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.     

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.     

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.     

The procurement and testing of the stainless steel in-vessel panels of the Wendelstein 7-X Stellarator

320 In-vessel water cooled stainless steel panels, poloidal closure plates and pumping gap panels, covering an area of approximately 100 m², are used in Wendelstein7-X to protect the plasma vessel. The panels are manufactured at Deggendorf, Germany by MAN Diesel & Turbo SE. The panels consist of a laser welded sandwich of stainless steel plates together with a labyrinth of cooling channels and have a complicated geometry to fit the plasma vessel of Wendelstein 7-X. The hydraulic and mechanical stability requirements whilst maintaining the tight tolerances for the shape of the components are very demanding. The panels are designed to operate at up to an average heat load of 100 kW/m² and a maximum heat load of 200 kW/m² with a water velocity of approximately 2 m s^?1. High heat flux testing of an un-cooled panel at a time averaged load of 200 kW/m² for 10 s were successfully performed to support the start up phase of Wendelstein 7-X operation. Extensive testing both during manufacture and after delivery to IPP-Garching demonstrates the suitability of the delivered panels for their purpose.     

Structural analysis of W7-X: Overview

The Wendelstein 7-X (W7-X) modular stellarator is in the assembly phase at the Max-Planck-Institut für Plasmaphysik (IPP) in Greifswald, Germany. The goal of the project is to demonstrate that this type of machine is a viable option for a fusion power-plant. The “pentagonal” magnet system of the machine encompasses 50 non-planar and 20 planar superconducting coils with sophisticated support structure. Structural reliability of components as well as resulting deformations and displacements during various modes of operation have to be considered not only for the magnet system but also throughout the whole cryostat whose main components are the plasma vessel, outer vessel, ports, and thermal insulation.A reliable prediction of the W7-X structural behaviour is only possible by employing complex finite element (FE) simulations with a hierarchical set of FE models. A special strategy has been developed and implemented for the task.The design is basically completed, main parameters are defined, and most of the W7-X components are manufactured. Therefore, the focus in the analysis is being shifted to the creation of parametric FE models which allow performing fast analyses of possible non-conformities, changes in the assembly procedure, and future exploration of operational limits.This paper gives an overview of the implemented analysis strategy, the applied safety margins, and focuses on the most remarkable results.     

Thermo-mechanical tests on W7-X current lead flanges

Fourteen pieces of high temperature superconducting current leads (CL) arranged in seven pairs, will be installed on the outer vessel of Wendelstein 7-X (W7-X) stellarator. In order to support the CL, it is provided with two glass fiber reinforce plastic (GFRP) flanges, namely, the lower cryostat flange (CF) remaining at room temperature and upper radial flange (RF) at about 5 K. Both the flanges i.e. CF & RF experience high mechanical loads with respect to the CL, due to the evacuation of W7-X cryostat, cool-down of cold mass including the CL, electro-magnetic forces due to current & plasma operations and self weight of CL. In order to check the integrity of these flanges for such mechanical loads, thermo-mechanical tests were carried out on these flanges at room temperatures and at liquid nitrogen (LN2) temperatures. The details of test set-up, results and modeling are described in the paper.     

Status of series production and test of the HTS current leads for Wendelstein 7-X

The Karlsruhe Institute of Technology (KIT) is responsible for design, production and test of the High Temperature Superconductor (HTS) current leads for the stellarator Wendelstein 7-X (W7-X). In total 14 current leads with a maximum current of 18.2 kA are required. Special feature is the upside-down orientation of the current leads because of the location of the power supplies in the basement of the experimental area of W7-X. One further important requirement is the Paschen tight electrical insulation of current leads and the connection to the bus bar system. Due to some very specific manufacturing steps, budget and time restrictions, it has been mutually decided between the project partners to manufacture most of the components in house, except the HTS stacks which have been produced and delivered by industry. As the semi-finished parts were manufactured in the central workshop of KIT, the assembly of the current leads was performed in the ITEP (Institute for Technical Physics). The final acceptance test of the current leads is performed at KIT, using a dedicated test cryostat assembled beside and connected to the main vacuum vessel of the TOSKA facility. The paper describes the status of the manufacturing of the current leads. In addition attention is given to specific problems that occurred during the manufacturing and testing.     

Thermal and mechanical analysis of Wendelstein 7-X thermal shield

The thermal insulation of Wendelstein 7-X cryostat consists of multi-layer insulation (MLI) and a thermal shield. The shield is cooled by helium gas flowing in pipes which are attached to the shields via copper strips or braids. The paper presents the basic thermal and mechanical layout of the thermal shield. The design is strongly influenced by the tight design space.Main mechanical loads on the shield are electromagnetic forces resulting from rapid shut down of the magnet system and the self weight. Design and calculations were performed iteratively. Copper and brass were checked in combination with different electrical isolation variants. The induced eddy currents will be reduced if the upper and the lower half shells of the cryostat are electrically isolated against each other. The cryostat shield and the port shields are made of brass.The expected heat loads on the shield were estimated. The resulting temperature distribution was then calculated for brass and copper shield panels. The average shield temperature is below 85 K and fulfills the thermal requirements.     

Design principles for handmade electrical insulation of superconducting joints in W7-X

The superconducting magnet system of the Wendelstein 7-X (W7-X) experiment consists of 50 non-planar and 20 planar coils, 121 bus bars and 14 current leads. The connection between bus bars, coils and current leads will be provided by 198 joints. The joints have to be insulated manually during the assembly of the machine in constraint positions and a tight environment. In general the insulation is based on glass tapes impregnated with epoxy resin and special G10 insulating pieces embedded in the glass tape insulation. In critical areas Kapton^®-foils are embedded in the insulation. All types of insulation were qualified at mock-ups in a 1:1 model of the expected environment in W7-X. The qualification programme comprises thermal cycling between room temperature and 77 K and high voltage tests under air, under vacuum and under reduced pressure (Paschen test). The paper describes the main principles used for different types of handmade Paschen-tight insulations in W7-X and the visual and electrical tests during and after assembly.     

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.     

Gate valve and shutter control system of the fusion experiment Wendelstein 7-X

The plasma vessel of the fusion experiment Wendelstein 7-X (W7-X) is a plasma vessel covering a plasma volume of about 30 m³. The vacuum conditions for plasma experiments inside the plasma vessel are supposed to be in a range of 1 × 10⁻⁸ mbar (ultra high vacuum conditions) after evacuation and conditioning. The 254 ports of the plasma vessel allow an external access to the inner space of the plasma vessel. Ports for heating and diagnostic systems are equipped with gate valves or with shutters. The vacuum gate valves are used as a controllable mechanical and a vacuum disconnection point between diagnostics and heating systems on the port side and the inner plasma vessel on the other side. The shutters are responsible for an optical and thermal protection for port windows or installed equipments inside the ports. After an overview of the main requirements for the control of the huge number of gate valves and shutters for the operational phases 1 and 2 of W7-X the design and realization of a centralized control system for controlling and observing all shutters and the majority of gate valves of the machine Wendelstein 7-X will be introduced and discussed.     

Thermal and structural analysis of the W7-X magnet heat radiation shield

The thermal insulation of the W7-X – cryostat consists of multi-layer insulation (MLI) and an actively cooled thermal shield. The shield is cooled by He gas flowing in pipes, which are flexibly attached via copper braids. The paper presents the basic mechanical and thermal layout of the complex plasma vessel shield, which is made of a glass fibre compound with three embedded copper nets.Main mechanical loads on the shield are electromagnetic forces resulting from rapid shut down of the magnet system, and the self weight. Design and calculations were performed iteratively to determine the number as well as orientation of electrical insulation gaps within the copper nets, and the number and positions of the supports.It is shown that the maximum displacements of the panels, the maximum forces on the supports, and the shield temperatures fulfil the requirements.     

Reverse engineering process of cryostat components of Wendelstein 7-X

The Wendelstein 7-X stellarator is a superconducting fusion experiment, presently under construction at the Greifswald branch of the Max-Planck-Institut für Plasmaphysik. This paper gives an overview of the reverse engineering processes applied on cryostat components of the W7-X superconducting magnet system.     

Simulation of Targets Feeding Pipe Rupture in Wendelstein 7-X Facility Using RELAP5 and COCOSYS Codes

Wendelstein nuclear fusion device W7-X is a stellarator type experimental device, developed by Max Planck Institute of plasma physics. Rupture of one of the 40?mm inner diameter coolant pipes providing water for the divertor targets during the “baking” regime of the facility operation is considered to be the most severe accident in terms of the plasma vessel pressurization. “Baking” regime is the regime of the facility operation during which plasma vessel structures are heated to the temperature acceptable for the plasma ignition in the vessel. This paper presents the model of W7-X cooling system (pumps, valves, pipes, hydro-accumulators, and heat exchangers), developed using thermal–hydraulic state-of-the-art RELAP5 Mod3.3 code, and model of plasma vessel, developed by employing the lumped-parameter code COCOSYS. Using both models the numerical simulation of processes in W7-X cooling system and plasma vessel has been performed. The results of simulation showed, that the automatic valve closure time 1?s is the most acceptable (no water hammer effect occurs) and selected area of the burst disk is sufficient to prevent pressure in the plasma vessel.     

Thermo-mechanical analysis of the Wendelstein 7-X divertor

The stellarator Wendelstein 7-X (W7-X) has a divertor consisting of 10 units installed inside the plasma vessel (PV). It was decided not to install the long pulse high-heat flux (HHF) divertor targets at the first two years stage of W7-X operation and to start with an adiabatically cooled test divertor unit (TDU) and shorter plasma pulses operation. This allows to accumulate operation experience with much simpler components, and as a result to adjust accurately the actively cooled HHF divertor which replaces the TDU for the stationary operation. Finite element (FE) analyses have been performed for better understanding of thermo-mechanical problems of divertor targets, and to guide the design of the TDU and HHF divertors. This paper presents the detailed results of the temperature response, the deformation and thermal stress of the divertor components.     

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.     

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.     

Probe manipulators for Wendelstein 7-X and their interaction with the magnetic topology

Probe manipulators are a versatile addition to typical plasma edge diagnostics.Equipped with material samples they allow for detailed investigation of plasma–wall interaction processes,such as material erosion,deposition or impurity transport pathways.When combined with electrical probes,a study of scrape-off layer and plasma edge density,temperature and flow profiles as well as magnetic topologies is possible.A mid-plane manipulator is already in operation on Wendelstein 7-X.A system in the divertor region is currently under development.In the present paper we discuss the critical issue of heat and power loads,power redistribution and experimental access to the complex magnetic topology of Wendelstein 7-X.All the aforementioned aspects are of relevance for the design and operation of a probe manipulator in a device like Wendelstein?7-X.A focus is put on the topological region that is accessible for the different coil current configurations at Wendelstein 7-X and the power load on the manipulator with respect to the resulting different magnetic configurations.Qualitative analysis of power loads on plasma-facing components is performed using a numerical tracer particle diffusion tool provided via the Wendelstein 7-X Webservices.     

Design analysis and manufacturing of the cooling lines of the in vessel components of WENDELSTEIN 7-X

All in vessel components (IVCs) of W7-X are actively cooled. Inside the plasma vessel about 4 km of pipes will be installed, supplying water to the IVC. 226 cooling circuits with 78 variants are necessary. The cooling circuits enter the cryostat and the plasma vessel through ad hoc flanged penetrations called “plug-ins”, which provide for the vacuum boundary between the plasma chamber and the torus hall atmosphere. The plug-ins are installed inside the W7-X ports. Some of the plug-ins are also used for the diagnostic cables. In total eighty plug-ins will be produced and installed. The inlet/outlet cooling lines are connected to the plug-ins using a welded hydraulic connector. The layout of the cooling lines is rather complex in consideration of the limited space and the routing between many component parts. Additionally the differential thermal expansion of the lines with respect to the supporting structures during the different operation scenarios had to be compensated by ad hoc supports and adjustments in the flexibility of the lines.