CEA studies and qualifications prior to the JT-60SA TF coils manufacture

Following the first conceptual design activity in which the general design of the JT-60SA TF system was defined in agreement with all the participants in the project (CEA, ENEA, F4E), a second phase dealing with the detailed design was engaged by each of the voluntary contributors. For the French part which includes the procurement of 9 of the TF winding packs and their integration in the casing, an industrial contract was signed mid 2011 with Alstom (France). Several actions have been carried out to prepare the manufacturing phase.To precisely define one of the main interfaces which is the temporary electrical connection of the coils to the current leads during cold test in the CEA facility as well as their final connection to the feeders at the Naka site, a design compatible with both requirements was developed by CEA, supported by the previous developments led on the joints and assembly techniques.In addition to prepare the coils manufacture, hydraulic qualification was led on the first conductor qualification length to set the parameters which will be used by the coils manufacturer for conductor acceptance.At last, mechanical characterizations of both the conductor and of the empty compacted jacket were performed in order to define as precisely as possible the elastic and plastic properties of these components. These are crucial properties used during the bending process which is one of the most important operations during the winding pack manufacture. These data will be very helpful for the winding machine parameters settings as well as for designing the local bending tooling needed to shape the conductors extremities at the connection area and at the double pancakes joggles.     

A coil test facility for the cryogenic tests of the JT-60SA TF coils

In the framework of the Broader Approach Activities, the EU will deliver to Japan the 18 superconducting coils, which constitute the JT-60SA Toroidal field magnet. These 18 coils, manufactured by France and Italy, will be cold tested before shipping to Japan. For this purpose, the European Joint Undertaking for ITER, the Development of Fusion Energy (“Fusion for Energy”, F4E) and the European Voluntary Contributors are collaborating to design and set-up a coil test facility (CTF) and to perform the acceptance test of the 18 JT-60SA Toroidal Field (TF) coils. The test facility is designed to test one coil at a time at nominal current and cryogenic temperature. The test of the first coil of each manufacturer includes a quench triggered by increasing the temperature.The project is presently in the detailed design phase.     

Feeder components and instrumentation for the JT-60SA magnet system

The modifying of the JT-60U magnet system to the superconducting coils is progressing as a satellite facility for ITER by both parties of Japanese government and European commission in the Broader Approach agreement. The magnet system requires current supplies of 25.7 kA for 18 TF coils and of 20 kA for 4 CS modules and 6 EF coils. The magnet system generates an average heat load of 3.2 kW at 4 K to the cryogenic system. The feeder components connected to the power supply provide current supply. The cooling pipes connected to the cryogenic system provide coolant supply. The instrumentation of the JT-60SA magnet system is used for its operation.     

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.     

2D thermal analysis for heat transfer from casing to winding pack in JT-60SA TF coils

In the framework of the Broader Approach Agreement, Europe is involved in the design activities for the Japanese Tokamak JT-60SA, investigating, among several issues, the operation of the superconducting TF magnets and their subsystems, aimed at the reactor conceptual design definition. In particular, one of the main critical aspects to study is the heating of the conductor due to both direct component of energy deposited by neutrons and by secondary gamma generated during plasma operation, and heat generated by the radiation on casing and transferred to the winding pack. Indeed, the operating temperature and the relevant temperature margin (i.e. the operating safety margin) of the magnet will depend strongly on the heat loads and on the capability of the coolant to remove it. Furthermore, the heat power to the conductor will depend on several aspects, namely the thickness of insulating material, the mass flow rate of helium flowing in the conductors and its thermodynamic properties at operating conditions, and the layout of the superconductors constituting the winding. Moreover, a crucial aspect in the final design will be the presence and position of the casing cooling channels. In this paper a 2D sensitivity analysis of heat transfer from casing to winding pack with respect to cooling channels number and position is presented, based on the reference layout of the magnet. As a result, we evaluated the optimum number and positioning of cooling channels needed, as a trade-off between magnet operating limits and available cryogenic power and if, at limit, they could be even neglected in normal operation, keeping dwell-time within reasonable values.     

JT-60SA vacuum vessel manufacturing and assembly

The JT-60SA vacuum vessel (VV) has a D-shaped poloidal cross section and a toroidal configuration with 10° segmented facets. A double wall structure is adopted to ensure high rigidity at operational load and high toroidal one-turn resistance. The material is 316L stainless steel with low cobalt content (<0.05%). The design temperatures of the VV at plasma operation and baking are 50 °C and 200 °C, respectively. In the double wall, boric-acid water is circulated at plasma operation to reduce the nuclear heating of the superconducting magnets. For baking, nitrogen gas is circulated in the double wall after draining of the boric-acid water.The manufacturing of the VV started in November 2009 after a fundamental welding R&D and a trial manufacturing of 20° upper half mock-up. The manufacturing of the first VV 40° sector was completed in May 2011. A basic concept and required jigs of the VV assembly were studied.This paper describes the design and manufacturing of the vacuum vessel. A plan of VV assembly in torus hall is also presented.     

Design and manufacturing of JT-60SA vacuum vessel

JT-60 is planned to be upgraded to JT-60SA tokamak machine with fully superconducting coils, which is a project of the JA-EU satellite tokamak program under both Broader Approach program and Japanese domestic program. The JT-60SA vacuum vessel (VV) has a D-shape poloidal cross section and a toroidal configuration with 10° facet segmented in toroidal direction. The material of the VV is 316L stainless steel with low cobalt content of <0.05 wt%. A double wall structure is adopted for the VV to ensure high rigidity and high toroidal one-turn resistance simultaneously.Fundamental welding R&D and a trial manufacturing of the 20° upper half of the VV have been performed to study the manufacturing procedure. After the confirmation of the quality of the mock-up, manufacturing of the actual VV started in November 2009.     

Quench propagation and quench detection in the TF system of JT-60SA

In the framework of the JT-60SA project, France and Italy will provide to JAEA 18 Toroidal Field (TF) coils including NbTi cable-in-conduit conductors. During the tokamak operation, these coils could experience a quench, an incidental event corresponding to the irreversible transition from superconducting state to normal resistive state. Starting from a localized disturbance, the normal zone propagates along the conductor and dissipates a large energy due to Joule heating, which can cause irreversible damages.The detection has to be fast enough (a few seconds) to trigger the current discharge, so as to dump the stored magnetic energy into an external resistor. The JT-60SA primary quench detection system will be based on voltage measurements, which are the most rapid technology. The features of the detection system must be adjusted so as to detect the most probable quenches, while avoiding inopportune fast safety discharges. This requires a reliable simulation of the early quench propagation, performed in this study with the Gandalf code.The conductor temperature reached during the current discharge must be kept under a maximal value, according to the hot spot criterion. In the present study, a hot spot criterion temperature of 150 K was taken into account and the role of each conductor component (strands, helium and conduit) was analyzed. The detection parameters were then investigated for different hypotheses regarding the quench initiation.     

Joint resistance measurements of pancake and terminal joints for JT-60SA EF coils

To evaluate the joint fabrication technology for the JT-60SA EF coils, joint resistance measurements were conducted using a sample consisting of pancake and terminal joints. Both joints are shake-hands lap joints composed of cable-in-conduit conductors and a pure copper saddle-shaped spacer. The measurements demonstrated that both joints fulfilled the design requirement. Considering these measurements, the characteristics of both joints were investigated using analytical models that represent the joints. The analyses indicated that the characteristics of the conductors used in the joints affect the characteristics of the joints.     

Parametric thermo-hydraulic analysis of the TF system of JT-60SA during fast discharge

The evolution of the conductor temperature and of the helium pressure of the central pancake of the TF superconducting magnet of the JT-60SA tokamak in a quench scenario are here discussed. The quench is triggered by a heat disturbance applied at the end of burning and followed by a fast safety discharge. A parametric study aimed at assessing the robustness of the calculation is also addressed with special regard to the voltage threshold, used to define the occurrence of the quench, and to the time delay, that cover all the possible delays in the fast discharge after quench detection. Finally, due to sensitivity analyses the influences of different parameters were assessed: the material properties of the strands (RRR, copper fraction), the magnitude and the spatial length of the triggering disturbance and the magnetic field distribution. The numerical evaluations were performed in the framework of the Broader Approach Agreement in collaboration with CEA, ENEA and the JT-60SA European Home Team using the 1D code Gandalf [1].     

Status of design and procurement activities in JT-60SA

The JT-60SA experiment is one of the three projects to be undertaken in Japan as part of the Broader Approach Agreement, conducted jointly by Europe and Japan, and complementing the construction of ITER in Europe. It is a fully superconducting tokamak capable of confining break-even equivalent deuterium plasmas with equilibria covering high plasma shaping with a low aspect ratio at a maximum plasma current of I_p = 5.5 MA. In late 2007 the BA Parties, prompted by cost concerns, asked the JT-60SA Team to carry out a re-baselining effort with the purpose to fit in the original budget while aiming to retain the machine mission, performance, and experimental flexibility. Subsequently the Integrated Project Team has undertaken a machine re-optimization followed by engineering design activities aimed to reduce costs while maintaining the machine radius and plasma current. This effort led the Parties to the approval of the new design in late 2008 and hence final design and procurement activities have commenced. The paper will describe the process leading to the re-baselining, the resulting final design and technical solutions and the present status of procurement activities.     

Present Status of JT-60SA Project and Development of Heating Systems for JT-60SA

Present status of the JT-60SA (JT-60 Super Advanced) project, implemented jointly by Europe and Japan since 2007, is described. The design of the main tokamak components was completed in late 2008, and all the scientific missions are preserved to contribute to ITER and DEMO reactors. The construction of the JT-60SA has begun with procurement activities for the superconducting magnet systems, vacuum vessel, in-vessel components and other components under the relevant procurement arrangements between the implementing agencies of JAEA (Japan Atomic Energy Agency) in Japan and Fusion for Energy in Europe. Designs and developments of the auxiliary heating systems for JT-60SA have been progressing at JAEA so as to provide the total injection power of 41 MW for 100 s.     

Technical aspects and manufacturing methods for JT-60SA toroidal field coil casings

JT-60SA is a superconducting tokamak machine to be assembled in Naka site, Japan, designed to contribute to the early realization of fusion energy by supporting the exploitation of ITER and research toward DEMO.In the frame of the Broader Approach Agreement a contract between ENEA and Walter Tosto (Chieti, Italy) started on July 2012 for the construction of 18 TF coil casings for JT-60SA. Two different sets of 9 casings each will be progressively delivered, from 2013 to the end of 2015, to ASG Superconductors (Genoa, Italy) and to Alstom (Belfort, France), where the integration of the winding pack into the casing will be carried out.Each TF coil casing (height 7.5 m and width 4.5 m) consists of four main components: one “Straight Leg Outboard” and one “Curved Leg Outboard” both with their own covers, “Straight Leg Inboard” and “Curved Leg Inboard”. The casing components are segmented in forgings and plates made of FM316LNL. The straight leg outboard is composed of two wings welded to a central core and two elbows welded at the ends with a cooling channel installed inside. Elbows of straight leg outboard are segmented in two half-elbows machined from 1 rough forging and welded to the central core made by plate. Welding of wings to the central core is performed in EBW (electron beam welding) and the straight part is welded to the elbows by NGTIG (TIG narrow gap) process. The curved leg outboard is composed of two wings welded to a central core for a final shape of “D”. Other supports are welded by TIG or Electrode process.This paper describes the technical design solutions, the manufacturing methods defined and the particular processes adopted, such as welding (EB, TIG), non-destructive examinations (NDE), vibration stress relief (VSR) and laser tracker survey, most of which have been validated by the construction of two different sets of full scale mock-ups representing the straight and the curved legs.     

Characterization of industrial NbTi strands at variable field for JT-60SA toroidal field coils

The mission of the JT-60SA Tokamak, to be built in Japan, is to contribute to the early realization of fusion energy by its exploitation in support of the ITER program. JT-60SA project is an important part of the “broader approach” activity as a satellite program for ITER. The toroidal field (TF) coils are a European “in kind” contribution and they will partly be built by France. JT-60SA TF coil uses the Cable In Conduit Conductor (CICC) with NbTi superconductor strands. TF conductors will have to operate at 5.7 T, 5 K and at current density of 450 A/mm² with sufficient margins. In the framework of JT-60SA TF coil manufacture, the variable temperature characterization is an important step to select NbTi strand. At an early stage of design, we had to choose the strand with acceptable performances. During the design qualification and validation stage, it is important to qualify strands in conditions close to the operation conditions. The industry has proposed various strands manufactured with different processes. This work and publication examines a strand with an internal CuNi barrier, which is expected to lead to better current distribution between strands, by more precise calibration and control of the inter-strand resistance. The strands were tested at the Grenoble High Magnetic Field Laboratory facility. The domain (B, T, J) explored was in the range of 4.5–11 T for the magnetic field intensity, 4.2–6.5 K for the temperature and between 40 A/mm² and 1200 A/mm² for the current density. For each strand, “critical current density” and “current sharing temperature” measurements have been carried out, with a temperature precision of few tens of mK. Once the measurements performed, the fitting parameters (of type J_C = f(B, T)) of each strand have been found, by performing regression analysis. This work will lead to select the strand with the best characteristics. In this paper, we present the results of this measurement task, the data and regression analysis (fits, T_cs, etc.) and the conclusion about the strand choice.     

Assembly study for JT-60SA tokamak

The assembly scenarios and assembly tools of the major tokamak components for JT-60SA are studied in the following. (1) The assembly frame (with a dedicated 30-tonne crane), which is located around the JT-60SA tokamak, is adopted for effective assembly works in the torus hall and the temporary support of the components during assembly. (2) Metrology for precise positioning of the components is also studied by defining the metrology points on the components. (3) The sector segmentation for weld joints and positioning of the vacuum vessel (VV), the assembly scenario and tools for VV thermal shield (TS), the connection of the outer intercoil structure (OIS) and the installation of the final toroidal field coil (TFC) are studied, as typical examples of the assembly scenarios and tools for JT-60SA.     

Overview of engineering design,manufacturing and assembly of JT-60SA machine

The JT-60SA experiment is one of the three projects to be undertaken in Japan as part of the Broader Approach Agreement, conducted jointly by Europe and Japan, and complementing the construction of ITER in Europe. The JT-60SA device is a fully superconducting tokamak capable of confining break-even equivalent deuterium plasmas with equilibria covering high plasma shaping with a low aspect ratio at a maximum plasma current of I_p = 5.5 MA. This makes JT-60SA capable to support and complement ITER in all the major areas of fusion plasma development necessary to decide DEMO reactor construction. After a complex start-up phase due to the necessity to carry out a re-baselining effort with the purpose to fit in the original budget while aiming to retain the machine mission, performance, and experimental flexibility, in 2009 detailed design could start. With the majority of time-critical industrial contracts in place, in 2012, it was possible to establish a credible time plan, and now, the project is progressing on schedule towards the first plasma in March 2019. After careful and focused R&D and qualification tests, the procurement of the major components and plant is now well advanced in manufacturing design and/or fabrication. In the meantime the disassembly of the JT-60U machine has been completed and the engineering of the JT-60SA assembly process has been developed. The actual assembly of JT-60SA started in January 2013 with the installation of the cryostat base. The paper gives an overview of the present status of the engineering design, manufacturing and assembly of the JT-60SA machine.     

Fundamental welding R&D results for manufacturing vacuum vessel of JT-60SA

The real vacuum vessel (VV) manufacturing of JT-60SA has started since November 2009 at Toshiba. Prior to starting manufacturing, fundamental welding R&Ds had been performed by three stages. In the first stage, primary tests for screening welding method were performed. In the second stage, the trial welding for 1 m-long straight and curved double shell samples were conducted. The dependences of welding quality and distortion on the welding conditions, such as arc voltage and current, setting accuracy, welding sequence, and the shape of grooves were studied. In addition, welding condition with low heat input was explored. In the last stage, fabrication sequence was confirmed and established by the trial manufacturing of the 20° upper half mock-up [1]. This paper presents the R&D results obtained in the first and second stages.     

Manufacturing of JT-60SA Cryostat Base

JT-60SA is a superconducting tokamak to be assembled and operated at the JAEA laboratories in Naka (Japan) [1]. The tokamak has been designed to prepare, support and complement the ITER experimental programme and will be manufactured and operated under the funding of the Broader Approach Agreement (between the government of Japan and the European Commission) and of the Japan Fusion National Programme. Within the European contribution to JT-60SA, Spain has to provide the cryostat. Due to functional purposes, the cryostat has been divided in two large assemblies: the Cryostat Base (CB) and the Cryostat Vessel Body the latter subdivided into Cryostat Vessel Body Cylindrical Section (CVBCS) and the Top Lid. Spain is committed to provide the design and subsequent manufacturing of the CB and CVBCS (excluding the Top Lid) through the National Laboratory of Fusion at Ciemat. The design of both components has been concluded and the CB is currently being manufactured by a Spanish company, IDESA. This paper aims to present the status of the manufacturing and pre-assembly at the factory of the CB that has to be delivered in November 2012.     

Progress in ECRF antenna development for JT-60SA

Structural, mechanical and optical design work on antennas/launchers for the electron cyclotron range of frequency heating and current drive system in JT-60 Super Advanced (JT-60SA) have been advanced based on a linear motion antenna concept. A CAD model of the launcher was built with realistic component sizes. A mock-up of the steering structure consisting of two different bellows sections for poloidal and toroidal beam scanning was fabricated to test movement of the bellows. The poloidal (?40° to +20°) and toroidal (?15° to +15°) injection angle ranges required in JT-60SA were shown to be realized by this steering structure and mirrors.     

Structural analysis of the JT-60SA cryostat base

Design and manufacturing of the JT-60SA cryostat is being performed by CIEMAT, according to the Broader Approach Agreement between Japan and the European Commission. Taking into account both the limitations of transport and the assembly sequence of JT60-SA, the cryostat is divided in two main parts, namely the cryostat base and the cryostat vessel body.The paper is focused on the structural analyses carried out by CIEMAT to evaluate the mechanical behavior of the JT-60SA cryostat base final design, since the cryostat vessel body will be designed and manufactured in a subsequent stage.The overall structural integrity of the cryostat base has been verified and confirmed utilizing the ‘limit analysis’ procedure defined in ASME code 2007 Section VIII, Div. 2. The study has been complemented by further finite element analyses that include the detail of the bolted fastenings, aimed to evaluate the mechanical behavior of the bolted joints themselves, as well as the stresses and deformations in the overall cryostat base structure.