Indigenous Manufacturing Realization of TWIN Source and Its Auxiliary

Indian negative-ion source development program has gained momentum with planned integration of Indian Test Facility (INTF) for International Thermonuclear Experimental Reactor (ITER)-Diagnostic Neutral Beam (DNB) characterization at the Institute for Plasma Research (IPR). Eight RF driver-based negative-ion source, being developed for DNB will be tested and operated in INTF. The Two driver-based Indigenously built Negative ion source (TWIN) source provides a bridge between the operational single driver-based negative-ion source test facility, ROBIN in IPR, and an ITER-type multidriver-based ion source. The source is designed to be operated in continuous mode with 180 kW, 1 MHz, 5-s on/600-s off duty cycle and also in 5-Hz modulation mode with 3-s on/20-s off duty cycle for three such cycles. The complete design of TWIN source and its test facility, from conceptual to detailed engineering, has been carried out in IPR. The manufacturing design has been optimized to match the capability of Indian manufacturers, without compromising on the specifications. Some examples of optimization are: 1) an improvised design of the Faraday shields where electrodeposition has been replaced by vacuum brazing; 2) a simplified design of the side walls of the plasma source, where jointing process is simplified, without the application of Electron Beam Welding; and 3) introduction of a fiber reinforced polymer-based integrated electrical and vacuum isolation scheme that replaces the application of a large ceramic. Finite-element analysis (FEA) based on heat load and structural load calculation ensure the functionality and structural integrity of each component of the source. Due to nonnuclear environment in TWIN source experimental area, vacuum brazing is an acceptable manufacturing process. The contract for manufacturing of the ion source has been awarded to an Indian manufacturing company for the first indigenous production of a large-size fusion grade ion source. TWIN source is designed in such a way that it can be operated both in air mode (RF driver coil antennas are exposed to air) as well as vacuum mode. (Whole source is immersed inside vacuum.) The TWIN source shall be manufactured as per ASME guidelines for pressure vessel. Experiments on the TWIN source are foreseen in the last quarter of 2015, as all the auxiliary systems such as 180-kW, RF generator system, vacuum vessel with pumping station, cooling water system, data acquisition and control system, and other power supply systems are already installed in the lab premises. This paper discusses the FEA-based engineering design, simplified manufacturing design, manufacturing experience with highlighting quality control, and the system integration activities undertaken for the TWIN source test facility.