Annex B TECHNICAL SPECIFICATION FOR PRE-COMPRESSION RINGS

Transcription

1 IDM # F4E_D_234FHQ Page 1 / 1 Ver. 1.5 TECHNICAL SPECIFICATION FOR PRE-COMPRESSION RINGS DMS # Call # F4E_D_234FHQ F4E-OPE-150 (MS-MG) Rev. Date [Purpose] First issue Chapters and swapped for consistency. Several small changes to improve clarity Tables 7 and 8 were updated to include Supplier input, added qualification schedule and adjusted deliveries to match with the required delivery schedule Options 3 and 4 were clarified in Chapter 5.1. Table 7 and 8 were revised to match with payment milestones and the ring naming was updated S2-glass material defined The delivery schedule was adjusted to match better with ITER assembly schedule. Author Reviewers Approver H. Rajainmaki C. Sborchia, M. Losasso, C. Annino, C. Harghel, E. Barbero Soto, J. Caballero M. Gasparotto

2 Page 1 / 34 Ver. 1.5 TECHNICAL SPECIFICATION FOR PRE-COMPRESSION RINGS Abstract This Technical Specification concerns the Supply of the Pre-compression Rings of the ITER magnet system. The number or the Pre-compression Rings to be delivered is 9 (including 3 spares) and the weight of each 5-metre diameter Pre-compression Ring is 3.3 tons. The deliveries are foreseen over 51 months from placement of the Contract.

3 Page 2 / 34 Ver. 1.5 Table of Contents TERMS AND DEFINITIONS... 5 APPLICABLE DOCUMENTS... 6 REFERENCE DOCUMENTS INTRODUCTION Introduction to ITER & Fusion for Energy Subject of this Technical Specification SCOPE OF THE TENDER Scope of Supply Engineering activities Hardware Items Supplied by F4E Boundaries TECHNICAL REQUIREMENTS Engineering activities FE analysis of composite behaviour Process qualification by UTS testing 1/5 scale Rings Definition of fabrication process for achievement of optimal performance Design, qualification and commissioning of final tooling Materials qualification Glass fibre Resin Composite Development of adequate Non-Destructive Evaluation (NDE) techniques Fabricating and NDE testing full scale qualification prototype Full mechanical characterization of samples extracted from the full scale qualifying prototype Hardware Functional and operational requirements Design and manufacturing requirements Raw Materials requirements Glass fibre... 20

4 Page 3 / 34 Ver Epoxy TESTS AT SUPPLIER WORKSHOP/TEST FACILITY OPTION 1: Fabrication of first-of-series Pre-compression Ring and proof test Objective and Deliverables Proof test and stress relaxation program Ring fabrication requirements Ring testing tooling requirements Ring testing requirements Proof test Relaxation test Examination of Ring LOGISTIC SUPPORT REQUIREMENTS Packaging for Transportation and Storage ASSEMBLY, COMMISSIONING AND TESTS ON SITE LONG TERM CONDITIONS APPLICABLE DESIGN REFERENCES Reference conditions Safety and regulatory requirements Codes and standards Environmental requirements DELIVERABLES AND SCHEDULING QUALITY ASSURANCE PROVISIONS IDENTIFICATION REQUIREMENTS COMPLIANCE MATRIX ANNEX I. PROCESSING AND TESTING AI.1 Processing AI.2 Nuclear issues AI.3 Voids in composites AI.4 Moisture absorption AI.5 Sample Testing precautions ANNEX II. FULL SCALE RING PROOF TEST TOOLING AII.1 Possible solution A... 33

5 Page 4 / 34 Ver. 1.5 AII.2 Possible solution B... 34

6 Page 5 / 34 Ver. 1.5 TERMS AND DEFINITIONS Term Definition Acronym Acceptance Data Is the documentation package linked with a deliverable to be submitted by the Supplier Package ADP Fusion for Energy The European Joint Undertaking for ITER and the Development of Fusion Energy Technical Responsible Officer TRO F4E s responsible for communicating all technical contractual actions and decisions to the Supplier Quality Officer F4E s responsible for QA for the Contract QAO IO ITER Organisation, sometimes referred to as ITER IO KOM Kick-Off Meeting of the Contract KOM NDE Non-Destructive Examination NDE Subcontractor All economic operators who supply items to the Supplier under the Contract --- Supplier Fibre Strand Tow Yarn Roving Fabric Tex Ring(s) The Supplier is the Contractor as defined in the Supply or Service Contract. The successful Bidder (Tenderer or Applicant) is referred in the document as the Supplier. The Supply-chain follows the scheme below Supplier -> Organization (F4E) -> Customer (e.g. IO ) A generic term for any one of the various types of matter that form the basic elements of a textile and that is characterized by having a length at least 100 times its diameter A single fibre, filament, or monofilament having a high ratio of length to diameter and normally used as a unit in rovings and yarns A non-twisted multifilament strand suitable for direct spinning into yarn A generic term for a continuous strand, filaments or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric A multiplicity of filaments or yarns gathered together into an approximately parallel arrangement without twist. Each filament diameter in a roving is the same. Differing numbers of filaments can be used to make up the roving in a range of weights, which is usually between 300 tex and 4800 tex. A planar structure consisting of yarns or fibres The unit of linear density, equal to the mass in grams of 1000 meters of fibre, yarn, or other textile strand, that is used in a direct yarn numbering system Abbreviation for Pre-compression Ring(s) RT Room Temperature RT OIS Outer Intercoil Structure OIS UTS Ultimate Tensile Strength UTS VPI Vacuum Pressure Impregnation (=RTM) VPI Pre-preg Glass fibre (woven fabric or tow) that has been pre-impregnated WW Wet Winding (=Filament winding) WW TBC To be confirmed by the supplier in their offer TBC F4E ---

7 Page 6 / 34 Ver. 1.5 APPLICABLE DOCUMENTS Ref number Doc Number Doc number and document title. [A1] F4E_D_233DAS Drawing 11PC TF Coil Pre-compression Ring [A2] F4E_D_22NF8U /1588 Development and testing of the Pre-compression rings mock-ups and characterization of the composite material [A3] F4E_D_22ZEFC ITER RAMI Analysis Program [A4] F4E_D_22VC5E ITER Vacuum Handbook [A5] F4E_D_232UYV ITER_Numbering_System_for_Parts_Components [A6] F4E_D_232Z7H ITER_Function_Category_and_Type_for_ITER REFERENCE DOCUMENTS Ref number Doc Number Doc number and document title. [R1] F4E_D_233UNU Drawing 1101CA_ TF Coil Pre-compression Ring counter flange [R2] F4E_D_22TREW TW1-TMS-MMFTRD Del 4 Final report on short term tests on monodirectional fiber composite for ITER rings [R3] F4E_D_22TXCF ITER Pre-Compression Rings Characterization [R4] F4E_D_22UXE ITER pre-compression Rings - Alternative Solutions [R5] F4E_D_22X2VC ITER Contract Pre-Compression Rings Final Design Qualification [R6] [R7] F4E_D_22WQFJ ESC Appendix_32_PCR_fabrication F4E_D_22XGKW Functional Specification of Pre-compression System on ITER [R8] F4E_D_22XGZV CTD Final ITER Ring Report (7211) [R9] F4E_D_22TSXZ Pre-compression rings article submitted to ICMC 2009 [R10] F4E_D_22XWWY ITER-specific Structural Design Criteria for Magnets Components SDC-MC Terminology relating to Textiles Test Method for stiffness of fabrics Tensile Properties of Yarns Sampling for Yarn Testing Classifying Visual Defects in Glass-Reinforced Plastic Laminate Parts Conditioning and Testing Textiles Glass Transition Temperature (DMA Tg) of Polymer Matrix Composites by Dynamic Mechanical Analysis (DMA) Test Method for Moisture Absorption Properties and Equilibrium Conditioning of Polymer Matrix Composite Materials Specific Gravity of Plastics by Displacement Void Content of reinforced plastics

8 Page 7 / 34 Ver ASTM E 543 ASTM E Test Method for Density of Plastics by the Density-Gradient Technique Constituent Content of Composite Materials Moisture Absorption Properties and Equilibrium Conditioning of Polymer Matrix Composite Materials Agencies Performing Non-destructive Testing Preparation of flat composite panels with processing guidelines for specimen preparation ASTM E 83 ASTM E 83 Verification and Classification of Extensometers ASTM E 74 ASTM E 74 Calibration of Force-Measuring Instruments for Verifying the Force Indication of Testing Machines ASTM E 4 ASTM E 4 Standard Practices for Force Verification of Testing Machines ASTM E ASTM E ASTM E 132 ASTM E EN ISO 3344 EN ISO 3344 MIL-HDBK- 17 ASM Handbook MIL-HDBK-17 ASM Handbook Standard Practice for Verification of Specimen Alignment Under Tensile Loading Tensile Properties of Polymer Matrix Composite Materials Test Method for Tensile Properties of Reinforced Thermosetting Plastics Using Straight-Sided Specimens Test Method for Poisson's Ratio at Room Temperature Test Method for Tension-Tension Fatigue of Polymer Matrix Composite Materials Test Method for Compressive Properties of Polymer Matrix Composite Materials with Unsupported Gage Section by Shear Loading Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method Test Method for Shear Properties of Composite Materials by V-Notched Rail Shear Method Test Method for In-Plane Shear Strength of Reinforced Plastics Test Method for In-Plane Shear Response of Polymer Matrix Composite Materials by Tensile Test of a 45 Laminate Standard Test Methods for Tensile, Compressive, and Flexural Creep and Creep- Rupture of Plastics Reinforcement yarns - Determination of moisture content Military Handbook of Polymer Matrix Composites Vol Composites

9 Page 8 / 34 Ver INTRODUCTION 1.1. INTRODUCTION TO ITER & FUSION FOR ENERGY The ITER project aims to build a fusion device, twice the size of the largest current devices, with the goal of demonstrating the scientific and technical feasibility of fusion power. It is a joint project between the European Union, China, India, Japan, South Korea, the Russian Federation and the USA. ITER will be constructed in Europe, at Cadarache in the south of France. The fusion reactor is expected to start operating in Most of the components that make up the ITER project are to be manufactured by each of the participating countries and contributed in kind through so-called Domestic Agencies including Fusion for Energy. In many cases the engineering and technologies required to manufacture these components are very advanced. The European Joint Undertaking for ITER and the Development of Fusion Energy or 'Fusion for Energy' is a type of European organisation known as a Joint Undertaking created under the Euratom Treaty by a decision of the Council of the European Union. 'Fusion for Energy' has three main objectives: Providing European contributions to the ITER international fusion energy research project being built in Cadarache, France; Providing European contributions to a number of joint projects with Japan that aim to accelerate the development of fusion - the "Broader Approach"; Coordinating a programme of activities to prepare for the first demonstration fusion reactors that can generate electricity (DEMO) SUBJECT OF THIS TECHNICAL SPECIFICATION This Specification specifies the technical requirements for the manufacturing and testing of the Pre-compression Rings of the ITER magnet system. The ITER magnet system is made up of four main sub-systems: the 18 Toroidal Field (TF) coils; the Central Solenoid (CS); the 6 Poloidal Field (PF) coils; and the Correction Coils. After energisation each TF coil experiences a bursting force as well as a resultant centripetal force. The resultant centring forces are reacted by the cylindrical vault formed by the 20 wedge shape of inboard straight legs of the TF coils (wedged concept). The coils are pressed together in firm contact along the inboard leg region, but once the coil begins to curve outwards, the resultant centring forces reduce to zero rapidly and the coils tend to separate. On the outboard equator of each coil the bursting forces tend to produce a local radial outward movement of the coil, despite the inward movement in the central vault. Both of these movements are detrimental to the out-of-plane support design as they make linking the coils more difficult. In addition, the CS and PF coils together with the plasma create time-varying out-of-plane forces on each of the TF coils, which vary around the perimeter of the coil. The resultant force on each TF coil is zero, but there is an overturning moment about the coil radial axis, which is supported by structural links between the coils, as the overall overturning moment on all 18 coils is also cancelled.

10 Page 9 / 34 Ver. 1.5 In the inboard curved region, the radial expansion of the coils during energisation results in the opening of toroidal gaps between adjacent cases. Although small, the radial movement would be sufficient to create a toroidal gap of about 0.3 mm between the shear key and the key slot. During plasma operation, the shear loads acting on the keys tend to increase this gap to more than 1 mm. In order to suppress this undesirable breathing effect and ensure that the keys do not become loose in their slots, each TF coil is put under a centripetal load of 60 MN at operating conditions thanks to 2 sets of 3 Rings placed on top and bottom of the TF coils. This substantially reduces the toroidal loads in the intermediate outer intercoil structure (OIS) of the TF coils, thus increasing the machine fatigue life significantly beyond the 60,000 design cycles (20 years of operation) with an allowable defect size of 100 mm 2 in the bulk material of the OIS. Figure 1. Two TF coils with the Rings installed ENEA has designed and set-up a hydraulic testing machine consisting of 18 radial pulling actuators for testing and characterization of ring mock-ups with a diameter of 1 m (1/5 of the Ring diameter). UTS tests were performed on 4 VPI ring mock-ups and on 2 WW ring mock-ups showing all very positive results. The UTS tests have shown an overall average strength of 1551 MPa (mean hoop stress in the cross section) and practically constant hoop modulus to the failure. 2. SCOPE OF THE TENDER 2.1. SCOPE OF SUPPLY The scope of the Supply is the fabrication and acceptance of Nine (9) Rings fabricated in S2-glass fibre / epoxy resin composite complying with drawing 11PC [A1] with required properties (in chapter 3). In addition, four options are foreseen: OPTION 1: Fabrication of additional first of the series Ring, NDE and proof test; OPTION 2: Fabrication of one additional Ring with the same specifications as the scope of the Supply;

11 Page 10 / 34 Ver. 1.5 OPTION3: Transport to ITER site in Cadarache (France) OPTION4: Conservation and storage in Suppliers premises ENGINEERING ACTIVITIES The following activities should be included in the Supply: 1. FE analysis of composite behaviour 2. Definition of fabrication process for achievement of optimal performance 3. Process qualification by UTS testing of four 1/5 scale Rings 4. Design, qualification and commissioning of final tooling 5. Materials qualification a. Glass fibre b. Resin c. Composite 6. Development of adequate Non-Destructive Evaluation (NDE) techniques 7. NDE validation with one 1/5 scale Rings 8. Full mechanical characterization of samples extracted from the full scale qualifying prototype HARDWARE The components and parts to be delivered to F4E are: 1. Nine (9) Rings to be delivered to ITER site 2.2. ITEMS SUPPLIED BY F4E CATIA models of the Ring interfacing elements and the loading conditions BOUNDARIES The interface between Rings and the TF Coil Ring flanges is shown in the following drawings: 11PC [A1] 1101CA_ [R1].

12 Page 11 / 34 Ver TECHNICAL REQUIREMENTS The unidirectional wound glass fibre/epoxy composite has been chosen as material of the rings. Glass fibre shall be S2- glass (S-glass with S2-glass properties), while the choice of the resin depends on the chosen manufacturing route. Unidirectional wound means that the basic fibre orientation is unidirectional, but filaments in other orientation are most probably also needed (the amount and orientation to be verified by the FE analysis). Figure 2. The Pre-Compression Ring. The allowable requirements of the final Rings composite structure will be determined with the FE Analysis. Thus, the requirements defined here will be adjusted accordingly. The expected ultimate strength of a unidirectional composite may be estimated using the relationship: E C II E v + E 1 F F R ( v ) F σ C II σ v + σ 1 F F R ( v ) F Subscript F stands for fibre, R for resin and C for composite, E for Young modulus and σ for UTS. Taking the properties listed in Table XX and using conservatively resin strength as 100 MPa and Young s modulus as 4 GPa, the properties outlined in Table 1 may be calculated for unidirectional composites. Table 1. Expected properties at RT for a composite with 65% S2-glass fibre content applying the Law of Mixtures UTS (MPa) 2,960 E (GPa) 56 Failure strain (%) 4.0 The UTS of the composite depends strongly on the fibre content, a minimum of 65% of fibre volume fraction in the composite is required. The glass transition temperature Tg of the cured composite shall be >80 C. If the composite is formed by winding on a mandrel, the glass layers shall be concentric and free from waves. The allowable amount of defects of the Rings composite structure will be determined with the FE Analysis and the following specified values may be relaxed.

13 Page 12 / 34 Ver. 1.5 The maximum allowable void content is 1.5% in volume. The void content measurement shall be primarily aiming to determine the efficiency with which the individual filaments within a glass roving or strand are wetted by the resin. Larger air bubbles which are trapped within the layers of composite shall be assessed on the basis of the guidelines outlined in the 2563 standard, which describes and lists a large number of possible defects. The Level of Acceptance for trapped air bubbles is defined as: Level 1 None; Level 2 Maximum diameter 1.5 mm and a maximum number within a defined area; Level 3 Maximum diameter 3.0 mm and a maximum number within a defined area. Level 2 classification of defects shall be applied with the presence of not more than 1 defect per 1000 mm 2, as allowable. The presence of cracks, crazings, any kind of foreign inclusions, delaminations, fractures, wormholes, or lack of fill-out are not allowed. The visual inspection shall be based on visual checks without the aid of magnification discriminates between critical and non-critical areas of a composite. The so called critical areas are those where the presence of imperfections is considered to be most detrimental for the structural performance of the composite. In this framework, notwithstanding surface defects, the complete cross-sectional area of the Rings shall be considered to be critical and the size and frequency of defects will be determined by examination of each Ring using the developed NDE techniques. When the composite is formed by winding on a mandrel, it is important that the glass layers are concentric and free from waves. During winding, the outer layers may compress and compact the inner layers, with the consequent need for these inner layers to shorten in length. This reduction in length may result in waving or wrinkling of these layers with a reduction of mechanical strength and stiffness. Level 2 of 2563 standard shall apply to wrinkles (maximum length 13 mm), but the depth shall be less than 1% of the wall thickness and the frequency not more than one per 60 Ring segment ENGINEERING ACTIVITIES The objective of the engineering activities is to qualify the fabrication process developed by industry complying with the technical requirements of this Annex B. This qualification work aims at ensuring the required mechanical performance for the 20 years machine design life. It implies to design and build adequate tooling, qualify the processes, characterize the materials and determine the expected mechanical performance of the Rings FE ANALYSIS OF COMPOSITE BEHAVIOUR A mechanical analysis will be carried out to determine the stress distribution in the Rings in the following 3 scenarios: 1) pre-loading at RT, 2) cooling down, 3) operation. The analysis will be performed following finite-element (FE) techniques with specialised software capable of performing micromechanics and macromechanics calculations, perform point-stress analysis, free-edge effects and environmental effects like moisture diffusion effects. It is recommended the use e.g. CompositePro or V-Lab, however other

14 Page 13 / 34 Ver. 1.5 specialized software could be used, provided it includes the demanded capabilities. Given the particular geometry and Rings working conditions, the development of purpose-defined routines and modules in the software will be probably required. The study will assess the impact of the following topics: 1. thermal cycles (x100) with a maximum allowable T during transients, 2. manufacturing defects (voids, resin rich areas, etc.) that could lead to microcracking and its long term behaviour under thermal cycles, cyclic loads (x cycles) and composites viscoelastic behaviour (creep or stress relaxation), 3. determination of strain for microcracks appearance onset and its rate of increase with strain, 4. effect of compressive loads transverse to the fibres direction, 5. Impact of operational conditions (4K at high vacuum for periods >1 year) in the Rings mechanical performance. F4E will provide the Supplier the CATIA models of the interfacing elements and the loading conditions. In addition, the materials properties will be provided by F4E based on the characterization work carried out by ENEA [A2]. Deliverables and acceptance This Task will consist of 2 phases, each with a Report: 1) Preliminary Mechanical Analysis Report this Report shall include all points aforementioned with the preliminary material properties provided by F4E based on the results of ENEA [A2]. Possible additional factors (such as thermal cycles, load cycles and moisture content) affecting the long term mechanical performance of the Rings will be addressed in this Report. 2) Final Mechanical Analysis Report - On the basis of the mechanical properties measurements described in chapter a new analysis of the Rings mechanical behaviour will be performed. This Final Report will list the safety design margins of the Rings PROCESS QUALIFICATION BY UTS TESTING 1/5 SCALE RINGS A qualification program with 1/5 scale Rings shall be carried out. The program shall address and verify the design choices. At least 2 processes are studied and the quality and mechanical performance compared. The manufacture of full scale Rings will require that the supply reels of glass fibre are changed a number of times. 1/5 scale Rings shall include such discontinuities and the Supplier shall define how fibre breakages and reel changes will be handled. The cross section of the Rings may deviate/vary from the full-scale Ring to address the different design choices. The Supplier is recommended to use an existing test facility to test scaled Rings to rupture. The Supplier shall propose the number of the 1/5 scale tests they need to verify the design, but a minimum of 2 of each ring type is mandatory. The Supplier shall also define the method of heating and cooling, which ensures that temperatures are within +/-5 C throughout the whole composite mass during the curing cycles. The UTS of the 1/5 scale Rings shall be >1500 MPa. Deliverables and acceptance

15 Page 14 / 34 Ver. 1.5 As a Final Report for this Task, the Supplier is responsible for submitting for F4E review and acceptance a Process Qualification on Sub-scaled Rings Report. The Report shall contain a technical justification of the decision on Rings design, raw materials, precise fabrication process and mechanical tests DEFINITION OF FABRICATION PROCESS FOR ACHIEVEMENT OF OPTIMAL PERFORMANCE Based on the conclusions of the 1st phase of chapter and results of chapter 3.1.2, the Supplier shall assess and propose the fabrication process for the Rings (the thorough assessment of at least 2 possible processes is required). The proposal must be duly justified and must show acceptable mechanical properties and margins as compared to the loads at the RT pre-loading in ITER. The risk assessment, which include process reliability, repair solutions in case of tooling breakdown during fabrication and schedule according to the ITER RAMI Analysis Program [A3], shall be included. Deliverables and acceptance The Supplier is responsible for submitting for F4E review and acceptance a Rings Design and Fabrication Report containing a technical justification for the Rings fabrication process proposal and the risk management. The Rings manufacturing drawings and an estimation of the Rings mechanical properties shall be included. At least a prediction of the following Ring properties shall be included 1) UTS (maximum hoop stress); 2) E 11, E 22, and G 22 ; 3) (σ U Tension ) 11, (σ U Compres ) 22 ; 4) (σ U ) 12 and (σ U ) 23 ; 5) ν 12 and ν DESIGN, QUALIFICATION AND COMMISSIONING OF FINAL TOOLING The design of the tooling will follow based on the outcome of the chapter A tooling qualification and commissioning plan will be prepared. In case the VPI process is chosen, a leak detection strategy of the mould complying with ITER Vacuum Handbook [A4] shall be addressed. In case the wet winding process is chosen, a vacuum degassing of the fibres for at least 5 s under a pressure of < 50 mbar immediately before wetting is mandatory. In case pre-preg is chosen, the mandrel shall be warm at a temperature such to allow the resin to melt and flow (the temperature on the mandrel will depend on the resin chosen) so to allow proper consolidation during winding. In all cases, provisions to ensure T < 10 C in all Ring mass during curing cycle shall be provided. Further details of processing issues to be taken into account are detailed in Annex I in chapter 13. Deliverables and acceptance The Supplier is responsible for submitting for F4E review and approval a Tooling Design, Qualification and Commissioning Report. This Report will include a complete set of tooling drawings and the results of the tooling commissioning. A detailed procedure of the fabrication process (including curing cycle) shall be proposed.

16 Page 15 / 34 Ver MATERIALS QUALIFICATION GLASS FIBRE The glass fibre shall be S2-glass (or S-glass with S2-glass properties). The Tex and the weave of the fabric shall be decided based on the results obtained as per chapters 3.1.1, Error! Reference source not found., and 3.1.2, and it requires F4E approval. The glass reels shall be kept in an area under temperature and humidity control conditions (23 ±2 C and 50 ±5% humidity) to avoid the degradation of the mechanical properties. The glass fibre conditioning before testing shall follow Further details are provided in Annex I. The glass fibre shall be mechanically tested upon rovings reception and re-tested not more than 1 week before the winding processes starts to ensure the mechanical properties from the Supplier are maintained. The stiffness of the fabric shall follow The yarns shall be mechanically tested following 2256 in its configuration A straight and in its condition 1 conditioned to moisture equilibrium. The specimen shall be chosen following Deviations of >10% from the suppliers datasheet are not accepted and will imply the rejection of the rovings. Degradation by > 10% of the mechanical properties, to be measured one week before the start of the winding, from the values achieved during the acceptance tests of the glass fibre, shall imply the rejection and thus replacement of those rovings RESIN The choice of the resin shall be technically justified (in chapter 3.1.2) depending on the fabrication process qualified under the process qualification program and shall comply with the requirements specified in caption The curing cycle shall be chosen such to ensure a glass transition temperature Tg > 80 C. The Tg is the approximate midpoint of the temperature range over which a reversible change takes place between a viscous or rubbery condition and a hard, relatively brittle condition, in an amorphous polymer, or in amorphous regions of a partially crystalline polymer. The glass transition temperature is dependent upon the physical property measured, the type of measuring apparatus and the experimental parameters used. With polymer matrix composites reinforced by continuous, oriented, high modulus fibres, it is determined with the Dynamic Mechanical Analysis Method (DMA) under flexural oscillation mode. This method is described in 7028, which applies. The same loading frequency and heating rate shall be used for both dry and wet specimens (moisture conditioned as per procedure B of 5229) to allow for comparison. The Supplier shall also define the method of heating and cooling that ensures temperatures are within +/-5 C in all mass during curing cycles COMPOSITE The constituent content of the composite material shall be known with a precision of +/- 0.05% in volume, in order to evaluate the quality of a fabricated material and the processes used during fabrication. The density of the composite shall be measured following 792 or The void fraction shall follow 2734, or 3171 in its procedure G.

17 Page 16 / 34 Ver. 1.5 The moisture equilibrium content of the composite, defined as the condition considered to be reached by a material when there is essentially no further change in its average moisture content with the surrounding environment for a given moisture exposure level, shall be determined following 5229 for 25%, 50%, 75% and 100% of air humidity. The moisture absorption properties of the composite for each of the aforementioned air humidity conditions shall be determined for the analysis of single-phase Fickian moisture diffusion within such materials as part of chapter following the procedures indicated in the referred Deliverables and acceptance The Supplier is responsible for submitting for F4E review and approval a Materials Selection and Qualification Report. This Report will include all tests performed to the glass fibres, resin and composite. The justification of the selected type of glass fibre fabric, resin and composite based on the technical requirements of chapter 3.1.1, phase 2, will be detailed DEVELOPMENT OF ADEQUATE NON-DESTRUCTIVE EVALUATION (NDE) TECHNIQUES Non-destructive Evaluation (NDE) techniques include testing, inspection and examination on a finished element to find, locate and size flaws. A thorough study shall be undertaken to determine the most suitable NDE to the Rings assessing all possible techniques detailed in the Chapter Non-destructive Testing of ASM Handbook Vol. 21. Based on the outcome of this study, a combination of all possible techniques will be developed to ensure that the allowable planar (i.e. de-laminations, ) and volumetric (i.e. voids, cracks, non wetted fibres, ) flaws specified in chapter 3.1.1, phase 2, are fulfilled in the 100% volume of the Rings. All personnel performing NDE shall be qualified in accordance with a nationally recognized NDE agency. All operations shall follow international standards, the standard used and its applicable revision shall be specified. If an agency is contracted, it shall be qualified and evaluated in accordance with ASTM E 543 in its latest version at the signature of the contract. The reliability and suitability of the proposed manufacturing technique & quality controls will be validated by the manufacture and analysis of an additional one fifth scale (1/5) mock-up (~1 m diameter with ~60 mm x 60 mm cross section) following the chosen procedure for the final Rings. Non-destructive evaluation of these models using suitable techniques shall then be confirmed by visual examination of the cross section after cutting and polishing. Analysis for fibre and void content according to chapter 3.1.1, phase 2, shall be carried out on sections cut from this mock-up Rings. If reliable NDE techniques cannot be established to full-size Rings, the Supplier shall propose a manufacturing technique with strict quality controls during Ring production to ensure that the F4E requirements will be met. Deliverables and acceptance The Supplier will provide F4E a Non-destructive Evaluation Plan. This Report will detail the techniques chosen to accomplish a NDE of 100% of the Rings volume to find, locate and size any possible flaw non-complying with the requirements set out in chapter 3.1.1, phase 2. All tests performed justifying the NDE techniques proposed shall be detailed with records of the tests carried out.

18 Page 17 / 34 Ver FABRICATING AND NDE TESTING FULL SCALE QUALIFICATION PROTOTYPE A full scale qualification prototype will be fabricated following the conclusions and tooling developed in the previous Tasks. The prototype Ring shall undergo a dimensional survey to check conformity with tolerances. The measurement uncertainty for this survey shall not exceed 20% of the tolerances specified in the drawing and shall be carried out with calibrated instruments certificated through an accredited body. An as-built drawing and a 3D CATIA model of the Ring shall be provided. The NDE techniques developed in chapter shall be applied to detect possible manufacturing defects, voids or de-laminations on 100% of the Ring volume, demonstrating the compliance within the specified limits detailed in chapter 3.1.1, phase 2. Deliverables and acceptance As outcome of this Task, the Supplier is responsible for submitting for F4E review and approval: 1. Prototype Ring Fabrication Report. This Report will serve as a record of the prototype manufacturing. It will include a history of the Rings fabrication including all data recorded, test results, non-conformities generated, NDE reports, and as-built drawings. 2. Prototype Ring Quality Plan and Manufacturing and Inspection Plan consisting of a detailed technical description of the manufacturing and inspection processes and all critical operations FULL MECHANICAL CHARACTERIZATION OF SAMPLES EXTRACTED FROM THE FULL SCALE QUALIFYING PROTOTYPE The Rings will withstand during operation mainly hoop and compressive radial load, though non negligible shear stresses and locally through thickness tension will be present. A full mechanical characterization of the Rings composite is required. The outcome of these tests will be used to refine the analysis performed in chapter 3.1.1, phase 1, and determine the allowable operational stress levels and design margins to be compared with the operational stresses calculated in the Final Mechanical Analysis Report. All samples shall be conditioned to their moisture equilibrium with the testing hall conditions following The testing hall shall have controlled air humidity within 10% and controlled temperature within +/-5 C. The specimens to be tested at 4K shall also be cooled from the moisture equilibrium condition. The definition of the following items at RT and 4K will be accomplished: Tensional stress matrix Compressive stress matrix Tensional stiffness matrix Compressive stiffness matrix Fatigue curve under tension Creep or stress relaxation characterization (only at RT) The techniques described in 5687 are to be followed to ensure the consistent production of satisfactory test specimens by minimizing uncontrolled processing variance during specimen preparation (particular attention shall be given to moisture absorption).

19 Page 18 / 34 Ver. 1.5 All measured properties (with the exception of the Creep and Stress relaxation characterization) shall be provided in their B-basis value to ensure a 95% confidence estimate of the 10 th percentile of the real value as recommended by MIL- HDBK-17 (assuming normal distribution the minimum number of samples is 16). The extensometers shall be calibrated according to ASTM E 83 and shall have the required resolution to conduct the tests, typically Class A as per the referred standard. The calibration of the testing tooling shall follow ASTM E 4 and ASTM E 74. The standards to be followed for tensional tests are the following: Table 2. Standards to be followed for tensional tests (σ U ) (σ U ) E or 5083 E or 5083 ν 12 ASTM E 132 or 3039 ν 23 ASTM E 132 or 3039 Fatigue 3479 The standards to be followed for compressive tests are the following: Table 3. Standards to be followed for compressive tests (σ U ) (σ U ) E E The standards to be followed for shear tests are the following: Table 4. Standards to be followed for shear tests (σ U ) or 7078 or 3846 (σ U ) , 7078 or 3846 G or 7078 Where the orientations of the sub-indices follows the ones indicated in Figure 3 extracted from Alternative standards to those specified are allowed subject to F4E approval.

20 Page 19 / 34 Ver. 1.5 Figure 3. Spatial orientation of the stiffness elements in the composite. In the values specified for the mechanical characterization of the Rings, the transverse isotropicity of the composite is assumed. However, slight differences might be observed; a demonstration of the validity of this assumption shall be provided with the measurement on at least 3 specimens of (σ U ) 13. The standards specified are defined for RT. An assessment of the implementation of the test method to 4K shall be performed and possible required modifications of test samples shape or procedures provided advices creep stress-rupture tests to establish a safe envelope inside which a creep test can be conducted; the basic information obtained being the time-to-failure at a given stress. Several curve-fitting techniques are proposed in the referred standard. The sensitivity, resolution and accuracy of the extensometers shall be suitable to define the creep characteristics with the precision required for the application of the data. The load on the specimen shall be applied rapidly and smoothly (between 1 s to 5 s); the timing shall start at the onset of the loading. Special care shall be taken to clearly draw the three creep characteristic phases for all specimens; this will imply a significantly higher number of strain measurements during the creep primary phase and tertiary phase. All specimens shall be conditioned prior to the tests to the closest moisture equilibrium status of the testing hall where the creep tests will take place (the creep test hall shall have a humidity and temperature control system allowing +/-10% of humidity and +/-5 C of temperature). There are two main parameters for determining creep behaviour: 1) the creep rate in the secondary or steady phase and 2) strain at the onset of tertiary phase. The interval for strain readings during the secondary phase shall not be more than 6 h or 0.1% of the estimated duration of the test, whichever is longer. At least 12 different stress levels shall be chosen such to provide the corresponding secondary creep rate fully covering at least 4 decades. High attention is to be implemented to increase the number of measurements whenever the tertiary phase is expected; at least 8 measurements of the tertiary phase onset shall be unambiguously identified. At least 8 valid measurement of the primary phase shall also be provided. It is to be noted that the measurement of the secondary creep phase doesn t require driving specimens to rupture; it is expected that at the lowest testing stresses chosen the specimens will not break in a reasonable time (tests are expected to last at least 3000 h). The data obtained will be used to draw Norton fitting curve and Nadai as per The determination of the onset of the tertiary creep phase will be used to draw creep rupture envelope as indicated in Figure X3.4 of the referred standard.

21 Page 20 / 34 Ver. 1.5 Deliverables and acceptance The Supplier is responsible for submitting for F4E review and approval a Rings Mechanical Characterization Report. The Report shall contain an explanation of the procedures followed; detailed test methodology and results and statistical methodology applied. All data recorded shall be provided in one Excel file with the data clearly organized to allow reassessing of the curves provided HARDWARE The Supplier shall manufacture 9 Rings complying with the requirements defined in chapter 3.1.1, phase FUNCTIONAL AND OPERATIONAL REQUIREMENTS In the Rings the most critical load combination appears at room temperature. During the assembly and the pre-loading at room temperature the composite material presents the lowest strength and the applied load is the highest, about 20% higher than the load needed at 4K. The higher load is required to compensate for the differential thermal expansion between stainless steel and the composite during cool-down. The expected time period from pre-loading to cool-down is months DESIGN AND MANUFACTURING REQUIREMENTS RAW MATERIALS REQUIREMENTS GLASS FIBRE The glass type shall be S2-glass or S-glass with the required properties of the glass at RT as indicated in Table 5. Table 5. Single Fibre Properties of S2-glass UTS (MPa) >4,400 MPa E (GPa) >85 Failure Strain (%) >5.5 Integrated Thermal Expansion (RT-4.5K) >0.085% Density (g/cc) 2.49 The chemical composition of the S2-glass is listed in Table 6. Table 6. Composition of S2-glass (Weight%) Component S2-Glass Silica (SiO 2 ) Alumina (Al 2 O 3 ) Lime (CaO) Magnesia (MgO) 8 10 Boric Oxide (B 2 O 3 ) --- Sodium/ Potassium Oxides (Na 2 O/ K 2 O) Iron Oxide (Fe 2 O 3 ) Zinc Oxide (ZnO) ---

22 Page 21 / 34 Ver. 1.5 Titania (TiO 2 ) --- Fluorides --- The weave of the yarn shall contain filaments in the fill-direction (90 with respect to the warp direction) to enhance the compressive strength in the radial direction of the Ring composite. In addition to the higher strength offered by S2-glass (S-glass with S2-glass properties)it is boron free which is an advantage at cryogenic conditions due to the presence of thermal neutrons (see Annex I, in chapter 13). A finish or coupling agent can be applied to the surface of the fibre by the manufacturer to improve the adhesion of the resin to the fibre. There is a wide range of finishes available and the Supplier shall select a glass with an epoxy compatible finish. When storing the glass fibres they shall be kept in a cool and dry area (23 ±2 C and 50 ±5% humidity) and away from other components which may damage the surface and result in broken filaments. Cotton gloves shall be worn when handling glass fibres or fabrics, and care taken to avoid abrasion that may damage filaments. The moisture content of fibres shall be <0.2% measured according to EN ISO The glass fibre shall be mechanically tested upon reels reception and re-tested not more than 1 week before the winding process starts to ensure the mechanical properties from the Supplier are maintained. The stiffness of the fabric shall follow The yarns shall be mechanically tested following 2256 in its configuration A straight and in its condition 1 conditioned to moisture equilibrium. The specimen shall be chosen following Deviations of >10% from the Suppliers datasheet are not acceptable and will imply the rejection of the reels. Degradation of 10% of the mechanical properties identified by re-tests, to be performed maximum 1 week prior to the start of the winding from the initial acceptable values identified during the acceptance tests of the glass fibre, shall imply the rejection and replacement of the involved reels EPOXY There are a number of possible ways in which the Rings may be produced and the resin should be selected to meet the requirements of the process chosen. Possible production techniques for the Rings include: I. Dry winding followed by vacuum pressure impregnation II. III. Wet filament winding with vacuum assisted wetting of the fibres during winding Use of pre-impregnated tapes. The resin to be used shall be suitable for the manufacturing process which will be selected. The resin is not required to have a high degree of radiation stability, but radiation sensitive materials such as aliphatic amines (including dicyandiamide for pre-preg formation) shall be avoided. The resin system is not required to be non-flammable. Therefore the formulation used shall not contain any particulate filler aimed at imparting fire retardancy, as any such material will reduce the maximum achievable fibre content and raise the viscosity, thus making the fibre wet out more difficult.

23 Page 22 / 34 Ver. 1.5 If vacuum pressure impregnation is used, an autoclave shall be used to eliminate the risk of air in-intake during curing providing reliability to the process. The mould and ancillary tooling will be significantly simplified since vacuum sealing at atmospheric pressure will not be required. Special care shall be taken in the position of the anchoring point for the fibres from different rovings to ensure that it does not become a weakening point for the final composite integrity. If wet filament winding with vacuum assisted to remove the air from the fibres is the chosen process, hot curing resin shall be used in order to have sufficient life for the winding of a Ring and the possibility of warming the resin during winding, in order to adjust viscosity to the desired level and achieve full wetting of the fibres. If pre-preg processing is selected, the pre-preg shall have sufficient out-life at room temperature to complete the work. Further mandatory indications related with each possible fabrication process are provided in Annex II in chapter MANUFACTURING REQUIREMENTS The manufacturing must be done in an area temporarily reserved for this purpose. This area may be either a marked-off area in a clean building or in a clean atmosphere, or a cleared area separated off by a tent, canvas or separating walls in an ordinary building. The area shall be frequently cleaned. Concrete surfaces shall be protected to prevent concrete dust. Lighting shall be provided as required for specific operations. The area shall meet room Class 9 as per ISO TESTS AT SUPPLIER WORKSHOP/TEST FACILITY All the Rings shall be visually inspected by F4E or its nominated representative prior to be shipped to the ITER site. F4E will sign-off for factory acceptance and allow the shipping of each of the Rings after this visual inspection guarantees that the surface quality of the Rings complies with the allowable surface defects indicated in section 3.1.1, phase 2. The acceptance tests at the Suppliers premised are the following: Visual inspection Dimensional inspection NDT inspection. As part of the factory acceptance of each component, and prior to its shipping to the ITER site, the Supplier shall provide an indexed manufacturing dossier that has been reviewed and preliminary approved by F4E (approval for shipping). F4E final approval of the manufacturing dossier will be done as part of the Receiving Inspection at ITER site. An electronic copy and hard-copy of the manufacturing dossier shall be delivered per Ring containing as a minimum the documents as listed here below including the deliverables listed in section 9. Section 1 - Contractor Release Note Completed Contractor Release Note Section 2 Quality Plans Section 3 - Raw Materials Procurement Specifications Sub-Orders Material Certification traceable back to components

24 Page 23 / 34 Ver. 1.5 Process, Inspection, Testing Specifications Control Reports, including Deviation Requests and Nonconformity Reports, if any Section 4 - Manufacturing Documents Curing cycle details Non-Destructive Procedures and personnel certificates Clean Conditions Specification Section 5 - Assembly and Test Documents Assembly Sequences, Control Specifications and Procedures Function Test Specifications Control Reports (Visual Examination, Non-Destructive Tests, Certification of Cleanliness, Geometric/Metrology Surveys, etc.). Concession and Nonconformity Reports Completed Manufacturing & Inspection Plans Manuals and Instructions for the handling, assembly and maintenance of all components and equipment Drawing marked and signed as as-built OPTION 1: FABRICATION OF FIRST-OF-SERIES PRE-COMPRESSION RING AND PROOF TEST OBJECTIVE AND DELIVERABLES The objective of work in OPTION 1 is to verify that the scaling-up form the 1/5 scale Ring result in the Ring properties predicted in chapter 3.1.1, phase 2. The Supplier would be responsible for submitting for F4E review and acceptance a Fabrication of the first-of-a-series and Proof Test Plan Report. First-of-the-series ring is the first ring produced after the manufacturing process has been frozen. At the end of the proof tests the Supplier shall prepare a Fabrication of the first-of-a-series and Proof Test Report that will include process details, materials details, relevant tooling details, as-built drawings, NDE, tests results and loaded composite NDE, and possible degradation assessment PROOF TEST AND STRESS RELAXATION PROGRAM In addition, the design of the required tooling for the proof test and a detailed schedule shall be provided. The Ring should be loaded to a specified hoop stress of 1500 MPa without breaking. Once the 1500 MPa load has been achieved, it shall be maintained and the Rings behaviour shall be monitored for five days RING FABRICATION REQUIREMENTS The manufacturing of the first-of-a-series qualification Ring shall be carried out using the processes, same materials and equipment as planned for the series production and as qualified and accepted by F4E. The same material batch used for the qualification should be used throughout the entire series production. If different batches are used, the equivalence of the materials properties within +/-10% between the batches is to be demonstrated. The developed NDE techniques shall be applied for the first-of-series Ring covering 100% of the Ring volume (if possible).

25 Page 24 / 34 Ver RING TESTING TOOLING REQUIREMENTS Preliminary studies on the Ring testing tooling can be found in Annex II RING TESTING REQUIREMENTS The test shall be carried out simulating as close as possible the ITER Ring assembly and loading conditions (18 pulling points). Two loading tests are foreseen for the Ring: Proof test and Relaxation test PROOF TEST The Ring shall be loaded to 1500 MPa and kept loaded for 1 minute without rupture. This shall verify the Ring fabrication process RELAXATION TEST As an extension of the Proof Test, the Ring loaded to 1500 MPa shall be kept at that stress level for five days. The viscoelastic behaviour of the full scale Rings shall be correlated with the creep curves shown in chapter The Rings shall be instrumented to allow an accurate measurement correlated with time of the viscoelastic behaviour. This relaxation test aims at the verification of the Ring design and performance under load EXAMINATION OF RING Once the stress relaxation test at 1500 MPa is completed, the first-of-the-series Ring will be unloaded and disassembled. A repetition of the NDE of the Ring will be carried out to determine the possible degradation of the composite after having been loaded to the proof stress. Wherever indications of degradation are detected, samples will be extracted and the possible presence of de-laminations, cracks or any other possible induced failure will be determined. Tests on specimens extracted from the tested Ring may be required to learn about the possible properties degradation. 5. LOGISTIC SUPPORT REQUIREMENTS 5.1. PACKAGING FOR TRANSPORTATION AND STORAGE Each Ring or each set of three Rings shall be packed in a rigid impermeable box with well defined lifting points. Dehydration agents will be enclosed to ensure the equilibrium moisture of the composite is maintained during transport. At least five 3-axis accelerometers or shock-recorders capable to record static and dynamic accelerations will be placed in optimal positions, to ensure the transport carried out without mechanical impacts. The Supplier shall define the acceptable accelerator level needed to protect the Rings. The Ring dimensions are detailed in drawing 11PC [A1]. These are ~5m diameter Rings, square cross section 0.337m x 0.288m with a weight of about 3,300 kg each. The atmospheric conditions (temperature gradients and humidity) can degrade the composite performance. In case provisions for long term storage of the Rings are required, the transport box will be used as a storage container. The

26 Page 25 / 34 Ver. 1.5 temperature of the storage hall shall be 20+/-5 C. The packaging system shall allow at least one opening and reclosing maintaining the required conditions to allow the full Ring visual inspection upon reception at ITER site. The following points will be monitored during transport and storage: Check of readings of the accelerometers (set at the level needed to protect the Rings). Humidity inside the watertight protection. It must respect the moisture specified based on tests carried out. OPTION 3: As the transportation is an option, and may be arranged by F4E, the Supplier shall define the transport conditions. However, in case F4E will choose to exercise the option, the Supplier shall ensure that: the ltems are clearly labelled and provided with official documentation that export is on behalf of the lo and its official activities; appropriate insurance against a risk of loss or damage to the ltems during transportation is in place; any export license or authorisation, if applicable, is obtained and any necessary customs formalities for the export of the ltems and for their transit through any country are carried out in compliance with Articles 5 and 6 of the Agreement on the Privileges and lmmunities of the ITER lnternational Fusion Energy Organization for the Joint lmplementation of the ITER Project. OPTION 4: Should the F4E make a duly justified request to postpone the delivery of the whole or part of the ltems at least 50 (fifty) calendar days prior to the stipulated date of shipment, the Supplier shall provide storage, protection and maintenance for the ltems at Suppliers premises up to 72 months. The temperature of the storage hall shall be 20+/-5 C. 6. ASSEMBLY, COMMISSIONING AND TESTS ON SITE The following points will be monitored on delivery: Check of readings of the accelerometers. Control of humidity inside the watertight protection. It must respect the moisture specified based on tests carried out. At the ITER site the visual inspection of the Rings at the arrival shall ensure that the surface status of the Rings signed off after the factory acceptance has been maintained. This shall be carried out by F4E/IO at the presence of the Supplier. As part of the Receiving Inspection, F4E shall verify the above mentioned checks. Further details regarding the Receiving Inspection, if necessary, will be provided by F4E. In addition, F4E shall approve the manufacturing dossier for each of the Rings. 7. LONG TERM CONDITIONS The Rings 1-3 (and 3 spares) will be installed in a temporary position in the ITER pit prior to the assembly of the machine. After the machine assembly, which is planned to last about two years, the Rings 1-3 and 4 6 will be assembled in their position and pre-loaded. Cool-down will take place about years after the pre-loading and then the Ring load reduces to the operation load. After the cool-down the Rings will be in vacuum at 4 K.

27 Page 26 / 34 Ver APPLICABLE DESIGN REFERENCES 8.1. REFERENCE CONDITIONS The operational temperature of the Rings is 4.2 K. They Rings are expected to be cooled down and warmed up several times during their operation lifetime. The cooling and warming rate will be controlled SAFETY AND REGULATORY REQUIREMENTS In accordance with Pressure Equipment Directive (PED), the ITER magnets are not classified as pressure equipment (pressure is not the major load driving the design). Piping and manifold components have to comply with the PED requirements (if applicable), and they are in the Sound Engineering Practice (SEP) Category CODES AND STANDARDS The product shall be designed according to the ITER Vacuum Handbook [A4]. The ITER-specific Structural Design Criteria for Magnets Components [R10] are applicable to the superconducting coils and structures. These are conductor, insulation, coil clamps and associated bracing structures including the Rings, gravity supports, superconducting busbars supplying the coils and cryogenic pipelines. The criteria are also applicable to the keys and bolts used for the coil and support structures. The manufacturing acceptance criteria are also described. The ITER SDC-MC has established a design code and component assessment methodology relevant to components operating in the range 4-77 K and extended to room temperature under abnormal operating conditions. Existing codes generally exclude this low temperature range, but the methodologies in these codes are in many cases applicable ENVIRONMENTAL REQUIREMENTS None. 9. DELIVERABLES AND SCHEDULING The following Milestones and Deliverables shall be included in the Quality Plan (Control Plan). Table 7. List of Milestones List of Milestones No. Name Comments Expected date (month) [1] Stage I 1 Quality Plan for Stage I Hold Point Kick-Off Meeting Manufacturing and Inspection Plan Hold Point TBC 3 Rings Mechanical Preliminary Analysis Report Authorization-To- Proceed Point TBC 1 After contract signature

28 Page 27 / 34 Ver Rings Final Mechanical Analysis Report Hold Point 24 5 Rings Design and Fabrication Report Authorization-To- Proceed Point 6 Process Qualification on Scaled Rings Report Authorization-To- Proceed Point TBC TBC 7 Tooling Design, Qualification and Commissioning Report Hold Point TBC 8 Materials Selection and Qualification Report Hold Point TBC 9 Non-destructive Evaluation Plan Hold Point TBC 10 Prototype Ring (PR) Quality Plan and Manufacturing and Inspection Plan Authorization-To- Proceed Point 11 PR Fabrication Report Hold Point Ring Mechanical Characterization Report Hold Point 24 OPTION1 Fabrication of First-of-a-series and Proof Test Plan Authorization-To- Proceed Point OPTION1 Fabrication of First-of-a-series and Proof Test Hold Point TBC Stage II 13 Rings Quality Plan and Rings Manufacturing and Inspection Plan for Stage II Hold Point 14 Pre-compression Rings Manufacturing dossier Hold Point Pre-compression Ring Spares Manufacturing dossier Hold Point Pre-compression Rings Manufacturing dossier Hold Point 40 (TBC) OPTION2 Pre-compression Ring Spare 4 + Manufacturing dossier Hold Point 51 (TBC) 17 Pre-compression Rings 4-6 and Spare 4 acceptance after storage TBC TBC TBC Hold Point 51 Table 8. List of Deliverables List of Deliverables No. Name / Nature Description Delivery date (month) [2] Stage I 1 Quality Plan for Stage I Kick-Off Meeting Manufacturing and Inspection Plan TBC 3 Rings Mechanical Preliminary Analysis Report TBC 4 Rings Final Mechanical Analysis Report 24 5 Rings Design and Fabrication Report TBC 6 Process Qualification on Scaled Rings Report TBC 7 Tooling Design, Qualification and Commissioning Report TBC 8 Materials Selection and Qualification Report TBC 9 Non-destructive Evaluation Plan TBC 10 PR Quality Plan and Manufacturing and Inspection Plan TBC 11 PR Fabrication Report Rings Mechanical Characterization Report 24 2 After contract signature

29 Page 28 / 34 Ver. 1.5 OPTION1 Fabrication of First-of-a-series and Proof Test Plan OPTION1 Fabrication of First-of-a-series and Proof Test Report Stage II 13 Rings Quality Plan and Rings Manufacturing and Inspection Plan for Stage II 14 Pre-compression Rings Manufacturing dossier Pre-compression Ring Spares Manufacturing dossier Pre-compression Rings Manufacturing dossier 40 (TBC) OPTION2 Pre-compression Ring Spare 4 + Manufacturing dossier 17 Pre-compression Rings 4-6 and Spare 4 acceptance after storage TBC TBC TBC 51 (TBC) QUALITY ASSURANCE PROVISIONS The Quality Assurance provisions are regulated by the Management Specification (Annex A of the Contract), which is part of the tender documentation. 11. IDENTIFICATION REQUIREMENTS All individual components delivered to the ITER site shall be clearly marked in a permanent way, but not damaging the composite surface, and located in a visible place. The system shall be agreed with F4E and be in line with the ITER Numbering System for Parts/Components [A5] and ITER Function Category and Type for ITER Numbering System [A6]. Besides the provision of hard-copies, all fabrication historical data will also be electronically archived following the F4E requirements and templates. 12. COMPLIANCE MATRIX The bidder shall establish a compliance matrix. The compliance matrix is a table which lists all the Fusion for Energy technical requirements and the associated provisions proposed by the bidder. The compliance matrix will be approved by Fusion for Energy. It ensures Fusion for Energy that all its requirements will be satisfactorily taken into account.

30 Page 29 / 34 Ver ANNEX I. PROCESSING AND TESTING AI.1 PROCESSING The most promising fabrication processes enumerated in this specification shall present the following characteristics: 1) Dry Winding and Vacuum pressure Impregnation The glass fibre in the required form is wound onto a mandrel, under tension and when the winding has been completed, the tension shall be maintained while the tool is closed and made ready for a vacuum impregnation process. The process may be completed by flooding the tool with resin in an autoclave or by having a vacuum sealed tool with maximum allowable leaks < 10-5 mbar/l s and working without a vacuum chamber. Working pressures of low vacuum (<1 mbar) are required in the mould or autoclave in order to avoid trapping gas within the structure as resin impregnates the wound fibres. Appropriate tooling for glass drying and resin degassing prior to impregnating is essential. 2) Wet filament winding with vacuum assisted wetting of the fibres during winding The winding machine pulls dry fibre glass from a number of reels held on supply racks through a resin bath, and winds the wet fibre around a mandrel in a variety of pre-determined angles. Both removable mandrels and insitu mandrels, which remain with the part, can be used. All fibres shall have equal tension to ensure uniform distribution of stress when the Rings are loaded and avoid waving. The rovings (or chosen form of glass fibre) shall be held under vacuum (<50 mbar pressure) at least 5 s immediately before they pass through the resin bath; the vacuum removes air from the fibre bundles and allows more efficient wetting of the roving by the resin. 3) Winding with pre-preg Pre-preg is a term used to describe glass fibre (woven fabric or tow) that has been pre-impregnated with resin/hardener mix and partially cured. Filament winding with pre-impregnated tow has the advantage of not needing a resin bath to wet the fibre during winding. It is essential to wind with the pre-preg/mandrel warm (or preheat the tape surface) to allow the resin to melt and flow and so allow proper consolidation during winding and avoid waving. In all the three cases, the curing tooling shall ensure a maximum T<10 C in the entire Ring mass. The drying, degassing, impregnation and curing processes will be monitored and recorded (temperatures, pressures, time, impregnation speed, etc.) and compared with the specified detailed process in the Design, Qualification and Commissioning of Tooling Report. AI.2 NUCLEAR ISSUES S2-glass (S-glass with S2-glass properties) has a high strength and it is boron free, which is an advantage in the in the neutron radiation environment. Boron has a large capture cross-section for thermal neutrons. Neutron capture of boron results in the release of α particle and the production of lithium, which would result in possible short term activation of the composite and extensive damage to the resin/glass bond. B n Li + α (1.78MeV ).

31 Page 30 / 34 Ver. 1.5 AI.3 VOIDS IN COMPOSITES The void volume of a composite material may significantly affect its mechanical properties. Higher void volumes mean lower fatigue resistance, greater susceptibility to moisture penetration and increased variation or scatter in strength properties. Knowledge of the void volume of a composite material is needed; it is an indication of the quality of a composite. A good composite shall typically not have >1% voids according to 2734, while a poorly made composite can have a much higher void content. The measurement of the void fraction is not straightforward. The densities of the resin, the reinforcement, and the composites are measured separately. Then, the resin content is measured and a theoretical composite density calculated. This is compared to the measured composite density. The difference in densities indicates the void content. Ability to estimate the void content is also determined by coupon size and limitations of measuring apparatus. For example, just with limitations of the analytical balance (accurate to 0.2 mg), a coupon of 0.2 g with a void volume of 1.0% would have an uncertainty of 10% (reported void volume in the range of 0.9 to 1.1%) on the void volume calculation as a result of a possible balance error. A 1 g sample would have an uncertainty of 2% in the void volume calculation (reported void volume in the range of 0.98 to 1.02%) because of a possible balance error for the same 1.0% void volume. The measurement of the void content is essential to understand the composite structure; the density and fibre volume fraction provides only a partial description. Figure AI-1 shows influence of void content in the density and volume fraction of a S2-glass/epoxy composite with densities 2.49 g/cm 3 and 1.18 g/cm 3 for glass fibres and epoxy, respectively. Density and S- Glass Content (W t %) 100 ~6 vol. % voids Glass Content (wt %) ~10 vol. % voids Zero voids ~3 vol. % voids Density (g/cm^3) Figure AI-1. Influence of Glass and Void Content on the Relative Density of an S-Glass Composite The measurement of the void content aims primarily at determining the efficiency with which the individual filaments within a glass roving or strand are wetted by the resin. Larger air bubbles that are trapped within the layers of composite are assessed on the basis outlined in 2563, which describes and lists a large number of possible defects.

32 Page 31 / 34 Ver. 1.5 AI.4 MOISTURE ABSORPTION The moisture content of a composite is related to such properties as electrical insulation resistance, dielectric losses, mechanical strength, appearance, and dimensions. The effect upon these properties of change in moisture content due to water absorption depends largely on the type of exposure (by immersion in water or by exposure to high humidity), shape of the part, and inherent properties of the composite. With non-homogeneous materials, such as laminated forms, the rate of water absorption may be widely different through each edge and surface. The influence of moisture in the mechanical performance of a given composite component is complex and highly non linear. For matrix-dominated mechanical property values (shear and compression for example) the degradation due to moisture content can be significant. For properties dominated by the glass reinforcement (unidirectional tension for example) this tendency may be even reversed. The Rings may be stored for a long period before being in operation; in addition, during machine operation 9 Rings will be under vacuum and at cryogenic conditions and 3 will be stored at RT. The moisture diffusion dynamics in the Rings and their possible performance degradation, due to thermal cycles and exposure to vacuum conditions every shutdown, shall be determined. Polymeric materials are capable of absorbing relatively small - but potentially significant - amounts of moisture from the surrounding environment. The physical mechanism for moisture dynamics in composites, assuming there are no cracks or significant defects, follows Fick s law. While material surfaces in direct contact with the environment absorb or desorb moisture rapidly, moisture flow takes place several orders of magnitude slower than heat flow in thermal diffusion. A conditioning procedure such as 5229 shall be followed, because it accounts for the diffusion process and terminates with the moisture content uniform through the thickness eliminating possible divergences in the results of the tests originated by different moisture content in the samples. The optimization of the mechanical performance of the Rings demands equal properties of the glass fibre. This implies the storage of the glass rovings under controlled conditions and the regular control of the conservation of the specified mechanical properties before each Ring winding process. Moisture equilibrium of the glass shall be considered as achieved if after free exposure to air, the change in weight of the specimen extracted from the rovings at successive intervals of not less than 2 h does not exceed 0.2% of the specimen weight as indicated in AI.5 SAMPLE TESTING PRECAUTIONS The maximum hoop strength will be achieved by arranging all fibres to be in the circumferential direction. However the resulting composite will be highly anisotropic, with high strength in one direction and (comparatively) significantly lower strength in the other two. This anisotropy in a thick Ring could give rise to some circumferential cracking. A test specimen represents a simplification of the structural part; its value lies in the ability to be extracted from the appropriate zone of the structure under test, in the right orientation with respect to the fibres, with the adequate cutting tools and following proper handling and storage. The techniques described in 5687 are to be followed to ensure the consistent production of satisfactory test specimens by minimizing uncontrolled processing variance during specimen preparation (particular attention shall be given to moisture absorption to reduce divergence in the measurements).

33 Page 32 / 34 Ver. 1.5 Bending stresses that inadvertently occur due to misalignment between the applied force and the specimen axes can cause significant errors. Departures from the ideal situation are caused by a combination of 1) poor alignment of the top and bottom grip centerline, 2) poor conformance of specimen centerline to top and bottom grip centerlines, and 3) asymmetric machining of the test specimen itself. The usual procedure in a uniaxial tension/compression test is to apply the load to the specimen through grips attached to a load-train and then correlate the strain response of the specimen, as measured with an appropriate extensometer, with the applied stress. In the case of ideal alignment, the top and bottom grip centerlines are perfectly in line with one another and with the centerlines of other components of the loading train. For low strains measurements, errors can be mitigated if strain is measured not only on one side of the specimen, but on opposite sides of the specimen; the reported strain shall be the average of the strains on the two sides as recommended in ASTM E In addition, the extensometer shall be attached to the specimen not to any load carrying parts joined to the specimen; the intervening joints and parts introduce significant extensions which are not accurately separable from the extension in the specimen alone.

34 Page 33 / 34 Ver ANNEX II. FULL SCALE RING PROOF TEST TOOLING In the Rings the worst load combination appears at room temperature. During the assembly and the pre-loading at room temperature the composite material presents the lowest strength and the applied load is the highest to compensate for the differential thermal expansion between stainless steel and the composite. Therefore, the test shall be done at RT. The testing equipment shall be designed and commissioned before the tests start. It has to provide the means to check the deformation and stresses due to the Rings assembly under the simultaneous load of 18 TF coils. The minimum system requirements are the following: Dimensions of Ring to be tested Testing temperature 288 mm x 337 mm, ID Ø 4975 mm 293 K Expected Ring elongation 2.5% Reproducibility < 0.1% (scattering of the results) The reproducibility < 0.1% addresses the changes in the apparent stress/strain working point that can be induced by temperature variation in the testing hall. Two possible solutions have preliminarily been studied [R4]; the choice between the solutions (or any alternative one) shall be evaluated based on feasibility and cost effectiveness. These solutions will probably require a remote tightening system which was not included in the preliminary study, but have to be proposed by the Supplier. AII.1 POSSIBLE SOLUTION A The solution A is based on the concept of making a self balanced machine. The machine is based on a counter-reacting concrete ring that is supposed to close the force loop. The main advantage of this solution is that it doesn t need a big basement structure because the pre-compression force is self balanced by the machine. The Ring will be progressively loaded acting on 36 Ø120 mm Inconel 718 Superbolts. Figure AII-1 shows the conceptual design of the testing equipment. The approximate overall sizes of the machine are: Outer diameter Inner diameter Height Total weight ~8.2 m ~4.8 m ~1.3 m ~150 t The radial load on each of the 18 mock-up magnet flanges to achieve 1500 MPa must be of the order of 50 MN. The main disadvantages of this design are related to the concrete reaction ring. This concrete ring has to be manufactured on site and shall be disposed when the test is over.

35 Page 34 / 34 Ver. 1.5 Figure AII-1. Test equipment solution A AII.2 POSSIBLE SOLUTION B Figure AII-2 shows a view of the solution B concept. As in the A solution the fibre Ring is pulled by means of Inconel Super Bolts. The tie rod force is reacted by 18 cast structures which are linked to the concrete basement by means of threaded tie rods anchored in the concrete floor. Figure AII-2a. Test equipment solution B Figure AII-2b. Reaction structure detail