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.     

Development of KSTAR in-vessel components and heating systems

In-vessel components of the Korea Superconducting Tokamak Advanced Research (KSTAR) were developed for 2010 campaign to provide a crucial circumstance for achieving the strongly shaped and diverted plasma. Moreover, the in-vessel components such as limiter, divertor, passive stabilizer, in-vessel control coil (IVCC) system demonstrated good performances satisfying the original design concepts. In addition to the plasma facing components and the IVCC, in-vessel cryo-pump (IVCP) system was also installed to leverage divertor operation. Besides the in-vessel components, there have been substantial progresses in development of the heating and current drive system. The KSTAR heating and current drive system includes all kinds of the major heating systems such as neutral beam injection (NBI), ion cyclotron range of frequency (ICRF), electron cyclotron resonance heating and current drive (ECH and ECCD), lower hybrid current drive (LHCD) systems. As an initial stage for full equipment of the heating systems to total power of 26 MW, several key systems such as 1st NBI (called NBI-1), ICRF, and ECH-assisted startup system successfully demonstrated their excellent feasibilities in the design and performances for dedication to the 2010 campaign.     

Optimization of an in-vessel visible inspection system for a long-pulse operation in KSTAR

To monitor the global formation of shaped plasmas, motion, and damage to the internal structures of the vacuum vessel, an in-vessel visible inspection system has been developed and operated on the Korean superconducting tokamak advanced research (KSTAR) device. The system contributed much to research progress on KSTAR such as the plasma start-up, plasma wall interactions, edge-localized modes, and disruptions. Moreover the need to perform inspections became important with high plasma power operation because of the increased frequency of first wall damage following off-normal events. Therefore the system is being improved from its original concept, and its final goal is operation during steady-state operation of the tokamak. The system consists of three fast visible cameras and two light-emitting diode illuminators. They are designed to be controlled fully from the control room to provide inspection capability at any time during hostile operating conditions. In this paper, we describe the upgrade of the system and recent results of the visible inspection system with the images of the KSTAR discharges for the last four years. Finally, we discuss the technical issues for a long pulse steady-state operation.     

Design and test of the KSTAR vacuum pumping system

The Korea Superconductor Tokamak Advanced Research (KSTAR) device is a tokamak mainly composed of a vacuum vessel, superconducting magnets, and cryostat. The internal volume of the vacuum vessel is about 110 m³ with a target pressure of 1 × 10⁻⁶ Pa, while the volume of the cryostat is 450 m³ with a target pressure of 5 × 10⁻³ Pa. To attain these target pressures, two identical vacuum pumping systems consisting of dry pumps, mechanical booster pumps, turbo-molecular pumps, and cryopumps were installed. The control system of the vacuum pumping systems was built using the experimental physics and industrial control system (EPICS), which has various merits such as easy access, convenient extension and flexible integration. The pump-down test of the pumping ducts was successfully executed under the control of the EPICS system.     

Design of neutral beam injection system for KSTAR tokamak

The neutral beam injection (NBI-1) system has been designed for providing a 300 s deuterium beam of 120 kV/65 A as an auxiliary heating and current drive system of the KSTAR (Korea Superconducting Tokamak Advanced Research) tokamak. The deuterium beam is produced from a long pulse ion source composed of a bucket-type plasma generator and a multi-aperture tetrode accelerator with the help of discharge power supplies and high voltage (HV) power supplies. The beamline components (BLCs) include a neutralizer with an optical multi-channel analyzer (OMA) section, a bending magnet (BM), an ion dump assembly, a movable calorimeter, beam scrapers, and a cryo-sorption pump system in a rectangular vacuum tank. A beam duct equipped with bellows and a voltage break is placed between the NBI vacuum tank and the KSTAR vacuum vessel. All data and parameters of the NBI system are controlled by a control and data acquisition (CODAQ) system through the EPICS based Ethernet interface.     

Design of a brazing connector for DEMO in-vessel components

The cost of electricity generated by fusion power will be strongly conditioned by the availability of future reactors. One key issue is the developing of feasible quick pipe connectors for the connection/disconnection of critical in-vessel components during maintenance operations. Brazing is a widely used joining technique which produces leak-proof high strength joints, with excellent stress distribution, little distortion and minimum oxidation. This work presents a design of a self-brazing/debrazing connector to be used with helium, lead–lithium and water pipes in DEMO. The remote handling compatible design includes an induction heating system, a brazing atmosphere supply, an inspection system (leak testing), a bolted/clamped union to provide stiffness against disruptions and thermal loads, and a positioning and alignment system.     

Fabrication of the KSTAR vacuum vessel and ports

The construction of the steady-state-capable superconducting KSTAR tokamak is in close proximity to the finalization. As one of the main components of the KSTAR device, the vacuum vessel is designed and manufactured during the construction period. The KSTAR vacuum vessel is composed of two large sectors forming the 337.5° of a full torus, and the remaining 22.5° section consisting of 24 small pieces. The large two sectors were welded at the site, and the 22.5° space was used for toroidal field coil assembly. The remaining 22.5° section of the vacuum vessel was assembled after 16 toroidal field coils assembly. The total 72 penetration ports were used to connect the vacuum vessel body and the cryostat. The major fabrication activity started in January 2003 after the finalization of fabrication design. The final components and structures were warehoused in June 2004 and site assembly is finished in 2007. Details of analysis, shop fabrication, and inspection results of the vacuum vessel including ports are summarized in the present work.     

Conceptual design of the KSTAR Motor Generator

The Korean Superconducting Tokamak Advanced Research (KSTAR) superconducting magnet power supply is composed of a Poloidal Field Magnet Power Supply (PF MPS) and a Toroidal Field Magnet Power Supply (TF MPS). When the PF MPS is operated, it requires a large amount of power instantaneously from the KSTAR electric power system. To achieve the KSTAR operational goal, with a long pulse scenario, a peak power of 200 MVA is required and the total power demand for the KSTAR system can exceed 200 MVA. The available grid power is only 100 MVA at the KSTAR site. Increasing the available grid power was uneconomical and inefficient which is why NFRI are installing a Motor Generator (MG).National Fusion Research Institute (NFRI) has made a contract with Vitzrotech and Converteam to design, manufacture and install the MG. Converteam has designed the electromagnetic and mechanical specification of the MG and Variable Voltage Variable Frequency (VVVF) converter.In this paper we discuss the conceptual design, including energy saving and electrical capacity of the MG system and the performance of the MG to satisfy the KSTAR 300 s operation scenario. In addition, the manufacturing and installation plan for the KSTAR MG is discussed.     

Design and operation results of nitrogen gas baking system for KSTAR plasma facing components

A baking system for the Korea Superconducting Tokamak Advanced Research (KSTAR) plasma facing components (PFCs) is designed and operated to achieve vacuum pressure below 5 × 10^?7 mbar in vacuum vessel with removing impurities. The purpose of this research is to prevent the fracture of PFC because of thermal stress during baking the PFC, and to accomplish stable operation of the baking system with the minimum life cycle cost. The uniformity of PFC temperature in each sector was investigated, when the supply gas temperature was varied by 5 °C per hour using a heater and the three-way valve at the outlet of a compressor. The alternative of the pipe expansion owing to hot gas and the cage configuration of the three-way valve were also studied. During the fourth campaign of the KSTAR in 2011, nitrogen gas temperature rose up to 300 °C, PFC temperature reached at 250 °C, the temperature difference among PFCs was maintained at below 8.3 °C, and vacuum pressure of up to 7.24 × 10^?8 mbar was achieved inside the vacuum vessel.     

Three-dimensional neutronic analysis of the ITER in-vessel coils

A complete neutronic analysis has been performed for the design of the in-vessel coil systems using the MCNP5 Monte Carlo Code in a full 3-D geometry. A detailed geometry of ELM and VS coils based on the latest design specifications has been integrated into the latest version of 40° sector of ITER MCNP model. Nuclear heating and helium production in the coils, absorbed dose in the insulator, dpa and transmutation of copper-alloy and neutron fluxes have been calculated. Neutron spectra have been used as input for an activation analysis performed with FISPACT inventory code for safety analysis and waste classification. The impact of the gaps between blanket modules and of the manifolds on the nuclear parameters has been evaluated as well as the effect on vacuum vessel reweldability. Different options for the conductor and the insulator have been examined.     

Present Status of the KSTAR Superconducting Magnet System Development

The mission of Korea Superconducting Tokamak Advanced Research (KSTAR) project is to develop an advanced steady-state superconducting tokamak for establishing a scientific and technological basis for an attractive fusion reactor. Because one of the KSTAR mission is to achieve a steady-state operation, the use of superconducting coils is an obvious choice for the magnet system. The KSTAR superconducting magnet system consists of 16 Toroidal Field (TF) coils and 14 Poloidal Field (PF) coils. Internally-cooled Cable-In-Conduit Conductors (CICC) are put into use in both the TF and PF coil systems. The TF coil system provides a field of 3.5 T at the plasma center and the PF coil system is able to provide a flux swing of 17 V-sec. The major achievement in KSTAR magnet-system development includes the development of CICC,the development of a full-size TF model coil, the development of a coil system for background magnetic-field generation , the construction of a large-scale superconducting magnet and CICC test facility. TF and PF coils are in the stage of fabrication to pave the way for the scheduled completion of KSTAR by the end of 2006.     

The operational results of the KSTAR PF cryo-circuit

The Koreas Superconducting Tokamak Advanced Research (KSTAR) PF cryo-circuit is designed for cooling the fourteen superconducting magnets (Nb3Sn, NbTi) and structures. Those are cooled down by the supercritical helium (4.5 K and 5.5 bar) of a forced flow (pressure gradient: 2 bar) in order to maintain the supercritical state of the helium. To supply a large amount of supercritical helium (>370 g/s), a circulator was inserted into the PF cryo-circuit. The compressed supercritical helium is distributed to five helium manifolds with cryogenic valves and supplied to each PF magnet. While the PF magnets had been operating, the mass flow rate reduced and the pressure head of the circulator was fluctuated depending on the PF magnet operation scenario. These phenomena could damage the circulator and could stop it during operation. Therefore, by-pass valve, which is parallel with in-line valve and is connected with inlet and outlet of the magnet, was opened in order to reduce of the circulator's pressure head. In this paper, we focused on the helium behavior of the superconducting magnet when the by-pass valve was opened in order to release the pressure head of the circulator and the results will be presented.     

Commissioning and initial operation of KSTAR superconducting tokamak

The commissioning and the initial operation for the first plasma in the KSTAR device have been accomplished successfully without any severe failure preventing the device operation and plasma experiments. The commissioning is classified into four steps: vacuum commissioning, cryogenic cool-down commissioning, magnet system commissioning, and plasma discharge.Vacuum commissioning commenced after completion of the tokamak and basic ancillary systems construction. Base pressure of the vacuum vessel was about 3 × 10^?6 Pa and that of the cryostat about 2.7 × 10^?4 Pa, and both levels meet the KSTAR requirements to start the cool-down operation. All the SC magnets were cooled down by a 9 kW rated cryogenic helium facility and reached the base temperature of 4.5 K in a month. The performance test of the superconducting magnet showed that the joint resistances were below 3 nΩ and the resistance to ground after cool-down was over 1 GΩ. An ac loss test of each PF coil made by applying a dc biased sinusoidal current showed that the coupling loss was within the KSTAR requirement with the coupling loss time constant less than 35 ms for both Nb₃Sn and NbTi magnets. All the superconducting magnets operated in stable without quench for long-time dc operation and with synchronized pulse operation by the plasma control system (PCS). By using an 84 GHz ECH system, second harmonic ECH assisted plasma discharges were produced successfully with loop voltage of less than 3 V. By the real-time feedback control, operation of 100 kA plasma current with pulse length up to 865 ms was achieved, which also meet the first plasma target of 100 kA and 100 ms. The KSTAR device will be operated to meet the missions of steady-state and high-beta achievement by system upgrades and collaborative researches.     

Completed installations and the individual commissioning of the KSTAR MG system

Peak power of 200 MVA is required in order to achieve the goal within a long pulse scenario for the final operation of the Korean Superconducting Tokamak Advanced Research (KSTAR). The available grid power is only 100 MVA at the National Fusion Research Institute (NFRI) site. Motor generator (MG) was considered as a method of resolving such problems. The design of the KSTAR MG system was completed in July 2010 and individual devices were produced by relevant manufacturers. The installation of individual devices was completed in December 2012. Specifically, the stator and rotor were assembled at the site due to their large size and weight. The bearings, variable voltage variable frequency (VVVF) and excitation systems were transported and installed on site after being manufactured externally.The building used for MG installation was built in 2011. With the building designed for ease of installation, an overhead crane was designed to allow access to the loading bay.In this paper, we discuss the installation of the MG system and the construction of the building suitable for installation of individual devices. In addition, performance on the test results of individual devices is also discussed.     

The in-vessel components of the experiment WENDELSTEIN 7-X

The in-vessel components of the WENDELSTEIN 7-X stellarator consist of the divertor components and the wall protection with its internal cooling supply. The main components of the open divertor are the vertical and horizontal target plates which form the pumping gap, the cryo-vacuum pumps and the control coils. The divertor volume is closed by graphite shielded baffle modules and with divertor closures. All these components are designed to be actively water-cooled. For the first commissioning phase planned in 2014, an inertial-cooled test divertor will be installed instead of the actively water-cooled high heat flux divertor. The wall protection consists of graphite-protected heat shields in the higher loaded areas and stainless steel panels in the lower loaded regions. The wall protection cooling circuits are connected through 80 supply-ports via so-called “plug-ins”. It is envisaged to protect the diagnostic ports by panel-type port-liners. Special graphite-shielded port liners are used on the diagnostic injector and the neutral beam injector ports. The in-vessel components are mainly manufactured and tested at the Max-Planck-Institute für Plasmaphysik in its Garching workshop. Panels, high heat flux target elements and control coils are delivered by industrial partners. Manufacturing of the KiP (“Komponenten im Plasmagefäß”) is in plan. Delivery of the components will be in time.     

Challenges left in the area of in-vessel melt retention

The in-vessel melt retention becomes an important safety objective for the present or future middle power nuclear plants, so care has to be taken in the evaluation of the various phenomena related to ensuring the feasibility of this objective. Since the prediction of the relevant phenomena has to be performed for the prototypical accident conditions, the applicability of the measured data or of the correlations derived from these measurements have to be established and the uncertainties determined. In this context, most uncertainties are introduced by the non-prototypicalities in the experiments. The paper describes the major findings from the OECD RASPLAV project and discusses the remaining challenges left in the area of in-vessel molten corium coolability.     

Consequences of material effects on in-vessel retention

In-vessel retention (IVR) consists in cooling the corium contained in the reactor vessel by natural convection and reactor cavity flooding. This strategy of severe accident management enables the corium to be kept inside the second confinement barrier: the reactor vessel. The general approach which is used to study IVR problems is a “bounding” approach which consists in assuming a specified corium stratification in the vessel and then demonstrating that the vessel can cope with the resulting thermal and mechanical loads. Thermal loading on the vessel is controlled by the convective heat transfer inside the molten corium in the lower head. If there is no water in the vessel and if the corium pool is overlaid by a liquid steel layer, then the heat flux might focus on the vessel in front of the steel layer (“focusing effect”) and exceed the dry-out heat flux (CHF or DHF). One of the critical points of these studies is linked to the determination of the height of the molten steel layer that can stratify above the oxidic pool. The MASCA experiments have highlighted that part of molten steel may stratify under the oxidic corium which reduces the thickness of the steel layer on top of the pool. This behavior can be explained by chemical interaction between the oxide and metallic phases of the pool which confirms that these materials cannot be treated as inert species. Following these conclusions, a methodology which couples physicochemical effects and thermalhydraulics has been developed to address the IVR issue. The main purpose of this paper is to present this methodology and its application for given corium mass inventories. Attention focuses on the influence of parameters such as the ratio U/Zr and oxidation ratio of zirconia. For a 1000 MW PWR, approximately 10 t of steel stratify at the bottom of the vessel for 40% Zr oxidation, and 25 t for 30% Zr oxidation. This leads to a 25–50% increase of the mass of molten steel that is required for avoiding vessel melt-through.     

Resonant loop system for the KSTAR ICRF current drive

The phased current distribution at current straps for the KSTAR ICRF antenna causes a power imbalance at each strap owing to the mutual couplings between current straps. In order to mitigate the effect of coupling, a decoupler connecting two phased feeding lines are designed based on both a lumped element antenna model and a distributed transmission line model. Though the decoupler parameter is dependent on the loading resistance, which depends on plasma condition, an analysis shows that the decoupling is effective in the wide range of loading resistance assuming the low variation of mutual inductance between straps. A circuit analysis also shows that the RF characteristics of a complex RF transmission system are matched well for the asymmetric antenna current spectrum aiming for a non-inductive current drive of KSTAR. The calibration result of decoupler after installation is also discussed.