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.     

Final design of the Switching Network Units for the JT-60SA Central Solenoid

This paper describes the approved detailed design of the four Switching Network Units (SNUs) of the superconducting Central Solenoid of JT-60SA, the satellite tokamak that will be built in Naka, Japan, in the framework of the “Broader Approach” cooperation agreement between Europe and Japan.The SNUs can interrupt a current of 20 kA DC in less than 1 ms in order to produce a voltage of 5 kV. Such performance is obtained by inserting an electronic static circuit breaker in parallel to an electromechanical contactor and by matching and coordinating their operations. Any undesired transient overvoltage is limited by an advanced snubber circuit optimized for this application. The SNU resistance values can be adapted to the specific operation scenario. In particular, after successful plasma breakdown, the SNU resistance can be reduced by a making switch.The design choices of the main SNU elements are justified by showing and discussing the performed calculations and simulations. In most cases, the developed design is expected to exceed the performances required by the JT-60SA project.     

Progress in development and design of the neutral beam injector for JT-60SA

Neutral beam (NB) injectors for JT-60 Super Advanced (JT-60SA) have been designed and developed. Twelve positive-ion-based and one negative-ion-based NB injectors are allocated to inject 30 MW D⁰ beams in total for 100 s. Each of the positive-ion-based NB injector is designed to inject 1.7 MW for 100 s at 85 keV. A part of the power supplies and magnetic shield utilized on JT-60U are upgraded and reused on JT-60SA. To realize the negative-ion-based NB injector for JT-60SA where the injection of 500 keV, 10 MW D⁰ beams for 100 s is required, R&Ds of the negative ion source have been carried out. High-energy negative ion beams of 490–500 keV have been successfully produced at a beam current of 1–2.8 A through 20% of the total ion extraction area, by improving voltage holding capability of the ion source. This is the first demonstration of a high-current negative ion acceleration of >1 A to 500 keV. The design of the power supplies and the beamline is also in progress. The procurement of the acceleration power supply starts in 2010.     

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.     

Status of European manufacture of Toroidal Field conductor and strand for JT-60SA project

In the framework of the JT-60SA project, part of the Broader Approach (BA) agreement, EURATOM provides to Japan, the Toroidal Field (TF) magnet system, consisting of 18 superconducting coils. The procurement of the conductor for the TF coils is managed by Fusion for Energy, acting as EU representative in the BA agreement. The TF conductor procurement is split into two contracts, one dedicated to the production of Niobium Titanium (NbTi) and Cu strand and the other to TF conductor production through strand cabling and cable jacketing operations.The TF conductor is a rectangular-shaped cable-in-conduit conductor formed by 486 (0.81 mm diameter) strands (2/3 NbTi–1/3 Cu) wrapped in a stainless steel foil and embedded into a stainless steel jacket.The 18 TF coils require (including spares) 115 ‘Unit Lengths’ (UL) of such conductor, each 240 m long for a total of about 28 km. Correspondingly about 10,000 km for NbTi and 5000 km for Cu strand are produced.The Japanese company Furukawa Electric Co. (FEC) is in charge of TF strand manufacture while the Italian company Italian Consortium for Applied Superconductivity (ICAS) is in charge of cabling and jacketing of TF conductor ULs. In the paper, we provide information on the production stages presently achieved in TF strand and conductor contracts.     

Safe disassembly and storage of radioactive components of JT-60U torus

Disassembly of the JT-60U torus was started in 2009 after 18 years of D₂ operations and was completed in October 2012 for assembling the JT-60SA torus at the same position. The JT-60U torus was featured by the complicated and welded structure against the strong electromagnetic force, and by the radioactivation due to deuterium–deuterium (D–D) reactions. Since this work is the first experience of disassembling a large radioactivated fusion device in Japan, careful preparations of disassembly activities, including treatment of the radioactivated materials and safety work, have been made. During the disassembly period over 3 years, careful measures against exposure were taken and stringent control of exposure dose were implemented, and as a result, accumulated collective effective dose of ∼41,000 person-day to workers was only ∼22 mSv in total and no internal exposure was observed. About 13,000 components cut into pieces with measuring the contact dose were removed from the torus hall and stored safely in storage facilities. The total weight of the disassembly components reached up to ∼5400 tonnes. Most of the disassembly components will be treated as non-radioactive ones after the clearance level inspection under the Japanese regulations in the future. The assembly of JT-60SA has started in January 2013 after this disassembly of JT-60U torus.     

Structural analysis of the JT-60SA cryostat vessel body

The JT-60SA cryostat is a stainless steel vacuum vessel (14 m diameter, 16 m height) which encloses the Tokamak providing the vacuum environment (10^?3 Pa) necessary to limit the transmission of thermal loads to the components at cryogenic temperature. It must withstand both external atmospheric pressure during normal operation and internal overpressure in case of an accident.The paper summarizes the structural analyses performed in order to validate the JT-60SA cryostat vessel body design. It comprises several analyses: a buckling analysis to demonstrate stability under the external pressure; an elastic and an elastic–plastic stress analysis according to ASME VIII rules, to evaluate resistance to plastic collapse including localized stress concentrations; and, finally, a detailed analysis with bolted fasteners in order to evaluate the behavior of the flanges, assuring the integrity of the vacuum sealing welds of the cryostat vessel body.     

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.     

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.     

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.     

5 MW CW supply system for the ITER gyrotrons Test Facility

ECH (Electron Cyclotron Heating) for ITER will deliver into the plasma 20 MW of RF power. The procurement of the RF sources will be shared equally between the three following partners: Europe, Japan and Russia. Moreover, Europe decided to develop a RF source capable of 2 MW CW of RF power, based on the design of a coaxial gyrotron with a depressed collector. In order to be able to develop and test these RF sources, a Test Facility (TF) has been built at the CRPP premises in Lausanne (CH).The present paper will first remind the main operation conditions considered to test safely a gyrotron. The power supplies parameters allowing to fulfill these conditions will be reviewed. The core of the paper content will describe the newly installed Main High Voltage Power Supply (MHVPS), to be connected to the gyrotron cathode and capable of ?60 kV/80 A-CW. The principle, the characteristics, the on-site test results will be described at the light of the requirements imposed by the gyrotron testing. Particular aspects of the installation and commissioning on-site will be highlighted in comparison with the ITER environment. The synchronized operation of the MHVPS and the BPS (Body Power Supply) on dummy load, piloted through the TF remote control, will be presented and commented.Since the TF supply structure has been built integrating the particular conditions and requirements expected for ITER, a conclusion will summarize the performances obtained at the light of these criteria.     

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 study of a wide-angle infrared thermography and visible observation diagnostic on JT-60SA

Design study of a wide-angle infrared (IR) thermography (surface temperature measurement) and visible observation diagnostics for JT-60SA are reported. The new design offers an optical solution without a “blind spot” which is one of the advantages. In order to image a large section inside the vacuum vessel (both in poloidal and toroidal directions), the optical system of endoscope is to provide a wide-angle view in the IR and visible wavelength ranges. The estimated IR optical spatial resolution is approximately 2 cm at a distance of 7.6 m from the front optics with a pupil diameter of 4 mm. For a surface temperature measurement it would be larger (∼4 cm for a surface temperature error less than 5%). The optics of this system can be divided into three parts: (1) a mirror based optical head (two set of spherical mirrors plus two flat mirrors) that produces an intermediate image, (2) a Cassegrain telescope system, and (3) a relay group of lenses, being adapted to the two kinds of detectors for IR and visible observations.     

The European Nb3Sn advanced strand development programme

Strands relevant for fusion with high critical current densities and moderate hysteresis losses were developed and already produced on industrial scale. Based on these achievements EFDA-CSU Garching has launched a Nb₃Sn strand development and procurement action inside Europe in order to assess the current status of the Nb₃Sn strand production capability. All six addressed companies have replied positively to the strand R&D programme which includes the three major Nb₃Sn production techniques namely the bronze, internal-tin and powder-in-tube (PIT) route. According to the strand requirements for the ITER TF conductor a critical current density of 800 A/mm² (at 12 T, 4.2 K and 10 μV/m) and overall strand hysteresis losses below 500 kJ/m³ have been specified as the minimum guaranteed strand performance.The second major objective of this programme is to motivate the strand manufacturers to develop and design high performance Nb₃Sn strands optimised for the ITER conductor. For this purpose, a target critical current density of 1100 A/mm² has been added to the specification. This paper describes the strategy behind the strand development programme, the actual status of the strand production as well as first preliminary results obtained from the strand suppliers.     

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.     

Overview of magnetic control in ITER

ITER is targeting Q = 10 with 500 MW of fusion power. To meet this target, the plasma needs to be controlled and shaped for a period of hundreds of seconds, avoiding contact with internal components, and acting against instabilities that could result in the loss of control of the plasma and in its disruptive termination.Axisymmetric magnetic control is a well-understood area being the basic control for any tokamak device. ITER adds more stringent constraints to the control primarily due to machine protection and engineering limits. The limits on the actuators by means of the maximum current and voltage at the coils and the few hundred ms time response of the vacuum vessel requires optimization of the control strategies and the validation of the capabilities of the machine in controlling the designed scenarios.Scenarios have been optimized with realistic control strategies able to guarantee robust control against plasma behavior and engineering limits due to recent changes in the ITER design. Technological issues such as performance changes associated with the optimization of the final design of the central solenoid, control of fast transitions like H to L mode to avoid plasma-wall contact, and optimization of the plasma ramp-down have been modeled to demonstrate the successful operability of ITER and compatibility with the latest refinements in the magnetic system design.Validation and optimization of the scenarios refining the operational space available for ITER and associated control strategies will be proposed. The present capabilities of magnetic control will be assessed and the remaining critical aspects that still need to be refined will be presented. The paper will also demonstrate the capabilities of the diagnostic system for magnetic control as a basic element for control. In fact, the noisy environment (affecting primarily vertical stability), the non-axisymmetric elements in the machine structure (affecting the accuracy of the identification of the plasma boundary), and the strong component of eddy current at the start-up (resulting in a poor S/N ratio for plasma reconstruction for I_p < 2 MA requiring a robust plasma control) make the ITER magnetic diagnostic system a demanding part of the magnetic control and investment protection systems. Finally the paper will illustrate the identified roles of magnetic control in the PCS (plasma control system) as formally defined in the recent first step of the design and development of the system.     

Modification,enhancement and operation of a water detritiation facility at the Tritium Laboratory Karlsruhe

For the design and development proposal of the European procurement package of the Water Detritiation System (WDS) for ITER, an experimental WDS was installed at the Tritium Laboratory Karlsruhe (TLK) to investigate the process and various components of the system. The WDS facility at TLK uses the Combined Electrolysis Catalytic Exchange (CECE) process and consists of two Solid Polymer Electrolyte (SPE) electrolysis cells and a stainless steel Liquid Phase Catalytic Exchange (LPCE) column with an effective length of 8 m. After installation and commissioning, the first experimental runs were performed with a tritium concentration up to 0.6 GBq kg^?1 in the feed water to test the operation modes of the facility, all the safety installations and procedures and the performance of the LPCE column during a runtime of up to 130 h.Regarding the final design of the WDS for ITER, the first experiments indicated several aspects which had to be modified in order to enhance the procedural and operating performance of the facility.     

The ITER full size plasma source device design

In the framework of the strategy for the development and the procurement of the NB systems for ITER, it has been decided to build in Padova a test facility, including two experimental devices: a full size plasma source with low voltage extraction and a full size NB injector at full beam power (1 MV). These two different devices will separately address the main scientific and technological issues of the 17 MW NB injector for ITER. In particular the full size plasma source of negative ions will address the ITER performance requirements in terms of current density and uniformity, limitation of the electron/ion ratio and stationary operation at full current with high reliability and constant performances for the whole operating time up to 1 h. The required negative ion current density to be extracted from the plasma source ranges from 290 A/m² in D₂ (D^?) and 350 A/m² in H₂ (H^?) and these values should be obtained at the lowest admissible neutral pressure in the plasma source volume, nominally at 0.3 Pa. The electron to ion ratio should be limited to less than 1 and the admissible ion inhomogeneity extracted from the grids should be better than 10% on the whole plasma cross-section having a surface exposed to the extraction grid of the order of 1 m².The main design choices will be presented in the paper as well as an overview of the design of the main components and systems.     

Optical design for divertor Thomson scattering system for JT-60SA

Optical design for divertor Thomson scattering system in JT-60SA has been conducted. The measurement system will use a Nd:YAG laser at 1064 nm, and scattered photons are collected by a collection optical system. The collection optics consists of primary mirror, secondary mirror, relay optics, and fiber collection optics. The laser transmission mirror and collection optics were designed to be installed in a slender lower port of JT-60SA. The assessment of the measurement errors in temperature was conducted for the designed collection optical system. Because of spatial limitation, the solid angle from the measurement points would be small especially for the measurement points in high field side, and consequently, the temperature errors in the high field side would be considerably large. The effects of several improvements on the error are discussed. Moreover, an assessment for the in-vessel laser transmission metallic mirrors is conducted for the present design.