Designing and manufacturing of the coil support structure of W7-X

Wendelstein 7-X (W7-X) is a fully optimized low-shear stellarator and shall demonstrate the reactor potential of this fusion plant. It is presently under construction at the Greifswald Branch Institute of IPP. The superconducting magnet system will allow continuous operation, limited only by the plasma exhaust system whose capacity is designed for 30 min full power operation. The Wendelstein 7-X (W7-X) coils and structures are part of the largest superconducting fusion device being constructed at present. They represent a technical challenge at industrial level and the need for proven techniques and manufacturing processes in accordance to the highest quality standards. The production of these components requires a management of monitoring for quality and tests. The coil system consists of 20 planar and 50 non-planar coils. They are supported by a pentagonal 10 m diameter, 2.5 m high coil support structure (CSS). The CSS is divided into five modules. Each module consists of two equal half modules. The manufacturing status of the CSS and the main project management and technical challenges will be presented. The lessons learned in the large scale production of this difficult kind of support structure will be presented as relevant experience for the realization of similar systems for future fusion devices, such as ITER.     

Engineering design for the HL-2M tokamak components

The HL-2A tokamak will be modified into HL-2M. The Bt at the plasma center (major radius R = 1.78 m) is 2.2 T, the minor radius is 0.65 m. The plasma current I_P of HL-2M will reach up to 2.5 MA, the elongation and triangularity is more than 1.8 and more than 0.5, respectively. The vacuum vessel torus consists of 20 sectors with “D” shaped cross-section and double wall structure. 20 toroidal field coil bundles comprise 140 turns which are designed with demountable joints, the poloidal field coils system consists of 25 coils. The engineering design and calculation for field coil system, vacuum vessel, support structure, etc. are finished, many key issues for manufacture process have been discussed with industry and the fabrication of main components of HL-2M tokamak will be carried out in factories.     

Influence of construction errors on Wendelstein 7-X magnetic configurations

Wendelstein 7-X, currently under construction at the Max-Planck-Institut für Plasmaphysik in Greifswald, Germany, is a modular advanced stellarator, combining the modular coil concept with optimised properties of the plasma. The magnet system of the machine consists of 50 non-planar and 20 planar superconducting coils which are arranged in five identical modules, forming a toroidal five-fold symmetric system. The majority of operational magnetic configurations will have rotational transform ι/2π = 1 at the boundary. Such configurations are very sensitive to symmetry breaking perturbations, which are the consequence of imprecisely manufactured coils or assembly errors. To date, all 70 coils have been fabricated, and the first two half-modules of the machine have been assembled. The comparative analysis of manufactured winding packs and estimates of the corresponding level of magnetic field perturbation are presented. The dependency of the error fields on the coil assembly sequence is considered, as well as the impact of the first assembly errors. The influence of different construction uncertainties is discussed, and measures to minimise the magnetic field perturbation are suggested.     

Overview of main-mechanical-components and critical manufacturing aspects of the Wendelstein 7-X cryostat

Wendelstein 7-X (W7-X) will be the world's largest superconducting helical advanced stellarator. This stellarator concept is deemed to be a desirable alternative for a future power plant like DEMO. The main advance of the static plasma is caused by the three dimensional shape of some of the main mechanical component inside the cryostat. The geometry of the plasma vessel is formed around the three dimensional shape of the plasma. The coils and their support structure are enclosed within the outer vessel. The space between the outer, the plasma vessel and the ports is called cryostat because the vacuum inside provides thermal insulation of the magnet system which is cooled down to 4 K. Due to the different thermal movements of both vessels and the support structure have to be supported separately. 10 cryo legs will bear the coil support structure. The plasma vessel supporting system is divided into two separate systems, allowing horizontal and vertical adjustments. This paper aims to give an overview of the main mechanical components of the cryostat. The authors delineate some disparate and special problems during the manufacturing of the components at the companies in Europe. It describes the current manufacturing and assembly.     

JT-60SA Toroidal Field Coils test cryostat development

Within the Broader Approach Agreement, Fusion for Energy will deliver to the Japanese Atomic Energy Association, amongst other components, the 18 Toroidal Field Coils (TFCs) for the superconducting Tokamak JT-60SA [1]. These coils will be individually tested at cryogenic temperatures and at the nominal current in a test cryostat. This cryostat is provided as an in-kind contribution by Belgium and is being developed jointly with CEA-Saclay/France.The vessel is large, oval shaped with an overall length of 11 m, a width of 7.2 m and a height of 6.5 m. To reduce the heat load to the coils the cryostat is covered by LN₂ cooled thermal shields. In addition to the cryostat, three test frames for the coils, the valve box vessel and the insulation vacuum system are also provided by Belgium. The Belgian contribution is design, manufacturing, assembly and test of the vacuum chamber, thermal shield and test frames by the Belgian company Ateliers de la Meuse (ALM), with the support of Centre Spatial de Liège (CSL). The TF coil test facility is assembled and the coil tests are performed by CEA/Saclay.The Belgian contribution, namely the design, manufacturing, assembly and test of the vacuum vessel, the thermal shields, and the test frames as well as of the vacuum pumping system are described in the presentation.     

Fabrication and installation of equilibrium field coils for the JT-60SA

Recently, fabrication of the first superconducting coil in JT-60SA tokamak (EF4 coil) was finished. EF4 coil has ten double pancake (DP) coils. All DP coils were stacked up to form the winding pack. In order to check the manufacturing error of DP coils, their circularities (in-plane ellipticities) were evaluated for all DP coils. Positions of conductors for each DP coil were measured before curing process. Error bars of the current centers, which were used for the index for DP coil's circularity, ranged between 1.1 and 2.5 mm. During stacking the DP coils, the positions of these coils were optimized in order to cancel the error of circulation of the winding pack. As the result, the manufacturing error of the radial current center was achieved 0.6 mm for the winding pack. This value was an order of magnitude smaller than the required manufacturing error of EF4 coil.     

Design and test program of a simplified divertor dummy coil structure for the WEST project

In order to fully validate actively cooled tungsten plasma facing components (industrial fabrication, operation with long plasma duration), the implementation of a tungsten axisymmetric divertor structure in the tokamak Tore-Supra is studied. With this major upgrade, so-called WEST (Tungsten Environment in Steady state Tokamak), Tore-Supra will be able to address the problematic of long plasma discharges with a metallic divertor target.To do so, it is planned to install two symmetric divertor coils inside the vacuum vessel. This assembly, called divertor structure, is made up of two stainless steel casings containing a copper winding pack cooled by a pressurized hot water circuit (up to 180 °C, 4 MPa) and is designed to perform steady state plasma operation (up to 1000 s).The divertor structure will be a complex assembly ring of 4 m diameter representing a total weight of around 20 tons. The technical challenge of this component will be the implementation of angular sectors inside the vacuum vessel environment (TIG welding of the coil casing, induction brazing and electrical insulation of the copper winding). Moreover, this complex assembly must sustain harsh environmental conditions in terms of ultra high vacuum conditions, electromagnetical loads and electrical isolation (13 kV ground voltage) under high temperature.In order to fully validate the assembly and the performance of this complex component, the production of a scale one dummy coil is in progress.The paper will illustrate, the technical developments performed in order to finalize the design for the call for tender for fabrication. The progress and the first results of the simplified dummy coils will be also addressed.     

Status of Wendelstein 7-X construction

Wendelstein 7-X (W7-X) represents the continuation of fusion experiments of the stellarator type at the Max-Planck Institute for Plasma Physics (IPP). The aim of W7-X is to demonstrate the suitability for a fusion reactor of this alternative type of magnetically confined plasma experiment. W7-X is being built at Greifswald in the northeast of Germany. The size of device (725 tons, height of 5 m, diameter 16 m) and the superconductive magnet system distinguish W7-X from earlier stellarators at IPP. The paper provides a summary of the status of the main components, the mastering of the technical challenges during component acceptance testing and during machine assembly. Latest results of the assembly work are especially highlighted. The scope of the construction of W7-X was modified and additional acceleration measures were implemented to mitigate risks and delays. Some aspects of these changes are explained in this paper.     

Effect of an additional ferromagnetic material on the toroidal magnetic field ripple in the ITER

In the ITER tokamak, the toroidal magnetic field (TF) ripple is estimated with TF coils only, with the installation of ferromagnetic inserts (FIs), and with test blanket modules (TBMs) by using a 2-D code for easy and fast calculation. We assessed the effects of the thickness of the FIs on the TF ripple in order to optimize the FI. And we analyzed how the TBMs distort the TF, and calculated the TF ripple for various amounts of a ferromagnetic material and the positions of the TBMs. Even in the case of moving the TBMs outward up to 60-cm, and reducing the ferromagnetic material to 52%, the TF ripple is not decreased below 0.38%. So we had to adopt ripple correction coils. With a 52% reduced amount of the ferromagnetic material in a TBM, we could reduce the TF ripple to 0.28% at a coil current of 100 kA turn per each coil. And with an outward recess of the TBM up to 60 cm, we could reduce the TF ripple to 0.23% at a coil current of 250 kA turn per each coil. As a combined approach, if we reduce the amount of a ferromagnetic material in a TBM to 30%, and recess the TBM to 15 cm, we can efficiently obtain the TF ripple of 0.25% at a coil current of 150 kA turn per each coil.     

Revisiting the poloidal magnetic confinement

This note proposes a closed poloidal magnetic configuration with an in-vessel coil system held by shielded supports. A dipole field is bounded by external coils and constrained into a hollow torus aiming at uniform intensity. In the horizontal mid-plane region the external coils and the dipole outer coils are broken in four arcs and bridged by couple of straight branches. Arcs and straight branches build a set of four side coils. In the clearance between their straight branches four tunnels in the poloidal magnetic field are achieved, to pass the supports and the feeders of the in-vessel coil system.A poloidal machine with a plasma thick as those of present large experiments is outlined. The dipole radius is 5.4 m, the plasma about it has a constant poloidal cross-section about 40 m², a volume about 1300 m³ and a minimum thickness 1 m in the outboard. The magnetic field ranges from 1.4 to 1.8 T.     

Manufacturing and assembly status of main components of the Wendelstein 7-X cryostat

The stellarator fusion experiment Wendelstein 7-X (W7-X) is at present in assembly at the Max-Planck Institut für Plasmaphysik (IPP).The toroidal plasma with a ring diameter of 11 m and an average plasma diameter of 1.1 m is contained within the plasma vessel. Its form is dictated by the shape of the plasma. The form of the plasma is controlled by the coil system configuration. To control the plasma form it is necessary that all the 20 planar and 50 non-planar coils should be positioned within a tolerance of 1.5 mm. To meet this requirement a complex coil support structure was created, consisting of the central support ring and the different inter coil supports. The coils and the support structure are enclosed within the outer vessel with its domes and openings. The space between the outer and the plasma vessel is called cryostat because the vacuum inside provides thermal insulation of the magnet system, and the entire magnetic system is then be cooled down to 4 K. Due to the different thermal movements the plasma vessel and the central support ring have to be supported separately. The central support ring is held by 10 cryo legs. The plasma vessel supporting system is divided into two separate systems, allowing horizontal and vertical adjustments to centre the plasma vessel during thermal expansion.This paper aims to give an overview of the main components in the cryostat like the plasma vessel, the outer vessel, the ports and the different support systems. It describes the current manufacturing and assembly status and the associated problems of these components, using pictures and text. This paper does not describe the general assembly situation or time schedules of the Wendelstein 7-X.     

Configuration space control for Wendelstein 7-X

The Wendelstein 7-X stellarator (W7-X) is a superconducting fusion experiment, presently under construction at the Greifswald branch of the Max-Planck-Institut für Plasmaphysik. W7-X is a device with high geometrical complexity due to the close packing of the components in the cryostat and their complex 3D shape e.g. of the superconducting coils. The tasks of configuration space control are to ensure that all these components do not collide with each other under a set of defined configurations, i.e. at the time of assembly, at 4 K or for various coil currents. To fulfill these tasks sophisticated tools and procedures were developed and implemented within the realm of a newly founded division that focuses on design, configuration control and configuration management.     

Radiation shielding mass saving for the magnet coils of the VISTA spacecraft

Radiation shielding structure of a design concept with inertial fusion energy propulsion for manned or heavy cargo deep space missions beyond earth orbit has been investigated. Fusion power deposited in the inertial confined fuel pellet debris delivers the rocket propulsion with the help of a magnetic nozzle. The nuclear heating in the super conducting magnet coils determines the radiation shielding mass of the spacecraft. It was possible to achieve considerable mass saving with respect to a recent design work, coupled with higher design limits for coil heating (up to 5 mW/cm³). The neutron and γ-ray penetration into the coils is calculated using the S_N methods with a high angular resolution in (r–z) geometry in S₁₆P₃ approximation by dividing the solid space angle in 160 sectors. Total peak nuclear heat generation density in the coils is calculated as 3.143 mW/cm³ by a fusion power of 17 500 MW. Peak neutron heating density is 1.469 mW/cm³ and peak γ-ray heating density is 1.674 mW/cm³. However, volume averaged heat generation in the coils is much lower, namely 74, 163 and 337 μW/cm³ for neutron, γ-ray and total nuclear heating, respectively. The net mass of the radiation shielding for the magnet coils is 200 tonne by a total mass of 6000 tonne of the space craft.     

AC operation of large titanium sublimation pumps in a magnetic field: Results of the test stand for the W7-X neutral beam injectors

A neutral beam injection (NBI) system is being built for the Stellarator experiment Wendelstein 7-X (W7-X) currently under construction at IPP Greifswald. The NBI system consists of two injectors which are essentially a replica of the system present in the Tokamak experiment ASDEX-Upgrade at IPP Garching. A vacuum system with high pumping speed and large capacity is required to ensure proper vacuum conditions in the neutral beam line. For this purpose, large titanium sublimation pumps (TSP) are installed inside the NBI boxes, consisting of 4 m long hanging wires containing Ti and the surrounding condensation walls. The wires are DC ohmically heated up with 142 A to Ti sublimation temperature. A TSP system has been operated since many years in the AUG-NBI system, sublimating Ti in the pauses between the plasma discharges, when no magnetic field is present. However, at W7-X the superconducting coils generate a magnetic field permanently during experimental campaigns, whose stray B field with a maximum of 30 mT, affects the TSPs. Operated with DC, the wires would be deflected against the surrounding panels due to the Lorentz force. A simple possible solution is heating with AC, which reduces the wire deflection amplitude, inducing a risky wire oscillation. The feasibility of the AC operation in an equivalently strong B field such as the stray B field around W7-X has been demonstrated in a test stand for different AC waveforms and frequencies. Several test campaigns have shown no qualitative difference in the pumping properties between AC and DC operation of the TSP and no critical dynamic behaviour of the wires.     

Concept of curved magnetically guided liquid lithium target without a back plate for IFMIF

Curved magnetically guided lithium target (MGLT) without a back plate was newly proposed in light of simplified structure, easy maintenance and enhanced availability and performance for international fusion materials irradiation facility (IFMIF). It can replace conventional lithium target with a curved material back plate under the most severe condition on neutron irradiation. Magnetic field suited for the curved MGLT is produced in combination of a couple of radiation-proof resistive coils and reduced activation ferritic/martensitic steel (F82H) parts (yokes, ducts/nozzles and high flux test module (HFTM)). Shape of the magnetic field becomes curved automatically in the target region by setting HFTM closely to MGLT. Characteristics of the lithium flow on MGLT was analyzed in detail by two dimensional equations of motion with the magnetic field calculated by the Poisson Superfish code. The necessary magnetic flux density at the target region was found to be about 0.5 T to fulfill the IFMIF target conditions, i.e., lithium flow speed of 15 m/s, curvature radius of 1–1.6 m and flow thickness of 0.025 m. A narrow gap (a few mm) between MGLT and HFTM could be controlled by adjusting the coil current. Future subjects for further development of this concept were identified.     

Analysis of the accident with the coolant discharge into the plasma vessel of the W7-X fusion experimental facility

Fusion is the energy production technology, which could potentially solve problems with growing energy demand of population in the future. Starting 2007, Lithuanian Energy Institute (LEI) is a member of European Fusion Development Agreement (EFDA) organization. LEI is cooperating with Max Planck Institute for Plasma Physics (IPP, Germany) in the frames of EFDA project by performing safety analysis of fusion device W7-X. Wendelstein 7-X (W7-X) is an experimental stellarator facility currently being built in Greifswald, Germany, which shall demonstrate that in the future energy could be produced in such type of fusion reactors. In this paper the safety analysis of 40 mm inner diameter coolant pipe rupture in cooling circuit and discharge of steam–water mixture through the leak into plasma vessel during the W7-X no-plasma “baking” operation mode is presented. For the analysis the model of W7-X cooling system (pumps, valves, pipes, hydro-accumulators, and heat exchangers) and plasma vessel was developed by employing system thermal-hydraulic state-of-the-art RELAP5 Mod3.3 code. This paper demonstrated that the developed RELAP5 model enables to analyze the processes in divertor cooling system and plasma vessel. The results of analysis demonstrated that the proposed burst disc, connecting the plasma vessel with venting system, opens and pressure inside plasma vessel does not exceed the limiting 1.1 × 10⁵ Pa absolute pressure. Thus, the plasma vessel remains intact after loss-of-coolant accident during no-plasma operation of Wendelstein 7-X experimental nuclear fusion facility.     

Manufacturing of the Wendelstein 7-X divertor and wall protection

The in-vessel components of Wendelstein 7-X (W7-X) with a total surface of 265 m² comprise the divertor and the wall protection. The high heat flux (HHF) and lower heat flux (LHF) target, the baffle, the end plates closing the divertor chamber, a cryo vacuum pump (CVP) and a control coil form one divertor unit. Steel panels and the graphite heat shield protect the wall, including the ports. The HHF target elements, the steel panels and the control coils are manufactured by industry. The remaining components will be manufactured by the Max-Planck-Institute für Plasmaphysik (IPP) at its Garching workshops. For all components the final acceptance tests will be performed by IPP. This paper summarizes the main aspects for manufacturing, the preceding development and qualification tests as well as the final acceptance tests for the in-vessel components.     

Fabrication and installation of KSTAR in-vessel control coils

The in-vessel control coil (IVCC) system, which has been designed for dedication of various active feedback plasma control functions, successfully fabricated and installed in the vacuum vessel of the Korea Superconducting Tokamak Advanced Research (KSTAR). The IVCC system consists of sixteen segmented coils that were independently fabricated outside the vacuum vessel and installed without any inside welding or brazing joints. The segmented coil system has several advantages such as eliminating possibility of cooling water leakage at the welded or brazed joints, simplification in fabrication and installation, and easy repair and maintenance of the coil system. Each segment contains eight oxygen-free high conductive coppers, which are grouped to four pairs, called as sections. Consequently, a segmented coil forms four sections for position control, field error correction (FEC), and resistive wall mode (RWM) control in accordance with electrical connection outside the cryostat. The eight conductors (or four sections) with internal coolant holes were enclosed in a rectangular welded jacket made of stainless steel 316LN and electrically insulated from the conductors by epoxy/glass composite layers. This coil system was commissioned up to 5 kA (30 kA-turns) for 5 s to achieve tentative use for the fast vertical plasma position control in the 2010 campaign of the KSTAR. This paper describes the several remarkable results in the fabrication and installation of the IVCC as well as commissioning results.     

Design and assembly technology for the thermal insulation of the W7-X cryostat

The Max-Planck-Institut für Plasmaphysik in Greifswald is building up the stellarator fusion experiment Wendelstein 7-X (W7-X). To operate the superconducting magnet system the vacuum and the cold structures are protected by a thermal insulated cryostat. The plasma vessel forms the inner cryostat wall, the outer wall is realised by a thermal insulated outer vessel. In addition 254 thermal insulated ports are fed through the cryogenic vacuum to allow the access to the plasma vessel for heating systems, supply lines or plasma diagnostics.The thermal insulation is being manufactured and assembled by MAN Diesel & Turbo SE (Germany). It consists of a multi-layer insulation (MLI) made of aluminized Kapton with a silk like fibreglass spacer and a thermal shield covering the inner cryostat surfaces. The shield on the plasma vessel is made of fibreglass reinforced epoxy resin with integrated copper meshes. The outer vessel insulation is made of brass panels with an average size of 3.3 × 2.0 m². Cooling loops made of stainless steel are connected via copper strips to the brass panels. Especially the complex 3 D shape of the plasma vessel, the restricted space inside the cryostat and the consideration of the operational component movements influenced the design work heavily. The manufacturing and the assembly has to fulfil stringent geometrical tolerances e.g. for the outer vessel panels +3/?2 mm.     

A Systematic study of modular coil characteristics for 2-field periods quasi-axisymmetric stellarator QAS-LA

Modular coil characteristics of a 2-field periods quasi-axisymmetric stellarator QAS-LA configuration with an aspect ratio A_p = 3, magnetic pressure ∼4% and rotational transform ι ∼ 0.15 per field period supplied by its own shaping have been detailed studied. In addition, the characteristics of modular coils for QAS-LA were compared with those of an intermediate QA configuration QAS-LAx and a tokamak based on the same center magnet field B₀, aspect ratio and number of coils. As expected, the B_max/B₀, force F and overturning moment M, increase with the increased complexity of the coil shape. The relationships between the modular coils’ parameters (such as radius curvature ρ, distance from coil to coil Δ_c–c and the cross-section of coils) and the electromagnetic characteristics have been systematically summarized. The approximate formula for the maximum magnetic field in the coil body as functions of modular coil parameters (Δ_c–c, ρ) was derived for a simple two wire system which will be useful when optimizations of coil properties are called for.