K o r e a S u p e r c o n d u c t i n g T o k a m a k A d v a n c e d R esearc h

21st IAEA Fusion Energy Conference

October 16-21, 2006Chengdu, China

H. L. Yang and the KSTAR TeamH. L. Yang and the KSTAR TeamH. L. Yang and the KSTAR TeamH. L. Yang and the KSTAR Team

KSTAR ASSEMBLY

ContentsContentsContentsContents

� Introduction

� Overview

� Scope of the KSTAR Assembly

� Key Features

� Progress

• Before TF Magnet Assembly

• TF Magnets

• After TF Magnet Assembly

• PF Coils

• CS Coils

� Status

� Integrated Commissioning

• Goal Parameters

• General Procedure

• Overall Schedule

� Summary and Future Milestone

Major Radius, R0

Minor Radius, a

Plasma Current, IP Elongation, κTriangularity, δToroidal Field, B0

Pulse Length

1.8m

0.5 m

2.0 MA

2.0

0.8

3.5 Tesla

300 sec

Dimension

Superconductor

Magnet Weight

Cryogenic System

8.6 m (H)

8.8 m (D)

Nb3Sn , NbTi

270 Ton

9 kW

Parameters Values

OverviewOverviewOverviewOverview

KSTAR ParametersKSTAR ParametersKSTAR ParametersKSTAR Parameters

Scope of the KSTAR AssemblyScope of the KSTAR AssemblyScope of the KSTAR AssemblyScope of the KSTAR Assembly

� Assembles all of the major systems

� Regulates the schedule, interface, space allocation, safety, and QS for In-

cryostat components and ancillary systems including

� Current feeder system

� He piping system

� Diagnostics for 1st plasma

� Heating systems for 1st plasma

� In-Vessel components for 1st plasma

� Local I&C sensors and cables

� Fueling & glow discharge systems

� Port blanking

� Establishes and maintains the survey and alignment (S&A) network

system

� Design, fabrication, and construction of the assembly jigs & tools system

PFC & IVCC

VV & PORT

CRYOSTAT

SC COILS

MAGNET STRUCTURE

THERMAL SHIELD

Warm Structures

ASSEMBLY TOOLS

KSTAR

Cold Structures

Major Systems of the KSTARMajor Systems of the KSTARMajor Systems of the KSTARMajor Systems of the KSTAR

Key FeaturesKey FeaturesKey FeaturesKey Features

1. Coordinate System

� Two coordinate sets during the assembly

� The 1st coordinate is established from the

geometry of cryostat support beam

� After assembly completion of the TF, the 2nd

data is set-up to provide a reference for SC

magnet installation

� Reference in the 2nd data set has offsets from

1st set to coincide each other in cryogenic

temp.

� Mid-plane Level of VV & Cryostat : 4,200 mm

� Mid-plane level of the SC magnets: 4,205 mm

� The TF is assembled 7 mm outward in radial

direction @ room temp.

Illustration - thermal contraction of the TF

Key FeaturesKey FeaturesKey FeaturesKey Features

Site

Welding

2. Assembly of the VV and TF Magnets

� TF magnet is inserted through the 22.5° gap of the VV, and positioned one by one

� Narrow clearance between VV (VVTS) and TF magnet

� Assembly tolerance requirement of the TF : within ±1mm

� VV sector 3 is divided into 24 small pieces

� It needs a special jig system

Sector 2 (157.5 °)

Sector 1 (180 °)

Concept of the TF Assembly VV Sector 3 (22.5° )

Main Assembly Jig SystemMain Assembly Jig SystemMain Assembly Jig SystemMain Assembly Jig System

Key FeaturesKey FeaturesKey FeaturesKey Features

Oute

r shell extensio

n

Gap after Heating

Heating Pad (Inner Shell)

Heating Pad (Outer Shell)

3. Assembly of the Central Solenoid

� Segmented CS coils operating in

difference current values

� Compressive force during reference

scenario

� Separation force between CS1 & CS2 :

about 10MN (MRF condition)

� Preload on CS coils to prevent coil

separation and lateral movement

� Designed preload : ~ 1,000 tons

� Strategy :

� Heating the shells

� Measuring strain

Inner shell extensio

n

Cryostat Base Gravity Support Assembly Jig for the TF Magnet

Assembly Jig Test with TF00Pre-Install. Of the Lower PF CoilsPositioning of the VV & VVTS

Site Weld of the VVVV 337.5° SectorInstall. of the VVTS

Progress Progress Progress Progress –––– Before TF Magnet AssemblyBefore TF Magnet AssemblyBefore TF Magnet AssemblyBefore TF Magnet Assembly

Site Delivery of a TF MagnetSite Delivery of a TF Magnet Insulation Plates BondingInsulation Plates Bonding Start Site Assembly of the TF MagnetStart Site Assembly of the TF Magnet

Loading on the Assembly ToolLoading on the Assembly Tool Insertion through 22.5 °°°° Gap of the V.V.Insertion through 22.5 °°°° Gap of the V.V. Installation on the Gravity SupportInstallation on the Gravity Support

Measurement & AlignmentMeasurement & Alignment TF Magnet System after Assembly FinishTF Magnet System after Assembly Finish

1111 2222 3333

55554444 6666

7777 99998888

Shear Key InsertionShear Key Insertion

ProgressProgressProgressProgress–––– Assembly of the TF MagnetAssembly of the TF MagnetAssembly of the TF MagnetAssembly of the TF Magnet

Components between Two TF MagnetComponents between Two TF MagnetComponents between Two TF MagnetComponents between Two TF Magnet

Cylindrical Shear Key

Rectangular Shear Key

Conical Bolt

Bolt & Nut

dx

dy

dz

x

z

y

tx

ty

tz

Translation

x

Alignment Result of the TF MagnetAlignment Result of the TF MagnetAlignment Result of the TF MagnetAlignment Result of the TF Magnet

Rotation

VVTS Sector 3VVTS Sector 3 VV Sector 3VV Sector 3

VV Support - Leaf Spring VV Support - Leaf Spring

1111 2222

4444

After the TF Magnet AssemblyAfter the TF Magnet AssemblyAfter the TF Magnet AssemblyAfter the TF Magnet Assembly

Bottom Vertical Port (12 ea) Bottom Vertical Port (12 ea)

3333

Assembly of the PF CoilsAssembly of the PF CoilsAssembly of the PF CoilsAssembly of the PF Coils

PF6U Coil

PF7U/L Coil

PF6L Coil

PF5L Coil

Assembly of the Central Solenoid (CS)Assembly of the Central Solenoid (CS)Assembly of the Central Solenoid (CS)Assembly of the Central Solenoid (CS)

Setup jig installation Bottom block assembly Lower buffer assembly CS4L subassembly CS4L turning over

CS4L standing CS4L assembly CS4L alignment CS3L assembly CS2L assembly

CS1L assembly CS1U assembly CS2U assembly CS3U assembly

Main Assembly

Preloading

CS4U assembly Wedges & block & shells Shell heater assembly Support lug assembly

PrePrePrePre----Loading of the CSLoading of the CSLoading of the CSLoading of the CS

72 78 84 90 96 1020

30

60

90

120

150

180

Tem

per

atu

re (

oC

)

Elapsed Time (hour)

Inner Shell(IS) & Outer Shell(OS) OS 01 OS 02 OS 03 OS 04 OS 05 OS 06 OS 07 OS 08

IS 01 IS 02 IS 03 IS 04 IS 05 IS 06 IS 07 IS 08

Temp. variation (5th heating)

72 78 84 90 96 102-400

-200

0

200

400

600

Str

ain

(µεµε µεµε

)

Elapsed Time (hour)

Outer Shell(OS) OS 01 OS 02 OS 03 OS 04 OS 05 OS 06 OS 07 OS 08 OS 01-1 OS 03-1 OS 05-1 OS 07-1

Strain variation (5th heating)Average value : 392

Temperature

Strain

Heating the CS Structure for Preloading

Results

• Max. Temperature : 140°C at outer shell• Expansion of the shell : 6 mm

• Preloading @ room temperature : 800 tons

CS after AssemblyCS after AssemblyCS after AssemblyCS after Assembly

Inside of the CS

Top of the CS Bottom of the CS

Outside of the CS

Installation of the CS on the TFInstallation of the CS on the TFInstallation of the CS on the TFInstallation of the CS on the TF

Cryostat Support Base Frame of Main JIg Cryostat Base Supports of Rail System Gravity Support

Partly Removal of Main Jig Accept. Test of Main JIg Assembled Main Jig Top Frame of Main Jig Main Column of Main Jig

Install. VV and VVTS Re-assemble of Main JIg Assembly of 1st TF Assembly of the Last TF VV Sector 3 after Site Weld

It took more than 1 year

Summary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly Progress

� Mechanical Assembly

Completion

� Port Blanking

� Basic Diagnostic Install.

� 1st Heating Device Install.

� Ready for Integrated

Machine Commissioning

Lower PF6 &7 Coils VV Support (Leaf Spring) Upper PF6 & 7 Coils Lower PF5 Coil Central Solenoid

Slanted/B&C Port Median Port (NBI/RF/EH) Cryostat Cylinder Base Thermal Shield Upper PF5 Coil

Cryostat Lid Top Vertical Port Pumping Duct Systems

Summary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly ProgressSummary of the KSTAR Assembly Progress

Status Status Status Status ---- Current Feeder SystemCurrent Feeder SystemCurrent Feeder SystemCurrent Feeder System

TF Magnet Terminal

TF Inter-coil Bus

TF OCB (CICC) TF OCB

TF CLB (Cryostat) TF CLB (He Tank)

TF Magnet Terminal TF Inter-coil Bus

TF OCB (CICC) TF OCB

TF CLB (Cryostat) TF CLB (He Tank)see Y. M. Park, et. al, FT/P7-1

Status Status Status Status –––– Inside of the Vacuum VesselInside of the Vacuum VesselInside of the Vacuum VesselInside of the Vacuum Vessel

Status Status Status Status –––– Assembly HallAssembly HallAssembly HallAssembly Hall

Cryostat Cylinder &

Thermal Shield

Cryostat Lid &

Thermal Shield

Inter-Coil Busline of the

TF MagnetsPF5U Coils

Cryostat Base Thermal Shield

under Installation

Pumping System

• Objective :

- to test the engineering performance and operational reliablity of the KSTAR device

� assembly status of the tokamak structures

� superconducting magnet system & interfaces

� vacuum system & gas fueling system

� cryogenic facility for cool-down

� power supply & quench protection system

� control system & local I&C

� plasma heating and diagnostics

� Safety & interlock

• Key parameters to achieve

� Vacuum in VV : 5.0 e-7 torr

� Vacuum in cryostat : 1.0 e-4 torr at room temp.

� Thermal shield temperature : 80 K

� Coil temperature : 5 K

� Toroidalmagnet flux density : 1.5 T

� Plasma heting device test : ECH system (0.5 MW)

� 1st Plasma : about 100 kA

Integrated Commissioning Integrated Commissioning Integrated Commissioning Integrated Commissioning ---- ObjectivesObjectivesObjectivesObjectives

•• System AssemblySystem Assembly

•• Individual System TestIndividual System Test

•• Evacuation & Leak checkEvacuation & Leak check

•• CoolCool--downdown

•• Coil ExcitationCoil Excitation

•• 11stst Plasma ScenarioPlasma Scenario

Overall Commissioning ProcedureOverall Commissioning ProcedureOverall Commissioning ProcedureOverall Commissioning Procedure

4 51

2008

2 63121110987654321

2007

Individual System Test Integrated Commissioning

Control System

Pumping System

Facility Test

Heating System

Diagnostic System

Tokamak Assembly & Test

Evacuation & Leak Check

Cool-down

Coil Excitation

First Plasma

Overall Commissioning ScheduleOverall Commissioning ScheduleOverall Commissioning ScheduleOverall Commissioning Schedule

Summary and Future Milestone

1. 2005. Dec: 13 TF Magnet Assembly

2. 2006. Mar: Completion of TF Magnet Assembly

3. 2006. Oct: Completion of CS Magnet Assembly

4. 2007. Mar: 154 kV Power Connection (50MVA)

5. 2007. Aug: Tokamak Assembly Finish

6. 2007. Oct: Operation of 9 kW He Cryo-plant

7. 2008. Jun: First Plasma

8. 2008. Oct: ICRH Heating Install

9. 2009. Dec: NBI(I) Heating Install

2005

Commissioning

1 3 4 862

2006 2007 2008 2009

Construction Operation

59

7

Thank You for Attention