERATING
FI
miii.
I oil!
Iii
20
DESIGN
30
mmm iI II
40
CURRENT
I (op)
I
50
60
(kA)
EFFECT of OPERATING CURRENT (Iop) at
on CICC LENGTH
CICC CONDUIT THICKNESS
COST
and O.H.COIL
G 8
20
12T
M.O.Hoeniq MIT
Jan 1989
12.5+T $=f(I~opfl
890106
0
0
Nl
0
0
cl
x
+
+
D
U,
0
*14
i'
'00
H
.0
0
0
tn)
0
H
0'4
0
1000eo0
0
'-4
4U)
to
r74
0
U)
_____0
CA)
G
11111 111
12
13
14
15
NOMINAL
FLUX
16
DENSITY
0
B(T)
EFFECT OF FLUX DENSITY
ON COIL COST AND FLUX
FIG 9
Note :
* M$/V-s [@B]
21
/
M$/V-s[@12.5T]
M.O.Hoeniq MIT
Jan 1989
12.5T $=f(B)
8901123
o
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@ 30 kA
2.5 T
zE-
i.H.COIL
14.5 T O.H.COIL @ 30 kA
0
0
Nl
-
op
op
0
r4I
8.0
9.0
10.0
11.0
B
12.0
[max]
13.0
14.0
15.0
16
(T)
COIL BORE FLUX DENSITY [T] FOR
12.5T AND 14.5 T
OHMIC HEATING COILS.
FIG 12
24
M.O.TI-oeni MIT
Jan1989
12.5T Iiop)=f(B) 890122
Table I
DETAILED CICC, COIL MODULE AND COIL
CHARACTERISTICS
FOR 30 kA OPERATION
I(op)
/ I(crit)
=
0.5
at
B = 12.5 T
to
I(op) / I(crit) = 1.0
FACTORS
INCLUDE:-
GEOMETRY, CURRENT DENSITY, STRESS,
FLUX, CICC LENGTHS, WEIGHTS AND COSTS.
FOR 3.7 m OH COIL
see Columns H-K
FOR 1.3 m TEST COIL
see Columns C-F
25
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Table
II
A SUMMARY TABLE
EFFECT OF 20 TO 60 kA OPERATING CURRENT I(op)
ON LENGTH OF CICC CONDUCTOR
[L
CONDUIT WALL THICKNESS
[t (wall)
COST AND FLUX.
AT 12.5 T AND
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