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